ZANDER HDK 140/100 Operating Instructions Manual Download

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High Pressure Dryer

HDK

50/100-600/350

Operating Instructions

Issue 05-2005/EN

Summary of Contents for HDK 140/100

Page 1: ...High Pressure Dryer HDK 50 100 600 350 Operating Instructions Issue 05 2005 EN ...

Page 2: ...2175 1 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 Mönckebergstraße 27 D 20095 Hamburg The assembly consists of pressure appliances according to the classification list attached to the technical documentation provided by the manufactu...

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Page 5: ...t time any appliance data not stated above to keep these appliance data up to date The above stated appliance data provide for a clear identification of the dryer and its components and significantly facilitate any service measures Further important data on the dryer such as the details on the permissible operating pressure and the electrical connection are found on the type plate for position of ...

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Page 7: ...ation and storage 23 Information on transportation packaging 23 What to do in the case of transport damage occurring 23 Transporting and installing the dryer 24 Installing and anchoring 25 Storing the dryer 26 Installation 28 Preconditions for installation 28 Connect piping 28 Installing the electrical connection 29 Start up 32 Requirements for initial start up 32 Setting times of the operating ph...

Page 8: ...ance 45 Regular maintenance intervals 46 Daily maintenance tasks 47 Weekly maintenance tasks 48 Maintenance work to be completed every 12 months 48 Maintenance work to be completed every 48 months 52 Identify and eliminate faults 56 Summary of faults 56 Index 59 Annex with technical documentation 62 Technical data 63 Replacement and wear parts list 65 Logic control diagram 68 Flow diagram 70 Dimen...

Page 9: ...9 0 2054 934 0 Telefax 49 0 2054 934 164 Internet www zander de E mail info zander de Service and orders Service and spare part order Telephone 49 0 2054 934 180 Telefax 49 0 2054 934 117 You can also use these telephone numbers to order consumables such as desiccant etc as well as spare parts When ordering spare parts always state the type and build no of the dryer Both are shown on the type plat...

Page 10: ...sed without prior approval and confirmation in writing 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 incorrect...

Page 11: ... 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 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 specialis...

Page 12: ...ified 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 instruction plates and danger zones at the dryer Signs and instructions Vessel plate Type plate of the dryer Type plate of the fi...

Page 13: ...horized specialist personnel only Warning against overpressure The entire dryer is under pressure Before commencing any work the plant must be depressurised Warning against sudden air ejection When the vessels are depressurised air flows suddenly out of the sound absorber This causes a sudden loud cracking noise Due to particles carried in the air flow there is a very considerable risk of eye inju...

Page 14: ...e 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 on the dryer described in these operating instructions Conversions and modifications Without prior approval by the ma...

Page 15: ...n escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Carry out all prescribed tests and checks The factory settings on the control board in the switchbox must not be changed on any account without prior approval by the manufacturer Before start up ensure that no tools or other foreign parts have been left lying in a part of the drye...

Page 16: ...ection Depressurising and shutting down the dryer on page 43 The unit may only be restarted after all defects have been eliminated Maintenance of the dryer and fault removal Hazard due to a sudden release of pressure Never remove any parts of the dryer or manipulate the same in any way for as long as the plant is still pressurised A sudden escape of pressure may cause serious injuries Before carry...

Page 17: ...emove any parts of the dryer or manipulate the same in any way for as long as the plant is still pressurised A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Dispose all parts of the dryer the drying agent and all other operating materials in an environmentally safe way and in accordance with all current statutory regulat...

Page 18: ...Summary drawing Front view Vessel pressure gauge Manometer On Off Switch Pressure reducer with manometer Control cabinet Power supply connector Differential pressure gauge Compressed air outlet Compressed air inlet Downstream filter Upstream filter Valves Hand drain Muffler ...

Page 19: ...aration are described below Adsorption Via a compressor humid compressed air is supplied to the upstream filter From here the compressed air flows upwards through the absorption vessel which is pressurised In so doing the drying agent dehumidifies the air The dry compressed air is supplied to the pipe network via the downstream filter Regeneration running in parallel to the adsorption At the same ...

Page 20: ...lowing options are available for the dryer Start up device Outside installation Auxiliary heater Signalling contacts of control system Regeneration gas return line for compressor synchronisation Dewpoint sensing control Pneumatic control Paint compatible design Start up device A start up device basically consists of a pressure holding device which is located at the rear of the dryer The pressure h...

