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| User Manual

Maintenance and repair of the dryer

BSP-MT 1-8/D3

Maintenance and repair of the dryer

In order to allow maintenance work on the dryer to be carried out effi ciently and without dan-

ger for maintenance personnel, you should comply with the following instructions.

Notes on maintenance

Danger!

There is a very considerable risk of personal injury, when carrying out work on

the activated and pressurised dryer.

Danger!

Before commencing any maintenance tasks always shut down the dryer as

described on page

Warning!

Maintenance tasks may be carried out only by authorized and qualiﬁ ed spe-

cialist personnel, and only with the plant in a switched off and depressurised

condition.

Note:

In order to ensure perfect maintenance and reliable operation we recommend

that you conclude a maintenance contract.

When exchange or replacement parts are ordered, always state the dryer type

and the build no. of the dryer. These data are found on the type plate.

◊

Carry out all maintenance work only when the plant has been shut down and depressur-

ised!

◊

Bolt connections must be undone with care! Note ram pressure values! Otherwise emerging

media may cause personal injury.

◊

Do not modify the factory settings of the control system in any way without prior consulta-

tion with the manufacturer.

◊

Never carry out any manipulations on a hollow profi le vessel or modify the same in any

way!

◊

Following maintenance work, always check all fl ange and bolt connections for leakage and

secure seating.

◊

Never use pipes and fi ttings as steps or holding points! The components might fracture, or

the distortions which occur may cause internal damage on the dryer. There is a risk of injury

by slipping off the components, components breaking off, and expanding compressed air!

◊

Never leave tools, loose parts or cloths at or on the dryer.

◊

Only use replacement parts that are suitable for the relevant function and meet the techni-

cal requirements stipulated by the manufacturer. This is always the case, if you use original

replacement parts only.

Summary of Contents for BSP-MT 1-8/D3

Page 1: ...BSP MT 1 8 D3 Dryer for Breathing air Operating manual 28 01 2020 rev01 EN Cod 398H272186 Generation 3 ...

Page 2: ......

Page 3: ...g 19 Installing the electrical connection 20 Start up 22 Requirements for initial start up 22 Setting times of the operating phases 22 Overview of operating and control elements 23 Start up dryer 25 Changing cycle mode optional 27 Monitoring dryer operation 28 With dewpoint sensing control optional 28 Shutdown and restart dryer 30 Emergency shutdown 30 Depressurising and shutting down the dryer 30...

Page 4: ...EN User Manual 2 BSP MT 1 8 D3 Annex with technical documentation 47 Technical data 48 Replacement and wear part list 49 Logic control diagram 51 Flow diagram 53 Installation on floor 54 ...

Page 5: ... these appliance data up to date The above stated appliance data provide for a clear identification of the dryer and its compo nents and significantly facilitate any service measures Further important data on the dryer such as the details on the permissible operating pressure and the electrical connection are found on the type plate for position of the type plate see page 8 ...

Page 6: ...as dryer consisting of 1 double chamber hollow section vessel fillied with drying agent 1 single chamber hollow section vessel filled with purifying agent 2 upstream filter 1 downstream filter Muffler Control system Associated documents Operating instructions present Technical documentation see annex Circuit diagrams see separate document Operating manual for installed filters separate document No...

Page 7: ...h 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 threa tening situations for yourself and or third parties Target group of these operating instructions These operating instructions are intended for all persons working on and using the dryer We assume that all such persons are special...

Page 8: ... A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer ﬁrst depressurise the plant Risk of injury due to voltage carrying parts The electrical supply cable and external power lines are live even after the dryer is switched off and in the event of body contact may cause serious injury Before carrying out any work on the electrical system the electrical sup...

Page 9: ...dries compressed air for industrial use The dryer is designed for compressed air which is free from aggressive water oil and solid matter constituents As standard the dryer is intended to be sited within a building and protected against the weather The dryer may be operated only in accordance with the data on the type plate and in accord ance with the contractual conditions Suspected misuse The dr...

