Parker DME012-RX, DME080-RX User Manual

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Page 1

Medical Air Dryer

DME012-RX - DME080-RX

User Guide

Original Language

aerospace climate control electromechanical

filtration

fluid & gas handling hydraulics pneumatics process control sealing & shielding

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DME012-RX - DME080-RX

Contents

1. Safety Information 4

1.1 Markings and symbols 5

1.2 Hazardous Substances 5

2. Description 6

2.1 Technical Specification 6

2.1.1 Dimensions 8

2.2 Unpacking the equipment 9

2.3 Overview of the equipment 10

3. Installation & Commissioning 11

3.1 Locating the equipment 11

3.2 Mechanical Installation 12

3.3 Electrical Installation 12

3.3.1 Mains supply 12

3.3.2 Hygrometer relay 13

4. Operating the equipment 14

4.1 Overview of Controls 14

4.2 Starting the equipment 14 Dewpoint Dependent Switching (DDS) 14

4.3 Stopping the equipment 14

5. Servicing 15

5.1 Cleaning 15

5.2 Service Intervals 15

5.3 Service Kits 16

5.4 Service Record 17

6. Troubleshooting guide 18

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DME012-RX - DME080-RX

1. Safety Information

Important: Do not operate this equipment until the safety information and instructions in this user guide have been read and understood by all

personnel concerned.

Only competent personnel trained, qualified, and approved by domnick hunter should perform commissioning, service and repair procedures.

Use of the equipment in a manner not specified within this user guide may impair safety and invalidate your warranty.

When handling, installing or operating this equipment, personnel must employ safe engineering practices and observe all related regulations, health & safety procedures, and legal requirements for safety.

Ensure that the equipment is depressurised and electrically isolated, prior to carrying out any of the scheduled maintenance instructions specified within this user guide.

Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and procedures. Accidents can be avoided by recognising that any machinery is potentially hazardous.

domnick hunter can not anticipate every possible circumstance which may represent a potential hazard. The warnings in this manual cover the most known potential hazards, but by definition can not be all-inclusive. If the user employs an operating procedure, item of equipment or a method of working which is not specifically recommended by domnick hunter the user must ensure that the equipment will not be damaged or become hazardous to persons or property.

Should you require an extended warranty, tailored service contracts or training on this equipment, or any other equipment within the domnick hunter range, please contact your local domnick hunter office.

Details of your nearest domnick hunter sales office can be found at: www.domnickhunter.com

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DME012-RX - DME080-RX

1.1 Markings and symbols

The following markings and international symbols are used on the equipment and within this user guide:

Warning

Caution

Warning

Risk of electric shock.

Highlights actions or procedures which, if not performed correctly, may lead to personal injury or death.

Highlights actions or procedures which, if not performed correctly, may lead to damage to this equipment.

Highlights actions or procedures which, if not performed correctly, could lead to electric shock.

Wear ear protection.

When disposing of old parts always follow local waste disposal regulations

Conformité Européenne

1.2 Hazardous Substances

The columns are filled with a powerful desiccant material which will dry out the atmosphere, eyes, nose, and mouth if exposed.

The columns should only be opened and the desiccant changed by domnick hunter trained, qualified and approved engineer.

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DME012-RX - DME080-RX

2. Description

domnick hunter desiccant dryers are designed to remove moisture vapour from compressed air.

The dryer comprises of an inlet and outlet manifold joined together by an aluminium column. The column has two internal chambers filled with desiccant material. During operation one chamber is on-line (drying), whilst the opposite chamber is regenerating. This process is known as Pressure Swing Adsorption (PSA).

Pressure Swing Adsorption (PSA)

A small percentage of dried air is taken from the dryer output flow and is used to regenerate the saturated chamber by expanding the dried air from line pressure to atmospheric pressure. During this process, the moisture is physically removed from the regenerating chamber and vented to atmosphere through the exhaust silencers.