Page 21: ...rd It is used for the transmission of operating signals and for the output of dewpoint alarms Regeneration gas return for compressor synchronisation Compressor synchronisation helps reduce energy costs as the dryer can be operated independently of the compressor When the compressor is switched off the regeneration gas return ensures that regeneration is continued as soon as a certain compressed ai...

Page 22: ...can reduce the quality of the paint finish Even minute quantities of oil and grease containing foreign materials or solvents above all silicones are sufficient to cause pits discolorations swellings and other contaminations in the paint finish Dryers in a paint compatible design comprise seals and filters that are absolutely free of grease and silicon and thus ensure a high quality of the compress...

Page 23: ...n on transportation packaging Depending on the type of transportation the dryer is delivered in different types of packaging All transportation types the apertures of the dryer are closed off by means of plugs In addition when transportation is effected by air the dryer is packaged in a wooden box In addition when transportation is effected by ship the dryer is packaged in a film material and in a...

Page 24: ...ation site it should be taken into account that the noise emission of the dryer can exceed 95 dB A temporarily for further information on the noise emission see also page 16 The installation area must be level firm and free of vibrations It must have the necessary carrying capacity for the weight of the dryer The weight of the dryer is specified in the technical data section of the annex The dryer...

Page 25: ...emove the packaging of the dryer Attach suitable lifting gear to the stand profiles and cross beams Risk of tilting The dryer should only be transported in an upright position However this means that the centre of gravity of the unit is located in the upper half of the dryer so that there is a serious risk that the unit might topple over When attaching the dryer to the lifting gear observe its cen...

Page 26: ...e dryer must be covered by a protective sheet The storage room must have an ambient temperature of at least 1 C 33 8 F In order to store the dryer proceed as follows Take dryer out of operation as described on page 43 Ensure that the compressed air inlet valve installed by the owner and the installed compressed air outlet valve installed by the owner are both closed and that the dryer is depressur...

Page 27: ...ote If you wish to take the dryer back into service after an extended period of storage please proceed as described for its first commissioning and start up see page 37 Store drying agents Do not store drying agents in the open air Protect drying agents against humidity ...

Page 28: ... All pipes couplings and connections must have the correct diameter and match the operating pressure Hazard caused by exceeding the limit values A safety device must be provided in order to protect against the maximum permissible operating pressure from being exceeded The data required to meet these preconditions are contained in the technical documentation attached in the annex Warning If the abo...

Page 29: ...t valve owner end 7 Outlet dry air Example of an installation The connection lines for the upstream filter 3 are to be installed at a slight incline in the direction of the upstream filter One shutdown valve each 2 6 is to be installed at the compressed air inlet and outlet ends of the dryer Installing the electrical connection Warning against electrical voltage Only qualified specialist personnel...

Page 30: ...to the connector and use bolt to remount the connector with seal on the switchbox In all phases the dryer must be protected against short circuits by means of fuses In order to relief cable strain re tighten the PG union Connecting the external signalling lines For compressor synchronisation The control system is equipped with a digital input that ensures that the dryer can only be operated while ...

Page 31: ...an for example be transmitted to a remote control room Dryer on contact made Power supply disconnected no contact Dewpoint alarm only with dewpoint sensing control option no contact To install the external lines proceed as follows Connect the lines of the fault signalling system to relay K5 see circuit diagram Check bolt connections Before the initial start up Check all unions and bolt connections...

Page 32: ...ted up Requirements for initial start up For the first start up the following preconditions must have been met The pipe system is free from scales thread abrasions welding beads and other contaminations All shutdown valves of the compressed air inlet and outlet valves installed by the owner are closed The dryer is correctly sited and installed Checks before start up Ensure that all pipe cable and ...

Page 33: ...maximum Overview of operating and control elements ON OFF switch The ON OFF switch 2 is located to the side of the control cabinet and above the mains plug 1 see figure If it is set to 0 the power supply is disconnected and the dryer is switched off The main and expansion valves are normally closed This ensures that the main flow direction is blocked when the dryer is switched off If the switch is...