Page 10: ...8 BSP MT 1 8 D3 Signs and hazard areas on the dryer Signs and labels Front view Please note these signs on the dryer Keep them complete and always legible Type plate of upstream filter Type plate of downstream filter Type plate of dryer ...

Page 11: ...ye injury When working on the dryer always wear eye and ear protection equipment Risk of damage to eyes If not properly secured the indicator tube might be propelled out of its holder When the needle valve is opened the indicator tube is secured by a union nut If the union nut is not properly tightened or if the oil indicator has been interfered with there is a risk that the tube might be propelle...

Page 12: ...torage instruc tions on page 13 Information on transportation packaging Depending on the type of transportation the dryer is delivered in different types of packag ing All transportation types the apertures of the dryer are closed off by means of plugs In addition when transportation is effected by air the dryer is packaged in a wooden box In addition when transportation is effected by ship the dr...

Page 13: ...yer is specified in the technical data section of the annex The dryer should be installed with sufficient spacing at the top sides and rear in order to be able to carry out maintenance work and change the drying agent without any hindranc es see figure If in doubt the installation site must be inspect ed by specialists If you have any queries in this regard please contact the manufacturer see pag ...

Page 14: ... the dryer are provided with pre drilled anchorage bores see figure Use suitable attachment material to anchor the dryer to the floor In the case of vibrating floors place the dryer on suitable vibration dampers Bores on the stand profiles Mount dryer on the wall Option The stand profiles can be rotated by 90 towards the rear side of the dryer and secured in this position see arrow in above figure...

Page 15: ...he owner and the installed compressed air outlet valve installed by the owner are both closed and that the dryer is depressurised Disconnect dryer from the compressed air system Disconnect the dryer from the electrical power supply and all external lines Use film material or similar to close the compressed air inlet apertures and compressed air outlet apertures on the dryer in order to protect the...

Page 16: ...ir from drying agent abrasions be fore it is fed into the compressed air system The two chambers of the hollow section vessel contain an extremely porous drying agent by means of which humidity is removed from the compressed air and stored just as in a sponge The stored humidity is then removed again from the drying agent and re introduced into the ambient environment To this end the two chambers ...

Page 17: ...enewed take up of humidity This process is called regeneration The regeneration is subdivided into three phases expansion dehumidification and pressure build up With the dewpoint sensing control option the regeneration phase is followed by a standby phase Expansion phase During the expansion phase the pressure in the regenerating chamber is released via the muffler down to ambient pressure within ...

Page 18: ...sensing control option When in standby phase the fully regenerated vessel is ready for absorption operation The system is switched to this vessel as soon as the measured dewpoint at the compressed air outlet has reached the set dewpoint value for switchover Switchover When the drying agent in the adsorbing chamber has taken up a sufficient level of humidity then the switchover between the vessels ...

Page 19: ... is treated as the prime controller The control system can also be equipped with an optional operation signalling contact with which the dryer operation can be monitored from an external device Dryers with the optional dewpoint sensing control are equipped with such a contact as standard It is used for the transmission of operating signals and for the output of dewpoint alarms Dewpoint sensing con...

Page 20: ... installed by the owner so that the dryer can be installed and maintained in a depressurised condition see also the installation example on page 19 All pipes couplings and connections must have the correct diameter and match the oper ating pressure Hazard caused by exceeding the limit values A safety device must be provided in order to protect against the maximum permissible operating pressure fro...

Page 21: ...ect to stress may burst due to the load placed on them during opera tion This may cause damage to property and personal injury Use steel pipes to connect the dryer to the compressed air system The following figure shows an installation example Compressed air system Item Component 1 2 3 5 6 7 4 Example of an installation with bypass line 1 Entry humid air 2 Compressed air inlet valve owner end 3 Up...

Page 22: ... the customer Make the electrical supply cable to the dryer voltage free Secure the electrical supply cable to the dryer against switch on Undo bolt 1 on the connector and withdraw connector with seal from the switchbox Use a suitable tool to remove the terminal block from the connection box Undo the PG union and pull the cable th rough the aperture 3 The exposed phase ends should not be longer th...

