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Sfd Dryer Applications

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October 2018
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SFD Air Dryer Owner’s Manual 10/09/2014 Table of Contents WARNING Read, understand and follow safety precautions and instructions in this manual and in the labels attached to the dryer system. Failure to do so could result in serious injury, death and property damage. SAFETY MESSAGES IN MANUAL AND IN WARNING LABELS ........................................................3 SEPARATOR FILTER DRYER ...................................................................................................................4 SPECIFICATIONS SFD DRYER SYSTEMS ..............................................................................................5 SFD DRYER SIZING CHART .....................................................................................................................6 GENERAL MOUNTING INSTRUCTIONS: ...............................................................................................7 BASIC OPERATION AND INSTALLATION MOUNTING INSTRUCTIONS ........................................8 Micro Logic Timer .................................................................................................................................................. 8 Programmable Logic Control (PLC) 120 thru 800 ............................................................................................... 10 Pneumatically Controlled (PC) 40 thru 200 CFM SFD Dryer Systems ............................................................... 11 ANNUAL INSPECTIONS ..........................................................................................................................12 MLT (Micro Logic Timer) Dryers .......................................................................................................................... 12 PLC (Programmable Logic Control) Dryers ......................................................................................................... 12 PC (Pneumatic Control) Dryers ........................................................................................................................... 12 FLOW DIAGRAMS ....................................................................................................................................13 SERVICE COMPONENTS .........................................................................................................................17 Micro Logic Timer (MLT) Applications (5 – 120 CFM Dryer Systems) ................................................................ 17 Programmable Logic Control (PLC) Applications (120, 240 400, 600, 800 CFM Dryer Systems)...................... 19 Pneumatically Controlled Applications ................................................................................................................ 21 TROUBLESHOOTING SFD AIR DRYER SYSTEMS .............................................................................23 MLT, PLC and Pneumatically Controlled Operation/Cycle & Problem Scenarios............................................... 23 SERVICE REPLACEMENT PROCEDURES SFD AIR DRYING SYSTEM ..........................................27 Desiccant Cartridge Kit Options .......................................................................................................................... 27 Adapter Plate/Cartridge Stud ............................................................................................................................... 27 Micro Logic Timer Replacement (MLT) ............................................................................................................... 29 Air Control Valve - MLT Dryer Systems............................................................................................................... 29 Inlet Check Valves ............................................................................................................................................... 30 Outlet Check Valve .............................................................................................................................................. 31 Regeneration Valve ............................................................................................................................................. 31 Heater Assembly ................................................................................................................................................. 32 Reset pneumatic control ...................................................................................................................................... 32 OIL COALESCER .......................................................................................................................................33 Installation and How It Works .............................................................................................................................. 33 Float Drain Service Procedures ........................................................................................................................... 35 ILLUSTRATIONS .......................................................................................................................................35 Service Components ........................................................................................................................................... 36 Air Dryer Systems ................................................................................................................................................ 40 ACCESSORIES ...........................................................................................................................................48 Moisture Minder® ................................................................................................................................................ 48 Regeneration Flow Cut-Off Kit ............................................................................................................................. 49 Installation ............................................................................................................................................................ 49 Troubleshooting Regeneration Cutoff Solenoid (RCS) ....................................................................................... 49 PART NUMBERS .......................................................................................................................................51 Service Components ........................................................................................................................................... 51 Air Dryer Systems ................................................................................................................................................ 52 GLOSSARY OF TERMS ............................................................................................................................52 WARRANTY...............................................................................................................................................60 2 SAFETY MESSAGES IN MANUAL AND IN WARNING LABELS Safety messages appearing in the manual and on warning labels utilize signal words that translate to a level of risk. Below are the definitions of the words used: WARNING: Indicates a hazardous situation that, if not avoided, could result in death or serious injury. CAUTION: Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. REMINDER: Indicates suggestions for proper use. Warning labels are attached to the air dryer. They look something like those below. Be sure that these labels are visible and in place. If they become damaged or illegible, contact SKF for replacement labels -WARNINGBEFORE SERVICING SFD DRYER UNIT(S) RELIEVE ALL AIR PRESSURE FROM DRYER UNIT(S) AND AIR LINES DO NOT OVER-TIGHTEN CARTRIDGE Lubricate threads, O-rings & flat gasket with grease provided before installing cartridge Tighten cartridge ½ turn only after gasket contacts casting surface 3 SEPARATOR FILTER DRYER (SFD) Protect compressed air lines from oil, water and particulate The easy to maintain SFD is a compact heatless desiccant air dryer which delivers high quality compressed air capable of achieving superior pressure dew points -40°F or lower. Use the SFD when precision work requires high quality air. Reduce energy and operating costs with the SFD. Contaminated compressed air lines drags down productivity, raises operating costs, and increases maintenance requirements. SFD benefits include: • Requires less electrical usage than alternatives • Extends service life of pneumatic driven devices • Avoid expensive downtime to repair or replace equipment • Reduces prep time in spray applications • Eliminates rework due to compressed air contaminants • Modular design allows for quick, easy and flexible expansion Desiccant Cartridge “A” 4a Wet air adsorbed onto desiccant bed 3a Wet air enters desiccant bed 2a After passing through 0.1 micron filter pad, wet air enters cartridge 1a Inlet Port (¾") wet air to dryer Desiccant Cartridge “B” 4b Wet air removed from desiccant bed 3b Dried air desorbs (removes) condensate from bed 2b Dried air enters desiccant bed via regeneration valve 1b Wet air removed from dryer Cartridge A @ system pressure Cartridge B @ atmospheric pressure Listed are types of operations that significantly reduced operating costs • Paint/foam spraying • Sand/shot blasting • Air tools • Vehicle wash stations • Packing equipment • Lab measurement equipment • Drilling equipment • Railcar braking systems & Loci’s • Mining car dump stations • Dust collection systems • Baghouse equipment • Bottling equipment • Plasma cutting • Drag line shovels • Batch mixing • Rail maintenance equipment Simple and easy to service: Maintenance personnel can easily spin off the desiccant cartridges and replace service components in a matter of minutes. Designed for outdoors - complies with NEMA 4 Standard - when equipped with thermostatically controlled heater package keeps dryer performing during winter months. 4 SPECIFICATIONS SFD DRYER SYSTEMS Micro Logic Timers (MLT) 110 volt .072 ampere NEMA 4 24 volt 3.33 ampere NEMA 4 12 volt 6.88 ampere NEMA 4 110 volt, 75 watts, .68 ampere each 24 Volt, 75 watts, 3.125 ampere each 12 Volt, 75 watts, 6.25 ampere each ¾" NPT <40 cfm *1 ½" NPT manifolds *619780 kit for 80 cfm dryer systems optional 90 - 190 PSI 2 cartridge system 40 lbs 2 cartridge system 50 lbs 4 cartridge system 100 lbs 2 desiccant w/ 4 pound cartridges 4 desiccant w/ 4 pound cartridges 6 desiccant w/ 4 pound cartridges 8 desiccant w/ 4 pound cartridges 12 desiccant w/ 4 pound cartridges 18 desiccant w/ 4 pound cartridges 24 desiccant w/ 4 pound cartridges <80 cfm 75 lbs 2 desiccant w/ 8 pound cartridges 4 desiccant w/ 8 pound cartridges 6 desiccant w/ 8 pound cartridges 12 desiccant w/ 8 pound cartridges 18 desiccant w/ 8 pound cartridges 24 desiccant w/ 8 pound cartridges Yes Programmable Logic Controller Electrical Requirements (PLC) 110 volt .090 ampere NEMA 4 (PC) Class 1 div 2 Meets NEMA 7 Requirements - - Heaters 110 volt, 75 watts, (.68 ampere) each 24 Volt, 75 watts, (3.12 ampere) each 12 Volt, 75 watts, (6.25 ampere) each Inlet/Outlet Ports 1 ½" NPT Operating Pressures (All Dryer Systems) 90 -190 PSI Weight Desiccant Cartridges 4 cartridge system 120 lbs 6 cartridge system 170 lbs 8 cartridge system 240 lbs 12 cartridge system 340 lbs 18 cartridge system 510 lbs 24 cartridge system 680 lbs Dimensions (include external SKF oil coalescing prefilter) H=23.00" L=13.62" W=10.75" H=23.00" L=36.00" W=10.75" H=23.00" L=51.00" W=10.75" H=56.00" L=36.00" W=10.75" - 2 rows H=56.00" L=51.00" W=10.75" - 2 rows H=78.00" L=51.00" W=10.75" - 3 rows H=102.00" L=51.00" W=10.75" - 4 rows Weight w/ 8 Pound Desiccant Cartridges <240 cfm -175 lbs <400 cfm - 251 lbs <480 cfm - 350lbs <800 cfm - 502 lbs <1200 cfm - 753 lbs <1600 cfm - 1004 lbs Dimensions (include external SKF oil coalescer) H=42.50" L=13.62" W=10.75" H=42.50" L=34.00" W=10.75" H=30.25" L=51.00" W=10.75" H=62.50" L=51.00" W=10.75" - 2 rows H=92.75" L=51.00" W=10.75" - 3 rows H=127.00" L=51.00" W=10.75" - 4 rows Modular (expandable) Yes 5 Pneumatically Controlled NA ¾" NPT <80 cfm 1 ½" NPT 90 - 190 PSI 2 cartridge system 50 lbs 4 cartridge system 120 lbs 6 cartridge system 170 lbs Contact SKF Customer Service @ (888) 753 3477 Yes SFD DRYER SIZING CHART Max CFM Flow HP 15 5 15 5 20/27 5/7.5 20/27 5/7.5 40 10 40 10 40 10 40 10 40 10 40 10 60/80 15/20 60/80 15/20 60/80 15/20 60/80 15/20 70 15 70 15 120 30 120 30 120 30 120 30 200 50 200 50 200 50 200 50 240 60 240 60 400 100 400 100 600 125 600 125 800 150 800 150 * Heater equipped MLT Part# Filtration (micron) Type Voltage 640377 640393 640316 640218 640300 640207 640112* 640124* 640390 640397 640451 640404 640490 640497 640902 640905 640690 640698 640805 640802 640815 640812 640790 640797 640825 640822 640835 640832 640845 640842 640855 640854 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 3.0 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 3.0 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter 3.0 .01 Prefilter MLT MLT MLT MLT MLT MLT MLT MLT PC PC MLT MLT PC PC MLT MLT PC PC PLC PLC PLC PLC PC PC PLC PLC PLC PLC PLC PLC PLC PLC 110 110 110 110 110 110 12 24 None None 110 110 None None 110 110 None None 110 110 110 110 None None 110 110 110 110 110 110 110 110 6 # of Dryers ( 2 cart. Bracket # of rows Ea) Wall Wall Wall Wall Wall Wall Universal Universal Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall Wall 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 3 3 4 4 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 1 2 2 2 2 3 3 3 3 4 4 6 6 9 9 12 12 Max Length (L) Weight (lbs.) 