Twr Heatless Desiccant Compressed Air Dryers

Transcript

TWR Heatless Desiccant Compressed Air Dryers Models TWR500 - TWR1600 User Guide TWR500 - TWR1600 USER GUIDE Preface This Parker FAF technical manual is intended to help you get to know the TWR Series adsorption dryer and to understand how to utilize its possibilities for application in accordance with its intended use. Furthermore, this manual contains important information for safe, proper and economic operation. All instructions must be followed in written order to avoid danger to personnel and damage to the dryer, which could result in downtime and/or premature wear and tear. In addition to the technical manual and the accident prevention regulations which are valid and compulsory in the country and in the particular workplace where the adsorption dryer is being used, the recognized special rules for safe and proper working procedures need to be reviewed. The technical manual must always be within reach wherever the adsorption dryer is being used. Each person involved with the set-up, start-up, operation, maintenance and repair of the adsorption dryer in the User Company must have first read and understood the technical manual and especially the safety tips. 2 TWR500 - TWR1600 USER GUIDE Contents 1. 2. 3. 4. Introduction 1.1 1.2 General Information Safety Instructions 1.3 1.4 Personnel Qualification Product Information 1.2.1 1.2.2 1.4.1 1.4.2 1.4.3 4 Identification of Signs and Symbols in this Technical Manual Safety Tips for Maintenance, Inspection and Assembly Work Transport Storage Pre and After Filter 5 6 6 6 Start Up / Shutdown General Operation 2.2.1 2.2.2 2.2.3 4 5 5 5 Section 2 2.1 2.2 4 4 Sequence of Operation System Layout & System Sequencing Electrical Control Section 3 6 7 7 8 9 9 3.1 Dryer Inlet Cooler Assembly 3.2 3.3 3.4 The Pneumatic Motor And Cooling Fan Blade The Pneumatic Motor And Cooling Fan Blade (Continued) The Pneumatic Regulator 10 11 11 3.5 Data Table For Cooler Assembly (for units with air motors only) 12 3.1.1 3.4.1 3.4.2 3.4.3 9 The Cooling Core 9 The Pneumatic Regulator (Continued) The Mist Lubricator The Separator Section 4 4.1 4.2 4.3 13 Replacement of the Desiccant Disposal of the Desiccant Filters 4.3.1 4.3.2 4.3.3 4.3.4 11 11 12 General Comments and Use Function Changing of Filter Elements Changing of Filter Elements (Continued...) 13 13 14 14 14 14 14 5. Section 5 15 6. Section 6 16 7. Section 7 17 8. Section 8 20 5.1 6.1 7.1 7.2 7.3 7.4 7.5 8.1 8.2 8.3 ALTERNATE FLOW PURGE SETTINGS: (Adjustments at various flows) Spare Parts List for TWR500 to TWR1600 Service Speed of Operation Maintenance Outlet Check Valve Exhaust Valves (depressurization) 16 17 17 18 18 19 Troubleshooting Guide Flow & Control Air Diagram Faults 8.3.1 8.3.2 8.3.3 15 The Dewpoint is too High The Dryer does not Switch Towers Back Pressure is too High During Regeneration Phase 20 21 22 22 22 23 9. Section 9 26 10. Warranty 33 9.1 9.2 9.2 Short-Term Shutdown Shutdown in case of a fault or for maintenance Restarting 3 26 26 26 TWR500 - TWR1600 USER GUIDE 1. Introduction 1.1 General Information The adsorption dryer of the TWR500 to TWR1600 series (and 1350 High Pressure) is built according to the latest technological developments and recognized safety rules. Its use however can endanger life and limb of the user or of third parties, and can lead to considerable damage to the adsorption dryer and other material assets if: • it is operated by personnel not trained or instructed in its use, • it is improperly used, • it is improperly maintained or serviced. This can result in the loss of all damage claims. This adsorption dryer is designed for neutral media free of aggressive water, oil and solid elements. Parker FAF accepts no liability for corrosion damage and malfunctions caused by aggressive media. Applications other than those mentioned in this manual must be agreed to by Parker FAF and confirmed in writing. In the interest of further development, Parker FAF reserves the right to make changes at any time, which, in keeping with the essential characteristics of the adsorption dryer described here, may be necessary for increasing efficiency or for reasons relating to safety or to normal business practice. 1.2 Safety Instructions This technical manual contains basic tips, which must be followed during set-up, operation and servicing. It is thus of utmost importance that it is read by the assembly technician before installation and start-up as well as by the specialist or operator in charge, and it must always be within reach at the location where the adsorption dryer is being used. 1.2.1 Identification of Signs and Symbols in this Technical Manual The safety tips contained in this technical manual, whose disregard could endanger people and property, are indicated by a general danger sign and the additional markings Danger! or Attention! Danger! / Caution! Safety sign in accordance with DIN 4844 - W9 Warning against electrical voltage! Safety sign in accordance with DIN 4844 - W8 Safety tips printed directly on the adsorption dryer must be heeded at all times and must be kept completely legible. Note: This sign refers to a procedure or sequence of particular interest or importance. All tips must be followed to ensure proper use of this adsorption dryer. • This dot refers to working or operational steps. The steps are to be carried out in the order of their appearance from top to bottom. - The sign of a hyphen marks enumeration. 