WALKER FILTRATION PROSFD, PROSFD PD0046, PROSFD PD0056, PROSFD PD0075, PROSFD PD0110 Series Manual
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PROSFD
PROSFD
PROSFD
The product to which this manual refers must not be supplied, installed,
used, operated or serviced until the contents of the manual has been
fully read and understood by all relevant personnel.
Please complete the following information at the time of installation
found on the rating label on the upper right hand side of dryer
Model Number
Serial Number
Regulated Inlet Pressure
Filtration present with Dryer
Inlet Flow of Dryer
Supply Voltage
Contents
1 Safety 5
Safety Guidelines 5
Symbols 6
2 General Description 7
Function of the Dryer 7
Controller Options 7
Package Contents 8
Primary Components 9 - 10
3 Technical Data 11
Environmental Conditions 11
Dimensional Specications 12
Sizing 13
4 Mechanical Installation 14
Orientation 16
Conguration of the inlet /outlet ports 17
Connecting the pre-lter to the dryer 18
Connecting the optional pre-lter drain valve 18
Installing the hygrometer (DMC models only) 19
Conguring the purge orice 20
5 Electrical Installation 22
PRODRY Controller power supply options 22
PRODRY Recommended power cable specications 22
LED Controller specications 23
DMC Controller specications 24
How to wire a DIN connector 25
Alarm connection details 26
6 Operation 27
Background / Function of the Dryer 27
Detailed operational description - LED Controller 27
Detailed operational description - DMC Controller 27
Start-up procedure 28
Shut-down procedure 28
Operational schematics 29
7 Energy Management 35
Overview 35
Developing a purge control strategy 35
Using a manual switch for purge control 35
Using a standard pressure switch for purge control 36
Using an electronic pressure switch for purge control 37
Using a hygrometer and process controller for purge control 38
Making connections between a switching device and dryer EM contact 39
8 Maintenance 40
9 Spares Information 41
Service kits 41 - 43
Accessory kits 44 - 45
10 Component Parts 46
11 Troubleshooting 50
12 Warranty 56
13 Declaration of Conformity 57
Section 1: Safety
Safety
The following safety guidelines must be
strictly observed.
• Leave this manual at the place of installation of
the product.
• It is essential that only Walker Filtration or it’s appointed
agents carry out maintenance and servicing work.
Users, maintenance and servicing personnel must be familiar
with:
• Accident prevention regulations.
• Safety information (general and specic to the unit).
• Safety devices of the unit.
• Measures to be taken in case of an emergency.
• Allow only suitably trained persons to be involved with
installation, start-up, operation, servicing and maintenance
of the product.
• It is the responsibility of the installer to ensure that the
pipe work to and from the dryer is suitable, in accordance
with applicable legislation and subject to inspection and
testing prior to being put into service. All piping must be
adequately supported.
• Before carrying out any maintenance or servicing work the
unit must be taken out of operation. Users and others will
be exposed to risk if work is carried out whilst the unit is
running. This means electrical disconnection plus isolation
from the compressed air supply and full depressurisation.
• Only trained and competent persons familiar with the
electrical requirements of the unit as laid out in this
manual and electrical safety rules and regulations should
be allowed to carry out work on the electrical components
and power supply to the unit.
• When carrying out any work on the unit, use only
correctly sized appropriate tools in good condition.
• Only use original spare parts and accessories from the
manufacturer. There is no guarantee that non-original
parts have been designed and manufactured to meet
the safety and operational requirements of the unit.
Walker Filtration assume no liability for any equipment
malfunction resulting from the use of non-approved parts.
• If carrying out installation work above head height, use
suitable and safe working platforms or other means of
working access.
• Do not make any constructional changes to the product.
Any changes or modications may only be carried out by
the manufacturer, Walker Filtration.
• Any faults or defects that could affect safety must be put
right fully before using the unit.
• Used items and materials must be disposed of in the
correct manner, complying with local laws and regulations,
in particular the desiccant cartridge.
5
Section 1: Safety
Figure 1.1: Definition of symbols
Risk of Danger
Risk of High Pressure
Risk of Electric Shock
Warning
Manual Handling
As with all areas of the workplace, Health and Safety is of
great importance and must be given due care and attention.
