WALKER FILTRATION PD0090 Manual Download Page 52

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LED Identification

Function

Indication

Remark

N/A

Power Off

Power supply disconnected

Power On

Left tower ‘Online’

Left tower drying

Right tower ‘Online’

Right tower drying

X & Y

Both towers ‘Online’

One tower drying, the other tower

repressurising

Left solenoid failure

Clean or replace solenoid

RESET

Section 11:

Troubleshooting

Troubleshooting - LED Display Status Identification

Summary of Contents for PD0090

Page 1: ...P R O S F D P R O S F D P R O S F D...

Page 2: ...e manual has been fully read and understood by all relevant personnel Please complete the following information at the time of installation found on the rating label on the upper right hand side of dr...

Page 3: ...14 Orientation 16 Configuration of the inlet outlet ports 17 Connecting the pre filter to the dryer 18 Connecting the optional pre filter drain valve 18 Installing the hygrometer DMC models only 19 Co...

Page 4: ...control strategy 35 Using a manual switch for purge control 35 Using a standard pressure switch for purge control 36 Using an electronic pressure switch for purge control 37 Using a hygrometer and pro...

Page 5: ...on from the compressed air supply and full depressurisation Only trained and competent persons familiar with the electrical requirements of the unit as laid out in this manual and electrical safety ru...

Page 6: ...r their own Health and Safety and the Health and Safety of others around them If you feel there is a significant risk you must take steps to either remove the risk altogether or reduce the risk prior...

Page 7: ...wer is then repressurised with the control system assuring each tower is at full operational pressure prior to changeover This ensures a reliable and efficient operation The air stream is switched and...

Page 8: ...uding certificate of conformity Note All dryers come equipped with eyebolts to facilitate removing the dryer from it s crate Simplex dryers include one eyebolt and duplex models include two Note All d...

Page 9: ...ipe 12 Exhaust silencer 13 Bottom manifold assembly 14 Dryer stand 15 Bottom extrusion tower plug 16 Tower circlip 17 Bottom trim cover 18 Hygrometer sample block 19 Hygrometer DMC models only Figure...

Page 10: ...ents Duplex Models PD0220 PD0360 10 P D PD00 6 PD0360 nstru tion Manual Walker Filtration Figure 2 7 Primary Components Duplex Models PD0220 PD0360 Se ct ion 2 General Description 7 8 9 13 14 15 16 17...

Page 11: ...e 7 barg 101 5 psig Inlet temperature 35 C 95 F Relative humidity of air at inlet 95 Pressure dewpoint standard version 40 C 40 F Specified Limitation for Operation Measurement Performance Maximum inl...

Page 12: ...4 1 1 306 180 1845 72 6 76 3 50 2 1000 39 4 150 4 1 1 374 220 1262 49 7 76 3 62 2 4 700 27 6 250 8 1 510 300 1596 62 8 76 3 62 2 4 850 33 5 315 8 1 612 360 1845 72 6 76 3 62 2 4 1000 39 4 362 8 A159XA...

Page 13: ...50 Farenheit F 68 77 86 95 104 113 122 Correction factor 1 3 1 2 1 1 1 0 75 0 65 0 45 Pressure dewpoint DCF Celcius C 20 30 40 70 74 Farenheit F 4 22 40 94 100 Correction factor 1 23 1 2 1 0 8 0 77 Dr...

Page 14: ...re 4 2 Level ground Mechanical Installation Section 4 Mechanical Installation To prevent back flow into the dryer a non return valve should be placed in line downstream of the dryer This is essential...

Page 15: ...tallation Figure 4 5 Exposure to heat Figure 4 3 Location Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Max 50O C 122O F Max 50...

Page 16: ...tion Figure 4 6 Drainage all tubing should be secured up to the point of drain to prevent whipping during discharge Orientation Figure 4 7 The PRODRY range of dryers is designed to operate in both ver...

Page 17: ...with provided pressure plugs Figure 4 8 Inlet outlet ports A C B D Any of the two outlet ports can be used on occasion Please ensure flow at outlet should not exceed specification Please adhere to re...

Page 18: ...tor All tubing should be secured up to the point of drain to prevent whipping during discharge 18 PRODRY PD0046 PD0360 Instruction Manual Walker Filtration s All tubing should be secured up to the poi...

Page 19: ...ly Remove hygrometer from packaging Carefully remove plastic cover from the sensor Hygrometer sample block is pre installed in the dryer s top manifold assembly Remove cover from threaded port Confirm...