4 TWR500 - TWR1600 USER GUIDE 1.2.2 Safety Tips for Maintenance, Inspection and Assembly Work The operator is to make sure that all maintenance, inspection, and assembly work is carried out by special personnel who are authorized and qualified, and who are adequately informed through careful study of the technical manual. For this reason, special attention should be paid to the following attention and danger signs: Caution! • Never make structural changes to the adsorption dryer! • Only use original Parker FAF spares and accessory parts! • Never weld on a pressure vessel or change it in any way! • Carry out maintenance work only when the adsorption dryer is switched off, is depressurized and disconnected from the electric power supply. Note: Refer to the desiccant material safety data sheet (MSDS) when installing or disposing of desiccant. Danger! Wear protective goggles when working with the desiccant! Note: • • • • 1.3 If desiccant comes into contact with the eyes, rinse eyes immediately with a large amount of clear water. If the desiccant is spilled, clean up without causing swirls of dust. In case of fire, there is no restriction on the use of fire extinguishing material; the reaction with water and foam is defined as strong. A mask must be worn to avoid inhalation of the desiccant dust. Personnel Qualification The personnel involved in operation, maintenance, inspection and assembly must have the corresponding qualifications to do this work. Areas of responsibility and supervision of the personnel must be precisely established by the operator. Should the personnel not possess the necessary knowledge, then they must be trained and instructed. If need be, this training may be carried out by the manufacturer / supplier at the request of the operator of the adsorption dryer. Further, the operator is to make sure that the personnel completely understand the contents of the technical manual. 1.4 Product Information At standard inlet conditions of 100ºF, 100 psig, and providing a –40ºF pressure dewpoint according to DIN ISO 7183. Note: All values given above assume a standard dryer with a standard scope of supply and standard operating conditions as explained above. Dryers that have been specifically modified for a particular application may have different values than those shown. 1.4.1 Transport After the adsorption dryer has been delivered, it must be checked for damage that may have occurred during transport. Any damages should be reported immediately to the transport company to begin the claim process. 5 TWR500 - TWR1600 USER GUIDE Note: For lifting and transportation, only the skid of the dryer may be used. Do NOT support the dryer by the interconnecting piping any other attached component. 1.4.2 Storage If the adsorption dryer is to be stored for a long period of time, its place of storage must be dry and free of dust. There has to be a minimum ambient temperature of 33°F (+1°C). 1.4.3 Pre and After Filter Both filters are equipped with a differential pressure gauge. Elements should be replaced annually regardless of the differential pressure indicated. 2. Section 2 2.1 Start Up / Shutdown Caution! All pipes and wire connections must be tightened! Furthermore, before start-up: • The pipes must be checked for the presence of scale, abraded material from the threading, or other similar impurities. • All shut off valves on the pre-filter, adsorption dryer, after-filter and on the bypass line should be closed. • Unless proper heat tracing is provided, the ambient temperature must not be less than 33°F (1°C) Breakdowns resulting from faulty installation do not fall under warranty obligation. Note: The following sequence is to be heeded for the initial start-up: • Slowly open the inlet valve and gradually increase the pressure by reading the chamber pressure gauge. Do not open the valve abruptly as the sudden pressure change may damage the dryer. • Set the pressure switches inside the control panel to 30 psig below the normal operating pressure. These switches are equipped with adjustment knobs and pressure scales. If these switches are not set below the operating pressure, the dryer will not cycle and an alarm light will flash on the control panel. • Adjust the purge adjustment valve in accordance with the parameters listed in the control panel and in section 5.3 of this manual. The (2) purge isolation valves must be left fully open at all times during operation. • TWR Models with Aftercoolers – set the regulator and oil mist lubricator in accordance with the table in section 3.3 of this manual. • Turn the switch to the “POWER ON” position. • The adsorption dryer should be operated for approximately 3 to 4 hours with the outlet valve closed. This is to fully regenerate the desiccant which will likely have been saturated during transportation and installation. • After the regeneration phase, slowly open the shut off valve behind the after-filter slowly while observing the chamber pressure gauge. Do not open the valve abruptly as a sudden pressure change may damage the dryer. • The adsorption dryer is now ready for operation and will function continuously and fully automatically. 6 TWR500 - TWR1600 USER GUIDE 2.2 General Operation Desiccant dryers work on the principle of adsorption. Adsorption is the process of removing water VAPOR from the air to be dried. All condensed liquid water should be removed from the inlet air stream prior to reaching the dryer by suitable separators, traps, filters, and drains. The dryer can not be burdened with liquid condensate carry-over. All desiccants are adversely affected by oil, aerosols, dirt, rust, scale or liquid water. Effective pre-filtration in conjunction with automatic condensate drainage is a must for proper dew point suppression and long desiccant life. The saturated inlet air is alternately cycled through each of the two desiccant beds. One bed is “on-line” at full line pressure and flow, adsorbing water vapor from the saturated inlet air. This is the drying bed. The other bed is “off-line” at atmospheric pressure (0 psig) being regenerated by a depressurized portion of the dried outlet air (purge air). This is the regenerating bed. The quantity of purge air for a standard pressure dryer is approximately 15% of inlet design flow. This air is taken