Dewpoint Dependent Switching (DDS)

DDS will adjust the dryer’s cycle in line with the moisture loading placed upon it, by constantly monitoring the processed air moisture content.

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DME012-RX - DME080-RX

2.1 Technical Specification

This specification is valid when the equipment is located, installed, operated, and maintained as specified within this user guide.

Parameter Units DME012-RX - DME040-RX DME050-RX - DME080-RX

Minimum Inlet Pressure

Maximum Inlet Pressure

Specific

Inlet Temperature

Inlet Connection NPT Inches 3/4” 1”

Outlet Connection NPT Inches 3/4” 1”

bar g

(psi g / MPa g)

bar g

(psi g / MPa g)

ºC

(ºF)

(232 / 1.6)

Parameter Units DME012-RX - DME040-RX DME050-RX - DME080-RX

Supply Voltage V ac 110V ac 50/60Hz ± 10%

Power W 52 30

Electrical

Fuse mA

500 (230v Supply) 1000 (110v Supply)

5 x 20mm time delay “T”

(58 / 0.4)

5 – 50

41 - 122

(188 / 1.3)

Parameter Units DME012-RX - DME080-RX

Temperature

Humidity -

IP Rating - IP65 / >NEMA 13

Pollution Degree - 2

Environmental

Installation Category - II

Altitude

Noise dB(A) <75dBA

(oF)

(ft)

2 – 45

35 - 113

50% @ 40ºC

(80% MAX ≤ 31ºC)

< 2000

(6562)

Caution

Before continuing with the installation and commissioning of this equipment:

Ensure that it is correctly sized for the inlet pressure, taking into consideration the pressure drop caused by the valves, pipes and filters within the system. Allowance should be made for purge air loss. The dryer should be typically sized at 1 bar (14 psi) 0.1MPa below nominal compressor output pressure.

The purge air flow is factory set for 6 bar g (87 psi g) minimum system pressure. Should the minimum supply pressure be lower than this figure the purge air flow must be reset in order to maintain the specified dewpoint.

Ensure that it is correctly sized for inlet temperature to meet the dewpoint specified.

Ensure that the electrical supply voltage and frequency meet the requirements detailed within this specification and on the equipment rating plate.

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DME012-RX - DME080-RX

2.1.1 Dimensions

DME012-RX - DME040-RX

HYGROMETER

110VAC

DEWPOINT

POWER

RELAY

SUPPLY

DME050-RX - DME080-RX

110VAC POWER SUPPLY

HYGROMETER DEWPOINT RELAY

Model

DME012-RX

DME015-RX

DME020-RX

DME025-RX

DME030-RX

DME040-RX

DME050-RX

DME060-RX

DME080-RX

(inches)

837

(32.9)

1003

(39.5)

1168

(46.0)

1333

(52.5)

1499

(59.0)

1747

(68.8)

1433

(56.4)

1599

(62.9)

1847

(72.7)

(inches)

302

(11.9)

302

(11.9)

302

(11.9)

302

(11.9)

302

(11.9)

302

(11.9)

566

(22.3)

566

(22.3)

566

(22.3)

(inches)

284

(11.2)

284

(11.2)

284

(11.2)

284

(11.2)

284

(11.2)

284

(11.2)

220

(8.7)

220

(8.7)

220

(8.7)

(inches)

794

(31.26)

960

(37.8)

1125

(44.29)

1290

(50.79)

1456

(57.32)

1704

(67.09)

1390

(54.72)

1556

(61.25)

1804

(71.02)

(inches)

352

(13.86)

352

(13.86)

352

(13.86)

352

(13.86)

352

(13.86)

352

(13.86)

395

(15.55)

395

(15.55)

395

(15.55)

Weight

(lbs)

(70)

(81)

(92)

(103)

(114)

(132)

(176)

(198)

104

(229)

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DME012-RX - DME080-RX

2.2 Unpacking the equipment

It is recommended that the equipment is moved into position before removing the packaging.

Remove the equipment from its packaging using the illustrations shown below for guidance and check that it has not been damaged in transit.