While working with this equipment, manual handling
regulations must be considered and adhered to.
Full advice, support and guidance should be detailed in your
Health and Safety Policy and Manual Handling guide, please
take the time to familiarise yourself with these documents.
The Manual Handling Operations Regulations apply to a wide
range of manual handling activities, including lifting, lowering,
pushing, pulling or carrying.
We ask every person handling this product to take the
responsibility for their own Health and Safety and the Health
and Safety of others around them. If you feel there is a
signicant risk, you must take steps to either remove the risk
altogether, or reduce the risk prior to carry out the activity. If
you need further support or guidance with this, please consult
your line manager or the HR Department.
There are safe systems of work and correct procedures in
relation to manual handling, please consult these documents
available within the workplace.
We ask everyone handling this product to:
• Follow appropriate systems of work laid down
for their safety.
• Make proper use of any equipment provided for
their safety.
• Inform the company if they identify hazardous
handling activities.
• Take care to ensure that their activities do not put
others at risk.
If in doubt, please seek further advice and ensure you always
follow the correct procedures and guidance.
For more information please see our Health and
Safety manual attached.
Equipment Protected by
Double Insulation
Important Note
A 3 amp fuse should be tted as per the wiring diagram.
6
Section 2: General Description
Controller Options
RESET
Controller Options
RESET
Dewpoint Hold (-40)
Dryer Dewpoint -43 PDP
Hours Run 1234
Service History # 0
General Description
This manual is valid for the following dryer models
PD0046
PD0056
PD0075
PD0090
PD0110
PD0150
PD0180
PD0220
PD0300
PD0360
Function of the Dryer
PRODRY is designed to provide a smooth, controlled and
uninterrupted delivery of dry compressed air. Wet air passes
through a pre-lter and travels down to the bottom valve
assembly. The air is then fed through the bottom of the
desiccant bed and moves through the high performance
desiccant until it becomes dry. On exit from the desiccant
cartridge, the air is passed through the outlet valve assembly.
During this process, the dryer control system cycles the process
air between the two desiccant towers. While one tower is on
stream removing water vapour, the other is being carefully
depressurised in preparation for regeneration. The desiccant
bed is regenerated by expanding a small amount of dry
process air, or purge air, through the saturated desiccant.
Purge air passes to atmosphere through the silencer, which
is tted to an exhaust valve. The tower is then repressurised,
with the control system assuring each tower is at full
operational pressure prior to changeover.
This ensures a reliable and efcient operation. The air stream is
switched and the cycle repeats on a continuous basis.
Figure 2.1: LED Controller
Features:
• Supplied as standard controller
• Microcontroller based design
• Available in 115V or 230VAC
• Energy Management Feature (EM)
• Alarm Outputs
Figure 2.2: DMC Controller
Features:
• (Optional) full feature controller
• PLC based design
• 24VDC only
• Includes Hygrometer
• Energy Management Feature (EM)
• Alarm Outputs
• Selectable output dewpoint levels (-20°C, -40°C, -74°C)
• Engages Dewpoint Hold during periods of low demand
• resulting in energy savings up to 81%.
7
Controller Options
Controller Options
Section 2: General Description
1
2
3
4
1
6
2
3
4
5
1
6
2
3
4
5
Package Contents
The dryer is delivered in protective packaging. Take care when transporting, loading and unloading the unit.
The package contains the following items (refer to gure 2.3):
1. Dryer unit
2. Instruction manual (including certicate of conformity)
3. Power connector
Figure 2.3: Package contents (All dryer models)
4. Purge Kit
Figure 2.4: Optional Items for DMC Dryer
Hygrometer Sample Block
(Installed into top valve block)
Hygrometer
Instruction manual
(including certicate of conformity)
Note: All dryers come equipped with
eyebolts to facilitate removing the dryer
from it’s crate. Simplex dryers include one
eyebolt and duplex models include two.
Note: All dryers include spare orice
components to allow the dryer to be
modied from the factory 7 barg (100 psig)
pressure setting to any pressure within the
specied operating range. The internal
purge valves within models PD046 & PD056
can be modied to suit all pressure settings
whilst models PD0075 to PD0360 require
additional components (which are supplied
with the dryer).