from the dry air outlet, directed through the purge flow controls, purge check valves, desiccant bed, and finally exhausted to atmosphere to accomplish regeneration. Purge air consumption is typically the largest cost involved with operating a heatless desiccant air dryer. (Purge air is “non-recoverable” and the air system in question must be designed to allow for this usage.) A minimum dryer system air pressure of 70 psig must be maintained for proper actuation of all pneumatic valves. Consult factory for operating pressures below 70 psig. Important! The dryer is designed to remove only water vapor. You might see a small amount of condensate forming at the exhaust due to the Joule-Thomson cooling effect created by the depressurizing air. Prior to switching a freshly regenerated bed “on-line” to become the drying bed, it must be slowly pressurized from atmospheric pressure to line pressure. This step is called repressurization. Repressurization prevents bed fluidization (lifting) and associated dusting. Following repressurization, the beds switch functions with the fresh bed now drying and the saturated bed being regenerated. Note that one bed is always “on-line” drying. Also note that purge air is always being consumed except during repressurization. This cycle will continue automatically unless the dryer is shut down, operated in the CycleLoc mode or equipped with a PowerLoc or Pro Purge. 2.2.1 Sequence of Operation The sequence is controlled by a Solid State Timing and Relay circuit (Sequence Annunciator) which in turn controls five electric solenoid valves. The Inlet Valves are Normally Open and are closed by applying pressure to the Actuator. The Exhaust Valves are Normally Closed and are opened by applying pressure to the Actuator. The fifth solenoid is a 2-Way or 3- Way depending on the size of the dryer. (500 cfm 2-way, 1000 and larger 3-way). This is the repressurization circuit. There are also four mechanical check valves, two outlet and two purge, that allow for proper air flow. 7 TWR500 - TWR1600 USER GUIDE STEP 1- LEFT DRYING, RIGHT REGENERATING SOLENOID #1 is de-energized sending no air to Exhaust Valve #1 (left side). Exhaust Valve #1 is closed. SOLENOID #2 is de-energized sending no air to Inlet Valve #1 (left side). Inlet Valve #1 is open. All of the wet inlet air is flowing through Inlet Valve #1 . It is dried as it passes through the left tower desiccant bed and exits out the left side Outlet Check Valve to the dryer outlet. The left tower is the Drying tower and the associated pressure gauge should read line pressure, typically 100 psig. At the same time SOLENOID #3 is energized sending a signal to Inlet Valve #2 (right side). Inlet Valve #2 is closed, preventing inlet air flow through the right tower. SOLENOID #4 is energized sending a signal to Exhaust Valve #2 (right side). Exhaust Valve #2 is open. (NOTE: When exhaust valve first opens, the associated tower will depressurize from line pressure to atmospheric pressure.) Purge air will now flow from the dry air outlet through the Purge Adjusting valve, Purge Orifice and the right hand Purge Check Valve. This purge air then proceeds through the right tower near atmospheric pressure, removing the moisture and exiting the right hand Exhaust Valve and Muffler in vapor form (at no time should the dryer expel any significant amount of liquid water from the muffler; this is a sure sign of trouble in the system). The right tower is the regenerating tower, the associated pressure gauge should read “0” psig. SOLENOID #5 is de-energized and closed. STEP 2- LEFT DRYING, RIGHT REPRESSURIZING While the left tower is still drying, Solenoid #4 will de- energize, relieving the control air signal on the right exhaust valve, returning that valve to its normally closed state. Closing this valve keeps air in the tower, allowing the depressurized part of the dryer to build up pressure or “repressurize”. At the same time Solenoid #5 is energized and opened, providing additional air to the tank coming from the purge line to ensure full repressurization of the dryer. Prior to switching towers, all of the gauges should equalize to line pressure. STEP 3- LEFT REGENERATING, RIGHT DRYING Step 3 is the reverse of step 1. Solenoid #1 is energized, providing control air to and opening the left exhaust valve. Solenoid #2 is energized, providing control air to and closing the left inlet valve. Solenoid #3 and #4 are de-energized. Thus the right inlet is open, and the right exhaust is closed. All the wet air is now flowing through the right tower and is being dried at line pressure. The left tower is being regenerated at atmospheric pressure. Solenoid #5 is de- energized and closed. 2.2.2 System Layout & System Sequencing 8 TWR500 - TWR1600 USER GUIDE Switching Failure Alarm Two pressure switches, sensing desiccant chamber pressure, are provided. An alarm will be activated if both chambers remain at full pressure when regeneration is required. The Switching Failure Alarm is self-resetting when condition is cleared. 