Page 34: ...tatus of the dryer Display panel at the switchbox LED Power 1 LED is on when dryer is switched on Flow diagram 2 The current operating phases of the dryer are indicated by means of 4 LEDs Vessel B1 Vessel B2 Regeneration 1 Regeneration 2 Adsorption 1 Adsorption 2 Depending on the operating phase the following LEDs might be on simultaneously Adsorption B1 and regeneration B2 or regeneration B1 and ...

Page 35: ...ata The range of display is 100 C 148 F to 20 C 68 F If the measured dewpoint exceeds the preset alarm limit 5 C 41 F above the switchover value the displayed dewpoint value is flashing With the optional dewpoint sensing control the following error messages might be displayed Display Cause 20 Upper measuring range limit exceeded 999 Dewpoint sensor defective sens or 999 Dewpoint sensor not powered...

Page 36: ...r attached to the pressure reducer allows operators to check the pressure settings Emergency shutdown In the event of an emergency shut down the dryer as described in chapter Depressurising and shutting down the dryer page 43 Start up dryer Warning against sudden air ejection During expansion the pressure is released suddenly through the muffler A loud cracking noise occurs which can injure your h...

Page 37: ...dryer is pressurised If necessary pressurise switch on compressor Slowly open compressed air inlet valve Avoid sudden pressure build up in any circumstance If pressure builds up too fast this may cause damage to the dryer Therefore the compressed air inlet valve must always be opened quite slowly Slowly open the compressed air inlet valve installed by the owner upstream of the dryer Switch on drye...

Page 38: ...the dryer Smaller compressed air systems can be pressurised also by means of compressed air fed through the dryer Slowly open compressed air outlet valve Avoid a sudden drop in pressure in any circumstance If pressure drops too fast this may cause damage to the dryer Therefore the compressed air outlet valve must always be opened quite slowly Slowly open the compressed air outlet valve installed b...

Page 39: ...point sensing control option these two optional devices can only started together The compressor synchronisation has thereby precedence over the dewpoint sensing control With regeneration gas return for compressor synchronisation optional If compressor synchronisation is enabled the dryer can only be operated in conjunction with the compressor As soon as the compressor is switched off the dryer is...

Page 40: ...0 How do I change cycle mode Wait until the dryer has reached the pressure build up phase phase prior to switchover One LED for Adsorption B1 B2 is on in the flow diagram Set the ON OFF switch to position II The programme continues the cycle ON OFF switch ...

Page 41: ...box shows the currently measured dewpoint The range of display is 100 C 148 F to 20 C 68 F If the set dewpoint is exceeded the system automatically completes a switchover between the vessels The dewpoint at which a switchover is made is preset at the factory After commissioning or extensive maintenance work check the dewpoint display at the dryer Under certain circumstances the desired dewpoint is...

Page 42: ...e closed all expansion valves are closed As a result the pressure at the inlet side of the dryer is increased while the compressor is on until the compressor is automatically switched off by the control system the pressure in the vessel without start up device is reduced as the compressed air outlet valve is open while compressed air is taken in from the pipeline system no compressed air is fed to...

Page 43: ...ressure in the dryer at both vessel pressure gauges The pressure gauges should show value 0 Disconnect voltage supply Switch off the dryer by setting the ON OFF switch to position 0 ON OFF switch If work is to be carried out on the electrical system Depressurise and shut down the dryer following the instructions in the above chapter Risk of injury due to voltage carrying parts The electrical suppl...

Page 44: ...r outlet valve Avoid a sudden drop in pressure in any circumstance If pressure drops too fast this may cause damage to the dryer Therefore the compressed air outlet valve must always be opened quite slowly Slowly open the compressed air outlet valve installed by the owner Observe the vessel pressure gauge of the pressurised vessel The pressure should not drop below the operating pressure if poss I...

Page 45: ...intenance work only 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 ...

Page 46: ...mponent Maintenance task to be carried out daily weekly 12 months 24 months 48 months see page Complete dryer Carry out visual and function checks 47 Vessel pressure gauge Check dam pressure For a dam pressure exceeding 0 3 bar Check muffler Check dust sieve Check drying agent 48 Upstream and downstream filters Check differential pressure on the upstream and downstream filters 48 Pressure reducer ...