Figure 2.5: Optional Items for DMC Dryer
Pre-lter drain valve
7
8
Section 2: General Description
Figure 2.6: Primary Components (Simplex Models PD0046 - PD0180)
DMC Models2b
1
2a LED Models
17
16
4
3
5
19
18
6
DMC Models
7
8
9
10
11
12
13
15
14
1. Front panel
2a. LED controller
2b. DMC controller
3. Top trim cover
4. Extrusion cover
5. Top extrusion tower plug
6. Tower spring
7. Desiccant cartridge
8. Extrusion tower
9. Top manifold assembly
10. Pre-filter (Optional)
11. Downpipe
12. Exhaust silencer
13. Bottom manifold assembly
14. Dryer stand
15. Bottom extrusion tower plug
16. Tower circlip
17. Bottom trim cover
18. Hygrometer sample block*
19. Hygrometer*
* DMC models only
9
Section 2: General Description
Figure 2.7: Primary Components (Duplex Models PD0220 - PD0360)
Se ctio n 2: General Description
Figure 2.7: Primary Components (Duplex Models PD0220 - PD0360)
6
2
DMC Models2b
3
4
5
21
7
8
9
20
DMC Models
10
11
12
13
1
19
14
15
18
17
16
1. Front panel
2a. LED controller
2b. DMC controller
3. Top trim cover
4. Extrusion cover
5. Top extrusion tower plug
6. Tower spring
7. Desiccant cartridge
8. Extrusion link
9. Extrusion tower
10. Top manifold assembly
11. Pre-filter (Optional)
12. Downpipe
13. Exhaust silencer
14. Bottom manifold assembly
15. Bottom manifold support clip
16. Dryer stand
17. Bottom extrusion tower plug
18. Tower circlip
19. Bottom trim cover
20. Hygrometer sample block*
21. Hygrometer*
* DMC models only
10
Section 3: Technical Data
Technical Data
Environmental Conditions
All dryers are designed to be safe under the following conditions:
• Indoor use
• Altitude up to 2,000m
• Ambient temperature 5°C (41°F) to 50°C (122°F)
• Mains supply voltage uctuations not to exceed +/- 10% of nominal
For operation extended from the above conditions, please contact Walker Filtration.
Excessive vibrations from external sources may cause
failure of this product.
Rated Conditions
Measurement
Inlet pressure 7 barg 101.5 psig
Inlet temperature 35°C 95°F
Relative humidity of air at inlet 95%
Pressure dewpoint, standard version -40°C -40°F
Performance
Specified Limitation for Operation
Measurement
Maximum inlet air pressure 13 barg 188.5 psig
Minimum inlet air pressure 4 barg 58 psig
Maximum ambient air temperature 50°C 122°F
Minimum ambient air temperature 5°C 41°F
Pressure dewpoint (LED & DMC Controller) -20°C to -74°C -4°F to -100°F
Electrical supply voltage (LED Controller) 115 VAC or 230 VAC
Electrical supply voltage (DMC Controller) 24 VDC
Performance
11
Section 3: Technical Data PD0046 - PD0360
Section 3: Technical Data PD0046 - PD0360
Dryer
model
Pipe
size
Inlet flow rate* Dimensions mm (inches)
Weight KgNo. of
cartridges
Recommended
Filter model
Filter
pipe size
Nm³/h
SCFM
ABCDEF
17745 655 (25.8) 76 (3) 50 (2) 600 (23.6) 50 2 ½
19455 735 (29) 76 (3) 50 (2) 700 (27.6) 58 2 ½
1 128 75 905 (35.6 76 (3) 50 (2) 850 (33.5) 66 2 ½
1 153 90 1030 (40.5) 76 (3) 50 (2) 1000 (39.4) 75 2
1 187 110 1260 (49.6) 76 (3) 50 (2) 700 (27.6) 105 4
1 255 150 1595 (62.8) 76 (3) 50 (2) 850 (33.5) 130 4 1
1 306 180 1845 (72.6) 76 (3) 50 (2) 1000 (39.4) 150 4 1
1½ 374 220 1262 (49.7) 76 (3) 62 (2.4) 700 (27.6) 250 8
1½ 510 300 1596 (62.8) 76 (3) 62 (2.4) 850 (33.5) 315 8
1½ 612 360 1845 (72.6) 76 (3) 62 (2.4) 1000 (39.4) 362 8 A159XA 1 ½
A
189189
175175
Models PD0046-PD0180
Models PD0220-PD0360
C
601601
B
A
175175
F
E
D
B
C
F
E
D
* Stated flows are for an inlet pressure of 7 barg (100 psig) with reference to 20°C (68°F), 1 barg (abs.), 0% relative water vapour pressure. For flow at other
pressures, apply the appropriate correction factors, terms and dewpoint.