2.2.3 Electrical Control Danger! Work on electrical installations may only be done by a specialist or by other persons instructed in this type of work as long as they are under the instruction and supervision of a specialist; the general rules for working with electricity must be followed 3. Section 3 3.1 Dryer Inlet Cooler Assembly This section will outline the operation of the dryer inlet cooler assembly for the TWR500 to TWR1600 dryers. There are five main elements of the cooler assembly on the TWR series dryer. They are the cooling core, the pneumatic motor with cooling fan blade, the air regulator, the mist lubricator and finally the cooler outlet separator. The cooler assembly requires minimal maintenance. There are adjustments that can be made to reduce air consumption of the cooler motor based on the flow and temperature of the air entering the cooling core. 3.1.1 The Cooling Core • • • • The cooling core provided is relatively maintenance free and there are only a few points that should be followed to assure satisfactory performance. Review the bullet points during installation and operation. The cooler should be installed in such a manner where the skid is level to allow liquids being condensed to drain towards the outlet connection of the assembly The cooler should be located in an area to permit free movement of the air around it. The warm discharge air must be free to dissipate to avoid being recycled into the cooler inlet. The cooler assembly has an outlet temperature gauge and this temperature should be monitored to assure the dryer inlet temperature does not exceed sizing limitations or the 9 TWR500 - TWR1600 USER GUIDE • dryer will no longer maintain an acceptable dewpoint and can become saturated. Verify the cooler core and finger guard for obstructions that can lead to elevated cooler outlet temperatures. Do not remove the finger guard from the cooler assembly unless cooler core service is being performed. After service the guard must be re-installed to provide protection and prevent debris from damaging the cooling fan blade and cooler core. Note: Cleaning the exterior fin surface may be required when discharge temperature increases beyond desired temperatures. Cleaning may be accomplished by low pressure steam jet (with detergent if necessary). Caution! DO NOT use caustic based chemicals. Verify detergents ensuring compatibility with aluminium. Cleaning of internal fin surfaces may be accomplished by circulating a degreaser solvent that is compatible with aluminium. Alkaline material should never be used. 3.2 The Pneumatic Motor And Cooling Fan Blade The pneumatic motor and cooling fan blade provided is relatively maintenance free and there are only a few points that should be followed to assure satisfactory performance. Review the bullet points during installation and operation. Note: The fan blade assembly should be inspected at time of installation and after every 4 weeks of operation to ensure integrity of the fan blades. DO NOT attempt to repair a damaged fan blade. A damaged fan assembly should only be replaced with factory original part. The air supply line to the cooler motor-fan assembly should be disconnected if fan service is to be performed. A damaged pneumatic motor can affect the integrity of the fan blades. If the cooler pneumatic motor fails the fan blade assembly should be inspected for stress cracks by a qualified person, or have the fan blade assembly replaced. The cooling fan may need replacement every 1-2 years depending on severe duty found at site. Caution! The exhaust stream from the pneumatic motor may contain solid particles or oil aerosol. Wear eye and skin protection at all times while in the proximity of this equipment. • • • • Ensure the oil mist delivery to the motor is properly adjusted. A data table of adjustments has been provided at the end of this section Ensure pneumatic motor outlet muffler is clean and unobstructed of dirt particles that will prevent normal operation of the motor Ensure the delivery pressure to the motor is set per the data table provided at the end of this section. For long term storage (several weeks) the motor should be properly lubricated at time of start up to ensure trouble free and long term performance. Refer to the service bulletin provided for steps on manually lubricating the motor 10 TWR500 - TWR1600 USER GUIDE Important! The pneumatic cooler motor provided requires oil lubrication. The type of oil recommended is GAST AD220, or a non-detergent SAE#10 automotive engine oil. Flushing of the motor may be required to remove excessive dirt, foreign particles moisture or oil. Use only (GAST AH255B) flushing solvent. Do not use kerosene or any other type of combustible solvents to flush motor. Refer to the service bulletin provided to maintain and repair the pneumatic motor provided. 3.3 The Pneumatic Motor And Cooling Fan Blade (Continued) • • • 3.4 A service valve has been provided to shut the supply air off to the motor if required. Verify the cooling fan blade for wear or damage to prevent an unbalanced fan blade from damaging the pneumatic motor bearings. The cooler assembly is designed to push air in an upward direction. Ensure the cooler outlet surface is free of obstruction. The Pneumatic Regulator The pneumatic regulator provided is the mechanism that allows for the adjustment of the cooling fan and motor RPM. The cooling motor and fan will increase in RPM as the delivery pressure increases to the pneumatic motor. Refer to the data table for correct adjustment of the delivery pressure for the dryer system. A regulator discharge pressure gauge is provided and will allow the operator to set the necessary secondary pressure. Review the below bullet points for more detail. Caution! The pneumatic regulator secondary discharge pressure must not exceed 100 psig or pneumatic cooler motor damage can result. If the cooler motor is out of service, the regulator and mist lubricator should be depressurised by closing the service valve provided. • • • During the operation of the dryer cooler system, the regulator needs to be set in accordance with the recommendation found in the data table provided later in this section. If the cooler inlet temperature is only 50ºF to 80ºF above ambient temperatures, the cooler motor and cooling fan RPM can be reduced thus reducing the amount of air consumed by the cooler package. Note the coalescing filter outlet temperature should not exceed 110ºF at any time or dryer outlet dewpoint will deteriorate. The pneumatic regulator will maintain a constant delivery pressure to the cooler motor even when the primary pressure floats due to pressure fluctuations in the compressor. 