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Identify and eliminate faults

WVM 45 -1450

Identify and eliminate faults

The following table provides information on what designatory abbreviations are to be used for

the various components. These designations are also found in the technical documentation.

Abbreviation

Component

Fittings, general

Butterfl y valve

Check valve

Cardan shaft

4/2-way tap cock

Dummy plug/fl ange

Sieve bottom/desiccant sieve/fl ow distributor

Silencer

Dessicant

Limit position monitor

Air heater

Moisture measurement/pressure dewpoint

Pressure measurement

Pressure gauge

Temperature measurement

TSH

Delimiter thermostat

Vacuum pump

Notes on error messages and errors

The error message from the dryer are displayed on the operating panel. The controller manual

provides appropriate information. You are given information on the possible causes for the

error and tips how to eliminate the error.

If the dryer is connected to a fault signalling 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 qualiﬁ ed technical

personnel! The electrical panel in particular must be opened and serviced by an

instructed trained electrician only.

Caution!

Arbitrary changes to the factory settings of the control programme may result

in damage to the dryer.

Summary of Contents for WVM Series

Page 1: ...to nella tua lingua Vedi le istruzioni dettagliate di questo manuale FR Avant l installation du produit utilisez le code QR ou visitez le site pour télécharger le manuel d utilisation complet dans votre langue Voir les instructions détaillées de ce manuel DE Verwenden Sie vor der Produktinstallation den QR Code oder besuchen Sie die Website um das vollständige Benutzerhandbuch in Ihrer Sprache her...

Page 2: ...il sito per scaricarti il manuale completo nella tua lingua Vedi le istruzioni dettagliate di questo manuale FR Avant l installation du produit utilisez le code QR ou visitez le site pour télécharger le manuel d utilisation complet dans votre langue Voir les instructions détaillées de ce manuel DE Verwenden Sie vor der Produktinstallation den QR Code oder besuchen Sie die Website um das vollständi...

Page 3: ... 26 Installation of pipelines 28 Connection of electrical components 29 Start up 30 Requirements for initial commissioning 30 Overview of the operating and display elements 30 Commissioning of the dryer 31 Preparation for commissioning 32 Monitoring dryer operation 35 Notes on specific operating situations 35 Shutdown and restart dryer 36 Emergency shutdown 36 Stopping the dryer 36 Depressurising ...

Page 4: ...EN Operating manual 4 WVM 45 1450 Notes on error messages and errors 48 Appendix Technical Documents 49 Technical data overview of standard dryers 50 Spare parts list 52 ...

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 compo nents 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 8 ...

Page 6: ...ts such as operating manuals for options or pertaining components must always be heeded They contain additional information e g regarding maintenance and are therefore necessary for safe operation of the plant Notes on upstream and downstream ﬁlters Upstream and downstream filters are not contained in the standard scope of delivery of the dryer For this reason the operator must install at least an...

Page 7: ...rovide you with hints and information on the safe and efﬁcient handling of machines and devices Warning These safety notes warn against damage to property and help you to avoid such 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 parti...

Page 8: ...operated by 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 informa tion and safety notes in these operating instructions when working with the dryer Signs and danger zones at the dryer Signs and instructions 1 2 1 Type plate 2 Vessel plate Please note the above p...

Page 9: ...ddenly released 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 flanged 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 slip...

Page 10: ...e 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 own safety when carrying out any work on the dryer comply with all applicable national safety regulations Personnel qualiﬁcation Only authorized and qualified specialist personnel may be tasked with the work ...

Page 11: ...st 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 can injure your eyes or skin Always wear eye and ear protection therefore when you are in the vicinity of the dryer Operate the dryer only within the permitted limits see type plate If the unit is operated under conditi...

Page 12: ...uent expulsion of the compressed air Never leave tools loose parts or cloths in at or on the dryer Following maintenance work always check all flange and bolt connections for leakage and secure seating 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 par...

