Sullair SAR 180 Maintenance Manual Download Page 28

Page: 28 / 34

8.1 - POOR DEWPOINT

Page 28 of 34

VISUAL

INDICATION

Low reading on
hygrometer

Moisture downstream

Low dewpoint

POSSIBLE CAUSE

Faulty sensor

No flow rate across
sensor

Insuficient purge air

Entrained water

Low inlet pressure

High inlet temperature

Overflow of dryer

Failure to switch, all
gauges showing line
pressure

High pressure drop
across dust filter

CHECK

Check by using other
sensor

Flow at exhaust from
sensor block

Check using rotometer

Check all drains

Gauges and dryer
sizing

Using temperature
gauge

Flow rate through
dryer and dryer sizing.

Cam timer rotation.

Desiccant attrition.

REMEDY

Change sensor

Adjust flow restrictor to
within spec.

Adjust if necessary

Repair if necessary

Resize compressor or
reduce air demand

Check compressor after
cooler

Adjust compressor
output, resize, Fit 100%
flow control devices
(FCD)

Check electric cam
motor is turning, Check
electric supply
Check fuses (pneumatic)

Change desiccant.

Summary of Contents for SAR 180

Page 1: ...MODELS SAR 180 to SAR 900 DESICCANT DRYERS MAINTENANCE MANUAL DATE 23mar2000 REVISION 1 ...

Page 2: ...uring that a high performance is achieved Serial numbers and customer order numbers should be referred to in any communication Serial numbers can be found on the identification plate on the left hand side of the instrumentation shroud The figure number and the appropriate diagram in this manual and the item number shown in circle will also assist in part identification Any warranty will be invalid...

Page 3: ...r on light is illuminated SHR versions only Monthly As above and include 1 Ensure cam timer motor rotates to specification 2 Ensure all manifold valve housing and end plate gaskets do not leak 3 Check all control valves pipe and fittings within instrumentation shroud for air leaks 4 Check interface operation green pneumatic indicator will show during operation ...

Page 4: ... A2 A3 A4 A5 A6 A7 A8 Description Inlet Valve Assembly Manifolds Exhaust Valve Assembly Column Assemblies Outlet Valve Assembly Control Instrumentation Piping Wiring Diagrams Fault Finding Guide Page 5 8 14 16 19 21 26 32 MAINTENANCE ...

Page 5: ...Page 5 of 34 SECTION A1 INLET VALVE ASSEMBLY A1 1 A1 2 A1 3 Inlet Head Removal Inlet Valve Disc Removal Cylinder Piston Seal Renewal ...

Page 6: ...ke plate before re fitting A1 3 Cylinder Piston Seal Renewal Remove 4 allen screws from cylinder body secure piston across flats and unscrew valve stem Remove circlip from cylinder body and pull out piston New seals should be fitted using silicon free grease press out retaining cover nose seal and renew For re assembly follow reverse procedure always fitting new moulded gaskets and O ring on cente...

Page 7: ...7 A2 8 A2 9 Upper Manifold Removal SAR Quick Re Pressurisation Valve Removal SAR Purge Plate Removal Purge Adjustment Controller Box Removal Lower Manifold Removal SAR Changeover Valve Maintenance Bolt Torque Sequence SAR Bolt Torque Sequences Inlet Outlet Exhaust Valve Assemblies ...

Page 8: ...ng eye bolts provided A2 2 Quick Re pressurisation Valve Removal SAR The Q R V can be removed without removing the end plate by removing the four retaining bolts To service the valve remove the end cap and withdraw the piston clean piston and refit Lubrication is not recomended A2 3 Purge Plate Removal Where Applicable Remove outlet housing as shown in Section A5 This will give access to 2 Hex hea...

Page 9: ...ever allow the float of the flow meter to go off the top of the scale and never pressurise the flow meter Using the brass purge plug adjust the purge flow to the correct flow rate for the dryer this must be carried out with the dryer at its MINIMUM operating pressure On certain dryers there will be two purge plugs on these dryers it is recommended that the plug nearest the inlet and outlet be full...

Page 10: ...t the dryer completely Remove the nylon pipes from the changeover valve and slacken bolts in the reverse order of torque sequence shown and lift manifold clear A2 8 Changeover Valve Maintenance Remove nylon pipes 2 allen screws and detatch from dryer foot To service unit remove end cap and withdraw spindle lubricate and re fit ensuring seals and O rings are in good condition For re assembly follow...

Page 11: ...Page 11 of 34 MANIFOLDS Bolt Torque Sequence Note Tighten the bolts in the numerical order shown always starting with the middle column working outwards TORQUE to 25lbs ft A2 9 SAR ...

Page 12: ...34 A 2 11 INLET OUTLET EXHAUST VALVE Bolt Torque Sequence When removing or assembling the INLET VALVE OUTLET VALVE or EXHAUST VALVE housings always loosen and tighten in the sequence shown above TORQUE TO 25lbs ft ...

Page 13: ...Page 13 of 34 SECTION A3 EXHAUST VALVE ASSEMBLY A3 1 A3 2 A3 3 Exhaust Valve Removal Exhaust Valve Disc Removal Cylinder Piston Seal Renewal ...

Page 14: ... Renewal Remove 4 cap screws from cylinder body secure piston across flats and unscrew valve stem Remove circlip from cylinder body and pull out piston New seals should be fitted using silicon grease press out retaining cover nose seal and renew A3 4 Exhaust Element Replacement Unscrew element and replace ELEMENTS ARE NOT REUSABLE Ensure o ring is firmly seated in groove and greased with silicone ...

Page 15: ...Page 15 of 34 SECTION A4 COLUMN ASSEMBLY A4 1 A4 2 Column Desiccant Removal Desiccant Replacement ...