3.4.1 The Pneumatic Regulator (Continued) • • • The pressure regulator has a locking handle. To adjust the regulator, lift the setting knob and turn clockwise (to increase pressure-fan RPM) or anti-clock wise (to decrease pressure-fan RPM) as required. Observe the adjusted pressure on the gauge provided. When set, depress the adjustment knob to lock the device. When lubricating or servicing the regulator, refer to the service bulletin provided. Do not wash down the regulator with solvents as some of the composite materials may be damaged. 3.4.2 The Mist Lubricator The mist lubricator mechanism will provide an aerosol mist stream to the pneumatic cooler motor. Review the data table later in this section to set the oil delivery rate for the appropriate dryer-cooler motor model. 11 TWR500 - TWR1600 USER GUIDE Caution! The mist lubricator is designed to operate with specific lubricants. Do not use oils with adhesives, compound oils containing solvents, graphite, detergents or synthetic oils. Refer to the pneumatic cooler motor lube specification when selecting a suitable oil or lube. • • • • • • During the operation of the dryer cooler system, the mist lubricator will need to be set in accordance with the recommendation found in the data table provided later in this section. The oil delivery consumption rate is such that 25 drops per minute is equal to 1 ounce of oil per hour The oil delivery adjustment is made by turning a knob on top of the lubricator. For a leaner oil delivery, turn clockwise, for a richer oil delivery turn counter clockwise. The drops per minute (DPM) can be counted in the sight dome located on the mist lubricator. Refer to the service bulletin provided for oil filling instructions and general maintenance procedures for this device A service valve is provided on the dryer system to isolate the lubricator when service or oil filling is required. 3.4.3 The Separator The separator located at the outlet of the cooling core is a high efficiency compressed air water separator designed to remove 99% of bulk liquid water. The separator is fitted with a fixed vortex generator. The separator comes standard with an automatic drain system to allow liquids to drain out of the housing. There is almost no maintenance required to maintain satisfactory operation of this filter. Review the bullet points below for more detail. • • • 3.5 The automatic drain is a critical component of this filter and must be verified for normal drain operation to prevent water carry over to the dryer prefilter. The drain should be routinely verified to ensure rust and pipe scale does not block the automatic drain operation. There is no filter element to replace in this separator housing. Data Table For Cooler Assembly (for units with air motors only) Dryer Model Regulator Pressure Oil Drip Rate Reg Series Luber Series Luber Volume Air Motor Consumption Air Motor Series TWR500 40 1 DPM F07R L17-600 32 OZ 25 CFM 4AM TWR1000 50 2 DPM F07R L17-600 32 OZ 70 CFM 6AM TWR1600 60 3 DPM P3NR L17-800 32 OZ 150 CFM 16AM Note: THE OIL DRIP RATE (DPM) FOR LUBRICATING THE PNEUMATIC AIR MOTOR REFERS TO DRIPS PER MINUTE. The suggested regulator setting (which affects the fan rpm and cfm of air flow) is the maximum pressure required to cool 400ºF air at 175 psig at maximum flow per the flow table found in section 5.1 “Dryer flow capacity”. The regulator pressure can be reduced significantly if operating at a reduced flow or with cooler temperatures significantly below 400ºF. The dryer inlet temperature at all times should be maintained below 110ºF in order to maintain dewpoint without a required reduction in flow rate through the dryer. 12 TWR500 - TWR1600 USER GUIDE 4. Section 4 MAINTENANCE Note In order to ensure continuous and trouble-free operation, a maintenance contract with your authorized Parker FAF distributor is highly recommended. The following points should be checked regularly: Daily • Carry out a general visual check and watch out for possible disruptions during operation. • Check function by manually operating the automatic condensate drain on the pre-filter. Weekly • Check the differential pressure on the pre-filter, which should not exceed 5 psid. Filter elements must be changed annually or earlier if the differential pressures exceeds 5 psid. • Check the differential pressure on the after-filter, which should not exceed 5 psid. Filter elements must be changed annually or earlier if the differential pressures exceeds 5 psid. • Check the pressure of the regenerating vessel during regeneration after depressurization. Any backpressure caused by blocked exhaust silencers will be show here. Backpressure on the regenerating tower should not exceed 5 psig. • Drain pilot air filter housing of any condensate. Annually or after every 2500 hours of operation • Check the desiccant for impurities and change it if necessary. A brown or yellow color indicates that it has been contaminated with oil. Desiccant has an operating lifetime of about 8000 hours under normal conditions. • Check the screens installed in the desiccant chambers for impurities and if necessary, clean them. • Check the function of the inlet valve by sending electrical control signals. • Check the seat o-rings on the outlet check valves. 4.1 Replacement of the Desiccant • • • • Close dryer inlet/outlet isolation valves. Depressurize and switch off the adsorption dryer. Remove the drain plug and empty the old desiccant into a container. Screw the plug back in and fill new desiccant from above into the vessels. Pressurize the adsorption dryer per the start-up instructions and restore power to the dryer. Note In order to ensure trouble-free operation, we recommend replacing the desiccant at least every 8000 hours, or 2 years. 4.2 Disposal of the Desiccant Danger! The desiccant can be disposed of at a suitable disposal site in accordance with local or official regulations. Note that the desiccant will remove and collect contaminants in the process air and may therefore contain concentrated pollutants! 