Page 23: ...stall the external line proceed as follows Connect the signalling line to the potential free busbar connection of the compressor to terminals 1 and 2 on the control board see circuit diagram Hinweis The compressor synchronisation controller is a higher level controller than the pressure dew point controller When both options are in place the compressor synchronisation controller is treated as the ...

Page 24: ...osed the electrical connections are in safe contact and in good condition owner end and pressurised parts such as safety valves or other devices are not blocked up by dirt or paint all compressed air system parts which are pressurised valves hoses etc are free from wear symptoms and defects Setting times of the operating phases In its standard version the dryer is delivered with a time dependent c...

Page 25: ... dryer is switched off If the switch is set to I the dryer is switched on and begins to operate in fixed cycle mode i e time controlled If the switch is set to position II the dryer is switched on and begins to operate with compressor synchronisation in variable cycle mode i e dew point cont rolled Position II is only relevant for operation with the optional compressor synchronisation and or dewpo...

Page 26: ... seconds In this example step 2 is being completed whereby there are 215 seconds remaining SEr After 8000 operating hours SEr service is displayed for periods of 1 minute alternating with the default display Notify the service personnel of the manufacturer as a routine service is now due 25 With the dewpoint sensing control option the display shows the currently measured dewpoint instead of the de...

Page 27: ...arted up Open compressed air supply and switch on dryer For start up please proceed in the sequence shown here Ensure that the compressed air inlet and outlet valves installed by the owner are closed see installation example on page 19 Ensure that the compressed air system upstream of the dryer is pressurised If necessary pressurise switch on compressor Slowly open compressed air inlet valve Avoid...

Page 28: ...mpressed air system downstream of the 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 circumstance If pressure drops too fast this may cause damage to the dryer Therefore the compressed air outlet valve must always be opened quite slowly Slowly open the compr...

Page 29: ...point sensing control With compressor synchronisation If compressor synchronisation is enabled the dryer can only be operated in conjunction with the compressor As soon as the compressor is switched off the dryer is automatically set to standby mode In standby mode the control system remains on and the dryer is ready for the next switcho ver which is made as soon as the compressor is switched on N...

Page 30: ...your country it may be necessary to perform initialisation according to the directive for pressure equipment Check the dryer regularly for externally visible damage and defects Any changes even in its operating behaviour must be reported immediately to the competent office or person In the event of an emergency or if a safety relevant disruption occurs e g escaping com pressed air defective compon...

Page 31: ...yed dewpoint value is flashing In addition an error message can be issued through the potential free busbar Error codes and their causes Display Cause 20 Upper measuring range limit exceeded 999 Dewpoint sensor defective sens o 999 Dewpoint sensor not powered Cable defective Sensor defective For instructions on how to eliminate faults see chapter Identify and eliminate faults ...

Page 32: ...tchover Note If the unit is equipped with a compressor synchronisation system ﬁrst switch off the compressor and then wait until the dryer has reached the standby phase before switching it off with the ON OFF switch This ensures that the regeneration cycle is completed and that the pressure in both chambers is at the same level As soon as the dryer is switched on again the programme continues the ...

Page 33: ...t the pressure outlet valve is open If the dryer is equipped with a dewpoint sensing control system it is depressurised gradu ally according to the read measuring current If compressed air system and dryer have remained at operating pressure Ensure that the compressed air inlet valve provided by the operator is open Set ON OFF switch to I The programme continues the cycle from the point at which i...

Page 34: ...e goggles In order to avoid any dust inhalation wear dust mask Restart the dryer Switch on the dryer and pressurise as described in section Open compressed air supply and switch on dryer page 22 The compressed outlet valve must be closed and the downstream filter housing must be open Operate the dryer for approx thirty minutes blowing the dust particles off from the down stream filter Shut down th...

Page 35: ... of the dryer These data are found on the type plate Carry out all maintenance work only when the plant has been shut down and depressur ised Bolt connections must be undone with care Note ram pressure values Otherwise emerging media may cause personal injury Do not modify the factory settings of the control system in any way without prior consulta tion with the manufacturer Never carry out any ma...