Page 47: ...t be completed Contact the service department of the manufacturer Clean dryer Remove any loose dust by means of a dry cloth and if required also by means of a moist and well wrung cloth Clean the surfaces with a moist well wrung cloth Check dam pressure If following depressurisation of a vessel e g after the expansion phase the overpressure has not decreased to 0 bar then there is a residual press...

Page 48: ...educer The pressure should be set to 8 bar If the pressure is set to a value above or below 8 bar turn the thumbscrew 2 to adjust the pressure reducer settings Pressure reducer with manometer Maintenance work to be completed every 12 months Renew filter elements on the filters The filter elements must be replaced every 12 months Depressurise dryer and take out of service see page 43 Remove the bot...

Page 49: ...property Therefore the mufflers must be replaced every 12 months and after each change of desiccant Warning against 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 flow act like bullets and can injure your eyes or skin Always wear eye and ear protection therefore when ...

Page 50: ... if subjected to forceful vibrations or shocks Therefore please handle the dew point sensor with great care at all times For calibration the pressure dewpoint sensor must be dismantled 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 9 and order a new dewpoint sensor Upon receipt of your old...

Page 51: ... caps and placed in a solid box Place the protective caps 4 5 onto the old dewpoint sensor and pack it properly in the box Send the old dewpoint sensor to the manufacturer Clean or replace check valves Check valves are wear parts and should be cleaned or replaced every 12 months Release pressure from dryer and shut down the unit see page 43 Remove check valves from the pipe bridge by opening the t...

Page 52: ... Renew drying agent The service life of the drying agent is usually approx 3 to 5 years However in favourable installation conditions the change of drying agent may be carried out at a substantially later date for notes on the installation site see also page 24 The change interval depends very significantly from the degree of contamination in the compressed air or the quality of the compressed air...

Page 53: ...be taken up immediately Remove used drying agent Depressurise dryer and take out of service see page 43 Place a suitable collecting vessel underneath the unit Disconnect the control block from the upstream filter 1 Loosen the connection between the lower pipe bridge and the vessels 2 Disconnect the solenoid valve block 3 Dismantling of the lower pipe bridge Remove the dust sieves from the vessels ...

Page 54: ...The dryer must not be misused as a climbing aid The components have not been designed for such loads and could fracture Only use approved climbing aids when filling the vessels Loosen connection at the pressure plate 1 Loosen connection at the pressure reducer 2 Disconnect the upper pipe bridge from the vessels 3 Dismantling of upper pipe bridge Remove the dust sieves from the vessels Clean dust s...

Page 55: ...er hammer to tap regularly against the vessel wall during filling or use a rod to distribute and compact the drying agent through the vessel opening Repeat the process on the second vessel Insert cleaned or new dust sieves Reconnect all pipelines Restart dryer see page 44 Check that the connection is leak tight Complete two dryer cycles the shut down the unit Replace muffler as described on page 4...

Page 56: ...xpansion valve Summary of faults There are different fault types In the case of most electrical faults e g short circuit defective fuse etc the main valves close In the case of some process faults the dryer will continue to operate for some time Faults on the dryer become noticeable e g due to unusual noises and dam pressures The following table shows who is allowed to remedy a fault the owner s s...

Page 57: ...element of muffler if necessary z z Pressure in vessel too low Excessive differential pressure at upstream filter Check differential pressure at the upstream filter replace filter element if necessary z Muffler contaminated Check muffler for contamination clean or replace if necessary z z Valve V7 V8 does not open properly see Backpressure during regeneration too high Dust filters blocked Clean or...

Page 58: ...s to open or close properly Check voltage at cables contacts and coils replace if necessary z With dewpoint sensing control optional Fault code Description of fault Possible cause Remedy Specialised personnel Service technician Drying capacity exceeded See instructions for commissioning If the drying agent is wet replace it z 20 Upper measuring range limit exceeded Error in programme Restart progr...

Page 59: ...9 D Danger notes Danger 11 Danger warning maintenance 47 Date of manufacture 5 Dehumidification explanation 19 Design paint compatible 22 Dew point sensor maintenance interval 46 Dewpoint sensing control 21 Digital display explanation 35 Documentation technical 62 Dryer maintenance interval 46 drying agent service life 52 Drying agent charging 21 maintenance interval 46 storage 27 drying agents ha...