Page 13: ...t view 1 2 3 4 5 6 7 8 9 10 1 Main outlet valve l 6 Control air filter and pressure reducer 2 Charge sleeve for desiccant 7 Dew point measuring chamber 3 Electrical panel with operating panel 8 Pressure build up valve 4 Pressure gauge Pressure transducer 9 Discharge sleeve for desiccant 5 Vessel 10 Main inlet valve ...

Page 14: ...ation air 2 Regenerating gas outlet temperature sensor 7 Heater electrical resistance 3 Regeneration air outlet 8 Expansion valve with silencer 4 Vacuum pump 9 Resistance thermometer for the control temperature of the regeneration air 5 Connector box of the heater electrical resistance with release button for the safety thermostat ...

Page 15: ... 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 vessels alternate between different operating modes Whilst in one ves sel 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...

Page 16: ...n the right vessel is released through the expansion valve until the ambient pressure is reached The escaping of the com pressed air is thereby audible at the silencer as a low hum Expansion phase Heating phase duration several hours A vacuum pump sucks ambient air through the heater to the vessel to be regenerated The air is thereby heated by the heater The warm air subsequently flows through the...

Page 17: ...ure build up line The vessel can now be switched from regeneration to absorption operation Pressure build up Stand by phase for dewpoint measurement option The regenerated vessel remains in the stand by phase as long as the pressure dewpoint 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 24 hours Switching...

Page 18: ...ted 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 opera tion because the following factors affect its function and service life Humidity from rain or other precipitation Corrosion due to high humidity or salt content in the ambient air Freezing of valves taps flaps and other components ...

Page 19: ... scope of delivery can also comprise supplementary documents such as data sheets or supplementary operating manuals Steam electric heater combination In this option the existing electric heater is supplemented by an additional steam heat ex changer This allows for three operating modes Pure steam operation Sufficient hot steam is available for regeneration The electric heater is not needed energy ...

Page 20: ...ally 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 transportation Please note therefore the following instructions as we...

Page 21: ...ure sufficiently effective regeneration and a suitable pressure dew point A higher ambient temperature or relative humidity must be specially considered when designing the dryer and recorded in the offer document if this proves to be unfeasible If the required cooling water is available you should implement the optional loop cooler Please also heed the appropriate notes in section Technical data V...

Page 22: ... dryer should be erected with sufficient clearance above to the sides and behind so that maintenance work can be carried out and the drying agent can be changed without hindrance see illustration P P P P P P Required clearances at the top and the sides of the unit minimum 1 m Lifting devices You should have lifting devices with an ade quate load capacity available for assembling and maintaining in...

Page 23: ...ckaging Attach suitable lifting gear to the lifting eyes on the vessels see Item 1 on the adjacent illustration Lifting eyes at vessel Note The vessels are ﬁlled with layers of various desiccants They must be transpor ted in an upright position in order to prevent the mixing of these desiccants as this could impair the operation of the dryer Risk of tilting The dryer should only be transported in ...

Page 24: ...se 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 Decommission dryer as described on page 36 Ensure that the inlet valve and the outlet valve installed on the site are closed and release all pressure from the dryer Make sure that existing steam valves with optional steam heat exchanger or cooling water valves w...

Page 25: ...and storage WVM 45 1450 25 Note To recommission the dryer after prolonged storage please proceed as descri bed for initial commissioning see page 31 Store drying agents Do not store drying agents in the open air Protect drying agents against humidity ...

Page 26: ...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 and exits All pipelines couplings and connections must have the correct diameter and be matched to the operating press...

Page 27: ... be installed in such a way that there is no risk of injury from hot regeneration air Rainguard when lines point upwards Rainguard when line exits to the side If both an inlet and an outlet line are installed ensure that the escaping hot regenera tion air is not again drawn into the inlet line The outlet opening of the outlet line should thus be positioned higher than the inlet opening If both an ...

Page 28: ...er to the compressed air system while heeding rated diameter and pressure The figure below shows a proper installation Compressed air system Item Component 1 1 Dryer 2 Humid air inlet 3 Compressed air inlet valve 4 Pre filter 5 Bypass line 6 Valve in bypass line 7 Bypass filter 8 Valve at outlet of by pass filter 9 Afterfilter 10 Compressed air outlet valve 11 Dry air outlet Example of a proper in...

