Sullair SM160 Maintenance Manual Download Page 4 | Manualshive

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Page 4 of 36

MAXI MAINTENANCE

CONTENTS

Section

A1

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

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Summary of Contents for SM160

Page 1: ...SM 160 to SM 800 MAINTENANCE MANUAL DATE 22Sep2004 REVISION 1 domnick hunter limited Dukesway Team Valley trading Estate Gateshead England NE11 0PZ Tel 44 0 191 4029000 Fax 44 0 1914826296 ...

Page 2: ...suring 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 invali...

Page 3: ...old and valve housings to discharge any entrained condensate 2 Ensure power on light is illuminated Monthly As above and include 1 Ensure all manifold valve housing and end plate gaskets do not leak 2 Check all control valves pipe and fittings within instrumentation shroud for air leaks ...

Page 4: ...ENTS Section A1 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 ...

Page 5: ...Page 5 of 36 SECTION A1 INLET VALVE ASSEMBLY A1 1 A1 2 A1 3 Inlet Head Removal Inlet Valve Disc Removal Cylinder Piston Seal Renewal ...

Page 6: ... 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 center ...

Page 7: ...A2 2 A2 3 A2 4 A2 5 A2 6 A2 7 Upper Manifold Removal Heatless Quick Re Pressurisation Valve Removal H L Purge Plate Removal Purge Adjustment Lower Manifold Removal Bolt Torque Sequence HEATLESS Bolt Torque Sequences Inlet Outlet Exhaust Valve Assemblies ...

Page 8: ...sing eye bolts provided A2 2 Quick Re pressurisation Valve Removal Heatless The QRV can be removed without removing the end plate by removing the four retaining bolts Disconect QRV soleniod coil 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 T...

Page 9: ...ng a 1 BSP plug blank off one of the exhaust ports so that all the purge air escapes through one port Ensure that the flow meter to be used has a full scale deflection larger than the required purge flow Using 1 BSP flexible hose connect from the exhaust port to the inlet of the flow meter NB never allow the float of the flow meter to go off the top of the scale and never pressurise the flow meter...

Page 10: ...etting may vary from site to site according to operational enviromental conditions In general for up to 35 C inlet temperatures the table below gives recommended flow settings for both 40 C and 70 C PDP Purge flow rates are factory set to 6 barg This may need to be re set by a domnick hunter trained installation engineer at other operatiing pressures during commissioning MAXI HEATLESS CODES SM160 ...

Page 11: ...tion A1 and A5 respectively remove exhaust silencers as shown in section A3 Remove shroud as detailed in A6 Remove the two eye bolts on the top manifold and invert 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 ...

Page 12: ...Page 12 of 36 MANIFOLDS Bolt Torque Sequence Note Tighten the bolts in the numerical order shown always starting with the middle column working outwards TORQUE to 35N m 25lbs ft A2 6 HEATLESS ...

Page 13: ... A 2 7 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 34Nm 25lbs ft ...

Page 14: ...Page 14 of 36 SECTION A3 EXHAUST VALVE ASSEMBLY A3 1 A3 2 A3 3 Exhaust Valve Removal Exhaust Valve Disc Removal Cylinder Piston Seal Renewal ...

Page 15: ... fitting A3 3 Cylinder Piston Seal 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 For re assembly follow reverse pr...

Page 16: ...Page 16 of 36 SECTION A4 COLUMN ASSEMBLY A4 1 A4 2 Column Desiccant Removal Desiccant Replacement ...

Page 17: ...olumn bolts can 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 a...

Page 18: ...5kg of 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 HEATLESS COLUMN ARRANGEMENT ...

Page 19: ...Page 19 of 36 SECTION A5 OUTLET VALVE ASSEMBLY A5 1 A5 2 Outlet Housing Removal Outlet Valve Disc Removal ...

Page 20: ...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 20 of 36 ...

Page 21: ...Page 21 of 36 SECTION A6 CONTROL INSTRUMENTATION A6 1 A6 2 A6 3 Control Shroud Removal Pressure Gauge Removal Control Box Removal ...

Page 22: ...SMART CON INSTRUMENTATION DDS SECTION A6 Page 22 of 36 ...