Page 60: ...28 Operating signalling contact installation 31 Operation signalling contact 21 Original replacement parts 17 45 Outside installation 20 overpressure hazard 13 P Packaging 23 Parameters preset 10 Personnel qualification 10 12 14 47 Power supply interrupted 42 Pressure build up explanation 20 sudden 37 Pressure reducer maintenance interval 46 pressure vessel 16 45 Programme sequence steps 68 Protec...

Page 61: ... symbols explanation 13 T Target group 11 Temperature ambient minimum maximum 64 Transport damage 23 Type plate 12 U Use intended 14 Use safe 11 V Variable cycle 21 Vessel pressure gauge maintenance interval 46 vibration dampers 26 Visual inspection 47 Voltage electrical 29 W Warranty 10 Waste code numbers 17 ...

Page 62: ...05 05 10 Annex with technical documentation This annex comprises the following information and technical documentation Technical data Replacement and wear parts list Logic control diagram Flow diagram Dimensional drawing ...

Page 63: ...70 1710 450 275 250 bar HDK 50 250 80 635 1155 400 110 HDK 80 250 140 635 1205 400 115 HDK 140 250 205 685 1220 400 132 HDK 250 250 420 740 1350 450 195 HDK 400 250 655 810 1410 450 245 HDK 600 250 1020 870 1710 450 375 350 bar HDK 50 350 130 635 1155 400 110 HDK 80 350 180 635 1205 400 115 HDK 140 350 255 685 1220 400 145 HDK 350 350 520 740 1350 450 225 HDK 400 350 367 810 1410 450 280 HDK 600 3...

Page 64: ...50 bar min operating overpressure 10 bar min ambient temperature 1 C 33 8 F max ambient temperature 50 C 122 F Rel humidity 60 Noise level 3 dB A relative to free field measurement 1 m surr field 65 95 dB A Mains voltage see type plate Protection class IP 65 Filling quantity Drying agent per vessel Top MS512 80 Bottom Ecosorb IIa 20 ...

Page 65: ...ment 1140 XP 211010011411 2 3 Filterelement 2010 XP 211010020110 Manual drain EV05 631120008001 Condensate trap optional Trap 2 250 Trap 2 400 104100000016 104100000018 Differential pressure gauge HZD80 420 bar 104000008000 3 Downstream filter G3V G5V G7V G9V 3 3 Filter element 1050 V 211040010500 3 3 Filter element 1070 V 211040010700 3 3 Filter element 1140 V 211040011410 3 3 Filter element 2010...

Page 66: ...50 Valves 9 Pressure build up valve Expansion valves DN 6 641400023001 10 Main valve DN 12 641400023001 13 Check valve ø 16 620300001629 14 Check valve ø 8 620300000825 15 Check valve ø 8 620300000840 Manometer 50 250 100 bar 50 250 250 bar 50 250 350 bar 18 Vessel manometer 650200032221 650200032521 650200032621 ...

Page 67: ...D80 420 bar 104000008000 3 Downstream filter G7V G11V 3 3 Filter element 1140 V 211040011410 3 3 Filter element 2020 V 211040020200 Manual drain EV05 631120008001 Differential pressure gauge HZD80 420 bar 104000008000 12 Control system 95 Dew point sensor option 655000010001 17 Pressure reducer 657500010010 21 Muffler complete 672200001501 Valves 9 Pressure build up valve Expansion valves DN 6 641...

Page 68: ...Logic control diagram 68 HDK350_EN_01_2005 05 10 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 69: ...Annex with technical documentation HDK350_EN_01_2005 05 10 69 Regeneration in B1 and adsorption in B2 ...

Page 70: ...0 Flow diagram Item Designation Item Designation 1 Vessel 12 Control cabinet 2 Upstream filter 13 14 15 Check valves 3 Downstream filter 17 Pressure reducer 7 Dust sieve 18 Vessel manometer 9 Pressure build up valve 21 Muffler 10 Main valve ...

Page 71: ...DK350_EN_01_2005 05 10 71 Dimensional drawing Type HDK 100 250 350 bar Dimensions mm 50 80 140 250 400 600 A 640 640 640 775 845 905 B 1155 1205 1220 1350 1410 1710 C 400 400 400 450 450 450 Connection G 1 2 G 1 2 G 1 2 G 1 2 G 3 4 G 3 4 ...

Page 72: ...Dimensional drawing 72 HDK350_EN_01_2005 05 10 Items Option ...

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