13 TWR500 - TWR1600 USER GUIDE 4.3 Filters 4.3.1 General Comments and Use Parker’s high efficiency pre-filter is designed to remove solids, oil and water condensate out of compressed air and other neutral, compressed gases. These filters provide high flows and low differential pressures. 4.3.2 Function The pre-filter is designed to flow from the inside to the outside. The after filter is designed to flow from the outside to the inside. Solids are filtered out by impact or by the effect of inertia, whereas oil particles and drops of moisture are filtered out by the effect of coalescence. By the force of gravity, the contaminants collect in the lower filter vessel and are drained automatically or manually. Maintenance Note • As a minimum, filter elements should be replaced when the differential pressure reaches 5 psid or after 1 year of operation, which ever comes first. • The functioning of the automatic condensate drain is to be tested weekly by manual operation. 4.3.3 Changing of Filter Elements Danger! The filter housings must be depressurized completely before attempting to replace filter elements. Caution! The elements can be disposal of at a suitable disposal site in accordance with local regulations. Note that the elements will remove and collect contaminants in the process air and may therefore contain concentrated pollutants! 4.3.4 Changing of Filter Elements (Continued...) Filter elements are to be changed according to the following steps: • Isolate and depressurize the entire dryer skid. • Separate the filter bowl (lower part) from the head (upper part). 1. Remove Nylon tubing, 2. Loosen nuts & bolts and remove all but one, and 3. Rotate lower part of assembly to access filter chamber. • Install the new element. Ensure that the element seats and seals perfectly. • Re-install the filter bowl (rotate back in place making sure gasket is seated). • Elements are disposable and CANNOT be cleaned with compressed air. 14 TWR500 - TWR1600 USER GUIDE 5. Section 5 DRYER FLOW CAPACITY & PURGE ADJUSTMENT 5.1 ALTERNATE FLOW PURGE SETTINGS: (Adjustments at various flows) To adjust the purge pressure, the following steps are to be followed, refer to the flow schematics at the end of this manual: • • @ (scfm) Purge Setting at 100 psi Purge Setting at 125 psi Purge Setting at 350 psi TWR500 510 46 36 n/a TWR500 400 33 25 n/a TWR500 300 22 15 n/a TWR1000 1000 50 37 n/a TWR1000 800 37 28 n/a TWR1000 600 25 16 n/a TWR1000 500 20 12 n/a TWR1600 1600 55 38 n/a TWR1600 1400 45 31 n/a TWR1600 1200 35 25 n/a TWR1600 1000 26 18 n/a TWR1600 800 20 12 n/a TWR1350 1350 - - 50 TWR1350 800 55 - - Dryer Model The power is turned on and the dryer is operating. When either tower is depressurized and being regenerated, adjust the pressure on the pressure gauge using the PURGE Pressure Control valve (see Item #15 on Flow Diagram). 15 TWR500 - TWR1600 USER GUIDE 6. Section 6 6.1 Spare Parts List for TWR500 to TWR1600 16 TWR500 - TWR1600 USER GUIDE 7. Section 7 7.1 Service Actuators are compact 90° rotary pneumatic devices to operate quarter-turn valves. They are designed for pressures (supply and/or exhaust) up to 120 psig maximum. Explosion. DO NOT EXCEED PRESSURE RATING: excessive pressure may rupture the actuator and cause personal injury and/or property damage. 7.2 • Actuators are shipped from the factory with an indicator. This indicator should be used in determining the mounting orientation of the actuator on the valve. • Before mounting, the actuator and the valve must be placed in the same position (fully counter-clockwise or fully clockwise). Check the valve and actuator mounting surfaces, bracket, stem adapter and valve stem for proper orientation and fit. • Utilize all mounting holes provided on the actuator and assure a full bolt diameter of thread engagement into the actuator housing as a minimum. • Tighten all bolts and nuts uniformly, taking care to center the actuator on the valve stem. • Actuators are shipped from the factory with the travel stops adjusted for approximately 90 rotation. * It is usually necessary to make slight adjustments to the stop adjusting screws alter the actuator’s installed on the valve, * Refer to the valve manufacturers recommendations for specific instructions. If valve manufacturer’s instructions are not available, adjust the open position actuator stop to allow for full opening of the valve. • Actuate the valve closed and adjust the closed position actuator stop to ensure that the valve is completely seated in the closed position, • Cycle the valve back and forth to check for repeatability of seating, • Be sure that the actuator travel slops are what ends the rotation. This will prevent prolonged shaft loading and maximize the life of compensators. Speed of Operation The speed of operation is determined by a number of factors such as the distance from the pressure source, supply line and control valve sites, the torque requirement of the valve, pipeline flow conditions, and the size of the actuator. Due to the interaction of those variables, it is difficult to specify a normal operating time. Clean, dry air or gas is essential for long service life and satisfactory operation. If instrument air of this type is not available, it’s recommended that an in-line filter be installed to prevent foreign particles (above 40 microns) from entering the actuator New air lines often contain scare, metal chips and other debris which will damage control valves and actuator seats. 