Page 20: ...ect valve body 1 2 or 3 hole and orifice disc 01 02 03 or 04 has been supplied with the dryer The discs have the number 01 02 03 or 04 stamped out at the top Every dryer is shipped with a purge orific...

Page 21: ...otches Alignment notches Figure 4 13 Purge valve assembly Purge Valve Assembly Reference figure 4 13 and the Purge Plug Identification Table on Page 20 Once the correct purge body 1 2 or 3 hole and or...

Page 22: ...ed to the correct socket as shown in figures 5 1 LED Controller and 5 2 DMC Controller The LED and DMC controller require a earth to be connected within the DIN connector The cable selection must suit...

Page 23: ...EMENT ALARM INPUT N C 2 1 Energy Management Connections Alarm Connections 5VDC N O 3 12 24VDC Section 5 Electrical Installation 23 PRODRY PD0046 PD0360 Instruction Manual Walker Filtration Fig ure 5 1...

Page 24: ...DC Remote Valve Pin 2 1 PIN 24VDC Remote Valve Pin 1 INPUT INPUT INPUT 1 2 3 1 2 3 1 2 3 1 2 3 1 2 POWER SUPPLY HYGROMETER ENERGY MANAGEMENT ALARM REMOTE DRAIN VALVE Section 5 Electrical Installation...

Page 25: ...h direction the cable gland should point C arefully pull the cable back through the case until the insert snaps back into place Take care to workthe wires around the retaining screw hole as they can b...

Page 26: ...d that a suitable cable is brought into the controller via the rear panel with a grommet An external power source is required Per Figures 5 5 LED Controller or 5 6 DMC Controller connect the switching...

Page 27: ...n on value 40 C 40 F 43 C 45 4 F 41 C 41 8 F Range 3 74 C 100 F Required outlet pressure dewpoint Purge shut off value Purge turn on value 74 C 100 F 76 C 104 8 F 74 C 100 F 27 PRODRY PD0046 PD0360 In...

Page 28: ...ure dewpoint is adequate Open valve B slowly Please note that the Energy Management feature should not be used when a hygrometer is installed in the dryer Shu t downProcedure Cl ose valve B Cl ose val...

Page 29: ...f With power off to the dryer both towers pressurise to line pressure All valves remain closed and the dryer remains air tight with the exception of a small bleed of air from the hygrometer sample blo...

Page 30: ...valve opens allowing the left exhaust shuttle valve to open Air rushes from the left tower out the silencer as it depressurises For 120 seconds a bleed of dry air from the outlet of the on stream righ...

Page 31: ...6 Operation Figure 6 5 Stage 2 Repressurisation At the completion of Stage 1 the left solenoid closes and the left tower repressurises for 25 seconds Note Any air flowing through dryer passes through...

Page 32: ...ve opens allowing the right exhaust shuttle valve to open Air rushes from the right tower out the silencer as it depressurises For 120 seconds a bleed of dry air from the outlet of the on stream left...

Page 33: ...6 Operation Figure 6 7 Stage 4 Repressurisation At the completion of Stage 3 the left solenoid closes and the left tower repressurises for 25 seconds Note Any air flowing through dryer passes through...

Page 34: ...rd Running Mode Hours Run 456 Service History 0 3 1 2 3 1 2 Left Solenoid Control Valve Silencer Silencer Right Solenoid Control Valve LED Controller DMC Controller XA Pre Filter DV1 Optional Drain Va...

Page 35: ...not being used Commonly used on point of use systems For example if the dryer is only used to supply air of the dryer will only berequired when the machine is in use and may beshut either manually or...

Page 36: ...ing a stand alone pressure switch the smaller the dead band the better When using a stand alone pressure switch the dryer is wired into the normally closed LED Controller or Normally open DMC Controll...

Page 37: ...y time an overview of the devices mentioned as they might be connected foruse in controlling d er between device manufacturers so in all cases the Se ct ion 7 Energy Management This setup is for examp...

Page 38: ...ion Criteria Selected wire should have Atleast 2conductors M ore conductors can be useful in the case of a conductor break Conductors can be swapped without having to run new cable A conductor gauge o...

Page 39: ...ulation back approx 3mm 1 8 If possible using a meter verify the switch function Insert conductors into pins 1 2ofinsert Tighten retaining screws securely Determine which direction the cable gland sho...

