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HDK-CNG_EN_03_2016

Contents

General Information ............................................................................................ 8

Manufacturer's details ............................................................................................................ 8

Details on the dryer ................................................................................................................ 8

About these operating instructions........................................................................................ 10

About your safety .............................................................................................. 11

Intended use of the dryer ...................................................................................................... 11

General safety notes ............................................................................................................ 12

Signs and hazard areas on the dryer .................................................................................... 14

Information on inerting the dryer ........................................................................................... 15

Transportation, installation and storage ......................................................... 16

Information on transportation packaging ............................................................................... 16

What to do in the case of transport damage occurring? ........................................................ 16

Transporting and installing the dryer ..................................................................................... 17

Installing and anchoring the dryer ......................................................................................... 17

Storing the dryer ................................................................................................................... 18

Technical Description ....................................................................................... 19

Layout drawing ..................................................................................................................... 19

Function ............................................................................................................................... 20

Available options .................................................................................................................. 22

Operating and control elements ...................................................................... 23

Control cabinet ..................................................................................................................... 23

Control unit ........................................................................................................................... 24

Control elements on the switch cabinet ................................................................................ 27

Other display elements ......................................................................................................... 27

Installation .......................................................................................................... 28

Requirements for installation ................................................................................................ 28

Connect piping ..................................................................................................................... 29

Installing the electrical connection ........................................................................................ 29

Commissioning .................................................................................................. 32

Requirements for initial start-up ............................................................................................ 32

Setting times of the operating phases ................................................................................... 33

Emergency shutdown ........................................................................................................... 34

Startup dryer ........................................................................................................................ 34

Changing cycle mode (optional) ........................................................................................... 36

Monitoring of the Operation ............................................................................. 37

With dewpoint-sensing control (optional) .............................................................................. 37

Содержание HDK-CNG Series

Страница 1: ...High pressure Dryer HDK CNG 250 250 2000 250 Dokument ID DMN HDK CNG250 2000 R03 Operating manual II 2G IIB T1 Revision 03_2016 EN...

Страница 2: ...he conformity assessment after having been classified in this group The products were classified as follows II 2G IIB T1 Archiving of documents as per 94 9 EG ATEX guideline is done by the named insti...

Страница 3: ...DK CNG2000 250 GH11 3 350 2 09 III H The following standards technical specifications were used harmonised standards DIN EN 12100 2011 3 DIN EN 61000 6 3 DIN EN 61000 6 2 DIN EN 60204 1 DIN EN 13463 1...

Страница 4: ...no Build no Vessel no Vessel no Year of manufacture The above stated appliance data provide for a clear identification of the dryer and its components and significantly facilitate any service measure...

Страница 5: ...late here Note the data on the type plate and keep them complete and always legible Note If an acceptance test of the complete system is required in accordance with ATEX this is a matter for which the...

Страница 6: ...nd installing the dryer 17 Installing and anchoring the dryer 17 Storing the dryer 18 Technical Description 19 Layout drawing 19 Function 20 Available options 22 Operating and control elements 23 Cont...

Страница 7: ...Regular maintenance intervals 42 Making preparations 43 Daily maintenance tasks 44 Weekly maintenance tasks 45 Maintenance work to be completed every 12 months 45 Maintenance work to be completed eve...

Страница 8: ...lter 1 after filter 1 Water separator Switch cabinet including control 1 Condensate trap with the option pressure dewpoint control With pressure dewpoint sensor ZHM100 with option of regeneration gas...

Страница 9: ...tructions 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 s...

Страница 10: ...Attention 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 l...

Страница 11: ...in accordance with the contractual conditions Non observance of the data given there is regarded as improper use ATEX compliant dryers in acc with designation CE Ex II 2G must only be used in Zone 1...

Страница 12: ...sh the dryer with inert gas ventilate the room thoroughly check dryer and pipework for leaks and repair them all In the event of an escape of natural gas Natural gas is toxic and explosive In the even...

Страница 13: ...caused by emptying and filling drying and purifying agents That in turn entails the hazard of sparks being caused For work in Ex protected rooms the vessels must all be earthed grounded while being fi...

Страница 14: ...the dryer or manipulate the same in any way for as long as the plant is still pressurised Sudden escapes of gas can lead to combustible flammable atmospheres in the area surrounding the dryer The Ex z...

Страница 15: ...em is pressurised during the inerting procedure There is a very considerable risk of personal injury when carrying out work on the activated and pressurised dryer Suddenly escaping compressed air migh...

Страница 16: ...efore the following instructions as well as the storage instructions on page 18 Information on transportation packaging Depending on the type of transportation the dryer is delivered in different type...