17 TWR500 - TWR1600 USER GUIDE 7.3 Maintenance When leakage is detected, new seals should be installed as soon as possible to avoid irreparable damage to the actuator. See the following servicing instructions. • Place paddle in bottom half of actuator housing at mid-stroke position. • Coat housing joint surface with high quality silicone sealant and replace top housing. • With paddle rotated to right side, snug down screws on left side, shoulder bolt first. Rotate paddle to left side of actuator and snug down screws on right side, shoulder bolt first. • Tighten all screws securely. Butterfly valves are designed and built to give long, trouble-free service. Properly applied, adjusted and operated, these valves should require minimum attention. All butterfly valves are factory adjusted and normally further adjustment is not required. However, if seepage does occur the following adjustments can be made. Tighten each of the adjustments bolts (or screws) 1/4 turn. Operate valve and check for leakage. Repeat as necessary to stop the seepage. The need for frequent adjustment of the bolts, and/or many adjustments turns indicates the seals are worn to the point of needing replacement. Excessive tightening of the adjustment bolts will MAINTENANCE, START-UP & USER MANUAL cause an increase in the valve stem torque. TWR-500 TO TWR-1600 REV 04 – Jun, 2010 7.4 Outlet 7.14 CheckOutlet ValveCheck Valve Bushing Seat O’ring Teflon Spacer 18 TWR500 - TWR1600 USER GUIDE MAINTENANCE, START-UP & USER MANUAL 7.5 Exhaust Valves (depressurization) 7.15 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 EXHAUST VALVES (depressurization) No Control Air at Inlet or Exhaust Valves 19 Page 25 of 40 REV 04 – Jun, 2010 TWR500 - TWR1600 USER NO CONTROL AIRGUIDE AT INLET OR EXHAUST VALVES: 8. Section 8 8.1 8.1 SECTION 8: TROUBLESHOOTING Troubleshooting Guide GUIDE DRYER NOT OPERATING: A. No Lights On: - inoperative: Replace. B. Lights On, Dryer Does Not Switch: Valve. Blown control fuse: Replace fuse. No power: Apply correct power. Solid State Controller Control Air Shut Off: Open - Dryer not in 100% load cycle. Check Setting. FAILURE TO SWITCH: - Time delay setting too short. Adjust properly. (Failure to Switch option only!). TD-2 Setting should be at 1 ½ minutes. - See dryer not operating. - Purge set to high. Check specifications and adjust. - Repressurization solenoid leaking: Repair, clean or replace. - Inlet valve leaking or not functioning: See below. - Leaking or inoperative control solenoid: Repair or replace. - Defective controller: Repair or replace. EXCESSIVE AIR LOSS ON REGENERATING TOWER: EXHAUST VALVE ON DRYING OR REPRESSURIZING TOWER LEAKING: - Valve dirty: Clean Valves. - Defective diaphragms or O-rings: Rebuild valve or replace. - Leaking control solenoid: Repair or replace. EXCESSIVE PRESSURE DROP: - Pre-filter dirty: Replace element. - Afterfilter dirty: Replace element. - Desiccant dirty: Replace desiccant. UNIT DOES NOT FULLY REPRESSURIZE: - Purge rate too low. Adjust purge. - Exhaust valves leaking: See above. - Repressurization solenoid faulty: Repair or replace. - Purge or repressurization orifice plugged: Clean. Note: On newer dryers orifice is a different color than the rest of the dryer. BACK PRESSURE IN REGENERATING TOWER: - Clogged mufflers: Clean, repair or replace. Check valves leaking: Clean, repair or replace. Purge flow too high: Adjust. Leaking inlet valves: See inlet valve not functioning. INLET OR EXHAUST VALVES NOT FUNCTIONING: - Bad diaphragms or O-rings: Rebuild valves with available kits or replace. - No control air: See below. - Control solenoids defective: Repair or replace. - No output from controller: Replace fuse or controller. 20 MAINTENANCE, START-UP & USER MANUAL TWR-500 TO TWR-1600 REV 04 – Jun, 2010 TWR500 - TWR1600 USER GUIDE - Control air shut off valve closed: Open. Control air filter dirty: Replace element. Leak in control air tubing: Repair. Control solenoid defective: Repair or replace. No output from controller: Replace fuse or controller. CONSTANT BLEED FROM CONTROL SOLENOID TOP EXHAUST PORT: - Associated inlet or exhaust valve defective: Rebuild or replace. - Dirty or defective control solenoid: Clean or replace. CONSTANT BLEED FROM VENT PORT ON INLET VALVE: - Defective diaphragms or O-rings: Rebuild valve or replace. NOTES: When factory assistance is required always provide model, serial number, full description of problem and a complete analyzing chart. - 8.2 8.2 If at any time a problem develops, fill out a copy of the analyzing chart. It is also good practice to fill out a chart monthly. Keep these charts on file for comparison purposes if a problem arises. Flow & Control Air Diagram FLOW & CONTROL AIR DIAGRAM Reference INSERT sheet 8.3 FAULTS 8.3.1 THE DEW POINT IS TOO HIGH Possible Cause Solution Operating pressure too low, air flow capacity too high Increase operating pressure, reduce air flow. Air inlet temperature too high Reduce temperature, or verify air cooler operation upstream Differential pressure at the pre-filter too high Check filter element for impurities, change if necessary Condensate drain is not functioning Check operation of the condensate drain and replace if necessary Desiccant is soiled or has disintegrated Check pre-filter for impurities and either change the filter element and change the complete desiccant and dispose of the old desiccant Volume of regeneration gas too low Check regeneration pure adjustment is set in accordance with the instructions in this manual. Back pressure in regenerating vessel Check if mufflers are clogged or if there is any valve leak. Drains not functioning correctly IMPORTANT: Check solenoid operation (use test button), increase drain ‘time open’ setting on control panel to a high number, Also open manual drain valves to clear lines. 