Page 36: ...task to be carried out Maintenance interval daily 12 months 24 months 48 months See page Complete dryer Carry out visual checks and function checks 35 Muffler BSP MT 1 2 Clean muffler replace if necessary 36 BSP MT 3 8 Mufflers must be replaced annually and after each desiccant change 36 Fine filter muffler option Replace silencer element annually and after each desiccant change 37 Sensor of optio...

Page 37: ...y be used once Switch off the controller Caution The electric line is still live Do not touch live parts Open the lid to the Multitronic controller The circuit board in housed underneath it Slot the dongle into the dongle interface X9 PC Press and hold the reset key S3 Switch on the controller The following appears in the display for a short time 0 SET then flashing OFF The service counter is then...

Page 38: ... Therefore mufﬂers must be checked at least once a year and cleaned BSP MT 1 2 or renewed BSP MT 3 8 if they are contaminated Warning against sudden air ejection During expansion the pressure is released suddenly through the mufﬂer A loud cracking noise occurs which can injure your hearing Particles carried in the air ﬂow act like bullets and can injure your eyes or skin Always wear eye and ear pr...

Page 39: ...ed to replace the dew point sensor every year This period depends howev er on the actual application and might thus be extended accordingly Dewpoint sensor 1 Warning The dew point sensor is a sensitive measuring device It can be damaged if subjected to forceful vibrations or shocks Therefore please handle the dew point sensor with great care at all times In order to limit the impact on the dryer o...

Page 40: ...he components have not been designed for such loads and could fracture Only use approved climbing aids when disassembling the top plate Risk of skidding If drying agent has been spilt on the ﬂoor there is a risk of skidding caused by the drying agent beads Therefore spilt drying agent must always be taken up immediately To replace the purifying agent you must first remove the top plate Depressuris...

Page 41: ...r Replace upper perforated plates Perforated plates designed to retain the drying and purifying agents are fitted under the check valve plate and above the solenoid valve plate If these perforated plates become blocked a dam pressure is generated which can cause compressed air fluctuations in the compressed air system In order to remove the upper perforated plates the check valve plate must be rem...

Page 42: ...n may occur In order to avoid any eye irritations wear protective goggles In order to avoid any dust inhalation wear dust mask Risk of skidding If drying agent has been spilt on the ﬂoor there is a risk of skidding caused by the drying agent beads Therefore spilt drying agent must always be taken up immediately Remove used drying agent Use an industrial vacuum cleaner to hoover up carefully the dr...

Page 43: ...al note of the next step Ensure that the drying agent is filled into the chambers with a high bulk density Note To achieve an optimum bulk density we recommend using a snowstorm ﬁlling pipe available from the manufacturer Otherwise tap the chamber wall with a rubber mallet while filling in the drying agent or use a stick to distribute the agent evenly inside the chamber Subsequently position the p...

Page 44: ...rvice Kit for 24 months Maintenance work to be completed every 48 months Replace check valves Check valves are wear parts and must thus be replaced every 48 months even if no damage is visible Release pressure from dryer and shut down the unit see page 30 Remove the securing screws at the rear of the check valve plate Insert new balls and new springs and ensu re that they are not jammed Replace th...

Page 45: ... dryer rear must be open when not energised valve piston without notch 2 Solenoid valves Y3 Y4 at the dryer front must be closed when not energised valve piston with notch 2 Position the new solenoid valves at the points at which they are to be mounted in order to prevent any confusion at a later stage For each solenoid valve proceed as follows Remove solenoid valve from the holder 3 Remove the va...

Page 46: ... expansion valve closes and the regeneration is interrupted In the case of some process faults the dryer will continue to operate for some time Other faults on the dryer become noticeable e g due to unusual noises and ran pressures The following table shows who is allowed to remedy a fault the owner s specialist personnel or the manufacturer s service engineer Table of possible faults Fault Possib...

Page 47: ...ly Compressor might be off Check compressor synchro nisation circuit Error in control programme Restart programme No expansion Solenoid valve Y3 Y4 can not be opened Check supply voltage ca ble contacts and solenoid replace if necessary Solenoid valve Y3 Y4 can not be opened properly audible humming sound or valve flapping Check supply voltage Check spring and solenoid replace if necessary Check s...