Страница 17: ...echnical data section of the annex The dryer should be installed with sufficient spacing min 1 m at the top sides and rear in order to be able to carry out maintenance work and change the drying agent...

Страница 18: ...3 8 F In order to store the dryer proceed as follows Take dryer out of operation as described on page 39 Ensure that the natural gas inlet and outlet valves installed by the operator are closed and th...

Страница 19: ...x heater Pressure relief valve Vessel pressure gauge pressure gauge Check valve Lifting eye vessel plate Vessel Control cabinet Type plate dryer Natural gas outlet After filter Regeneration gas outlet...

Страница 20: ...back to the compressor inlet Installed upstream and downstream filters purify the natural gas directed into the dryer and or directed onwards from dryer to consumers The two vessels contain an extreme...

Страница 21: ...partial flow is generated This partial flow regeneration gas is heated by a heating unit The heated dried regeneration gas flows through the regenerating vessel from top to bottom This causes the flow...

Страница 22: ...heat exchanger the regeneration gas can also be cooled enabling the water to condense out more effectively Auxiliary heater For installation sites with temperatures under 15 C the wet side of the dry...

Страница 23: ...lves are closed and de energised That means that the dryer is closed in its main direction of flow and no flow through thr dryer no flow to the regeneration piping With switch S1 and with the optional...

Страница 24: ...keys 2 Arrow keys 4 Numerical keypad The program can be started by pressing this key The program is stopped by pressing this key You can navigate through the menus using this keypad With key 0 possibl...

Страница 25: ...In the menu level Dryer Settings all submenus are protected with a password To enter the password observe the following steps Select the desired menu level Select desired menu item using arrow keys En...

Страница 26: ...nd the counter is set to 0 the status diplay is not shown but the message service interval with date and time will be shown This message can be acknowledged with the S3 button and will thus be extende...

Страница 27: ...the relevant sub menu refer to page 61 for details of menu layout To enable the remote function the desired alternative must be shown in brackets Press the key to return to the screen status Note With...

Страница 28: ...re Connect the outlets from the regeneration gas safety valves to the line used to evacuate escaping gas The disposal line on the regeneration gas safety valves must not include any shutdown valves Ha...

Страница 29: ...r the upstream filter are to be installed at a slight incline in the direction of the upstream filter One shutdown valve is to be installed at each of the natural gas inlet and outlet ends of the drye...

Страница 30: ...ped the dryer regeneration also stops When the compressor restarts regeneration also restarts To install the external lines proceed as follows Connect the signalling line to the potential free busbar...

Страница 31: ...rounded properly Existing Ex zones near the dryer may need to be cancelled The earth ground rails are mounted on the back of the switch cabinet Here the dryer is connected to the potential compensatio...

Страница 32: ...re carrying out any work on the dryer first depressurise the plant Requirements for initial start up Attention The dryer must be taken into operation by trained personnel only Untrained personnel does...

Страница 33: ...s such as safety valves or other devices are not blocked up by dirt or paint all natural gas system components which are pressurised valves hoses etc are free from wear symptoms and defects Note Run t...

Страница 34: ...losed Ensure that the natural gas network upstream of the dryer is pressurised Switch on dryer to this end pressing the key S3 for longer 3s and than briefly pressing the key S2 Open natural gas inlet...

Страница 35: ...reases with the size of the natural gas system downstream of the dryer Smaller natural gas systems can also be pressurised by the natural gas directed through the dryer Slowly open user installed natu...

Страница 36: ...educe energy costs as the dryer can be operated independently of the compressor As soon as the compressor is switched off the dryer is automatically set to standby mode In standby mode the control sys...

Страница 37: ...herefore the owner must provide suitable protective equipment e g ear protection Check the dryer regularly for externally visible damage and defects Any changes even in its operating behaviour must be...

Страница 38: ...considerable danger An explosive atmosphere can build up especially during commissioning and when replacing the drying agent To avoid this the dryer must be purged with inert gas both before placing...

Страница 39: ...eneration gas return valve key S3 key S2 Switch OFF of the power supply to the dryer If work is to be carried out on the electrical system Depressurise and shut down the dryer following the instructio...

Страница 40: ...lowly Slowly open owner installed natural gas outlet valve Observe the vessel pressure gauge of the pressurised vessel The pressure should not drop below the operating pressure if poss If necessary ke...

Страница 41: ...for the gas in the system in a convenient location prepare appropriate protective measures with ATEX compliant dryers before work first cancel the Ex zone ensure that the individual components of the...

Страница 42: ...the expansion phase the vessel is pressurised by what is known as dam pressure This might be due to the regeneration gas return line not being free contamination of the dust sieves drying agent which...

