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WVM_BASIS_EN_03—07/2016

Appendix: Technical Documents

The appendix of this operating manual contains the following technical
documents and data::



Technical data



List of service and desiccant kits



Process diagram



Pneumatic diagram of the control air unit



Dimension drawing



Electrical diagrams

Summary of Contents for WVM 1080

Page 1: ...Adsorption dryer WVM 40 1450 Operating manual Revision 03 07 2016 EN Cod 398H271785 ...

Page 2: ...by Lloyd s Register Quality Assurance GmbH Hamburg is available The quality assurance system is monitored by the service provider stated below Lloyd s Register Quality Assurance GmbH Identification number 0525 Am Sandtorkai 41 D 20457 Hamburg The assembly consists of pressure appliances according to the classification list attached to the technical documentation provided by the manufacturer Pressu...

Page 3: ...WVM 40 10 DN40 Art 4 3 Art 4 3 WVM 50 10 DN40 Art 4 3 Art 4 3 WVM 65 10 DN50 Art 4 3 Art 4 3 WVM 85 10 DN50 Art 4 3 Art 4 3 WVM 120 10 DN80 Art 4 3 Art 4 3 WVM 150 10 DN80 Art 4 3 Art 4 3 WVM 200 10 DN80 Art 4 3 Art 4 3 WVM 235 10 DN100 Art 4 3 Art 4 3 WVM 300 10 DN100 Art 4 3 Art 4 3 WVM 355 10 DN100 Art 4 3 Art 4 3 WVM 410 10 DN150 I A WVM 475 10 DN150 I A WVM 525 10 DN150 I A WVM 620 10 DN150 I...

Page 4: ... 2 16 57 II H WVM 525 FL30 2 16 57 II H WVM 620 FL30 2 16 57 II H WVM 710 FL40 2 16 93 III H WVM 800 FL60 2 16 165 III H WVM 920 FL60 2 16 165 III H WVM 1080 FL60 2 16 165 III H WVM 1230 FL100 2 16 280 III H WVM 1450 FL100 2 16 280 III H The following standards technical specifications were used harmonized standards DIN EN ISO 12100 2011 03 DIN EN 61000 6 1 DIN EN 61000 6 3 DIN EN 60204 The follow...

Page 5: ...r is obliged to enter missing unit data in the above table regularly update the unit data The above device specifications are necessary to quickly identify the dryer and its components and facilitate servicing Other important data regarding the dryer such as permitted operation pressure and electrical power are found on the type plate For location of the type plate see page 11 ...

Page 6: ...sport damage occurring 25 Transporting dryer to its location of installation 26 Storage 29 Installation 31 Requirements for installation 31 Installation of pipelines 33 Connection of electrical components 34 Start up 35 Requirements for initial commissioning 35 Overview of the operating and display elements 36 Commissioning of the dryer 36 Preparation for commissioning 37 Monitoring dryer operatio...

Page 7: ... maintenance work 48 Maintenance work to be completed every 12 months 49 Maintenance work to be completed every 24 months 51 Maintenance work to be completed every 48 months 51 Identify and eliminate faults 55 Notes on error messages and errors 56 Index 57 Appendix Technical Documents 60 Technical data overview of standard dryers 61 Spare parts list 63 ...

Page 8: ...eater 1 Vacuum pump 1 Switch cabinet including control system 1 Key for switch cabinet Piping and silencer Supplementary documents standard scope Operating manual i e this document Operating manual of pertaining controller Operating manual of fitted vacuum pump Technical documents see appendix Dimensional drawing Process diagram Pneumatic diagram of the control air unit Electrical diagrams ...

Page 9: ...ng by the manufacturer for purposes other than those specified in these operating instructions or contractually agreed If preset parameters e g on the control system etc are changed without prior approval and confirmation in writing by the manufacturer If the dryer is transported or stored incorrectly If the dryer is sited and installed incorrectly If the dryer is repaired or maintained incorrectl...

Page 10: ...id serious or life threatening 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 specialist personnel e g fitters or electricians Operating instructions handling These operating instructions must be continuously available at the site w...

Page 11: ... non qualified personnel not used within its intended design specifications is repaired or maintained incorrectly Note For your own safety and to prevent machine damage please note the information and safety notes in these operating instructions when working with the dryer Signs and danger zones at the dryer Signs and instructions 1 Type plate 2 Vessel plate Please note the above plates and instru...

Page 12: ...leased through expansion and relief valves can lead to serious injury Hot surfaces During operation certain surfaces of the dryer reach temperatures above 120 C At insulated dryers screw connections might protrude from the insulation Voltage Various parts of the dryer are live These components may only be connected opened and serviced by authorised technical personnel Risk of slipping During the e...