21 TWR500 - TWR1600 USER GUIDE 8.3 Faults 8.3.1 The Dewpoint is too High Possible Cause Solution Operating pressure too low, air flow capacity too high Increase operating pressure, reduce air flow Air inlet temperature too high Reduce temperature, or verify air cooler operation upstream Differential pressure at the pre-filter too high Check filter element for impurities, change if necessary Condensate drain is not functioning Check operation of the condensate drain and replace if necessary Desiccant is soild or has disintegrated Check pre-filter for impurities and either change the filter element and change the complete desiccant and dispose of the old desiccant Volume of regeneration gas too low Check regeneration pure adjustment is set in accordance with the instructions in this manual Check if mufflers are clogged or if there is any valve leak. Back pressure in regenerating vessel Drains not functioning correctly IMPORTANT: Check solenoid operation (use test button), increase drain ‘time open’ setting on control panel to a high number. Also, open manual drain valves to clear lines. 8.3.2 The Dryer does not Switch Towers Possible Cause Solution Chamber pressure switch contact is defective Verify switch contact and replace if necessary Chamber pressure below pressure switch settings Set switch 30 psig below normal operating pressure Exhaust valve not fully closed Verify valve for obstruction. Verify pilot air to exhaust valve is removed during the repress stage. Solenoid valve leaks Verify for air leakage on non-activated solenoid Purge isolation valves partially open or closed Purge isolation valves (2) are to be fully open at all times Inlet valve failed to operate position Verify pilot air to inlet valve actuator Verify solenoid valve Inlet/exhaust valve failed to activate Verify wiring to terminal strip Verify wiring connector on the solenoid valve assembly Verify pilot air service valve is open Verify pilot air filter element is not soiled Outlet check valve failed to close Verify bushings on check valve are worn Verify spring on check valve Verify check valve seat o-ring 22 TWR500 - TWR1600 USER GUIDE 8.3.3 Back Pressure is too High During Regeneration Phase Possible Cause Solution Silencer is blocked Clean or replace silencer Outlet check valve failed Verify springs and bushings on valves Verify seat o-ring is not damaged Exhaust valve not fully open Verify operation of pneumatic actuator Verify pilot air to actuator Verify if valve is obstructed Inlet valve leaks across ports Remove valve and test for across port leakage Install new seals Inlet valve not fully positioned Verify the pneumatic actuator for 90º operation Verify for leaks across vane of actuator Pilot air pressure failed due to plugged pilot filter or damaged pilot line Caution! If you are not able to fix a problem, call your local distributor or the Parker FAF Service Department. A service technician will help you with the problem or, if necessary, be sent to site. 23 TWR500 - TWR1600 USER GUIDE MAINTENANCE, START-UP & USER MANUAL 24 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 TWR500 - TWR1600 USER GUIDE MAINTENANCE, START-UP & USER MANUAL 25 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 TWR500 - TWR1600 USER GUIDE 9. Section 9 9.1 Short-Term Shutdown Note • Wait until dryer is in repress, or at anytime that both towers are at full pressure. • Switch off the adsorption dryer. • Close all the shutoff valves up and down stream of the dryer. Caution! Dryer will remain pressurized. 9.2 Shutdown in case of a fault or for maintenance Danger! Before any kind of maintenance or repair work is done, the adsorption dryer must be depressurized and disconnected from the power source. Apply general safety procedures. Note The following sequence is to be heeded when switching off the adsorption dryer: 1. Wait until dryer is in repress. 2. Switch the power off. 3. Close all the shut off valves up and downstream of the adsorption dryer. 4. Depressurize the dryer by using the hand valve mounted at the bottom of the after filter & separator. 9.2 Restarting 1. Close the outlet isolation valve mounted down stream of the dryer. 2. Slowly open the inlet isolation valve and slowly pressurize the adsorption dryer up (per the previous start-up procedures) to line pressure by keeping the outlet isolation valve closed 3. Switch on the power. 4. If the adsorption dryer is being re-started following a long period of shut down, proceed as described in section 3.1. 26 MAINTENANCE, START-UP & USER MANUAL TWR500 - TWR1600 USER GUIDE 27 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 TWR500 - TWR1600 USER GUIDE MAINTENANCE, START-UP & USER MANUAL 28 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 TWR500 - TWR1600 USER GUIDE & USER MANUAL MAINTENANCE, START-UP 29 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 TWR500 - TWR1600 USER GUIDE MAINTENANCE, START-UP & USER MANUAL 30 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 MAINTENANCE, START-UP & USER MANUAL TWR500 - TWR1600 USER GUIDE 31 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 MAINTENANCE, START-UP & USER MANUAL TWR500 - TWR1600 USER GUIDE 32 TWR-500 TO TWR-1600 REV 04 – Jun, 2010 10. Warranty WARRANTY REGISTRATION IMPORTANT! Mail or Fax (716-685-1010) Today! Fold and Seal and your Service Warranty will be registered immediately. We are here to help. For more information on service or installation call the Service Department at 1-855-587-9323. Email to: [email protected] Model # Serial # Company Address City State/Province Telephone Contact Title Department Date Purchased Date installed Zip Purchased From COMMENTS Please indicate a response on a scale of (1) being the lowest to (5) being the highest Condition of Arrival Ease of Installation Ease of Start-Up Product Quality Technical Assistance Clarity of Instruction/Warranty Manual FINAL OPERATION CHECK LIST Inlet air temperature is Inlet PSIG is The dew point temperature controller reads between and Is the dryer a minimum of 3’ from any structure on all sides? Yes What could we do better? No The Y strainer for drains has been cleaned after first 8 hours of operation Yes No What are your thoughts on the operation of the dryer? 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