Страница 43: ...d on page 39 Depressurise the dryer and shut it down Before working on dryer first purge the system with inert gas and depressurise it On no account place the dryer into service or take the dryer out...

Страница 44: ...loth with water wring it out well and do not use additives Dryers that are not intended for an ATEX environment Clean the dryer once a week with a damp cloth Only dampen the cloth with water wring it...

Страница 45: ...setting at pressure reducer Damage to heating If regeneration gas pressure is too high the following components may get damaged and this would impair the function of the dryer Never set pressure on t...

Страница 46: ...sensor every year This period depends however on the actual application and might thus be extended accordingly Attention The dew point sensor is a sensitive measuring device It can be damaged if subje...

Страница 47: ...k tight Cleaning solenoid valve bodies and replacing if necessary Solenoid valve bodies are wearing parts and must therefore be cleaned every 12 months and replaced if necessary Depressurise the dryer...

Страница 48: ...l gas levels in the system to fluctuate To remove the dust sieves the check valve block and attached angle pipes also need to be removed Risk of falls The dryer must not be misused as a climbing aid T...

Страница 49: ...generation When emptying the drying agent increased dust generation may occur In order to avoid any eye irritations wear protective goggles In order to avoid any dust inhalation wear dust mask Risk of...

Страница 50: ...limbing aids when filling the container Dismantle upper pipe bridge and connection to downstream filter also refer to page 48 Fill the several drying agents in as separate layers according to the tech...

Страница 51: ...one individually using the relevant keystrokes Note A fault alarm is shown on the Alarm menu display with date and time Summary of faults In the case of some process faults the dryer will continue to...

Страница 52: ...oo old Check drying agent for contamination if nec renew drying agent Cable defective Replace cable TF1 defective Replace transmitter fault dew point sense Regeneration gas too low Check function of v...

Страница 53: ...switching value 36 37 Dewpoint sensing control 22 36 Documentation technical 55 Dryer maintenance interval 42 Drying agent maintenance interval 43 service life 49 Drying agents storage 18 Dust genera...

Страница 54: ...ion explanation 21 Restarting Pressure characteristics 39 Risk of slipping change of drying agent 49 S Safety instructions 11 Safety notes general 12 Warning 10 Safety valves 28 33 Scope of delivery 8...

Страница 55: ...with technical documentation This annex comprises the following information and technical documentation Technical data Replacement and wear parts list Logic control diagram Menu diagram of controller...

Страница 56: ...GH7 250XP CNG GH7 250ZP CNG GH7 250ZP CNG STH001P HDK 750 250 750 G 1 i GH11 250XP CNG GH11 250ZP CNG GH11 250ZP CNG STH003P HDK 1200 250 1200 G 1 i GH11 250XP CNG GH11 250ZP CNG GH11 250ZP CNG STH003...

Страница 57: ...000 Service kits wear part kits Model Scope of supply Maintenance interval Order no HDK CNG 250 O ring filter element 12 months SKHDK CNG250 250 12 HDK CNG 750 2000 SKHDK CNG2000 250 12 HDK CNG 250 Se...

Страница 58: ...40NGO F40380 2 5 HDK CNG 1200 Heater 1 ET HEE65 40NGO F40380 4KW HDK CNG 2000 Heater 1 ET HEE80 40NGO F40380 HDK CNG 250 2000 Pressure regulator 1 ET DRM G10 GHR J50 C B9 Condensate drain 1 11LD 28TG...

Страница 59: ...vessel B1 Regeneration vessel B2 V1 open V1 closed expansion max 5 min V4 open heating start ca 20 min heater on V6 open Drain V7 alternating open 3 sec closed 30 sec cooling start ca 5 min heater of...

Страница 60: ...ration vessel B1 V2 open V2 closed expansion max 5 min V3 open heating start ca 20 min heater on V6 open Drain V7 alternating open 3 sec closed 30 sec cooling start ca 5 min heater off cooling stop bl...

Страница 61: ...Annex with technical documentation HDK CNG_EN_03_2016 61 Menu diagram of controller...

Страница 62: ...V26 Condensate drain 2 prefilter V8 V9 Condensate valve 3 After filter B1 B2 Vessel 4 Water separator 5 Pressure reducer V1 V2 Inlet valves 6 Heater V3 V4 Regeneration valves V6 V7 Regeneration valve...

Страница 63: ...Annex with technical documentation HDK CNG_EN_03_2016 63 Time diagram for valve setting...

Страница 64: ...K CNG_EN_03_2016 Dimensional Drawing Type Connection Dimensions mm Weight A C E F kg HDK CNG 250 763 990 1771 380 HDK CNG 750 1 874 592 1139 2110 690 HDK CNG 1200 1 919 760 1264 2110 990 HDK CNG 2000...

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