Page 13: ...tructions on page22 must be complied with The dryer may be operated only in accordance with the data on the type plate and in accordance with the contractual conditions Suspected misuse The dryer must not be misused as a climbing aid Pipes valves and similar fittings have not been designed for such loads They could fracture tear off or become damaged in another way General safety notes For your ow...

Page 14: ...ly escaping gas While the unit is under pressure never remove any components or otherwise interfere with the dryer Suddenly escaping gases can lead to serious injury Prior to any work release all pressure from the unit Execute the stipulated tests and checks On no account should the factory settings of the control programme be altered without consulting the manufacturer Prior to commissioning make...

Page 15: ... or manipulate the same in any way as long as the unit is pressurised Suddenly escaping compressed air might cause serious injuries Prior to any work release all pressure from the unit Carry out all maintenance work only when the plant has been shut down and depressurised Do not modify the factory settings of the control system in any way without prior consultation with the manufacturer Bolt conne...

Page 16: ...e dryer Notes on the disposal of used desiccant As the used desiccant is contaminated with various substances its properties differ from those of new desiccant For this reason the manufacturer or supplier of desiccant cannot give any information on the used product Deliver used desiccant to a controlled dumping while heeding local official regulations Waste codes New product 060899 European waste ...

Page 17: ...ressure transducer 2 Control air filter and pressure reducer 8 Vessel 3 Filler sleeve for desiccant 9 Dew point measuring chamber 4 Switch cabinet with operating panel 10 Pressure build up valve 5 Vessel pressure gauge 11 Discharge sleeve for desiccant 6 Stop valve for vessel pressure gauge 12 Main inlet valve ...

Page 18: ...safety thermostat 1 Resistance thermometer for regeneration gas final temperature 6 Suction opening for regeneration gas 2 Vacuum pump 7 Heater 3 Lashing eye 8 Expansion valve with silencer 4 Regeneration gas outlet of the vacuum pump 9 Resistance thermometer for the control temperature of the regeneration gas ...

Page 19: ...ate between different operating modes Whilst in one vessel compressed air is de humidified adsorption in the other vessel the humid drying agent is prepared for another charge regeneration These two states which run in parallel during compressed air preparation are described below Adsorption The humid air is supplied through a compressor and the inlet valve of the dryer The compressed air is then ...

Page 20: ... humid desiccant removing the water contained in the agent which is fed out in the form of steam together with the air through the piping This can be either a steam or an electrical heater but also a combination of both heater types Heating phase Cooling phase duration approx one hour The hot dried desiccant must now be cooled and is then ready for absorption The heater is switched off so that the...

Page 21: ... is better than the set switch over value Switch over only occurs when the switch over value is reached or after a maximum cycle duration of 48 hours Pressure build up Switching over In the fixed cycle A switch over between the vessels occurs after 6 hours After switching over the process described above is repeated whereby adsorption and regeneration is performed in the other vessel respectively ...

Page 22: ...yer is subject to frequent change of air wind draught etc at the installation site The following components should be insulated The vessels of the dryer The heater Adaptation for outdoor installation The standard dryer is designed for installation in confined places and not for outdoor operation because the following factors affect its function and service life Humidity from rain or other precipit...

Page 23: ... cooled heat exchanger The operator must provide a cooling water connection and appropriate cooling water valves Note The heat exchanger choice depends on the quality of the cooling water For this purpose you should contact the dryer manufacturer beforehand Steam heat exchanger To heat the regeneration air a steam heat exchanger can also be used as an alternative to the standard electric heater Th...

Page 24: ...egrade the paint quality Diminutive amounts of foreign particles containing oil and grease or solvents in particular silicones can result in craters discolourations swells or other paint impurities Paint compatible dryers are equipped with seals and filters that are absolutely free of grease and silicone and thus ensure a high compressed air quality for painting ...

Page 25: ...ecure the unit during transport Only use suitable and technically perfect lifting gear with a sufficient carrying capacity During transportation the dryer must be carefully secured against falling over Remove the transport packaging at the installation site only and dispose of it in a proper manner The manufacturer will not be liable for any damage caused by incorrect storage or incorrect transpor...

Page 26: ...C Implement an additional heating if necessary see page 22 In this context please also heed the information regarding insulation on the following page If possible the ambient temperature should not exceed 30 C and the relative humidity not exceed 60 in order to ensure sufficiently effective regeneration and a suitable pressure dew point A higher ambient temperature or relative humidity must be spe...