Page 16: ...an then be removed and the column lifted clear A4 2 Desiccant Replacement Ensure columns are free from dust and that the lower manifold gasket is in good condition Refilling can now take place In order to maintain dryer performance the columns must be refilled using a snow storm filling device which will achieve maximum packing density The best results are obtained by using a smooth and continuous...

Page 17: ...f desiccant material Sullair suggests a performance life of 10 000 30 000 hours however many factors can influence this nominal figure which should only be used as a guide Accurate dewpoint monitoring with a hygrometer is the only true indication of the desiccant condition consult Sullair The upper manifold can be replaced as described in section A2 ...

Page 18: ...Page 18 of 34 SECTION A5 OUTLET VALVE ASSEMBLY A5 1 A5 2 Outlet Housing Removal Outlet Valve Disc Removal ...

Page 19: ...are when removing the valve strike plate A5 2 Outlet valve disc removal Remove valve and spring from guide secure valve stem and unscrew retaining nut Inspect strike plate before re fitting For re assembly follow reverse procedure Always fitting new graphite gaskets seals and o ring on centre retaining bolt Page 19 of 34 ...

Page 20: ... INSTRUMENTATION A6 1 A6 2 A6 3 A6 4 A6 5 A6 6 A6 7 A6 8 Control Shroud Removal Pressure Gauge removal Moisture Indicator removal Cam Timer Removal SAR Pilot Valve Removal Cam Motor Gearbox Removal Contactor Removal Interface Removal ...

Page 21: ...rear of the unit A6 4 Cam Timer Removal SAR Isolate electrical supply and disconnect cable Remove nylon tubes from pilot valves and interface Remove front cover this will give access to 2 mounting screws Cam timer can now be lifted free OPERATION The operation cycle is as follows Side A Purge 100 seconds Side B Drying 120 sec Repressurisation 20 seconds Side B Purge 100 seconds Side A Drying 120 s...

Page 22: ...Page 22 of 34 CONTROL INSTRUMENTATION A6 8 Interface Removal Disconnect the nylon pipe and wiring Remove the interface fron the DIN rail by gently pulling forward from the top Fig B Fig A Fig B ...

Page 23: ...Page 23 of 34 SECTION A7 Piping Wiring Schematics A7 1 A7 2 A7 3 SAR Electric Piping Schematic SAR Pneumatic Piping Schematic SAR Electric Wiring Diagram ...

Page 24: ...7 2 SAR ELECTRIC PIPING SCHEMATIC Page 24 of 34 ...

Page 25: ...7 3 SAR PNEUMATIC PIPING SCHEMATIC Page 25 of 34 ...

Page 26: ...7 4 SAR ELECTRIC WIRING DIAGRAM Page 26 of 34 ...

Page 27: ...Page 27 of 34 SECTION A8 FAULT FINDING GUIDE A8 1 A8 2 A8 3 A8 4 POOR DEWPOINT FAILURE TO DEPRESSURISE FAILURE TO REPRESSURISE GENERAL ...

Page 28: ... Check by using other sensor Flow at exhaust from sensor block Check using rotometer Check all drains Gauges and dryer sizing Using temperature gauge Flow rate through dryer and dryer sizing Cam timer rotation Desiccant attrition REMEDY Change sensor Adjust flow restrictor to within spec Adjust if necessary Repair if necessary Resize compressor or reduce air demand Check compressor after cooler Ad...

Page 29: ...t Temperature Air flow demand to high Contaminated desiccant Faulty cycle operation REMEDY Ascertain reason for contamination Change desiccant Check dryer operation Adjust where necessary Check air flow at moisture indicator Change indicator paper Chech for correct purge rate reset if necessary Check pre fliters drains Check inlet pressure Check inlet Temperature Check for peak demand exessive air...

Page 30: ...oming supply Check free movement of timer Check fuse Check using pressure gauge at cylinder Remove and check operation manually Remove non pressurised side tube check for air leak from fittings Check function by bypassing Check for air leak at exhaust valve Exhaust valve failure to open Check operation and leaks on changeover valve REMEDY Replace fuse check wiring Replace motor gearbox Replace fus...

Page 31: ...lve stems due to desiccant dust Weak signal to operate inlet valves Damaged O ring on spool in changeover valve damaged seal on inlet cylinder No signal to open exhaust cylinders cam timer not rotating Faulty seals on cylinder Faulty NOT logic REMEDY Check power supply Clean and renew where necessary Check desiccant condition Check for air leaks on valve fittings Replace if necessary Replace chang...

Page 32: ...maged valve disc Sticking valve stem Damaged guide bush Broken or damaged exhaust valve disc Exhaust valve unable to close Cam timer rotation Electrical supply Damaged seals o rings gasket failure Damaged pipe tube connections Both inlet valves closed REMEDY Check control signal from logic element black control pipe If OK change valve If no signal change logic Check and adjust where necessary Chec...

Page 33: ...essure drop across dryer package Excessive purge CHECK Element media blocked up with water or desiccant Air inlet and compressor discharge Excessive outlet flow Blocked pre filters Excessive outlet flow Purge rate to high REMEDY Replace elements Check dust filter for signs of desiccant attrition Check autodrains on pre filters As above If excessive oil usage desiccant change may be required Check ...

Page 34: ... S A Chemin de Genas BP 639 69800 Saint Priest France Telephone 33 72232425 FAX 33 78907168 SULLAIR CORPORATION Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City Indiana 46360 U S A Telephone 1 800 SULLAIR USA Only or 1 219 879 5451 FAX 219 874 1273 FAX 219 874 1835 Parts FAX 219 874 1805 Service Specifications Subject To Change Without Prior Notice ...

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