Page 29: ... terminal strip the circuit diagram is attached inside the electrical panel 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 electrical panel base and terminal connections for power supply Connection of dryer with a remote alarm system There is an ex works option to connect the dryer to a remote alarm syst...

Page 30: ...yer body all connections are properly secured the electric connections are properly secured and in good condition the operator supplied components such as safety valves and other equipment holding pressure are not blocked by dirt or paint all components of the compressed air system that are under pressure valves hoses etc are free of wear or other defects sufficient amounts of required supply medi...

Page 31: ... 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 Operate the dryer only within the permitted limits Operation of the dryer under conditions for which it is not designed may lead to damage to persons and property On no account should the fact...

Page 32: ...e pressure increase at the vessel pressure gauge see page 13 In one of the vessels the pressure must be increased until it reaches the operating pressure Compressed air inlet to the dryer Avoid abrupt pressure drop Avoid abrupt pressure drops by all means Too fast a pressure drop or too high ﬂow rates can cause damage to the dryer For this reason make sure to open the pressure outlet valve only sl...

Page 33: ...e colour of the housing and extends over several cooling fins Wait until the vacuum pump is fully started Then stop the dryer The fan wheel continues rotating for a short period of time During this time the assistant must check whether the wheel rotates in the correct direction The vacuum pump direction is correct if the fan wheel rotates in the direction of the arrow Procedure if direction of rot...

Page 34: ...on see above Commissioning of dryer Set main switch to position I Start dryer see the operating manual for the controller The unit is now fully switched on provided that no error message is displaye 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 operat...

Page 35: ... This is the case 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 ...

Page 36: ... 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 28 Stop the dryer see the operating manual for the controller The dr...

Page 37: ... regenerated at the same time Depressurise the adsorbing vessel e g by opening the manual drain valve on the downstream filter Wait until the pressure on the vessel pressure gauge of the adsorbing vessel has dropped to 0 bar Using the vessel pressure gauge check whether both vessels have been depressurised For maintenance work wait until the dryer has cooled down Risk of injury from hot surfaces C...

Page 38: ...g manual for the controller If necessary slowly open the compressed air inlet and outlet valves installed by the operator The dryer is now ready for operation and continuous automatic cycle If compressed air system and dryer have not remained at operating pressure If disconnected reconnect the voltage supply of the dryer Pressurise and switch on the dryer as described in the section on page 31 The...

Page 39: ... all maintenance work only when the plant has been shut down and depressur ised Bolt connections must be undone with care Note entrap 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 welding work on a vessel or modify the same in any way Following ...

Page 40: ...ol air filter and clean or replace if necessary 42 Dewpoint trans mitter Renew 42 Vacuum pump Inspect bearing and replace if nec essary 44 Dessicant sieve Check Dessicant sieve for contami nation and clean if necessary 44 Desiccant Check desiccant for contamination and replace if necessary 44 Preliminary and afterfilter op tional Please refer to the manuals of the installed filters for details on ...

Page 41: ... for dam pressure if the dryer functions correctly the respective pressure gauge indicates 0 5 bar Then there is no dam pressure If the dam pressure is greater than 0 5 bar Depressurise the dryer and shut it down see page Depressurising and shutting down the dryer 37 Dam pressure can be caused by a blocked muffler a malfunction of the expansion valve a leaking pressure build up valve The respectiv...

Page 42: ...even cause the silencer to burst Risk posed by a blocked silencer Dangerous excess pressure may develop at blocked silencers causing the silencers to burst Flying debris could injure persons and damage property Silencer elements should therefore be checked annually and replaced if soiled Beware of sudden air blast Pressure suddenly escapes via the silencer during expansion A loud expansion noise o...

Page 43: ... This period depends however on the actual application and might 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 manufact...