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 13.5 36.0 36.0 36.0 36.0 13.5 13.5 36.0 36.0 36.0 36.0 54.0 54.0 54.0 54.0 36.0 36.0 54.0 54.0 54.0 54.0 54.0 54.0 46 46 50 50 50 50 50 50 50 50 120 120 120 120 53 53 120 120 120 120 170 170 170 170 240 240 340 340 510 510 680 680 WARNING Read, understand and follow safety precautions and instructions in this manual and in the labels attached to the dryer system. Failure to do so could result in serious injury, death and property damage. • • • • • • • • • Read and understand entire instruction manual before installing or servicing of SFD SFD dryer systems not designed for use other that removal of water from compressed air SFD dryer systems cannot be used for breathable air Never connect or disconnect a pipe/line containing air pressure or remove a component, fitting or pipe plug unless you are certain all air pressure has been shut off and relieved Always wear proper eye protection and never look directly into ports of SFD Sound decibels without silencer @ 120 db / with silencer @ 37db Never exceed recommended working air pressure of 190 psi/13.1 bar A by-pass system recommended making servicing of SFD dryer units easier and safer Use only proper tools and observe all precautions pertaining to the use of those tools GENERAL MOUNTING INSTRUCTIONS: • • • • • • • • • • Allow 2” min above cartridges for cartridge removal Air line routing and connections may be modified to accommodate space and application All air line connections require thread sealant Aluminum threads require an anti-seize compound (included within SFD dryer service kits) Optional thermostatically - controlled heaters available for MLT and PLC dryer systems SFD dryer systems must be mounted with the exhaust ports positioned downward and desiccant cartridges in upright position Mount SFD utilizing 3/8” grade 5 bolts, washers, lock washers and nuts are recommended and not furnished with air dryer kits Manifold design may be either square or round Plug electrical connection to dedicated and accessible wall receptacle Electrical cord replacement only with timer and coil only – cord and plug not serviced separately 7 BASIC OPERATION AND INSTALLATION MOUNTING INSTRUCTIONS Micro Logic Timer (MLT) manages regeneration cycles by energizing and de-energizing the air control valve at twominute intervals. However, when the air dryer is initially powered on, the MLT begins a startup sequence of four tensecond cycle intervals, and when completed, MLT begins cycling every two minutes. An LED on the MLT will be "on" during energized (charge) cycle and "off" during de-energized (regeneration) cycle. When LED is on, the left desiccant cartridge receives wet air and the right desiccant cartridge regenerates. After two minutes MLT (dryer) switches, LED is off as left canister now begins regeneration process and right desiccant cartridge receives wet air. A light flow of air from the desiccant cartridge through dryer’s exhaust port is normal during regeneration cycle. There should be no venting of air from desiccant cartridge when receiving wet air. When an SFD cycles, there will be a momentary burst of air from one SFD exhaust port (muffler). This is normal and will occur each time dryer cycles. Four cartridge MLT systems will have two cartridges regenerating one from each dryer unit, e.g., cartridges 1, 3 charge cycle, cartridges 2, 4 regeneration cycle 1. SFD dryer systems must be mounted with the exhaust ports positioned downward and desiccant cartridges in upright position 2. Power source: 120 Volt AC (grounded) surge protected (recommended) electric receptacle required for MLT and PLC dryer systems 3. Mount SFD down stream of air compressor reservoir 4. Mount SFD dryer with sufficient space around unit(s) to facilitate service and to provide visual access for periodic inspection allowing at least a 2" clearance above desiccant cartridges for removal 5. Installing a series of lines and shut-off valves in conjunction with installation of SFD dryer systems provides a by-pass system providing the ability to maintain operation of air system, when servicing unit 40 Max SFD Dryer Systems w/ MLT Mounting 1. Determine proper location for SFD as described in “General Mounting Instructions” pg. 7 2. Universal mounting brackets may be inverted to adapt for mounting units as required 3. Mount base assembly at chosen location making certain a minimum 2" clearance above desiccant cartridges for future service. Mark mounting hole locations and attach SFD to mounting location with a minimum of two (2) 3/8” bolts, lock washers and nuts 4. Use thread sealant on air line fittings to prevent air leaks a. Connect air line coming from compressor reservoir to SFD inlet port b. Connect SFD outlet port to air system 5. Apply an anti-seize (included with dryer) onto muffler threads and install muffler into each exhaust port of SFD 6. Plug-in MLT power cord to 110 -120 Volt AC grounded receptacle (surge protected recommended) REMINDER: 12 & 24 VDC MLT’s device are polarity sensitive. MLT will not operate if power (+) and neutral (-) leads are switched 8 7. Ensure that all air line fittings are properly connected 8. CAUTION: Slowly pressurize system 9. Check air line fittings for leaks and repair as necessary 10. Observe dryer operation for proper function as described in ANNUAL INSPECTIONS / AIRFLOW DIAGRAMS section 80 – 120 Max SFD Dryer Systems w/MLT Mounting 1. Determine proper location for SFD as described in “General Mounting Instructions” pg. 7 2. Install wall strut with slots against the wall and on top 3. Mount SFD base assemblies into wall strut slots 4. Assemble inlet and outlet manifolds to base assemblies making sure to apply an anti-seize (included with dryer) to threads of each retainer bolt. Inlet and outlet ports may be installed on right or left side of dryer to accommodate hose routing 5. Connect air lines to inlet and outlet ports of manifolds using appropriate thread sealant on air line fittings to prevent leaks 6. Install black ¼" air line so it connects front left port of SFD control unit to left front port of SFD auxiliary unit 7. Install ¼” air line so it connects right rear port of SFD control unit to right rear port of SFD auxiliary unit. 8. Apply anti-seize onto muffler threads and install muffler into each exhaust port of SFD 9. CAUTION: Slowly pressurize system 10. Check air line fittings for leaks and repair as necessary 11. Observe dryer operation for proper function as described in SFD OPERATION/CYCLE section Optional Manifold kits for MLT 619780 – 4 canister dryer systems 619785 – 6 canister dryer systems 9 Programmable Logic Control (PLC) 120 thru 800 Programmable Logic Control (PLC) manages regeneration cycles by energizing and de-energizing air control valves within PLC at 45-second intervals. When PLC is initially powered on, it begins a startup sequence cycling each dryer one time at five-second intervals then continues to cycle dryers at 45-second cycle intervals. During operation, a light flow of air from ONE exhaust port (muffler) is normal as this represents regeneration cycle of desiccant. The air flow will switch from one exhaust port (muffler) to the next one approximately 45 seconds in conjunction with PLC cycles. Example: 120 cfm – 1 cartridge regenerates every 45 seconds as three cartridges continue to receive wet air. Multiple row dryer systems will regenerate one cartridge from each row e.g., cartridge 1 row 1 cartridge 1 row 2, etc. Dryer cycles produce a momentary burst of air from one SFD exhaust port (muffler). This is normal and will occur each time SFD cycles. Mounting 1. Determine proper location for SFD as described in “General Mounting Instructions pg 7” 2. Install wall strut with small slots next to wall and on top 3. Mount SFD base assemblies into wall strut(s) a. 120 cfm (1 row with 2 dryer units - 4 cartridges 1 PLC) b. 200 cfm (1 row with 3 dryer units - 6 cartridges 1 PLC) c. 240 cfm (2 rows with 4 dryer units - 8 cartridges 1 PLC) d. 400 cfm (2 rows with 6 dryer units - 12 cartridges, 1 PLC e. 600 cfm (3 rows with 9 dryer units - 18 cartridges, 1 PLC f. 800 cfm (4 rows with 12 dryer units - 24 cartridges, 1 PLC REMINDER: Top rows of 240 – 800 cfm dryer systems have “T” fittings on side of dryer Bottom row of dryers have 90º fittings on sides of dryers 4. Assemble inlet and outlet manifolds to base assemblies making sure to apply an anti-seize (included with dryer) to threads of each retainer bolt. REMINDER: Inlet and outlet ports may be installed on right or left side of dryer to accommodate hose routing 5. Connect high-pressure air lines to inlet and outlet ports of manifolds applying appropriate thread sealant on air line fittings to prevent leaks 6. PLC signal line connections: a. 120 & 200 systems - connect first ¼” air line to 90º fitting located on primary unit die cast aluminum manifold to PLC fitting identified ”Pilot” (see “System Illustrations” pg. 43) b. Connect four (4) ¼” (120 cfm system) or six (6) ¼” (200 cfm system) air lines from signal ports of PLC to fitting located on sides of dryers c. 240 – 800 cfm systems - connect first ¼” air line to 90º fitting located on a primary units’ die cast aluminum manifold to PLC fitting identified ”Pilot (see “System Illustrations” pg. 43) d. Connect ¼” air lines from signal ports of PLC to “T” fitting on each side of dryers located on top row(s) of dryer system (see “System Illustrations” pg. 43) 10 e. Connect ¼” air line from top row “T” fittings to dryers located directly below f. Connect ¼” air line to 90˚fittings located on bottom row of dryers 7. CAUTION: Slowly pressurize system 8. Check air line fittings for leaks and repair as necessary 9. Observe dryer operation for proper function as described above in “Pneumatically Controlled” Pneumatically Controlled (PC) 40 thru 200 CFM SFD Dryer Systems Pneumatic Control (PC) manages regeneration cycles by metering a measured air flow through pneumatic manifold at approximately 60 second intervals– no electrical requirements. Example: 120 cfm – 1 cartridge regenerates every 60 seconds as three cartridges continue to receive wet air. During operation, a light flow of air from ONE exhaust port (muffler) is normal as this represents regeneration cycle of desiccant. The air flow will switch from one exhaust port (muffler) to the next one approximately 60 seconds in conjunction with pneumatic manifold cycles. Dryer cycles produce a momentary burst of air from one SFD exhaust port (muffler). This is normal and will occur each time SFD cycles. Mounting 1. Determine proper location for SFD as described in “General Mounting Instructions” pg. 7 2. Install wall strut with small slots next to wall and on top. 3. Mount SFD base assemblies as follows: a. 40 CFM (2 cartridges) units direct to wall or at point of use b. 80 cfm (primary and auxiliary unit – 4 cartridges c. 120 cfm 2 auxiliary units (4 cartridges) d. 200 cfm 3 auxiliary units (6 cartridges) 4. Assemble inlet and outlet manifolds to base assemblies making sure to apply an anti-seize (included with dryer) to threads of each retainer bolt. REMINDER: Inlet and outlet ports may be installed on right or left side of dryer to accommodate hose routing 5. Connect high-pressure air lines (190 psi/13.1 bar max) to inlet and outlet ports of manifolds REMINDER: Use appropriate thread sealant on air line fittings to prevent leaks 6. 80 CFM: a. Install black ¼” air line to connect front right side port of SFD primary unit to right front port of SFD auxiliary unit b. Install black ¼” air line from left side of primary unit to left side of auxiliary unit 7. 