Page 48: ...ed Replace sensor sens o 999 Sensor not powered or cable or sensor defective Sensor sensor cable or sensor adapter defective Visual inspection check power supply 24 V to terminals 4 and 6 Replace defective com ponent s SEr Display for service interval Regular maintenance tasks must be carried out The display appears after every 8000 operating hours Inform the manufactur er s service staff and orde...

Page 49: ...cumentation BSP MT 1 8 D3 47 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 Dimensional drawing ...

Page 50: ...ominal temp C BSP MT 1 8 1 4 AOP010AGFI AAP010AGFI AOP010AGMI 16 50 BSP MT 2 15 1 4 AOP010AGFI AAP010AGFI AOP010AGMI 16 50 BSP MT 3 25 1 4 AOP010AGFI AAP010AGFI AOP010AGMI 16 50 BSP MT 4 35 1 4 AAP010AGFI AAP010AGFI AOP010AGMI 16 50 BSP MT 6 56 1 2 AOP015CGFI AAP015CGFI AOP015CGMI 16 50 BSP MT 7 72 1 2 AAP015CGFI AAP015CGFI AOP015CGMI 16 50 BSP MT 8 86 3 4 AOP020DGFI AAP020DGFI AOP020DGFI 16 50 1 ...

Page 51: ...ity H2 O 5 C 5 C 10 F 100mg m3 15 ppm 67 ppm oxygen O2 21 1 20 23 21 5 20 8 21 1 20 4 21 4 Oil quantity 0 5 mg m3 0 5 mg m3 0 5 mg m3 1 0 mg m3 0 003mg m3 0 1 mg m3 odoriferous aro matic substance Free free Free Free Free free Sufur dioxideSO2 0 1 ppm 1 ppm nitrous gases NO NO2 1 ppm 2 ppm Pressure dewpoint below inlet temperature Corresponding pressure dewpoint 50 C to 45 C at 7 bare All values r...

Page 52: ...odule valve membranes muffler and filter elements BPS MT 6 to BPS MT 7 48 months SKK6 K7 BP3 48 Reset module valve membranes solenoid coils check valves de misters perforated plates muffler and filter elements BPS MT 8 12 and 36 months SKK8 BP3 12 Reset module muffler and filter elements BPS MT 8 24 months SKK8 BP3 24 Reset module valve membranes muffler and filter elements BPS MT 8 48 months SKK8...

Page 53: ...EN User Manual Annex with technical documentation BSP MT 1 8 D3 51 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 54: ...EN User Manual Annex with technical documentation 52 BSP MT 1 8 D3 Regeneration in B1 and adsorption in B2 ...

Page 55: ...rated plate 100 Muffler 10 107 Demister left 130 152 Top plate 10 108 Demister right 130 153 Bottom plate 10 109 Left perforated plate 130 154 Seal 10 110 Conical pressure spring 130 155 Perforated plate 10 111 Right perforated plate 195 Oil indicator 50 Regeneration gas orifice plate Optional devices 60 Control unit 110 Start up device 70 Control system 701 Dewpoint sensing unit 75 Upstream filte...

Page 56: ...ions mm Weight kg A B C D E F BSP MT 1 1 4 530 400 216 376 101 101 16 5 BSP MT 2 1 4 530 575 216 551 101 101 21 5 BSP MT 3 1 4 530 825 216 801 101 101 29 0 BSP MT 4 1 4 530 1075 216 1051 101 101 36 0 BSP MT 6 1 2 730 1203 300 1097 132 132 75 0 BSP MT 7 1 2 730 1428 300 1322 132 132 85 0 BSP MT 8 3 4 730 1628 300 1522 132 132 97 0 ...

Page 57: ......

Page 58: ...ico MI Italy Sede Operativa Gas Separation and Filtration Division EMEA Strada Zona Industriale 4 35020 S Angelo di Piove PD Italy tel 39 049 971 2111 fax 39 049 9701911 Web site www parker com hzd e mail technical support hiross parker com A division of Parker Hannifin Corporation ...

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