380(15) 310 (12.2)
380(15) 310 (12.2)
380(15) 310 (12.2)
380(15) 310 (12.2)
380(15) 490 (19.3)
380(15) 490 (19.3)
380(15) 490 (19.3)
380(15) 310 (12.2)
380(15) 310 (12.2)
380(15) 310 (12.2)
Weight KgNo. of
cartridges
Recommended
Filter model
Filter
pipe size
A
189189
175175
Models PD0220-PD0360
B
C
F
E
D
Dryer
model
PD0046 1 77 45 655 (25.8) 380 (15) 310 (12.2) 76 (3) 50 (2) 600 (23.6) 46 2 A058XA ½
PD0056 1 94 55 735 (29) 380 (15) 310 (12.2) 76 (3) 50 (2) 700 (27.6) 51 2 A059XA ½
PD0075 1 128 75 905 (35.6) 380 (15) 310 (12.2) 76 (3) 50 (2) 850 (33.5) 62 2 A059XA ½
PD0090 1 153 90 1030 (40.5) 380 (15) 310 (12.2) 76 (3) 50 (2) 1000 (39.4) 70 2 A078XA ¾
PD0110 1 187 110 1260 (49.6) 380 (15) 325 (12.8) 76 (3) 50 (2) 700 (27.6) 85 4 A079XA ¾
PD0150 1 255 150 1595 (62.8) 380 (15) 325 (12.8) 76 (3) 50 (2) 850 (33.5) 105 4 A108XA 1
PD0180 1 306 180 1845 (72.6) 380 (15) 325 (12.8) 76 (3) 50 (2) 1000 (39.4) 122 4 A109XA 1
PD0220 1½ 374 220 1262 (49.7) 380 (15) 490 (19.3) 76 (3) 62 (2.4) 700 (27.6) 154 8 A128XA 1 ¼
PD0300 1½ 510 300 1596 (62.8) 380 (15) 490 (19.3) 76 (3) 62 (2.4) 850 (33.5) 195 8 A128XA 1 ¼
PD0360 1½ 612 360 1845 (72.6) 380 (15) 490 (19.3) 76 (3) 62 (2.4) 1000 (39.4) 225 8 A159XA 1 ½
* Stated ows are for an inlet pressure of 7 barg (100 psig) with reference to 20°C (68°F), 1 barg (abs.), 0% relative water vapour pressure. For
ow at other pressures, temperatures and dewpoints apply correction factors on page 13.
Inlet flow rate* Dimensions mm (inches)
Pipe
size
Nm³/hr SCFM A B C D E F
Weight KgNo. of
cartridges
Recommended
Filter model
Filter
pipe size
12
Section 3: Technical Data PD0046 - PD0360
Dryer correction factors
Operating pressure (PCF)
barg
psig
Correction factor
4 5 6 7 8 9 10 11 12 13
58 72 87 100 115 130 145 160 174 189
0.62 0.75 0.87 1 1.12 1.25 1.37 1.5 1.62 1.75
Temperature (TCF)
Celcius °C
Farenheit °F
Correction factor
Pressure dewpoint (DCF)
Celcius °C
Farenheit °F
Correction factor
PRODRY Sizing Example
To correctly select the PRODRY model suitable for your application the following information is required: Minimum
Inlet Pressure, Maximum Inlet Temperature, Maximum Compressor Inlet Flow and Required Pressure Dewpoint (PDP).