The following items have been included with your equipment:

Description Qty

DME-RX Dryer 1

Dryer Test Certificate 1

If any items are missing or damaged please contact your local domnick hunter office.

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DME012-RX - DME080-RX

ECO

2.3 Overview of the equipment

Referring to diagram below, the major parts of the dryer are as follows:

DME012-RX - DME040-RX

110VAC

HYGROMETER

POWER

DEWPOINT

SUPPLY

RELAY

DME050-RX - DME080-RX

ECO

110VAC

HYGROMETER

POWER

DEWPOINT

SUPPLY

RELAY

ECO

1 Mains Supply Cable

2 Hygrometer Relay Cable

110VA C

POWER

SUPPLY

HYGROMETER

DEWPOINT

RELAY

3 Dryer Outlet

4 Dryer Inlet

5 Dryer Status Indicators

6 Outlet Sight Glass

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DME012-RX - DME080-RX

ECO

3. Installation & Commissioning

Only competent personnel trained, qualified, and approved by domnick hunter should perform installation, commissioning and service procedures.

Warning

3.1 Locating the equipment

Identify a suitable location for the equipment taking into consideration the minimum space requirements for maintenance and lifting equipment as shown in the diagram below. When considering the final location of the equipment take into account the noise generated when in use.

The dryer can be free standing or secured to the floor via the fastener points provided in the base.

50% @ 40oC (80% MAX ≤ 31oC)

+45oC

+5oC

±2°

500 CRS

ECO

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DME012-RX - DME080-RX

3.2 Mechanical Installation

The Dewpoint Dependent Switching (DDS) system requires a sampling point to be inserted into the piping at the outlet of the dryer.

It is important to ensure that all piping materials are suitable for the application, clean and debris free. The diameter of the pipes must be sufficient to allow unrestricted inlet air supply to the equipment and outlet gas / air supply to the application.

When routing the pipes ensure that they are adequately supported to prevent damage and leaks in the system.

All components used within the system must be rated to at least the maximum operating pressure of the equipment. It is

recommended that the system be protected with suitably rated pressure relief valves.

A by-pass line may be installed into the system to provide a constant air supply during maintenance.

The by-pass line will allow untreated air to pass to the application and should only be used when the dryer has been shut down.

Caution

3.3 Electrical Installation

A fully qualified electrical engineer must undertake all electrical work in accordance with local regulations

Warning

3.3.1 Mains supply

The dryer is supplied with a 3 core non-detachable mains supply cable as identified below.

110 VAC

POWER

SUPPLY

The Green / Yellow cconductor of the 3 core cable must be bonded to earth (ground)

Warning

LIVE

NEUTRAL

EARTH / GROUND

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DME012-RX - DME080-RX

HYGROMETER

DEWPOINT

RELAY

The equipment should be connected to the electrical supply through a switch or circuit breaker. This device should be clearly and indelibly marked as the disconnecting device for the equipment and located in close proximity to the equipment and be easily accessible to the operator.

Overcurrent protection must be fitted as part of the building installation. This protection should be selected in accordance with local and national code regulations and based upon the technical data supplied for this equipment.

3.3.2 Hygrometer relay

The dryer is supplied with a 3 core non-detachable hygrometer relay cable as identified below.

The mains supply cable and hygrometer relay cables are clearly identified at the cable gland. Ensure that the correct cable is selected prior to continuing the installation

Warning

For correct operation of the DDS system, conductors 1 When in operation, the contacts should close when the dewpoint reaches the set point and remain closed until the moisture content rises above the set point.

Note: The dryer has an internal moisture over-ride which has been factory set at 30 minutes. This means that the dryer will revert to normal operation after 30 minutes regardless of the dewpoint.

and 2 should be connected across a set of volt free contacts as shown.

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DME012-RX - DME080-RX

4. Operating the equipment

4.1 Overview of Controls

The facia of the dryer consists of indicators only as follows:

Power “ON” Indicator

ECO (DDS) Indicator

Column A Pressure Gauge

Column B Pressure Gauge

4.2 Starting the equipment

Start-up should be undertaken by a domnick hunter trained, qualified and approved service engineer.