120 /200 CFM units: a. Connect one ¼” air line from primary unit with a 90° fitting located on a dryer’s die cast aluminum manifold to pilot port of PC control b. Install ¼” air lines one to each remaining connectors located at back of PC 11 8. CAUTION: Slowly pressurize system 9. Check air line fittings for leaks and repair as necessary 10. Observe dryer operation for proper function as described above in “Pneumatic Control” ANNUAL INSPECTIONS MLT (Micro Logic Timer) Dryers Operational Check: 1. Check electrical power to MLT 2. Check all air connections for leaks or damaged signal lines 3. Unit should exhaust (discharge) every two minutes 4. Refer to flow diagram detailed in FLOW DIAGRAM 5. If dryer fails to cycle, unplug timer, and manually cycle dryer several times turning small brass screw from 12 o’clock position to 2 o’clock position (approximately ¼ turn) located on spool valve. If dryer cycles manually, return brass screw back to original vertical position and reference “Troubleshooting SFD Air Dryer Systems”. Brass Screw PLC (Programmable Logic Control) Dryers Operational Check: 1. Check electrical power to PLC (Green light on switch) 2. Check all air connections for air leaks or damaged signal lines 3. Unit should exhaust (discharge) every 45 seconds 4. Refer to flow diagram detailed in FLOW DIAGRAM 5. If dryer fails to cycle refer to TROUBLE SHOOTING SFD AIR DRYER SYSTEMS PC (Pneumatic Control) Dryers Operational Check: 1. Check pneumatic connections for leaks, broken pilot signal lines, etc. 2. Unit should exhaust (discharge) approximately every 60 seconds 3. Refer to flow diagram detailed in FLOW DIAGRAM 4. If dryer fails to cycle, refer to TROUBLESHOOTING SFD AIR DRYER SYSTEMS 12 FLOW DIAGRAMS Internal Purge Twin Tower w/MLT The descriptions detailed in this internal purge schematic represent the sequencing of airflow as it relates to the actual drying process and transition – wet air to dry air - within all dryer systems including both Programmable Logic (PLC) and Pneumatically Controlled (PC) systems 1b Outlet Port dried air flows to system 4a Dried air enters "1" purge reservoir check valve open 4b Wet air exits"2" internal reservoir via orifice (check valve closed) 1 2 3a Wet air enters "1" desiccant bed 3b Wet air removed from "2" desiccant bed 2a Check valve "1" open 2b Check valve "2" closed 1a Inlet Port wet air enters dryer 1b Outlet Port wet air exhausted from dryer Wet Air Transition Air Dry air Internal Flows Total Cycle Sequence 240 sec. Cartridge 1 receives wet air for 120 sec. while cartridge 2 regenerates for 120 for sec. - MLT switches Cartridge 2 receives wet air for 120 sec. while cartridge 1 regenerates for 120 for sec. - MLT switches 13 Twin Tower w/MLT The descriptions detailed in this twin tower schematic represent the sequencing of airflow as it relates to the actual drying process and transition - wet to dry - within all dryer systems including both Programmable Logic (PLC) and Pneumatically Controlled (PC) systems 1b Outlet Port dried air flows to system 2a Wet air enters "1" desiccant bed 2b Wet air removed from "2" desiccant bed 1 2 3a Dried air leaves "1" desiccant bed 3a Dried air enters "2" desiccant bed 4b Regen valve "1" open 4b Regen valve "2" closed 1a Inlet Port wet air enters dryer 1b Outlet Port wet air exhausted from dryer Wet Air Transition Air Dry air Internal Flows Total Cycle Sequence 240 sec. Cartridge 1 receives wet air for 120 sec. while cartridge 2 regenerates for 120 for sec. - MLT switches Cartridge 2 receives wet air for 120 sec. while cartridge 1 regenerates for 120 for sec. - MLT switches 14 80 CFM w/MLT The descriptions detailed on page “Twin Tower w/MLT” schematic represents the sequencing of air flow as it relates to the actual drying process and transition - wet to dry - within all dryer systems including Programmable Logic (PLC) and Pneumatically Controlled (PC) systems 1 Wet Air 2 3 Transition Air 4 Dry air Internal Flows Total Cycle Sequence 120 sec. Cartridge 1, 3 receives wet air for 120 sec. Cartridge 2, 4 regenerate for 120 for sec. MLT switches Cartridge 2, 4 receives wet air for 120 sec. Cartridge 1, 3 regenerate for 120 for sec. MLT switches 15 120 CFM w/PLC and PC systems REMINDER: PC controller not illustrated however, distributes pilot signals in same sequence as a PLC controller. The descriptions detailed on page “Twin Tower w/MLT” schematic represents the sequencing of air flow as it relates to the actual drying process and transition - wet to dry - within all dryer systems including Programmable Logic (PLC) and Pneumatically Controlled (PC) systems. 1 Wet Air 2 3 Transition Air 4 Dry air Internal Flows PLC Total Cycle Sequence 180 sec. Cartridge 1 regenerates for 45 sec. Cartridge 2, 3, 4 receives wet air. PLC switches Cartridge 2 regenerates for 45 sec. Cartridge 1, 3, 4 receives wet air. PLC switches PC Total Cycle Sequence 240 sec. Cartridge 1 regenerates for 60 sec. Cartridge 2, 3, 4 receives wet air. PC switches Cartridge 2 regenerates for 60 sec. Cartridge 1, 3, 4 receives wet air. PC switches 16 SERVICE COMPONENTS Micro Logic Timer (MLT) Applications (5 – 120 CFM Dryer Systems) 1. Identify dryer system by counting numbers of desiccant cartridges, e.g., 2, 4, 6 2. Locate service component identity, e.g., A, B, C, etc. 3. Under “QTY”, order appropriate number of kits specific to cartridge totals Dryer Systems with 2 Illustration ref. 4 6 Cartridges Qty Qty Part Number 619000 619705 619710 619700 Qty 1 1 1 1 2 2 2 3 3 3 619667 619704 619734 619735 619708 619715 619702 1 1 1 1 2 2 1 2 2 2 2 4 2 3 3 3 3 6 3 619755 619925 619020 1 1 1 - - SFD "O" Ring/Gasket Kit Internal Purge 2 lb. Desiccant Cartridge Kit 4 lb. Desiccant Cartridge Kit Full Service Kit - (2) 4 lb cartridges, 2 inlet check valves, 2 purge valves, 1 outlet check valve 8 lb. Desiccant Cartridge Kit 4 lb. Desiccant Cartridge Kit Right hand adaptor plate with stud Left hand adaptor plate with stud Regeneration Valve Kit (includes 2 .016) Regeneration Valve Kit (includes 2 .030) Valve Service Kit - includes 2 inlet check valves, 2 purge valves, 1 outlet check valve Air Control Valve - Three air lines Air Control Valve - Two air lines Max 20 cfm prefilter coalescer complete assembly 619081 619160 1 - 1 - 1 Max 80 cfm prefilter coalescer complete assembly Max120 cfm prefilter coalescer complete assembly M N Not Shown 619245 619246 619860 619790 619792 619794 619935 619740 619701 619772 619750 619782 619784 619990 619995 619775 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 2 1 1 1 2 2 2 4 2 2 1 1 3 1 1 1 3 3 3 6 3 3 1 Max 200 cfm oil coalescing .01 prefilter w/pneumatic drain service kit Max 20 cfm oil coalescing .01 prefilter w/pneumatic drain service kit Integrated filter kit 110 Volt Timer 12 VDC Timer 24 VDC Timer MLT/Heater Wire Harness Pressure Relief Valve Inlet Check Valve Kit - Includes 2 inlet check valves Muffler 110 Volt Heater Kit (optional) 12 VDC Heater Kit (optional) 24 VDC Heater Kit (optional) Wall Mounting Bracket Universal Mount Bracket Moisture Minder (optional) O P P Not Shown Not Shown 619917 619780 619785 619942 619926 1 1 4 1 1 6 1 - Manifold Retaining Bolt Manifold/Mounting - two dryers (4 cartridges) Manifold/Mounting - three dryers (6 cartridges) Wall Strut single unit Regneration cut off kit A A, F A,D,I,J A A,F B C C D,I,J E E F G Not Shown H J K L Descriptions 17 Service Schematic dryer w/ MLT (Represents one dryer within MLT dryer system) A B C D, I, J E H G K L M F Internal filtration External to air dryer .01 filtration w/oil coalescer P O Optional Manifold kits for MLT 619780 – 4 canister dryer systems 619785 – 6 canister dryer systems 18 Programmable Logic Control (PLC) Applications (120, 240 400, 600, 800 CFM Dryer Systems) 1. Identify dryer system by counting numbers of desiccant cartridges, e.g., 2, 4, 6 2. Locate service component identity, e.g., A, B, C, etc. 3. Under “Qty”, order appropriate number of kits specific to cartridge total Dryer System with 4 6 8 12 18 24 Cartridges Illustration ref. A Part Number 619000 619704 A,I,J 619700 2 3 4 6 9 12 A,F 619710 619734 619735 619730 619731 2 2 2 4 - 3 3 3 6 - 4 4 4 8 - 6 6 6 12 9 9 9 18 12 12 12 24 619702 2 3 4 6 9 12 1 - 2 - - - - 1 - 2 3 4 1 1 2 2 3 4 619860 619740 619701 2 2 2 4 4 3 3 3 4 6 6 6 9 9 9 12 12 12 619772 619750 619990 619775 619917 619780 619785 619812 619820 4 2 2 1 4 1 1 - 8 4 3 1 8 1 1 6 3 4 1 6 2 1 - 12 18 24 6 9 12 6 12 24 Contact Customer 6 18 24 2 3 4 1 1 1 B C I,J 619160 619242 F 619245 H J K L M Not Shown O P P Q Q Qty Qty Qty Qty Qty Qty Descriptions 2 2 3 3 4 4 6 6 9 9 12 12 SFD "O" Ring/Gasket Kit Desiccant Cartridge Kit Full Service Kit - includes 2 cartridges, 2 inlet check valves, 2 purge valves, 1 outlet check valve & 10 micron filter package Desiccant Cartridge Kit (includes 2 cartridges Right hand adaptor plate with stud Left hand adaptor plate with stud Regeneration Valve Kit (includes 2 .060) Regeneration Valve Kit (includes 2 .090) Valve Service Kit - includes 2 inlet check valves, 2 purge valves, 1 outlet check valve Max 120 cfm .01 prefilter coalescer complete assembly Max 200 cfm .01 prefilter coalescer complete assembly Max 200 cfm oil coalescing .01 prefilter w/pneumatic drain service kit Integrated filter kit Pressure Relief Valve Inlet Check Valve Kit - Includes 2 inlet check valves 19 Muffler 110 Volt Heater Kit Wall Mounting Bracket Moisture Minder Manifold Retaining Bolt Manifold/Mounting - two dryers (4 cartridges) Manifold/Mounting - three dryers (6 cartridges) PLC Control Box PLC Control Box Schematic Dryer Components w/ PLC Represents one dryer within the dryer system ; A Q B C H I, J K L M F Internal to air dryer External to air dryer .01 filtration w/oil coalescer P O Optional Manifold kits for PLC 619780 – 4 canister dryer systems 619785 – 6 canister dryer systems 20 Pneumatically Controlled Applications 1. Identify dryer system by counting numbers of desiccant cartridges, e.g., 2,4,6 2. Locate service component identity, e.g., A, B, C, etc. 3. Under “Qty”, order appropriate number of kits specific to cartridge total Dryer Systems with 2 4 6 Canisters Illustration ref. Not Shown A Part Number 619000 619704 A,D,J,I A,F Qty Qty Qty 1 1 2 2 3 3 619700 1 2 3 1 1 1 2 2 2 2 4 3 3 3 C 619710 619734 619735 619715 - SFD "O" Ring/Gasket Kit Desiccant Cartridge Kit Full Service Kit - includes 2 cartridges, 2 inlet check valves, 2 purge valves, 1 outlet check valve Desiccant Cartridge Kit Right hand adaptor plate with stud Left hand adaptor plate with stud Regeneration Valve Kit (includes 2 .030) C 619730 - - 6 Regeneration Valve Kit (includes 2 .060) 619702 1 2 3 E 619985 1 - E 619987 1 E 619989 - - Valve Service Kit - includes 2 inlet check valves, 2 purge valves, 1 outlet check valve Pneumatic Control Valve - 1 Pneumatic Control Valve 1 1 1 H 619081 619160 619242 619245 619246 619860 619740 1 1 1 1 1 1 2 2 1 1 1 3 3 Max 80 cfm prefilter coalescer complete assembly Max 120 cfm prefilter coalescer complete assembly Max 200 cfm prefilter coalescer complete assembly Max 200 cfm prefilter coalescer complete assembly Max 20 cfm prefilter coalescer complete assembly Integrated filter kit Pressure Relief Valve J 619701 1 2 3 Inlet Check Valve Kit - Includes 2 inlet check valves K 619772 2 4 6 Muffler M 619990 1 2 3 Wall Mounting Bracket Not Shown 619775 1 1 1 Moisture Minder (optional) Not Shown 619942 1 - - Wall Strut O 619917 4 6 Manifold Retaining Bolt P 619780 1 - Manifold/Mounting - two dryers (4 cartridges) P 619785 - - 1 Manifold/Mounting - three dryers (6 cartridges) B D,J,I F Descriptions Pneumatic Control Valve 21 Service Schematic W/ Pneumatically Controlled Represents one dryer within the dryer system A E B C D, I, J H K M F Internal to air dryer External to air dryer .01 filtration w/oil coalescer P O Optional Manifold kits for Pneumatically Controlled #619780 – 4 canister dryer systems #619785 – 6 canister dryer systems 22 TROUBLESHOOTING SFD AIR DRYER SYSTEMS MLT, PLC and Pneumatically Controlled Operation/Cycle & Problem Scenarios Micro Logic Timer (MLT) manages regeneration cycles by energizing and deenergizing the air control valve at two-minute intervals. However, when the air dryer is initially powered on, the MLT begins a startup sequence of four ten-second cycle intervals, and when completed, MLT begins cycling every two minutes. An LED on the MLT will be "on" during energized (charge) cycle and "off" during de-energized (regeneration) cycle. When LED is on, the left desiccant cartridge receives wet air and the right desiccant cartridge regenerates. After two minutes MLT (dryer) switches, LED is off as left canister now begins regeneration process and right desiccant cartridge receives wet air. A light flow of air from the desiccant cartridge through dryer’s exhaust port is normal during regeneration cycle. There should be no venting of air from desiccant cartridge when receiving wet air. When an SFD cycles, there will be a momentary burst of air from one SFD exhaust port (muffler). This is normal and will occur each time dryer cycles. Four cartridge MLT systems will have two cartridges regenerating one from each dryer unit, e.g., cartridges 1, 3 charge cycle, cartridges 2, 4 regeneration cycle Programmable Control Box (PLC) controls regeneration cycles by energizing and de-energizing air control valves at 45-second intervals. A flow rate of approximately 3.5 cfm (99.1 lpm) air from ONE exhaust port (muffler) per dryer row occurs as normal regeneration air flow for desiccant bed drying. This air flow will alter in 45 second intervals from one exhaust port(s) to other in conjunction with PLC cycles. With dryer cycles (switching from one cartridge to other), a momentary burst of air expels from one exhaust port as remaining cartridges continue to receives wet contaminated air. This short burst of air is normal occurring each time dryer cycles. Pneumatically Controlled (PC) SFD dryer systems regenerate by energizing and de-energizing air control valves at approximately one (1)-min intervals. A continuous flow rate of approximately 3.5 cfm (99.1 lpm) air from ONE exhaust port (muffler) per dryer row occurs as normal regeneration air flow for desiccant bed drying. This air flow will alter in 60-second intervals from one exhaust port(s) to other in Pneumatic Controller (PC) conjunction with Pneumatic cycles. When dryer cycles (switching #619985 Shown from one cartridge to other) a short burst of air expels from one exhaust port as remaining cartridges continue to receive wet contaminated air. This short burst of air is normal occurring each time dryer cycles. 