Requirements Correction Factor
Maximum compressor inlet ow
Actual minimum inlet pressure
to the dryer
Maximum inlet temperature
Pressure dewpoint (PDP)
Corrected dryer ow rate
Appropriate Dryer Size
20 25 30 35 40 45 50
68 77 86 95 104 113 122
1.3 1.2 1.1 1 0.75 0.65 0.45
-20 -30 -40 -70 -74
-4 -22 -40 -94 -100
1.23 1.2 1 0.8 0.77
56 scfm -
6 barg PCF = 0.87
25°C (77°F) TCF = 1.2
-74°C (-100°F) DCF = 0.77
Inlet ow rate
PCF x TCF x DCF56(0.87 x 1.2 x 0.77)
Dryer model is selected based on the corrected ow rate, i.e. PD0075.
= =
69.7 scfm
(118 Nm³/hr)
Technical notes
Pre-filtration, including a water separator is essential to maintain dryer performance.
1.
An appropriate Water Separator must be installed. If bulk water enters the adsorption dryer it can cause heat
expansion to the desiccant, substantial rise in the dryer differential pressure, lead to poor outlet dewpoint, and
2.
cause potential dryer failure.
Walker Filtration recommends fitting an RXA dust filter to the outlet.
3.
Call your nearest Walker Filtration sales team for further information.
4.
13
Section 4: Mechanical Installation
Mechanical Installation
Figure 4.1: Typical installation
C
XA
To prevent back flow into the dryer a non-return valve should be placed in-line, downstream
of the dryer. This is essential when more than one dryer is used in a single application.
Figure 4.2: Level ground
WS X1 XA
RXA
14
Section 4: Mechanical Installation
>Max 50OC (122OF)
Figure 4.3: Location
Figure 4.4: Hard piped installation
Figure 4.5 Exposure to heat
Max 50OC (122OF)
>Max 50OC (122OF)
15
Section 4: Mechanical Installation
Figure 4.6: Drainage (all tubing should be secured up to the point of drain to prevent whipping during discharge)
Orientation
Figure 4.7: The PRODRY range of dryers is designed to operate in both vertical and horizontal orientation.
16
Section 4: Mechanical Installation
Re conguration of the inlet / outlet ports
PD0046 – PD0360 models
• Dryer can be recongured to interchange position of
inlet and outlet ports as per gure 4.8.
• PRODRY has two inlet ports (A and B) and two outlet
ports (C and D). Either (A or B) can be used for inlet
and (C or D) for outlet. Make sure the un-used ports are
blanked off with provided pressure plugs.
Figure 4.8: Inlet/outlet ports
C
A
D
B
Any of the two outlet ports can be used on
Tools required
occasion. Please ensure flow at outlet should not
exceed specification. Please adhere to regional
regulations.
It is strongly advised to connect a non-return
valve to the outlet port of the dryer.
• Adjustable spanner
• Ratchet with 17mm Hexagonal connection
(PD0046 - PD0180)
• Ratchet with 1” Hexagonal connection
(PD0220 - PD0360)
Only use one inlet port at any one time
Ensure original seals are in place.
Check dryer is leak-free prior to operation.
17
Section 4: Mechanical Installation
Figure 4.9: Co nnecting a pre- filter
Figure 4.9: Conn ecting a pre- filte r
Figure 4.10 : Conn ecting filte r dr ain
Connecting the pre-lter to the dryer
PD0046 – PD0360 models
• Attach pre-lter (purchased separately) utilising a pipe
nipple and/or pipe adapter.
• Pipe away condensate with tubing from drain outlet.
Ensure condensate is drained into an oil/water
separator.
• Fit any further ltration and/or ancillary equipment.
• Pre-lter is typically supplied with an autodrain installed
in the bowl drain port. On DMC models, this can
be replaced with a solenoid drain valve which is an
optional extra sold separately.
All tubing should be secured up to the point of
drain to prevent whipping during discharge.
• It is recommended that a bypass line including XA lter
is installed, as per gure 4.1.
Connecting the optional pre-lter drain valve
• Available on DMC models only.
• If necessary, remove existing autodrain valve from
pre-lter.
• Install pipe adapter into pre-lter drain port.
• Install optional solenoid drain valve onto pipe adapter(s)
taking care to note ow direction as indicated by arrow
etched into the side of the drain valve body.
• Pipe away condensate with tubing from drain outlet.
Ensure condensate is drained into an oil/water
separator.
Figure 4.9: Connecting a pre-filter
Figure 4.10: Connecting filter drain
All tubing should be secured up to the point of
drain to prevent whipping during discharge.
18
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