Warning

1. Ensure that the isolation valves on the inlet and the outlet of the dryer are closed.

2. Connect the electrical supply to the dryer and verify that the Power On indicator is illuminated.

3. Slowly open the isolation valve on the inlet of the dryer. Verify that there are no leaks.

4. Check that the system pressure relief valve is closed.

5. Test the condensate drains of the filters and verify that they are discharging correctly into a suitable collection vessel.

6. When the dryer is pressurised to full system pressure, slowly open the outlet isolation valve.

If a bypass line has been fitted, close the bypass valve.

7. Verify that the column pressure gauges are cycling between zero and full system pressure every three minutes.

The dryer is fully automatic and requires no user intervention until shut-down.

Dewpoint Dependent Switching (DDS)

If the dryer is producing air at a better dewpoint than specified the DDS system will hold the dryer at a point just before the changeover occurs. The green “ECO” LED will illuminate and both pressure gauges will read full system pressure.

The dryer will resume normal operation the instant the DDS system monitors a fall in dewpoint to the specified level.

4.3 Stopping the equipment

1. Close the isolation valve on the outlet followed by the isolation valve at the inlet.

If a bypass line has been fitted, simultaneously open the bypass valve.

2. De-pressurise the dryer by venting through the drain ball valve on the outlet dust filter.

Note: The drain valve should be opened gradually.

3. Disconnect the electrical supply to the dryer.

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DME012-RX - DME080-RX

5. Servicing

The recommended Service procedures identified in table 5.2 and all other repair and calibration work should be undertaken by a domnick hunter trained, qualified and approved engineer.

5.1 Cleaning

Clean the equipment with a damp cloth only and avoid excessive moisture around any electrical sockets. If required you may use a mild detergent, however do not use abrasives or solvents as they may damage the warning labels on the equipment.

5.2 Service Intervals

Description of Service Requirement Typical Recommended Service Interval

Component Operation

Daily

Dryer Check POWER ON indicator is illuminated. - - - - - -

Dryer

Dryer Check for air leaks. - - - - - -

Dryer

Dryer Check for cyclic operation. - - - - - -

Check STATUS / FAULT indicators located on the control panel.

Check the pressure gauges during purging for excessive back pressure.

Check the condition of electrical supply cables and conduits.

- - - - - -

Weekly

- - - - - -

3 Months

6 Months

12 Months

24 Months

30 Months

Dryer

Filtration

Dryer Replace / Calibrate dewpoint transmitter - - - - - -

Dryer

Replace the active exhaust silencers

Recommended Service A

Replace the inlet, outlet and control air filters, and service drains.

Replace the valve seats and seals.

Recommended Service D

Replace the Desiccant.

Recommended Service E

Check

- - - - - -

Replace

Table 5.2

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DME012-RX - DME080-RX

5.3 Service Kits

Service Kit Description Kit No Quantity

A – Silencer Service

D – Valve Service

Kit: Exhaust Silencer DME012-RX - DME040-RX 608233670 1

Kit: Exhaust Silencer DME050-RX - DME080-RX 608330001 1

Kit: Valve Overhaul DME012-RX - DME040-RX 608330006 1

Kit: Valve Overhaul DME050-RX - DME080-RX 608330007 1

AA 11.2 Litre Bag 608203661 See table below

Kit: Column Seals DME012-RX - DME040-RX 608203733 1

E – Desiccant Service

DME012-RX DME015-RX DME020-RX DME025-RX DME030-RX DME040-RX DME050-RX DME060-RX DME080-RX

Dryfil AA 1 1 2 2 2 2 3 4 5

Seals 1 1 1 1 1 1 1 1 1

Kit: Column Seals DME050-RX - DME080-RX 608330010 1

Snow storm filler DME012-RX - DME040-RX 608200622 1

Snow storm filler DME050-RX - DME080-RX 608201051 1

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DME012-RX - DME080-RX

5.4 Service Record

Date of Commissioning

Service (Hours)

4,000

8,000

16,000

20,000

24,000

28,000

32,000

36,000

40,000

Hours

Shown

Date

Serviced By

Comments / Observations

Print Initials

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DME012-RX - DME080-RX

6. Troubleshooting guide

In the unlikely event that a problem occurs on the equipment, this troubleshooting guide can be used to identify the probable cause and remedy.