Page 27: ...ree from vibration It must be capable of bearing the dryer s weight You will find the dryer s weight in the technical data in the appendix Please add another 10 to the dryer s weight in your calculations This will ensure the moisture trapped by the desiccant later is accounted for Lateral clearances The dryer should be erected with sufficient clearance above to the sides and behind so that mainten...

Page 28: ... the dryer Remove packaging Attach suitable lifting gear to the lifting eyes on the vessels see Item 1 on the adjacent illustration The lashing eyes Item 2 are intended to secure the unit during transport and are not suited to lift the dryer Lifting and lashing eyes at vessel Note The vessels are filled with layers of various desiccants They should therefore be transported in an upright position i...

Page 29: ... If the dryer is not to be installed immediately after delivery it must be stored at a suitable location that fulfils the following requirements The dryer must not be stored outdoors The storage room has to be dry The storage room must be free of dust otherwise cover dryer with a tarpaulin The ambient temperature in the storage room may not be below 1 ºC To storage the dryer proceed as follows Dec...

Page 30: ...neration gas at the heater regeneration gas outlet at the vacuum pump cooling water intake and exit with optional loop regeneration hot steam intake with optional steam heat exchanger Cover the dryer with a tarpaulin if possible The dryer is not suitably prepared for prolonged storage Note To recommission the dryer after prolonged storage please proceed as described for initial commissioning see p...

Page 31: ...of the compressed gas increases Warning Safe dryer operation cannot be ensured if the requirements described here are not met This can also degrade the dryer s function For proper installation the operator must provide the following Connections and lines must be provided for compressed air intake and exit The operator must install shut off valves for compressed air and supply media at the intakes ...

Page 32: ... see figure If necessary the exit point of lines should be barred with grilles in order to prevent foreign objects or animals from entering the dryer Rainguard when lines point upwards The outlet line must be installed in such a way that there is no risk of injury from hot regeneration gas Rainguard when line exits to the side If both an inlet and an outlet line are installed ensure that the escap...

Page 33: ...pressed air system while heeding rated diameter and pressure The figure below shows a proper installation Compressed air system Item Component 1 Dryer 2 Humid air inlet 3 Compressed air inlet valve 4 Preliminary filter 5 Bypass line 6 Valve in bypass line 7 Bypass filter 8 Valve at outlet of bypass filter 9 Afterfilter 10 Compressed air outlet valve 11 Dry air outlet Example of a proper installati...

Page 34: ... strip the circuit diagram is attached inside the switch cabinet Connect the dryer s earth cable to the PE terminal Protect the dryer against short circuits by installing fuses to all phases Cable recess in switch cabinet base and terminal connections for power supply Connection of dryer to the fault signalling system There is an ex works option to connect the dryer to a fault signalling system Wi...

Page 35: ...valves are closed The dryer has been properly set up wired and connected The compressors are ready for operation At the outlet side a compressed air consumer is present i e compressed air can flow through the dryer Operators for the components are available Inspection to be carried out prior to commissioning Ensure that all pipe cable and screw connections have been retightened none of the lines a...

Page 36: ...e pressure build up phase the indication on the pressure gauge should again rise to operating overpressure level both vessel gauges indicate the same operating pressure Commissioning of the dryer Risk of injury from escaping hot regeneration gas Hot humid air might escape from the the regeneration gas outlet at the vacuum pump Therefore keep clear of the blow off outlet during operation of the uni...

Page 37: ...relevant malfunctions are observed immediately switch off the dryer The dryer may only be restarted after the malfunction has been eliminated Preparation for commissioning For the commissioning of the dryer follow the instructions as set out below Pressurisation of unit Check the stop valves at the vessel pressure gauges to ensure that they are opened see page 17 Check the valves at the inlet and ...

Page 38: ...mp Note For the next steps you will need an assistant Ensure that the main switch is in position 0 Open switch cabinet door Remove fuses of the heater for location of the fuses see electrical diagram This is necessary to ensure that the heater is not inadvertently switched on and thereby damaged Set main switch to position I Start the dryer see the operating manual for the controller After the exp...

Page 39: ...nect dryer from power supply Caution Risk of electrocution Prior to adjusting direction of rotation disconnect the unit from the power supply Otherwise there is a risk of serious injury from live cables and components Exchange cables L1 and L2 at the terminals Check direction of rotation of the vacuum pump as described on page 38 Insert heater fuses Proceed with starting the dryer Note Checking ca...