Page 40: ...intenance Maintenance Service Intervals Applicable Service Kits Pre Filter Element Every 1 year or 6000 hours Exhaust silencer Every 1 year or 6000 hours Desiccant cartridges Every 2 years or 12000 ho...

Page 41: ...360 12000 12 000 Hours or 2 Years Section 9 Spares Information 12 000 hour High Performance Desiccant Cartridge Silencer Service Kit for use where 74 C 100 F dewpoint is required Dryer Model Kit Part...

Page 42: ...0 2 and valve body stem and all associated seals reference figures 10 6 24 000 Hours or 4 Years PD0056 PDSK0056 24000 S115 24 000 Hours or 4 Years PD0075 PDSK0075 24000 S115 24 000 Hours or 4 Years PD...

Page 43: ...service kit reference figures 10 2 and valve body stem and all associated seals reference figures 10 6 24 000 Hours or 4 Years PD0056 PDSK0056BA 24000 S115 24 000 Hours or 4 Years PD0075 PDSK0075BA 2...

Page 44: ...yers operating between 4 and 13 barg and appropriate purge orifice discs fully assembled reference figure 10 6 Dryer Model Kit Part Number Description PD0046 PD3PPK1 PD0046 PD0056 Purge valve kit PD00...

Page 45: ...Kit Kit includes hygrometer only Dryer Model Kit Part Number Description PD0046 PD0360 PD3HK01 Hygrometer Kit Drain Valve Kit Kit includes 1 solenoid drain valve with attached female DIN connector Dry...

Page 46: ...ifold connection O ring Exhaust manifold O ring Down tube O ring 2 13 14 Valve Service Plug O ring Included in Service Accessory Kit Valve Service Shuttle Service 44 Walker Filtration Component parts...

Page 47: ...2 2 2 4 4 1 Itm Qty Description 2 3 4 5 6 7 8 9 10 Tower extrusion Extrusion tower plug Desiccant cartridge Quantity varies per dryer model Cartridge pressure spring Support circlip Service cap outer...

Page 48: ...tion 2 3 4 5 6 7 8 9 10 Tower extrusion Front Tower extrusion Rear Extrusion tower plug Desiccant cartridge Cartridge pressure spring Support circlip Clamp assembly Floor mounting bracket Service cap...

Page 49: ...fice Disc 1 2 3 1 1 2 3 4 5 13 14 6 7 8 12 9 11 10 Fig 10 5 Controller assemblies PD0046 PD0180 Section 10 Component Parts Fig 10 6 Purge valve assembly 47 Walker Filtration 0 Section 10 Component Par...

Page 50: ...ridges Desiccant contaminated Check inlet filter and drains replace cartridges EM is active when air is flowing through dryer Check EM wiring DMC and or control method used Power to dryer off while ai...

Page 51: ...emove external wiring from the dryer s EM contacts On LED controllers dryer should enter EM mode On DMC controllers place jumper between pins 1 and 2 of EM male connector Dryer should enter EM mode If...

Page 52: ...ace solenoid RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET R...

Page 53: ...ntroller reset Activated when the reset magnet is applied N A Power Failure Replace controller RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RESET RES...

Page 54: ...g mode service overdue Line message 1 STANDARD RUNNING MODE Line message 2 Line message 3 SERVICE OVERDUE Line message 4 SERVICE HISTORY XX Service overdue 12000 hours continuous operation Energy mana...

Page 55: ...e active 74 service overdue Line message 1 DEWPOINT MODE 20 40 74 Line message 2 DRYER DEWPOINT XXX PDP Line message 3 SERVICE OVERDUE Line message 4 SERVICE HISTORY XX Dewpoint mode active dryer in s...

Page 56: ...lker Filtration Ltd desiccant dryer range is designed for warrantied and intended for use in fixed industrial compressed air applications only Use on non fixed installations such as marine e g offshor...

Page 57: ...EMEA Notified Body No 0038 71 Fenchurch Street London EC3M 4BS England Conformity Assessment Module Pressure Equipment Directive PED Only PD0046 PD0180 Cat II Module D1 COV0310124 1 PD0220 PD0360 Cat...

Page 58: ...3770B Laird Road Unit 2 Mississauga Ontario L5L 0A7 Tel 800 951 0777 Fax 905 820 3490 www cagpurification com...

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Summary of Contents for PD0090

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WALKER FILTRATION PD0090, Manual, Page: 52 / 58

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Summary of Contents for PD0090

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