Troubleshooting should only be attempted by competent personnel. All major repair, and calibration work should be undertaken by a domnick hunter trained, qualified and approved engineer.

Warning

Problem Indication Probable Cause Remedy

Poor dewpoint Crystals go clear in the outlet

sight glass (DME040 - 080-RX Models only)

Entrained Water

Excessive air flow demand

Check pre-filtration drains.

Check actual flow against rated flow of dryer Check for recent additions to air system

Inlet pressure too low

Excessive inlet air temperature

Insufficient purge air flow

Exhaust silencers blocked

Contaminated desiccant

Electrical fault Flashing Yellow LED Hardware fault

High differential pressure Pressure gauges Excessive outlet flow Check and regulate air demand

Failure to purge

Outlet air flow stops

No depressurisation and poor dewpoint

Downstream pressure drops. Yellow LED “OFF”

Purge valve blocked or shut. Exhaust silencers blocked.

Electrical fault. Blown fuse in plug.

Check against technical specification

Factory set for 6 bar g (87 psig) system pressure.

domnick hunter trained personnel to adjust

Change by domnick hunter trained personnel

Eliminate source of contamination. Desiccant change by domnick hunter trained personnel

Contact domnick hunter customer services

domnick hunter trained personnel to adjust. Change by domnick hunter trained personnel

Constant depressurisation Erratic air flow from exhaust Damaged valve.

Change by domnick hunter trained personnel

Page 19

Declaration of Conformity EN

Parker Hannifin ltd, Industrial division

Dukesway, TVTE, Gateshead, Tyne & Wear, NE11 0PZ. UK

DME012-RX, DME015-RX, DME020-RX, DME025-RX, DME030-RX, DME040-RX, DME050-RX, DME060-RX, DME080-RX

Directives 97/23/EC

Adsorption Dryer

2006/95/EC 2004/108/EC 93/68/EEC, 92/31/EEC

Standards used EN 61010-1 : 2001

PED Assessment Route : B & D EC Type-examination Certificate: LDS 9900792/5 Notified body for PED: Lloyds Register Verification

Authorised Representative Derek Bankier

Divisional Quality Manager Parker Hannifin ltd, Industrial division

EN 61000-6-1 : 2005EN 61000-6-2 : 2001 EN 61000-6-3 : 2001EN 61000-6-4 : 2001 EN 61000-3-2 : 2000 EN 61000-3-3 : 1995 Generally in accordance with ASMEVIII Div 1 : 2004.

71 Fenchurch St. London EC3M 4BS

Declaration

I declare that as the authorised representative, the above information in relation to the supply / manufacture of this product, is in conformity with the standards and other related documents following the provisions of the above Directives.

Signature: Date: 22/01/2010

Declaration Number: 0028/220110

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AE – UAE, Dubai Tel: +971 4 8127100 [email protected]

AR – Argentina, Buenos Aires Tel: +54 3327 44 4129

AT – Austria, Wiener Neustadt Tel: +43 (0)2622 23501-0 [email protected]

AT – Eastern Europe,

Wiener Neustadt Tel: +43 (0)2622 23501 900 [email protected]

U – Australia,Castle Hill

Tel: +61 (0)2-9634 7777

AZ – Azerbaijan, Baku Tel: +994 50 2233 458 [email protected]

BE/LU – Belgium, Nivelles Tel: +32 (0)67 280 900 [email protected]