23 Troubleshooting SFD Dryer Systems Heavy air flow from exhaust ports (all models) NOTE: Light air flow of 1.6 cfm from either exhaust port (muffler) is normal as this represents the regeneration cycle Possible Cause Remedy Clean cavities and replace valve assemblies included in service kit Worn inlet check valves (O-rings) Item A,D Inlet Valve O- rings Retainer Inlet Location Worn purge valve or dirt/foreign material stuck in purge valve Clean cavities and replace purge valve assemblies included within service kit A,D Purge Valve O- rings Seal Retainer Purge Location Regeneration valve not closing Clean cavities and replace regeneration valve assemblies within service kit C Prior to serial number #xxxxxx all regeneration valves white Regeneration Valves (#619708) Red = .016" (max 27 cfm) (#619716 ) Black = .030" (max 40 cfm) (#619730) White = .060" (max 400 cfm) (#619731) Blue = .090" (max 800 cfm) 24 Troubleshooting SFD Dryer Systems cont’d Dryer will not cycle (switch) every two minutes w/Micro Logic Timer Possible Cause Micro logic timer (MLT) malfunctioning Remedy Kit ID's Test: Unplug timer, manually cycle dryer by turning brass screw several times in valve assembly to 2 o’clock (1/4 turn right) and back to 12 o’clock position. If dryer cycles replace MLT Ensure MLT is connected to surge protected power source Replace MLT timer Air control valve malfunction, i.e., leaking Vents Brass Screw G Test: Unplug timer, manually cycle dryer by turning brass screw several times in valve assembly to 2 o’clock (1/4 turn right) and back to 12 o’clock position. If dryer does not cycle replace air control valve Note: Brass screw (slot) must be in vertical (12 - 6 o'clock) run position Air Control air vents clogged (plugged) Clean air control vents Air tubing connecting air control valve and valve Replace ¼ air line tubing housing and/or manifold damaged or missing Replace air control valve E Inadequate air flow (volume) down stream from air dryer (all models) Possible Cause Desiccant cartridges require service Air flow restriction Remedy Replace desiccant cartridges - service kit Contact SKF Customer Service 1 888 SKF FIRST Kit ID's A Remedy Replace desiccant cartridges - service kit Replace MLT Replace air control valve assembly Replace regeneration valves Kit ID's A G E C Water in air system (all models) Possible Cause Desiccant cartridge contaminated Micro Logic Timer (MLT) malfunctioning Air control valve malfunctioning Regeneration valve malfunctioning 1/4" tubing connecting air control valve and valve housing and/or manifold damaged or missing Worn, stuck or clogged purge valve Purge Valves incorrectly serviced Compressed air usage exceeds drying capacity of dryer system Repair or replace ¼ air line tubing Replace purge valve assemblies Align exhaust ports in purge valve as detailed within service kit instructions D Contact SKF Customer Service 1 888 SKF FIRST Dryer will not cycle (switch) every 45 seconds (Programmable Logic Control PLC Models Only) Possible Cause Programmable Control Box (PLC) ¼ tubing connecting air control valve and valve housing and/or manifold damaged or missing Air Control air vent clogged (plugged) Remedy Ensure PLC is connected to power source (green light) Ensure air pressure though pilot signal line Disconnect one ¼ air line at a time from PLC checking for steady air flow during a regeneration cycle. If not replace PLC Q Repair or replace ¼ air line tubing and check all fittings for cracks or leaks Clean air control vent 25 Troubleshooting SFD Dryer Systems cont’d Dryer will not cycle (switch) approximately 60 seconds Class 1 Div 2 (PC Models only) Possible Cause Remedy Pneumatic Control Valves Contact SKF customer service 1 888 SKF FIRST ¼ tubing connecting air control valve and valve housing and/or manifold damaged or missing E Repair or replace ¼ tubing and check all fittings for cracks or leaks Pressure relief valve opens (all models) Possible Cause System pressure exceeds 200 psi (13.7 bar) relief valve setting Remedy Kit ID's Reduce system pressure Pressure control valve malfunction Replace pressure relief valve service kit H Inadequate air flow (volume) down stream from air dryer (all models) Possible Cause Desiccant cartridges require service Air flow restriction Remedy Replace desiccant cartridges - service kit Contact SKF Customer Service 1 888 SKF FIRST Kit ID's A Water in air system (all models) Possible Cause Desiccant cartridge contaminated Micro Logic Timer (MLT) malfunctioning (PLC) malfunctioning Pneumatic Control unit malfunctioning Air control valve malfunctioning Regeneration valve malfunctioning 1/4" tubing connecting air control valve and valve housing and/or manifold damaged or missing Worn, stuck or clogged purge valve Purge Valves incorrectly serviced Compressed air usage exceeds drying capacity of dryer system Remedy Replace desiccant cartridges - service kit Replace Micro Logic Timer (MLT) Replace Programmable Logic Control (PLC) Replace Pneumatic Control Unit assembly (PC) Replace air control valve assembly Replace regeneration valves G Q E E C Repair or replace ¼ air line tubing Replace purge valve assemblies Align exhaust ports in purge valve as detailed within service kit Contact SKF customer service 1 888 753 3477 or local SKF representative Inoperable Heaters (if equipped) Possible Cause Water in air dryer inlet/purge valve frozen Air dryer does not exhaust every two minutes Air dryer will not exhaust (purge) under 32º F Remedy Replace heater assemblies Replace heater assemblies Replace heater assemblies 26 L L L SERVICE REPLACEMENT PROCEDURES SFD AIR DRYING SYSTEM WARNING Read, understand and follow safety precautions and instructions in this manual and in the labels attached to the dryer system. Failure to do so could result in serious injury, death and property damage. Desiccant Cartridge Kit Options “A” #619700 Full Service Kit includes: - 2 - 4 lb. desiccant cartridges - 2 purge and 2 inlet check valves - 1 outlet check valves (used only in <80 systems) #619704 Desiccant Cartridge kit - 2 - 4 lb. cartridges #619705 Desiccant Cartridge Internal Purge kit includes - 2 - 2lb cartridges #619667 Desiccant Cartridge Kit; includes 2 - 8 lb. cartridges 1. 2. 3. 4. 5. 6. 7. 8. 619705 619700 619704 619667 WARNING: Relieve all system air pressure. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove it. Discard. Remove and discard O-ring from adapter plate stud Clean top surface of adapter plate and threaded stud Apply a light coating of grease on O-ring (included in kit). Install O-ring on stud Install filter pad around stud Apply a generous coat of grease on the new desiccant cartridge gasket surface Thread new cartridge onto stud turning clockwise. When gasket contacts adapter plate, tighten cartridge 1/2 to 3/4 turn REMINDER: DO NOT OVER TIGHTEN as it will result in damage to dryer and make it difficult to remove desiccant cartridge! Adapter Plate/Cartridge Stud (B) #619734 - #619735 (Instructions for <40 cfm dryers) 1. WARNING: Relieve all system air pressure 2. Remove air line from outlet port of dryer 3. Remove 8 screws (4 on each side) of dryer manifold and remove manifold from dryer and discard 2 O-rings 4. Remove spring and regeneration valve from defective adapter plate and second adapter plate 5. Remove 6 - ⅜" bolts attaching adapter plate to valve body 6. Remove 2 - ⅜" allen head bolts from top of adapter plate and remove adapter plate, gasket and/or O-ring 7. Remove all remaining gasket material from valve housing and clean sump of valve house 8. Position gasket and/or O-ring onto valve body 9. Align adapter plate with holes onto valve body 10. Install new O-rings onto air dryer manifold and position into adapter plates 27 11. Reinstall 8 screws (4 on each side) and torque to 5 – 6 ft. lbs. 12. Reattach the 6 bolts through valve body into adapter plate – do not tighten 13. Reattach 2 ⅜" allen head bolts through adapter plate into valve body 14. Torque all bolts to 50 – 60 ft. lbs. 15. Reinstall both regeneration valves and springs into adapter plates 16. Install 2 new O-rings onto shoulders of manifold and install into adapter plates 17. Reinstall 8 screws (4 on each side) into manifold and torque to 5 – 6 ft. lbs. 18. Reconnect air line to outlet port of manifold 19. Slowly apply air pressure and check for leaks Instructions for 80- 800 cfm air dryer systems 1. WARNING: Relieve all system air pressure 2. Remove air line from outlet port manifold 3. Remove “T” bolts from outlet manifold, remove manifold and discard green O-rings Outlet Manifold 4. Remove 8 screws (4 on each side) of dryer manifold, remove manifold from dryer and discard O-rings 5. Remove spring and regeneration valve from defective Dryer Manifold adapter plate and second adapter plate 6. Remove 6 - ⅜" bolts attaching defective adapter plate to valve body 7. Remove 2 ¼” allen head bolts from top of adapter plate and remove adapter plate, gasket and/or O-ring 8. Remove all remaining gasket material from valve housing and clean sump of valve house 9. Position gasket and/or O-ring onto valve body 10. Align adapter plate with holes onto valve body 11. Reattach the 6 bolts through valve body into adapter plate – do not tighten 12. Reattach 2 ⅜" allen head bolts through adapter plate into valve body 13. Install new O-rings onto air dryer manifold and position into adapter plates 14. Reinstall 8 screws (4 on each side) and torque to 5 – 6 ft. lbs. 15. Install a new O-ring to connections between manifold and dryer and “T” bolts and manifold 16. Torque bolts attaching new adapter plate to 50 – 60 ft. lbs 17. Torque “T” bolts to 50 – 60 ft. lbs. 18. CAUTION: Slowly pressurize system and check for any air leaks Desiccant Cartridge, Filter Pad Element and Filter Plate Replacement “F” #619710, #619860 1. WARNING: Relieve all system air pressure 2. Disconnect air line from inlet port of dryer 3. Using a strap wrench, turn the desiccant cartridge counterclockwise, remove, and discard 4. Remove and discard O-ring from adapter plate stud and filter elements 5. Remove four (4) 3/8" allen head bolts located at top of adapter plate castings 6. Remove twelve (12) 3/8" hex head bolts attaching bottom valve housing to adapter plate castings 7. Remove bottom valve housing assembly 8. Remove two filter plates, gaskets and O-rings (late model version only) and discard 28 Optional in dryers prior to Serial # xxxxxx 9. Clean valve housing sump, gasket surface and inside of two (2) adapter plates of oil and contaminates 10. Place new gasket or O-ring at each valve housing bolt flange 11. Place new filter plate into each valve housing cavity position filter plates in cavities, as shown in Fig 1, with arrows pointed toward front of valve housing 12. Reinstall valve housing assembly to adapter plate castings 13. Torque (16) bolts to 25-30 ft. lbs. 14. Clean top surface of adapter plates and threaded studs 15. Position new filter pad element around each stud and onto adapter plate 16. Using grease supplied, apply a light coating onto O-rings and install onto threaded studs 17. Apply a generous coat of grease on new cartridge gasket surface 18. Thread new cartridge onto studs turning clockwise. When gasket contacts adapter plate, tighten cartridge 1/2 turn. DO NOT OVER TIGHTEN! 