Page 40: ...ssage is displayed How to proceed if an error message is displayed Warning In an emergency and in the event of safety related faults e g a sudden escape of compressed air defective components take the plant out of operation immediately as described on page 42 Stop the dryer Set main switch to position 0 Eliminate the error heed the malfunction table in the controller manual Repeat commissioning ...

Page 41: ... if the operating parameters match or slightly fall below the specified values Dryer performance can degrade if the dryer often operates at part load Dryer performance increases as soon as the load is raised Part load operation can occur due to too low flow rates 30 of rated value by operating the plant with predried air i e the relative humidity of supply compressed air is below 30 RH due to an o...

Page 42: ... compressed air outlet valve The dryer is now shut down Restart the dryer only after having eliminated all errors Stopping the dryer Please proceed as follows if no compressed air is needed at night or at weekends When the compressor remains on Close compressed air outlet valve Leave the customer s intake valve for compressed air open see installation example on page 33 Stop the dryer see the oper...

Page 43: ...g water and steam The dryer is separated from the compressed air network and can be shut off now Set the master switch to 0 Note Do not let any compressed air flow through the dryer after it has been shut down The desiccant in one of the vessels will otherwise continue to be loaded with moisture without the other vessel being regenerated at the same time Depressurise the adsorbing vessel e g by op...

Page 44: ...er voltage free Secure the electrical supply cable to the dryer against switch on Restart Restarting dryer compressed air system and dryer under operating pressure If the dryer was shut off switch on the dryer by setting the main switch to I Otherwise Start the dryer see the operating manual for the controller If necessary slowly open the compressed air inlet and outlet valves installed by the ope...

Page 45: ...y when the plant has been shut down and depressurised 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 consultation with the manufacturer Never carry out welding work on a vessel or modify the same in any way Following maintenance work always check ...

Page 46: ...an or replace if necessary 49 Dewpoint transmitter Renew 50 Vacuum pump Inspect bearing and replace if necessary 51 Dust filter Check dust filter for contamination and clean if necessary 52 Desiccant Check desiccant for contamination and replace if necessary 52 Preliminary and afterfilter optional Please refer to the manuals of the installed filters for details on the maintenance tasks to perform ...

Page 47: ...controller manual Check whether compressed air has reached the set pressure dewpoint In units equipped with dewpoint dependent control optional the dewpoint is shown at the display Check dam pressure If following depressurisation of a vessel e g after the expansion phase the overpressure has not decreased to 0 5 bar then there is a residual pressure designated as dam pressure in the vessel Check f...

Page 48: ... the ambient air is heavily soiled Please note the respective hints in sections Options Six monthly maintenance work Check the screw and clamp connections After six months at the latest all the switch cabinet s screw and clamp connections must be checked to ensure that they are secure The maintenance interval should be reduced in the case of a vibrating substrate or a vibrating compressor feed lin...

Page 49: ...oise occurs which may damage your hearing Particles carried along with the air flow can damage your eyes or skin For this reason you must always wear eye and hearing protection when you are near the dryer De pressurize the dryer and shut it down see page 42 Unscrew the silencer as shown in the illustration to the right Fit new silencer in place and screw tight Unscrewing the silencer Restart the d...

Page 50: ...t thus be extended accordingly 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 operation to a minimum we recommend that you contact the manufacturer well in advance for contact details see page 8 and order a...

Page 51: ...nicians Alternatively ask us for a training session for the servicing of the vacuum pump You will find the telephone number of our customer services department on page 8 Maintenance work to be completed every 48 months To complete the following maintenance tasks you must dismantle the pipe bridges and the vessels We therefore recommend that you carry out these tasks together Note In accordance wit...

Page 52: ...ieves with compressed air or a suitable tool e g soft wire brush Renew gaskets Disassembling of desiccant sieve Mount cleaned desiccant sieves mount base gasket insert desiccant sieve mount top gasket Repeat the process on the second vessel Re mount and secure the upper arch pipe system If no other maintenance work is required Restart dryer see page 44 Check that the connection is leak tight Renew...

Page 53: ...at the sleeve This procedure also cleans the screen base and removes any residual material and deposits Equip the sleeve plug with a non locking thread seal and screw in Check thread seal and replace if necessary Removing plug from filler sleeve Repeat the procedure for the second vessel Caution If the dryer has been improperly operated the desiccant might be contaminated with pollutants Please ta...

Page 54: ...e 52 Ensure that discharge sleeve is closed Unscrew the plug of the filling hole with a suitable tool see illustration Slowly fill in new desiccant and make sure to heed the next step Use a funnel if necessary Unscrew the sleeve plug Make sure to compact the filling in the vessel Equip the sleeve plug with a non locking thread seal and screw in Repeat the procedure for the second vessel Restart th...