Page 44: ...mplete 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 with national regulations a pressure vessel inspection may be prescribed to be carried out at regular intervals by an independent supervisory ofﬁce For an inspection of the pressure vessels the drying agent must be removed as d...

Page 45: ...5 years Under favourable conditions the desiccant might not have to be replaced at that stage and can be used for longer period see also page 21 However the service life depends greatly on the contamination of the compressed air or the effectiveness of the preliminary compressed air filter respectively and the contamination of the ambient air at the site Oil dust and dirt particles tend to deposit...

Page 46: ...ht be contami nated with pollutants Please take this into account when disposing of the desiccant 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 dumpi...

Page 47: ...e sure to heed the next step Use a funnel if neces sary Removing plug from ﬁller sleeve 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 the dryer if no other maintenance work is required Operate the dryer for two cycles then shut it down again Replace silencer as described on page 42...

Page 48: ...iter thermostat V Vacuum pump Notes on error messages and errors The error message from the dryer are displayed on the operating panel The controller manual provides appropriate information You are given information on the possible causes for the error and tips how to eliminate the error If the dryer is connected to a fault signalling system all error messages are transmitted through the potential...

Page 49: ...450 49 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 Declaration of Conformity ...

Page 50: ...WVM 60 610 9 5 800 218 210 25 WVM 80 800 9 5 900 276 210 25 WVM 125 1170 14 2 1350 410 300 25 WVM 155 1470 19 1460 526 375 25 WVM 210 2050 27 5 1870 716 550 25 WVM 310 3050 37 5 2610 1058 750 25 WVM 370 3700 43 5 2900 1276 900 25 WVM 520 5050 73 4275 1762 1460 25 WVM 615 6050 73 4735 2090 1460 25 WVM 750 7300 86 5380 2540 1800 25 WVM 800 25 WVM 1080 25 WVM 1230 25 WVM 1450 25 relative to 1 bar abs...

Page 51: ... 45 WVM 1450 Fluid class according to PED 2 Supply voltage see type plate Protection class IP54 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 Max dust contents of the regeneration air mg m3 50 Noise level 3 dB A related to free...

Page 52: ...SKW45 W80 VM5 E 48 WVM 45 80 48 month Control air filter ele ment pneumatic block expansion valve V5 pressure build up valve V4 maintenance parts for the regeneration gas flap V3 check valve RV SKW125 W210 VM5 E 48 WVM 125 210 48 month SKW310 W370 VM5 E 48 WVM 310 370 48 month SKW520 W750 VM5 E 48 WVM 520 750 48 month SKW800 W1080 VM5 48 WVM 800 1080 48 month SKW1230 W1450 VM5 48 WVM 1230 1450 48 ...

Page 53: ...kets DN250 SDD 25 AL WVM 45 370 1 Silencer SDD 25 AL WVM 520 1080 2 Silencers SDD 40 AL WVM 1230 1450 6 Silencers ZHM100 450 WVM 45 1450 1 Dewpoint sensor RKSCD F50 16 VA WVM 45 80 1 flow distributors RKSCD F80 16 VA WVM 125 210 1 flow distributors RKSCD F100 16 VA WVM 310 370 1 flow distributors RKSCD F150 16 VA WVM 520 750 1 flow distributors RKSCD F200 16 VA WVM 800 1080 1 flow distributors RKS...

Page 54: ...no WVM 45 WVM45DESMIX WVM 520 WVM520DESMIX WVM 60 WVM60DESMIX WVM 615 WVM615DESMIX WVM 80 WVM80DESMIX WVM 750 WVM750DESMIX WVM 125 WVM125DESMIX WVM 800 WVM800DESMIX WVM 155 WVM155DESMIX WVM 1080 WVM1080DESMIX WVM 210 WVM210DESMIX WVM 1230 WVM1230DESMIX WVM 310 WVM310DESMIX WVM 1450 WVM1450DESMIX WVM 370 WVM370DESMIX ...

Page 55: ......

Page 56: ...aboto 1 Palazzina A 20094 Corsico 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 A division of Parker Hanniﬁn Corporation ...

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