19. Re-connect air line to air dryer inlet port Micro Logic Timer Replacement (MLT) item “G” #619790 (MLT Dryer Systems only) 1. 2. 3. 4. 5. 6. Disconnect power cord from electrical outlet or VDC power source Remove round locking screw by turning counterclockwise Remove MLT from stem of air control valve Install new MLT onto stem of air control valve Reinstall round locking screw by turning clockwise (hand tighten only) Reconnect MLT to electrical or VDC power source (timer will cycles) Air Control Valve - MLT Dryer Systems “E” #619925 (two air lines) #619755 (three air lines) 1. Disconnect power from MLT 1.1. With system pressurized, cycle dryer several times turning small brass screw from 12 o’clock position to 2 o’clock position approximately ¼ turn (located right of MLT) 1.2. If exhaust air burst does not occur, replace valve 1.3. If exhaust air burst does occur, turn screw back to original position counterclockwise (screw slot must be in vertical position for normal operation) 1.4. Failure of dryer to exhaust could also be due to malfunctioning MLT or purge valve Refer to “MLT Dryer Systems Operation/Cycle & Problem Scenarios” 2. If valve #619925 is diagnosed as faulty, replace as follows: 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. WARNING: Relieve all system air pressure Unplug MLT from power source Remove two (2) air lines connected to fittings in air valve Remove plastic retaining nut and MLT from valve stem and set aside both for re-assembly later Remove three (3) screws holding valve to manifold. Remove valve and discard Install new push connect air line fittings to open ports of new valve Install new small O-ring on top of valve (use small amount of grease to hold in place) Attach valve to manifold with three (3) screws included within kit Tighten screws to 15-20 in lb. Re-connect two (2) air lines to push connect fittings in back ports of valve 29 2.11. Re-assemble MLT assembly onto valve stem and secure with retaining nut (finger tight) 2.12. Re-connect electrical power (110 - 120 volt) 3. If valve is diagnosed as faulty, replace 619755 as follows: 3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8. 3.9. 3.10. 3.11. WARNING: Relieve all system air pressure WARNING: Unplug MLT from power source Remove three (3) air lines connected to fittings in air valve (2 in back – 1 in front) Remove plastic retaining nut and MLT from valve stem and set aside both for re-assembly later Remove three (3) screws holding valve to manifold remove valve and discard Install new (3) push connect air line fittings to open ports of new valve Attach valve to manifold with three (3) screws included within kit Tighten screws to 15-20 in lb. Re-connect air line from manifold to front port of air valve Re-connect two remaining air lines to back ports of valve Re-assemble MLT assembly to valve stem and secure with retaining nut (finger tight) 3.12. Re-connect electrical power (110 - 120 volt) #619702 Valve Service Kit Purge (Exhaust) Valves - (All models) 1. WARNING: Relieve all system air pressure 2. Remove two bolts that attach the purge valve retainer and remove from housing 3. Remove the purge valve assembly and O-ring from the purge cavity, trash screen and discard 4. Clean the cavity thoroughly 5. Remove the three (3) O-rings from retainer and discard 6. Using lubricant supplied, lightly grease all three new O-rings 7. Install on the retainer, the two (2) larger O-rings. Then install the third (smaller) O-ring 8. Apply a light coating of grease around the O-ring seat on valve assembly and install the thin Oring on the purge valve seat 9. Install new trash screen (small end first) into valve housing 10. Install valve assembly into cavity and insure that hole in valve sleeve aligns over housing exhaust port (muffler). Use care not to dislodge the thin O-ring from its seat REMINDER: If the SFD purge valve port does not align with housing exhaust port, SFD will not exhaust! 1. 2. 3. Install retainer to housing Apply a light coating of grease on the threads of the two retainer bolts Install two retainer bolts and tighten to 15 ft. lb. Inlet Check Valves - (All models) 1. WARNING: Relieve all system air pressure 2. Remove two bolts from inlet check valve retainer and remove seal retainer 3. Remove inlet check valve spindle from cavity and discard 4. Clean cavity thoroughly 5. Remove all O-rings from retainer and discard 30 6. Install two (2) large O-rings and (1) smaller O-ring into grooves of seal retainer 7. Lubricate O-rings on check valve sleeve and install valve assemble (small end first) into the inlet cavity. Make sure spindle is completely seated 8. Lubricate O-rings on seal retainer and reinstall retainer. AVOID TWISTING SEAL RETAINER 9. Apply a light coating of grease on the threads of the two retainer bolts 10. Reinstall the retainer bolts torque to 15 ft. lb. Outlet Check Valve – (MLT equipped dryers only) 1. WARNING: Relieve all system air pressure 2. Disconnect air line from dryer outlet port 3. Remove check valve nut 4. Remove and discard O-ring, spring, spindle, and ball 5. Clean nut and check valve cavity thoroughly REMINDER: If excessive oil is evident in check valve cavity, oil separator and desiccant cartridges require servicing 6. Install new ball into cavity 7. Install spindle with spring pocket facing up into cavity 8. Place spring into spring pocket of spindle 9. Apply a light coating of grease onto O-ring and place onto check valve nut 10. Apply light coating of grease to nut threads Install nut and tighten to 60 ft. lbs. 11. Re-connect air line to outlet port Regeneration Valve - #619708, #619716, #619730, #619731 Dryers not equipped with SFD manifold kits 1. WARNING: Relieve all system air pressure 2. Disconnect air line from dryer outlet port 3. Remove the eight (8) socket head bolts fasting manifold to dryer 4. Remove manifold 5. Discard O-rings, springs and regeneration valves 6. Clean valve cavities in housing 7. Position new valve spindles into cavities with spring pockets out 8. Position springs into valves 9. Lubricate new O-rings and install onto manifold bosses 10. Position manifold onto adaptor castings ensuring O-rings are properly positioned in bores. 11. Install eight (8) socket head bolts and tighten to 5-6 in. lbs. Torque. 12. Reconnect air line to outlet port. Dryers equipped with SFD manifold kits 1. WARNING: Relieve all system air pressure 31 2. Disconnect system air line from manifold 3. Remove black retainer bolts from outlet manifold and remove manifold from dryer unit 4. Discard O-rings between manifolds, 5. Remove the eight (8) socket head bolts fasting manifold to dryer(s) and remove 6. Discard O-rings, springs and regeneration valves 7. Clean valve cavities in housing 8. Position new valve spindles into cavities with spring pockets out 9. Position springs into valves 10. Lubricate new O-rings and install onto manifold bosses 11. Position manifold onto adaptor castings ensuring O-rings are positioned properly in bores. 12. Install eight (8) socket head bolts and tighten to 5-6 in. lbs. Torque. 13. Install new O-rings into recess of manifolds 14. Position outlet manifold onto dryer and reinstall black retainer bolts and tighten to 50 -60 ft. lbs. torque 15. Reconnect air line to manifold Heater Assembly (if equipped) 110 Volt #619750, 24 VDC #619784, 12 VDC #619782 REMINDER: Heater prevents inlet and purge valves from freezing when SFD mounted in an area where ambient air temperatures may fall below 32° F (0° C) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Disconnect heater lead wire Remove two screws attaching heater connector to casting Remove heater/thermostat assembly and discard Slide new O-ring over heater and thermostat into position around connector flange Apply a light coating of anti-seize to the heater element and thermostat cavity Insert heater element into hole and twist slightly to spread anti-seize Place thermostat into position in cavity and ensure thermostat sits flat in cavity Place foam cube on top of thermostat, Insert the (2) 8-32 x 1/2” screws in heater base inserting one screw through eyelet of ground wire Position heater assembly into position and secure. Reminder: make sure ground wire is secured Reconnect heater Reset pneumatic control system to home (run) position (40, 80, 120) #619785, 1. Remove one small valve identified as L25320 from assembly and with regulated air pressure 619785 (35 min – 120 max psi) carefully blow into port 1 2. Remove other small valve identified as L25320 from assembly and with regulated air pressure (35 min – 120 max psi) carefully blow into port 12 619787 619789 #619787 or #619789 1. Remove one small valve identified as L25320 from assembly and with regulated air pressure (35 min – 120 max psi) carefully blow into port 12 2. Reinstall valve 3. Slowly Return air pressure to unit and check for 45 second cycles REMINDER: an erratic cycle may occur, however, should sequence normally after one complete cycle 32 OIL COALESCER Installation and How It Works WARNING Read, understand and follow safety precautions and instructions in this manual and in the labels attached to the dryer system. Failure to do so could result in serious injury, death and property damage. It is the responsibility of installer and/or end user to collect condensate and oil into appropriate container and dispose according to local ordinances How to Route Air Lines for Automatic Filter Drain 1 Route a pilot line from the pilot signal port, located on the bottom of the drain, to "T" fitting on the SFD Dryer. 2 Run a drain line from the drain outlet (located on the side of the drain) to an appropriate discharge and collection location How It Works Condensation (1) rests in the bottom of the filter housing, waiting for the drain to be actuated. 1 1 2 Filter drain at rest (2) Pilot signal from air dryer received 8 Pilot signal (3) causes piston to shift (4), closing off drain port 2 (9). As piston continues to move it opens up the stainless ball check (8) allowing condensate to be forced into the internal reservoir creating a discharge pressure 9 4 3 Valve at Rest 8 When pilot signal is relieved (6), piston returns to relaxed 3 position (7), ball check closes (8), preventing zero pressure loss in system; drain port (9) opens and stored condensate is ejected from the drain port. 7 6 33 9 Coalescing Element Replacement (6 month intervals) WARNING Read, understand and follow safety precautions and instructions in this manual and in the labels attached to the dryer system. Failure to do so could result in serious injury, death and property damage. It is the responsibility of installer and/or end user to collect condensate and oil into appropriate container and dispose according to local ordinances Filter Head Filter Head Remove pilot signal line (1) and drain tube (2) from filter assembly. Outer Tube Bottom Cap Remove outer tube (3) from filter head by holding filter head and rotating tube counter clockwise. Using a 5/16” wrench (4), remove baffle nut from threaded rod below oil coalescing filter. 1 3 4 Remove bottom baffle, filter, top baffle nut, and Oring (5). 5 6 Replace new O-ring, top baffle plate, element, bottom baffle plate and nut (6). Reinstall outer tube by rotating onto filter head (7), Reinstall pilot signal line (8) and drain tube (9) from filter assembly. 