Page 55: ...chnical documentation Abbreviation Component AA Fittings general AK Butterfly valve AR Check valve AU Cardan shaft AV 4 2 way tap cock BB Dummy plug flange BF Sieve bottom desiccant sieve flow distributor BS Silencer BT Dessicant GS Limit position monitor H Air heater MT Moisture measurement pressure dewpoint PT Pressure measurement PI Pressure gauge TT Temperature measurement TSH Delimiter thermo...

Page 56: ...ling system all error messages are transmitted through the potential free busbar connection to the operator s control room Also heed the following notes when working at the electric system Electric current warning Work on the electrical system must only be carried out by qualified technical personnel The electropneumatic switch cabinet in particular must be opened and serviced by an instructed tra...

Page 57: ... 22 Direction of rotation of vacuum pump 38 correct 39 incorrect 39 Discharge sleeve 17 Documents technical 60 Drucktaupunktsensor Wartungsintervall 46 Dryer maintenance interval 46 Drying agent charging 22 storage 30 Dust filter maintenance interval 46 Dust formation 14 53 Dust mask 14 E Emptying hole 54 Error tracking procedure 56 Example of installation 33 Expansion valve 18 Expansion principle...

Page 58: ...t 24 Parameters preset 9 Personnel qualification 9 11 13 47 Pressure build up valve 17 Pressure build up principle 21 Pressure drop abrupt 38 Pressure drop abrupt 38 Pressure increase abrupt 37 Pressure transducer 17 pressure vessel 15 45 R Regeneration principle 19 Regulations for accident prevention 25 Replacement parts 15 45 Resistance thermometer 18 Risk information maintenance 46 Risk of crus...

Page 59: ...3 07 2016 59 Use safe 9 V Vacuum pump maintenance interval 46 Vacuum pump 18 Vacuum pump 20 Variable cycle 22 Vessel pressure gauge 17 Visual inspection 47 Voltage 12 electrical 34 W Warranty 9 Weather protection 26 ...

Page 60: ... Documents The appendix of this operating manual contains the following technical documents and data Technical data List of service and desiccant kits Process diagram Pneumatic diagram of the control air unit Dimension drawing Electrical diagrams ...

Page 61: ...300 25 WVM 150 1500 1350 18 20 470 375 25 WVM 200 1980 1782 23 70 656 550 25 WVM 235 2350 2115 36 70 827 750 25 WVM 300 2930 2637 36 70 910 750 25 WVM 355 3550 3195 43 70 1178 900 25 WVM 410 4100 3690 43 70 1348 900 25 WVM 475 4740 4266 48 70 1652 1150 25 WVM 525 5250 4725 63 20 1718 1460 25 WVM 620 6210 5589 73 20 2153 1460 25 WVM 710 7100 6390 84 20 2425 1800 25 WVM 800 8000 7200 89 20 2967 1800...

Page 62: ...lations apply accordingly Typ WVM 40 WVM 1450 Fluid class according to PED 2 Supply voltage see type plate Protection class IP 54 min max Operating overpressure bar see type plate Ambient temperature C 1 50 Max intake temperature for regeneration air C please heed the table below that relates the moisture of the intake air to the temperature 1 40 ax dust contents of the regeneration air mg m 50 No...

Page 63: ... element magnet valve wear parts kit for the expansion valve V5 wear parts kit for the pressure build up valve V4 wear parts kit for the regeneration gas flap V3 check valve RV SKW65 W85 VM4 48 WVM 65 85 48 months SKW120 W200 VM4 48 WVM 120 200 48 months SKW235 W355 VM4 48 WVM 235 355 48 months SKW410 W710 VM4 48 WVM 410 710 48 months SKW800 W1080 VM4 48 WVM 800 1080 48 months SKW1230 W1450 VM4 48...

Page 64: ...asketsDN200 WVM 1230 1450 GasKIT250W 1 Flat gasketsDN250 WVM 40 355 SDD 25 AL 1 Silencers WVM 410 1080 SDD 25 AL 2 Silencers WVM 1230 1450 SDD 40 AL 6 Silencers WVM 40 1450 ZHM100 450 1 dewpoint sensor WVM 40 50 RKSCD F40 16 VA 1 flow distributors WVM 65 80 RKSCD F50 16 VA 1 flow distributors WVM 120 200 RKSCD F80 16 VA 1 flow distributors WVM 235 355 RKSCD F100 16 VA 1 flow distributors WVM 410 7...

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