BR – Brazil, Cachoeirinha RS Tel: +55 51 3470 9144

BY – Belarus, Minsk Tel: +375 17 209 9399 [email protected]

CA – Canada, Milton, Ontario Tel: +1 905 693 3000

CH – Switzerland, Etoy Tel: +41 (0) 21 821 02 30 [email protected]

CL – Chile, Santiago Tel: +56 2 623 1216

CN – China, Shanghai Tel: +86 21 5031 2525

CZ – Czech Republic, Klecany Tel: +420 284 083 111 [email protected]

DE – Germany, Kaarst Tel: +49 (0)2131 4016 0 [email protected]

DK – Denmark, Ballerup Tel: +45 43 56 04 00 [email protected]

ES – Spain, Madrid Tel: +34 902 33 00 01 [email protected]

FI – Finland, Vantaa Tel: +358 (0)20 753 2500 parker.[email protected]

FR – France, Contamine s/Arve Tel: +33 (0)4 50 25 80 25 [email protected]

GR – Greece, Athens Tel: +30 210 933 6450 [email protected]

HK – Hong Kong

Tel: +852 2428 8008

HU – Hungary, Budapest Tel: +36 1 220 4155 [email protected]

IE – Ireland, Dublin T

el: +353 (0)1 466 6370

[email protected]

IN – India, Mumbai Tel: +91 22 6513 7081-85

IT – Italy, Corsico (MI) Tel: +39 02 45 19 21 [email protected]

JP – Japan, Tokyo Tel: +(81) 3 6408 3901

KR – South Korea, Seoul Tel: +82 2 559 0400

KZ – Kazakhstan, Almaty Tel: +7 7272 505 800 [email protected]

LV – Latvia, Riga Tel: +371 6 745 2601 [email protected]

MX – Mexico, Apodaca Tel: +52 81 8156 6000

MY – Malaysia, Shah Alam Tel: +60 3 7849 0800

NL – The Netherlands,

Oldenzaal Tel: +31 (0)541 585 000 [email protected]

NO – Norway, Ski Tel: +47 64 91 10 00 [email protected]

NZ – New Zealand,

Mt Wellington

Tel: +64 9 574 1744

PL – Poland, Warsaw Tel: +48 (0)22 573 24 00 [email protected]

PT – Portugal, Leca da Palmeira Tel: +351 22 999 7360 [email protected]

RO – Romania, Bucharest Tel: +40 21 252 1382 [email protected]

RU – Russia, Moscow Tel: +7 495 645-2156 [email protected]

SE – Sweden, Spånga Tel: +46 (0)8 59 79 50 00 [email protected]

SG – Singapore

Tel: +65 6887 6300

SK – Slovakia, Banská Bystrica Tel: +421 484 162 252 [email protected]

SL – Slovenia, Novo Mesto Tel: +386 7 337 6650 [email protected]

TH – Thailand, Bangkok Tel: +662 717 8140

TR – Turkey, Istanbul Tel: +90 216 4997081 [email protected]

TW – Taiwan, Taipei Tel: +886 2 2298 8987

UA – Ukraine, Kiev Tel +380 44 494 2731 [email protected]

UK – United Kingdom,

Warwick Tel: +44 (0)1926 317 878 [email protected]

US – USA, Cleveland Tel: +1 216 896 3000

VE – Venezuela, Caracas Tel: +58 212 238 5422

ZA – South Africa,

Kempton Park Tel: +27 (0)11 961 0700 [email protected]

Parker Worldwide

European Product Information Centre

Free phone: 00 800 27 27 5374

(from AT, BE, CH, CZ, DE, DK, ES, FI, FR, IE,

IT, NL, NO, PL, PT, RU, SE, UK, ZA)

Publication Reference: 176034100 01/10 Rev.000

Parker Hannifin ltd Industrial division Dukesway, Team Valley Trading Est Gateshead, Tyne and Wear England NE11 0PZ Tel: +44 (0) 191 402 9000 Fax: +44 (0) 191 482 6296 www.domnickhunter.com