7 9 8 34 2 Float Drain Service Procedures WARNING Read, understand and follow safety precautions and instructions in this manual and in the labels attached to the dryer system. Failure to do so could result in serious injury, death and property damage. Locate bottom cap on 20 series oil coalescing filter Remove bottom cap from outer tube by rotating counter clockwise Rotate stem of float drain clockwise to remove float drain from bottom cap (stem) Install new float drain by inserting stem first into bottom cap, hold stem and turn bottom cap clockwise Turn bottom cap clockwise to replace cap on outer filter tube Complete 35 ILLUSTRATIONS Service Components Bottom Cap Valve Positions 4 lb. Desiccant bed Desiccant Cartridges Included in kits #619700, #619704, #619710 2 lb. Desiccant bed Internal Regeneration Cartridges < 15 cfm #619705 8 lb. Desiccant bed Red = .016 Black = .030 White = .060 Blue = .030 Desiccant Cartridges included in Kit #619667 Regeneration Valves included in kits #619708, #619715, #619730, #619731 Outlet check valve Included in kits #619700, #619702 Inlet check valves included in kits #619700, #619702 36 Service Component Illustrations, cont’d Purge valves included in kits #619700, #619702 Air Control Valve Kit #619925 (two air lines) #619755 (three air Pressure Relief Valve #619740 (200 ± 6 psi max,65 CFM max) #619734 RH adapter plate #619735 LH adapter plate Manifold System 444444 #619780 Manifold System #619785 Manifold Retaining Bolt #619917 O - Ring Gasket Kit #619000 37 Service Component Illustrations, cont’d MLT - Micro Logic Timer 110 Volt #619790 12 VDC #619912 24 VDC #619924 Programable Logic Control PLC #619812 - 4 & 8 cart, #619820 - 6 - 24 cart Integrated filter kit #619860 Oil coalescing prefilter element #619245, #619246 38 Service Component Illustrations, cont’d Heaters: 110 VDC #619750 12 VDC #619782, 24 VDC #619784 12, 24 vd MLT/Heater wire harness connector #619935 Pneumatic Control Service Valves #619785 Pneumatic Control Service Valves #619787 Pneumatic Control Service Valves #619789 Wall Mount Bracket #619990 Universal Mounting Bracket #619995 39 Air Dryer Systems Micro Logic Timer (MLT) models W L W H1 H SFD Dryer System Max CFM Micron Filtration 640207 640218 640300 640316 40 27 40 27 .01 external .01 external 3.0 internal 3.0 internal With Pre-filter Oil Coalescer H L W 34.00" 13.62" 13.75" 34.00" 13.62" 13.75" Without pre-filter Oil Coalescer H L W 23.00" 13.62" 10.75" 23.00" 13.62" 10.75" W L H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 34.00" 36.00" 10.75" Without pre-filter Oil Coalescer H L W 640404 80 .01 external 640443 80 3.0 internal 23.00" 32.50" 10.75" Allow at least an additional 2" above desiccant cartridge for service removal 40 Programmable Logic Control PLC models W L H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 34.00" 36.00" 10.75" Without pre-filter Oil Coalescer H L W 640802 120 .01 external 640805 120 3.0 internal 23.00" 32.50" 10.75" Allow at least an additional 2" above desiccant cartridge for service removal W L H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 34.00" 51.00" 10.75" Without pre-filter Oil Coalescer H L W 640812 200 .01 external 640815 200 3.0 internal 23.00" 45.50" 10.75" Allow at least an additional 2" above desiccant cartridge for service removal 41 Programmable Logic Control PLC models L W H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 56.00" 36.00" 10.75" Without pre-filter Oil Coalescer H L W 640820 240 .01 external 640825 240 3.0 internal 46.00" 32.50" 10.75" Allow at least an additional 2" above desiccant cartridge for service removal 42 Programmable Logic Control PLC models W L H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 56.00" 51.00" 10.75" Without pre-filter Oil Coalescer H L W 640832 400 .01 external 640835 400 3.0 internal 46.00" 45.50" 10.75" Allow at least an additional 2" above desiccant cartridge for service removal 43 Programmable Logic Control PLC models L W H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 78.00" 51.00" 10.75" Without pre-filter Oil Coalescer H L W 640842 600 .01 external 640845 600 3.0 internal 68.00" 45.50" 10.75" Allow at least an additional 2" above desiccant cartridge for service removal 44 Programmable Logic Control PLC models L W H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 102.00" 51.00" 10.75" Without pre-filter Oil Coalescer H L W 640852 800 .01 external 640855 800 3.0 internal 92.00" 45.50" 10.75" Allow at least an additional 2" above desiccant cartridge for service removal 45 Programmable Logic Control PLC models W L W H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 34.00" 13.62" 11.75" Without pre-filter Oil Coalescer H L W 640397 40 .01 external 640390 40 3.0 internal 22.00" 13.62" 11.75" Allow at least an additional 2" above desiccant cartridge for service removal L W H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 34.00" 34.00" 11.75" Without pre-filter Oil Coalescer H L W 640490 80 .01 external 640497 80 3.0 internal 21.00" 30.40" 11.75" Allow at least an additional 2" above desiccant cartridge for service removal 46 Pneumatically Controlled (PC) models L W H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 34.00" 34.00" 11.75" Without pre-filter Oil Coalescer H L W 640696 120 .01 external 640690 120 3.0 internal 21.00" 30.40" 11.75" Allow at least an additional 2" above desiccant cartridge for service removal W L H SFD Dryer System Max CFM Micron Filtration With Pre-filter Oil Coalescer H L W 24.00" 51.00" 11.75" Without pre-filter Oil Coalescer H L W 640797 200 .01 external 640790 200 3.0 internal 21.00" 45.60" 11.75" Allow at least an additional 2" above desiccant cartridge for service removal 47 ACCESSORIES Moisture Minder® • #619775 • Automatically operates each time compressor cycles • Requires no electricity • Stainless steel reservoir • Various mounting options included • Seals made of Teflon® and Viton® • Standard valve rated at 300psi • Valves operate without pressure drop in air system • Made in the U.S.A. • Can use with synthetic oils • Saves money How it Works Condensation enters Moisture Minder® through inlet port (1) Pilot signal (1) causes piston to shift closing off drain port (2). Piston (3) engages stainless steel check ball (4) directing condensate up into external reservoir. 4 3 1 When dryer regenerates, pilot signal is relieved, piston returns to home position (5), and check ball closes (6) preventing zero pressure loss from system. Drain port (2) opens draining condensate from external reservoir 6 5 1 2 48 2 Regeneration Flow Cut-Off Kit • • • • #619926 Reduces air compressor run times Designed for 7HP air compressors or less SFD Dryer package regenerates only when compressor motor operating (pumping) a minimum (2) two minute (120 seconds) cycles MLT (Micro Logic Timer) #619790 not included in kit WARNING Read, understand and follow safety precautions and instructions in this manual and in the labels attached to the dryer system. Failure to do so could result in serious injury, death and property damage. Installation • Disconnect air line from outlet port of air dryer • Disconnect two (2) ¼” air lines from air control valve located on back of control valve • Remove MLT from air control valve and set aside for later installation • Remove eight (8) bolts fastening manifold to adaptor castings • Remove manifold assembly from adaptor castings and discard • Lubricate new O-rings and install onto manifold bosses of new manifold/valve assembly • Position manifold/valve assembly onto adaptor castings ensuring O-rings are properly positioned in bores REMINDER: Make sure valves & springs remain in position in both bores of adaptor castings • Reinstall eight (8) bolts and tighten to 45-65 in. lbs. torque • Reinstall MLT, previously removed, onto control valve of new assembly • Reconnect two (2) ¼” air lines previously removed to air control valve • Connect open power lead to appropriate 120 Volt AC power source controlling compressor motor low pressure “On” and high pressure “Off” cycles • Re-connect air line to dryer outlet port • Check all connects for air leaks Troubleshooting Regeneration Cutoff Solenoid (RCS) Regeneration Cutoff Solenoid (RCS) manages regeneration purge cut off by energizing and de-energizing the air control valve in unison with compressor’s pressure control switch. When air compressor electric motor runs (pumping), the RCS allows pilot air to flow to air control valve located under manifold. During compressor “on” time, the air dryer pneumatically cycles every two minutes with Micro Logic Timer (MLT). When air compressor reaches cut off pressure, the electrical power to RCS will be off, which allows air control valve to switch, cutting off pilot signal to air control valve located under manifold. The MLT continues to cycle electrically, however, with pilot air removed from air control valve, dryer no longer 49 cycles pneumatically thereby cutting of continuous purge flow during compressor “off” or non-pumping cycle. When an SFD cycles, there will be a momentary burst of air from one SFD exhaust port (muffler). This is normal and will occur each time dryer cycles. Four cartridge MLT systems will have two cartridges regenerating one from each dryer unit, e.g., cartridges 1, 3 charge cycle, cartridges 2, 4 regeneration cycle G Regeneration Cutoff Solenoid (RCS) Connect Wires to Air Compressor Pressure Control Switch E Air Control Valve 1 #619925 MLT (Micro Logic Timer) refer to pg. 15 E Air Control Valve #2 #619755 RCS (Regeneration Cutoff Solenoid) Possible Cause Regen air does not stop when compressor pump is off Remedy Check ekectrical connection on compressor pressure switch Cracked or broken pilot signal hose #1 to air control #2 Replace ¼″ hose Plug vents Remove vents, clean and reinstall Defective coil and/or air control valve RCS and Air Control valve test procedures Step 1: Disconnect coil from air compressor pressure control switch. G E Brass Screw Vents Dryer does not cycle every two minutes when compressor is on Step 2: With compressor pumping , manually cycle air control valve by turning brass screw in air control valve to 2 o’clock (1/4 turn right) and back to 12 o’clock position. If regen stops flowing, replace coil assembly "G". If regen does not stop flowing, proceed next step Step 3: Replace air control valve "E", reinstall RCS onto air contol vlave and reconnect electrical connections to pressure control switch. Note: make sure brass screw is in 12 - 6 o'clock position for normal operation Refer to Micro Logic Timer (MLT) section: Dryer will not cycle (switch) every two minutes w/Micro Logic Timer on pg. 15 50 G E PART NUMBERS Service Components 619000 619020 619081 619160 619242 619245 619246 619667 619700 619702 619704 619705 619708 619710 619715 619730 619731 619734 619735 619740 619750 619755 619765 619772 619775 619780 619782 619784 619785 619790 619912 619924 619812 619820 619860 619917 619925 619926 619935 619942 619985 619987 619989 619990 619995 Service Components SFD "O" Ring/Gasket Kit for all valves 20 cfm prefilter coalescer 40 - 80 cfm prefilter coalescer 120 cfm prefilter coalescer 200 cfm prefilter coalescer Service kit for Prefilter coalescer #619081, #619160, #619242 Service kit for Prefilter coalescer #619020 Desiccant Cartridge Kit; includes 2 - 8 lb. cartridges Full Service Kit; includes 2 - 4 lb. dessicant cartridges, 2 purge valves, 2 inlet check valves, 1 outlet check valve Valve Service Kit includes 2 purge valves, 2 inlet check valves 1 outlet check valve Desiccant Cartridge kit 2 - 4 lb. cartridges Desiccant Cartridge Internal Purge kit includes 2 - 2 lb. cartridges Regeneration Valve Kit ( .016 orifice); includes 2 red valves Desiccant Cartridge Kit with internal filters; includes 619704 (2) desiccant cartridges, 2 sets of filters Regeneration Valve Kit (.030 orifice); includes 2 black valves Regeneration Valve Kit (.060 orifice); includes 2 white valves Regeneration Valve Kit (.090 orifice); includes 2 blue valves Right hand adaptor plate with stud Left hand adaptor plate with stud Pressure Relief Valve 200 psi 110 Volt Heater Kit Air Control Valve - Three air lines Obsolete Cartridge Mounting Stud use RH 619734 or LH 610735 Muffler includes 1 Moisture Minder includes 1 Manifold/Mounting - two dryers 12 VDC heater 24 VDC heater Manifold/Mounting - three dryers 110 Volt Timer 12 VDC Timer 24 VDC Timer PLC Control Box for 4 or 8 cartridges PLC Control Box for 6,12,18,24 cartirdges Filtration/Oil Separator Kit; includes set of 2 Manifold Retaining Bolt includes 1 Air Control Valve - Two air lines Regeneration flow cut off kit Wire harness Wall Strut single unit Pneumatic Control Valve for single dryer assembly Pneumatic Control Valve for 2 dryer assembly Pneumatic Control Valve for 3 dryer assembly Wall Mounting Bracket Universal Mount Bracket 51 Air Dryer Systems 640200 640207 640216 640218 640300 640316 640390 640392 640393 640397 640400 640404 640405 640450 640443 640455 640490 640497 640650 640690 640697 640790 640797 640800 Air Dryers 40 CFM, MLT design with two 4 lb. cartridges, 12 volt w /Heater, internal filters, universal truck mount bracket for moble applications 40 CFM, MLT design with two 4 lb. cartridges, 24 volt w /Heater, internal filters, universal truck mount bracket for moble applications Future Obsolete Use 640207 40 CFM, 110 volt MLT design with two 4 lb. cartridges, 2 mufflers, #619081 prefilter coalescer Future Obsolete use 640218 27 CFM, 110 volt MLT design with two 4 lb. cartridges, 2 mufflers # 619020 prefilter coalescer 40 CFM,110 volt MLT design, with two 4 lb. cartridges, 2 mufflers 27 CFM, 110 volt MLT design with two 4 lb. cartridges, 2 mufflers 40 CFM, PC design with two 4 lb. cartridges, 2 mufflers Class I Div II 15 CFM, 110 volt MLT design with 2 internal purge 2 lb. cartridges, 2 mufflers 15 CFM, 110 volt MLT design with 2 internal purge 2 lb. cartridges, 2 mufflers, #619020 prefilter coalescer 40 CFM, PC design with two 4 lb. cartridges, 2 mufflers, #619020 prefilter coalescer, Class I Div II Future Obsolete use 640404 80 CFM, w/manifolds 110 volt MLT design with four 4 lb. cartridges, 