Page 23: ...lies Reassemble in reverse order FILTER CHANGE Control Air Dewpoint Sample Air Unscrew filter bowls Unscrew filter elements Reassemble in reverse order SOLENOID VALVE REPLACEMENT Discconect solenoid coil Unscrew four retaining screws Remove the valve Reassemble in reverse order TIMER REPLACEMENT HEATLESS Disconnect electrical supply Remove four retaining screws from control box Allow panel to hing...

Page 24: ...ur retaining nuts down the side of the panels located through the orange brackets attached to the shroud Ease the facia power off the shroud approximately 30cm Unclip the flying leads from the rear of the PCB controller Remove facia panel Remove rubber sealing strips and fit to new facia panel Remove pressure guages and fit to new facia panel Reassemble in reverse order Page 24 of 36 ...

Page 25: ... and unscrew clamp nuts Rotateclamping ring anticlockwise remove ring pressure gauge can now be withdrawn OPERATION The operation cycle is as follows Side A Purge 150 seconds Side B Drying 180 sec Repressurisation 30 seconds Side B Purge 150 seconds Side A Drying 180 sec Repressurisation 30 seconds Complete cycle time 6 minutes ...

Page 26: ...n Connectors The Green Connect will unplug from the board to aid removal Disconnect the eight Solenoid Coils from the feed wires make a note of the electrical connections Tape the Black Wires together to allow removal of the Wires and Conduit Undo Conduit Lock Nuts Remove Conduit and Wires from Box Disconnect the three Pressure Gauge Pipes Remove Facia Retaining Screw Covers Undo Facia Retaining S...

Page 27: ...Page 27 of 36 SECTION A7 Piping Wiring Schematics A7 1 A7 2 Heatless SMART Piping Schematic Heatless Controller Schematic mk 2 ...

Page 28: ...7 1 HEATLESS SMART PIPING SCHEMATIC Page 28 of 36 ...

Page 29: ...7 2 HEATLESS SM DS SCHEMATIC Page 29 of 36 ...

Page 30: ...Page 30 of 36 SECTION A8 FAULT FINDING GUIDE A8 1 A8 2 A8 3 A8 4 A8 5 POOR DEWPOINT FAILURE TO DEPRESSURISE FAILURE TO REPRESSURISE LOSS OF POWER TO DRYER GENERAL ...

Page 31: ...ng 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 Check timer cycle Check solenoid valves for leaks Check exhaust valve Desiccant attrition REMEDY Change sensor Adjust flow restrictor to within spec Adjust if necessary Repair if necessary Resize compressor or reduce air d...

Page 32: ... Inlet 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 sensor adjust if required Check for correct purge rate reset if necessary Check pre fliters drains Check inlet pressure Check inlet Temperature Check for peak demand exessive air flow Check...

Page 33: ...e at cylinder Remove and check operation manually Remove non pressurised side tube check for air leak from fittings Check function by bypassing Check function by removing tubes Check for air leak at exhaust valve Check cycle time Exhaust valve failure to open Check operation and leaks on solenoid valve REMEDY Replace fuse check wiring Trace leak causing low pressure Lubricate if necessary or repla...

Page 34: ...es damaged seal on inlet cylinder No signal to open exhaust cylinders cam timer not rotating Weak signal to operate exhaust cylinders Broken diaphram in soleniod valve REMEDY Check for air leaks on valve fittings Replace if necessary Check and renew cylinder seals where necessary Check electrical supply Check exhaust valve solennoid operation Check all fittings for air leaks Replace where necessar...

Page 35: ...Dryer locked off CHECK Q R valve not opening Purge valve closed or blocked Damaged valve disc Sticking valve stem Damaged guide bush Broken or damaged exhaust valve disc Exhaust valve unable to close Damaged seals o rings gasket failure Damaged pipe tube connections Both inlet valves closed REMEDY Check control signal to solenoid black control pipe If OK change valve If no signal check output from...

Page 36: ...dryer package CHECK Element media blocked up with water or desiccant Air inlet and compressor discharge Excessive outlet flow Inlet filters Blocked pre filters Excessive outlet flow 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 outlet flow from dryer regulate if neces...

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