4 mufflers, # 619081 prefilter coalescer 80 CFM, w/manifolds, 110 volt MLT design with four 4 lb. cartridges, 4 mufflers, superseded to 640404 80 CFM, 110 volt MLT design with four 4 lb. cartridges, 4 mufflers 80 CFM, w/manifolds, 110 volt MLT design with four 4 lb. cartridges, 4 mufflers 40 CFM, auxillary design, two 4 lb cartridges, 2 mufflers 80 CFM, PC design with four 4 lb. cartridges, 4 mufflers, Class I, Div II 80 CFM, PC design with four 4 lb. cartridges, 4 mufflers, #619081 prefilter coalescer Class I, Div II 120 CFM, 110 volt MLT design with six cartridges, 6 mufflers (manifold not included) 120 CFM, PC design with four 4 lb. cartridges, 4 mufflers, Class I, Div II 120 CFM, PC design with four 4 lb. cartridges, 4 mufflers, #619160 prefilter coalescer, Class I, Div II 200 CFM PC design with six 4 lb. cartridges, 6 mufflers, Class I Div II 200 CFM, PC design with six 4 lb. cartridges, 6 mufflers, #619242 prefilter coalescer; Class I Div II Future Obsolete. Use 640802 640802 120 CFM, 110 volt PLC design with four 4 lb. cartridges, 4 mufflers, 2 manifolds, control box, # 619160 prefilter coalescer 640805 640810 120 CFM, 110 volt PLC design with four 4 lb. cartridges, 4 mufflers, 2 manifolds, control box Future Obsolete. Use 640812 640812 200 CFM 110 volt PLC design with six 4 lb. cartridges, 6 mufflers, 2 manifolds, control box, #619242 prefilter coalescer 640815 200 CFM 110 volt PLC design with six 4 lb. cartridges, 6 mufflers, 2 manifolds, control box 240 CFM 110 volt PLC design with eight 4 lb. cartridges, 8 mufflers, 4 manifolds, control box , 2 - 619160 prefilter coalescer 240 CFM 110 volt PLC design with eight 4 lb. cartridges, 8 mufflers, 4 manifolds, control box 400 CFM 110 volt PLC design with twelve 4 lb. cartridges, 12 mufflers, 4 manifolds, control box, 2 #619242 prefilter coalescers 400 CFM 110 volt PLC design with twelve 4 lb. cartridges, 12 mufflers, 4 manifolds, control box Future Obsolete. Use 640842 600 CFM 110 volt PLC design with eighteen 4 lb. cartridges, 18 mufflers, 6 manifolds, control box, 3 #619242 prefilter coalescers 600 CFM 110 volt PLC design with eighteen 4 lb. cartridges, 18 mufflers, 6 manifolds, control box Obsolete. Use 640852 800 CFM 110 volt PLC design with Twenty four 4 lb. cartridges, 24 mufflers, 8 manifolds, control box, 4 #619242 prefilter coalescers 800 CFM 110 volt PLC design with Twenty four 4 lb. cartridges, 24 mufflers, 8 manifolds, control box 640112 640124 640820 640825 640832 640835 640840 640842 640845 640850 640852 640855 52 GLOSSARY OF TERMS Adsorb A method causing a liquid or gas to condense on the surface only of an adsorbing material Air dryer A device for drying compressed air by means of condensation obtained by over-compression or cooling, absorption, adsorption or a combination of the above methods Airflow The motion of air relative to a body in it Ancillary equipment Components subordinate to the compressor Atmospheric dew point Temperature at which water vapor begins to condense at atmospheric pressure and the same as dew point, but is related to atmospheric air only Bag house A dust-collection chamber containing numerous permeable fabric filters through which the exhaust gases pass. Finer particulates entrained in the exhaust gas stream collect in the filters for subsequent treatment/disposal Bar A unit of pressure equal to 0 99 atmospheres or 14 233 psi Breathing air Specialty compressed air treatment meeting OSHA Grade D breathing air requirements Bubble In spray painting applications, air trapped in a paint film caused by poor atomization during spraying Capacity Capacity of a compressor is the full rated volume of flow of gas compressed and delivered at certain set conditions CFM ACRONYM - Cubic feet per minute. An air flow measurement of volume Compressed air Air under pressure greater than that of the atmosphere Compressor A machine that compresses air, gases Condensate Liquid that separates from a vapor during condensation Contaminate Foreign matter carried in the air, gas or fluid to be filtered out. Includes air borne dirt, metallic particles produced by wear of moving parts of the air compressor, rust from metal pipelines Control valve A valve that controls the flow in air lines Cut in - cut out pressure Minimum pressure or the pressure that the system reduces to before air volume is required Cycle A single complete operation consisting of progressive phases starting and ending at the neutral position Cycle time Amount of time for a compressor to complete one cycle Cylinder The piston chamber in a compressor or actuator 53 Delta P Describes pressure drop through a component relating to difference in pressure between two points Demand Flow of air under specific conditions required at a particular point Desiccant An adsorption type material used in compressed air dryers industry standards are activated alumina, silica gel and molecular sieves Desorption Opposite of absorption is adsorption, in filtration, it relates to the downstream release of particles previously retained by the filter. Dew point Of a gas is the temperature at which the vapor in a space (at a given pressure) will start to condense (form dew) dew point of a gas mixture is the temperature at which the highest boiling point constituent will start to condense Filter A device that removes solid contaminates, such as dirt or metal particles, from a liquid or gas (air is a gas), or that separates one liquid from another, or a liquid from a gas The term filter describes the complete unit housing, filter element, inter-l by pass Filter separator Filtering unit that separates solids and liquid droplets from gas (air) widely used in removing oil from a gas or air Flow The volume of a substance passing a point per unit time, e.g., meters per second, gallons per hour, etc. Flow control valve A valve controlling flow of air that passes through the valve used often for retardation or timing circuits, but especially for regulating the piston speed in cylinders Flow meter An instrument for measuring the amount of air flow of a compressor measured in CFM Flow rate The rate flow measured in liters, gallons per minute, cubic meters or cubic feet per second, or other quantity per time unit. Air related flows are usually expressed in CFM, SCFM, ACFM, and ICFM Full load Achieved when the air compressor is running at full RPM with a fully opened inlet and discharge, delivering the maximum volume at the rated pressure Gauge An instrument for measuring, testing, or registering Gauge pressure A pressure as determined by most instruments and gauges Heatless dryer Heatless reactivated dryer by means of expanding cold dry air to near atmospheric pressure inside the regeneration tower, the dryer air picks up moisture from the saturated desiccant bed and purged to atmosphere Horsepower (HP) A unit of work equal to 33,000-foot pounds per minute, 550-foot pounds per second, or 746 watts Humidity The moisture content of air Humidity specific The weight of water vapor in the air vapor mixture per pound of dry air 54 Humidity relative The relative humidity of a gas (or air) vapor mixture as a ratio of the partial pressure of vapor to vapor saturation pressure at the dry bulb temperature of the mixture Inlet pressure Total pressure (static plus velocity) at the inlet flange of the compressor Inlet temperature Temperature at the inlet flange of the compressor Leak air A crack or hole that accidentally admits a gas or lets it escape Maximum operating pressure Highest operating pressure system or component designed to withstand Mayonnaise An oily condensate discharged by lubricated air compressors. The term derived from the appearance of condensate under normal conditions oily condensate should just be cloudy, like a small amount of milk in a bucket of water. When a lubricated compressor begins to fail, then the condensate becomes thick and sticky, in fact almost identical in appearance to term it has been given Membrane dryer Reduce dew point by passing compressed air through a bundle of hollow membrane fibers; water vapor and a portion of the compressed air then permeate the membrane walls and vent to atmosphere Micron Micrometer or one millionth of a meter; micron is sometimes represented in filtration by the Greek letter µ (mu) A micron is 0 000039" Contaminate particles are measured by micron size and count Micron rating A measurement applied to filters or filter media to indicate removal of particle size at which suspended solids above that size Micro Logic Timer An electronic timer and coil assembly designed to cycle SFD air dyers Molecular sieves A solid adsorbent used for drying compressed air Molecular theory All matter consists of molecules that are in constant motion and held together by molecular forces. In a solid, the molecules are closely packed and arranged in such a pattern that the influence of the molecular forces is very strong. This gives the solid its consistency and form. Molecular motion consists largely of oscillations around points of equilibrium. In a liquid, the molecules are about as close as in a solid, but not arranged in a lattice and the cohesive forces are weaker. The molecules are more mobile in relation to each other, whereby the characteristic liquid phase develops; the liquid accommodated itself to the walls of the containing vessel, and its free surface aligns itself horizontally in response to the force of gravity. In a gas, however, the molecules are farther apart, and they move freely about each other since the molecular forces are not as strong. A gas therefore expands through space and mixes with other gasses present. The total volume of the molecules in a gas is very small in relation to the volume of the gas. A gas, therefore may be compressed into a small part of its original volume. 55 NEMA - National Electrical Manufacturer Association National Electrical Code – PC Models only National Electrical Code (NEC) defines hazardous locations as those areas "where fire or explosion hazards may exist due to flammable gases or vapors, flammable liquids, combustible dust, or ignitable fibers or filings." A substantial part of the NEC is devoted to the discussion of hazardous locations. That is because electrical equipment can become a source of ignition in these volatile areas. The writers of the NEC developed a short-hand method of describing areas classified as hazardous locations. One of the purposes is to explain this classification system. The National Electrical Code classifies hazardous locations in three ways: TYPE, CONDITION, and NATURE. National Electrical Manufacturer Association (NEMA) ratings are standards that are useful in defining the types of environments in which an electrical enclosure can be used. The NEMA rating system is defined by the National Electrical Manufacturer Association, and frequently signifies a fixed enclosure's ability to withstand certain environmental conditions. NEMA 7: Indoor use in locations classified as Class I, Division 1, Groups A, B, C or D hazardous locations as defined in the National Electric Code (NFPA 70) (Commonly referred to as explosion-proof). Class I Locations: According to the NEC, there are three types of hazardous locations. The first type of hazard is one created by the presence of flammable gases or vapors in the air, such as natural gas or gasoline vapor. When these materials are found in the atmosphere, a potential for explosion exists, which could be ignited if an electrical or other source of ignition is present. The Code writers have referred to this first type of hazard as Class I. Therefore, a Class I Hazardous Location is one in which flammable gases or vapors may be present in the air in sufficient quantities to be explosive or ignitable. Some typical Class I locations are: • Petroleum refineries, and gasoline storage and dispensing areas • Dry cleaning plants where vapors from cleaning fluids can be present • Spray finishing areas • Aircraft hangars and fuel servicing areas • Utility gas plants • Operations involving storage and handling of liquefied petroleum gas or natural gas All of these are Class I - gas or vapor - hazardous locations and all require special Class I hazardous location equipment. Class II Locations: The second types of hazard listed by the National Electrical Code are areas made hazardous by the presence of combustible dust. These areas are referred to in the Code as "Class II Locations" as finely pulverized material, suspended in the atmosphere and can cause as powerful an explosion as one occurring at a petroleum refinery. Some typical Class II locations are: • Grain elevators • Flour and feed mills • Plants that manufacture, use or store magnesium or aluminum powders • Producers of plastics, medicines and fireworks • Producers of starch or candies • Spice-grinding plants, sugar plants and cocoa plants • Coal preparation plants and other carbon handling or processing areas 56 Normal air A term used for average atmospheric air at sea level in a temperature zone where it contains some moisture It is defined in the ASME Test Code For Displacement Compressors as being at 14 696 psi A, 68 °F, 36% RH and weighing 0 075 lb./cu ft. The k value is 1 395 Oil free compressor A positive displacement air compressor that has no oil injected into the compression chamber for lubrication, cooling or sealing Operating pressure The gauge pressure at which a pressure vessel maintains a normal operation Orifice An opening such as a hole or vent through which air can pass, or a restricted opening placed in a pipe line to provide a means of controlling or measuring flow PC -Pneumatically Controlled Pneumatic logic is a reliable and functional control method for industrial processes. Pneumatic devices are used in processes where compressed air is the only energy source available or upgrade cost, safety, and other considerations outweigh the advantage of modern digital control. Piston displacement Net volume actually displaced by the compressor piston at rated machine speed, generally expressed in cubic feet per minute (usually CFM). For multistage compressors, the piston displacement of the first stage only is commonly stated as that of the entire machine PLC - Programmable Logic Control The automation of many different processes, such as controlling machines or factory assembly lines, accomplished with small computers called a programmable logic controller (PLC’s). This is actually a control device that consists of a programmable microprocessor, and programmed using a specialized computer language. A modern programmable logic controller is usually programmed in any one of several languages, ranging from ladder logic to Basic or C. Typically, the programs written in a development environment on a computer, and then is downloaded onto the programmable logic controller directly through a cable connection. The program is stored in the programmable logic controller in non-volatile memory Pneumatic Of, relating to, or using air moved by air pressure filled with compressed air Pneumatics Engineering science pertaining to gaseous pressure and flow Pneumatic tools Tools that operate by air pressure Point of use Single outlet or limited number of outlets in a building used to connect tools or equipment to the air system Positive displacement compressors Compressors in which successive volumes of air or gas are confined within a closed space and compressed and may be either reciprocating or rotating (trap air and then squeeze it to the desired pressure) PSI - Pounds per square inch Pressure Force per unit area, usually expressed in pounds per square inch (PSI) or BAR Pressure dew point Temperature at which moisture begins to condense in a compressed air system PSI Pounds per square inch PSIG 57 Pounds per square inch pressure indicated by a pressure gauge Purge air The portion of dry, full line pressure, compressed air taken from the drying side tower of a dual tower desiccant dryer system allowing to expanded to a very low pressure and passed across the wet desiccant to strip the moisture in the desiccant of the regenerating tower. In the case of an external blower type dryer, the purge air is atmospheric air compressed by a blower and heated by an external heater to strip moisture off a wet desiccant bed Quick coupler A coupling device that consists of a spring-loaded shutoff valve and a positive locking mechanism used to connect tools, hoses and other accessories. Also known as Quick Disconnect Safety relief valve An automatic pressure-relieving device actuated by the static pressure upstream of the device, which opens in proportion to the increase in pressure over the opening pressure Saturated air vapor mixture Is one in which the space occupied by the mixture is saturated with water vapor at the mixture temperature Saturated vapor pressure Is the pressure existing at a given temperature in a closed vessel containing a liquid and the vapor from that liquid after equilibrium conditions have been reached. It is dependent only on temperature and must be determined experimentally Saturation Occurs when vapor reaches dew point or saturation temperature corresponding to its partial pressure as a gas never becomes saturated with a vapor. However, the space occupied jointly by the gas and vapor may be saturated SCFM Standard cubic feet per minute or flow of free air measured at some reference point and converted to a standard set of reference conditions (e g , 14 4 psia, 80° F, and 60% relative humidity). CFM means cfm at standard conditions, however, standards vary and some care is necessary. In the United States, the usual standard is 14.696 psiA and 60°F. Some chemical engineers will use one ATA and 0°C, but usually will be specific about the reference point. Europeans normally use one ATA and 0°C. It is not the same to all people; therefore, it is best that the reference pressure and temperature be definitely specified Screw compressor Is a positive displacement rotary compressor Single stage compressors Machines in which air or gas is compressed in each cylinder or casing from initial intake pressure to final discharge pressure Silica gel A desiccant most commonly used in heat regenerative type dryers Standard air Air at a temperature of 68 °F, a pressure of 14 70 psia and a relative humidity of 36 per cent (0 0750 density) (as per A S M E however in the gas industry the temperature of standard air is usually given as 60 °F (Unless specifically stated otherwise) Temperature discharge Temperature existing at the discharge port of the compressor Temperature inlet Temperature at the inlet flange of the compressor Temperature intake The total temperature at the intake flange of the compressor Two stage compressor 58 Machines that compress air or gas from initial pressure to an intermediate pressure in one or more cylinders or casings Unload The air compressor continues to run, usually at full RPM, but no air delivered because inlet either closed off or modified, not allowing inlet air to be trapped Unloaded horsepower The power consumed to overcome the frictional losses when operating in an unloaded condition Venturi A tube with a narrow throat (a constriction) increasing velocity and lowering pressure of liquid passing through it that creates a partial vacuum immediately after the constriction in the tube. The vacuum created has a sucking effect, and a venturi is commonly used to introduce a liquid (such as a refrigerant) or gas (such as air) into a flowing water stream Volumetric efficiency The ratio and percent of the actual delivered capacity (measured at inlet temperature, pressure and gas composition) to the piston displacement 59 WARRANTY Warning Proper selection of products listed for sale in this owner’s manual is essential to minimize the risk of any seal, bearing or other product failure. Such failures can result in property damage or severe personal injury to operators of machinery, vehicles or to others. You must carefully evaluate the particular applications on or into which you intend to install the products. Products in this owner’s manual require installation by an experienced professional technician or qualified The product properties and operating parameters described in this owner’s manual are based upon test conducted by SKF or reported by others. SKF does not assume any responsibilities for errors in the data published in this owner’s manual. The life and performance of the products ultimately depend on a number of factors. These include, for example, selection of the product design type, selection materials for different properties, handling and installation, operating conditions, including shaft service or bore conditions, quantity and chemistry of lubricants and other factors. Severe environments can adversely affect product life or performance. For help in realizing longer SKF product life, and optimal performance for your specific application, contact SKF’s Customer Services Department at 1-888-SKFFIRST or visit us at http://www.skf.com Limited Warranty SKF as the seller of the products contained in this owner’s manual warrants to the first user/purchaser that the products sold by it, when properly installed, will be free from defects in material and workmanship. SKF’s sole obligation and liability for any defect found to exist in a product sold by SKF contrary to this warranty, and purchaser’s sole and exclusive remedy for such defect, shall be limited to: (A) SKF furnishing without additional charge to purchaser, including transportation, a replacement for any of the products which cannot be repaired or replaced by SKF, SKF shall credit or refund purchaser the purchase price paid therefore: provided, that SKF is advised in writing of such product non-conformance within thirty (30) days of the date of discovery thereof, and that the non-conforming product is returned f.o.b. to SKF’s designated warehouse promptly thereafter, but in any case not later than twelve (12) months from the date of original shipment of the product to purchaser by SKF. In no event shall SKF be obligated under this warranty or otherwise in any way whatsoever for normal wear and tear, or for any products sold by SKF which, after delivery by SKF and in SKF’s sole determination, have been sunjected to accident, abuse, misapplication, improper or faulty repair or installation, improper or faulty maintenance or lubrications, any alteration or neglect, excessive loading or other excessive operating conditions, or defects caused by resulting from purchaser’s specifications or designs or otherwise caused by purchaser. TO THE FURTHEST EXTENT PERMITTED UNDER APPLICABLE LAW, SKF DISCLAIMS LIABILTIY, IN TORT OR CONTRACT, IN NEGLIGENCE, STRICT LIABILTIY, OR OTHERWISE, FOR ANY OTHER Remedy OR DAMAGE, WHETHER DIRECT OR INDIRECT, INCIDENTAL OR CONSEQUENTIAL WITH RESPECT TO ITS PERFORMACE HEREUNDER, INCLUDING WITHOUT LIMITATION WITH RESPECT TO THE PRODUCTS SOLD OR PROVIDED HEREUNDER BY SKF And ITS PROVISION OF ANY RELATED SEVICES. THIS EXPRESS WARRANTY IS TO THE EXCLUSION OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILTIY OT FITNESS FOR A PARTICULAR PURPOSE. COSTS INCURRED FOR ROUTINE MAINTENANCE ARE NOT COVERED BY THIS WARRANTY. Without 60 limiting the generality of the foregoing disclaimer, SKF specifically disclaims liability to purchaser for any loss, cost, or damage incurred as a result of equipment downtime, or loss of use or availability of worksite, lost revenues or lost profits, or losses or liability arising, regardless of whether SKF is on notice of the possibility of such damage or loss and did or could have anticipated same. No other person shall has been authorized by SKF to undertake or make on behalf of SKF any further representation, warranty or guarantee in addition to or contrary to SKF’s warranty made herein or contrary to the limitations and disclaimers provided herein. The exclusive remedies provided in this limited warranty shall not be deemed to have failed of their essential purpose so long as SKF is willing and able to perform to the extent and in the manner prescribed in this warranty. INFORMATION: Inquiries can be directed to: SKF Customer Services Department, 890 Forty Foot Rd. P.O. Box 352, Lansdale, PA 19446, or call 1-888 SKF-FIRST. LIMITATIONS ON RETURNS: Any product that is not in conformance with purchaser’s description given in its order is returnable for credit or replacement by SKF, provided that SKF is advised in writing within 30 days after the product’s delivery to purchaser by SKF, and only after written authorization therefore is given by SKF. Approved returns must be shipped freight prepaid and arrive in good salable condition to qualify for credit or replacement. NOTICE: The SKF part numbering systems for the SKF products are proprietary to SKF. Any improper or unauthorized use of these numbering systems, including adoption or use od any ot their part numbers or part number lists, even where the subject of modification or addition, is strictly prohibited and will be prosecuted by SKF as a violations of U.S. and foreign copyright, trademark and unfair competition laws. In addition, use of any SKF trademarks, trade names or packaging schemes, systems, colors or designs is likewise considered a violation of the trademarks, trade names and trade identities rights of SKF USA Inc. and their affiliates. Possible violation of such use should be brought to the attention of SKF: SKF USA Inc. 890 Forty Foot Rd. P.O. Box 352, Lansdale, PA 19446 USA Attn: Catalog Manager. 61

Sfd Dryer Applications

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