WALKER FILTRATION PROSFD, PROSFD PD0046, PROSFD PD0056, PROSFD PD0075, PROSFD PD0110 Series Manual

...

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 Specications 12

Sizing 13

4 Mechanical Installation 14

Orientation 16

Conguration 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

Conguring the purge orice 20

5 Electrical Installation 22

PRODRY Controller power supply options 22

PRODRY Recommended power cable specications 22

LED Controller specications 23

DMC Controller specications 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 specic 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 modications 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.

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

signicant 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.

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 efcient 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%.

Controller Options

Section 2: General Description

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 certicate 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 certicate 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 orice

components to allow the dryer to be

modied from the factory 7 barg (100 psig)

pressure setting to any pressure within the

specied operating range. The internal

purge valves within models PD046 & PD056

can be modied 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

Section 2: General Description

Figure 2.6: Primary Components (Simplex Models PD0046 - PD0180)

DMC Models2b

2a LED Models

DMC Models

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

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)

DMC Models2b

DMC Models

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

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

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

189189

175175

Models PD0046-PD0180

Models PD0220-PD0360

601601

175175

* 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) 490 (19.3)

380(15) 310 (12.2)

Weight KgNo. of

cartridges

Recommended

Filter model

Filter

pipe size

189189

175175

Models PD0220-PD0360

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

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.

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

cause potential dryer failure.

Walker Filtration recommends ﬁtting an RXA dust ﬁlter to the outlet.

Call your nearest Walker Filtration sales team for further information.

Section 4: Mechanical Installation

Mechanical Installation

Figure 4.1: Typical installation

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

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)

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.

Section 4: Mechanical Installation

Re conguration of the inlet / outlet ports

PD0046 – PD0360 models

• Dryer can be recongured 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

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.

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.

Section 4: Mechanical Installation

Hygrometer

Sample Block

Hygrometer

DIN Plug

PD0046 – PD0360 models

•

Installing the hygrometer (DMC models only)

•Remove hygrometer from packaging.

• Carefully remove plastic cover from the sensor.

•

Hygrometer sample block is pre-installed in the dryer’s top manifold assembly. Remove cover from threaded port.

Confirm the threads on the hygrometer sample block are clean and free from any dirt, water, cutting lubricant, liquid thread sealant, oil and/or grease.

Per figure 4.11, insert hygrometer into the hygrometer sample block and turn to clockwise to tighten . Tighten

lightly with adjustable spanner.

Fit hygrometer DIN plug to the hygrometer and tighten screw with pozi-head screwdriver.

Section 4: Mechanical Installation

Do not touch white sensor tube.

Open 2 full turns = 5Nl/min

Hygrometer Silencer Setting

Installing the hygrometer (DMC models only)

PD0046 – PD0360 models

• Remove hygrometer from packaging.

• Carefully remove plastic cover from the sensor.

Do not touch white sensor tube.

• Hygrometer sample block is pre-installed in the dryer’s top manifold assembly. Remove cover from threaded port.

• Conrm the threads on the hygrometer sample block are clean and free from any dirt, water, cutting

lubricant, liquid thread sealant, oil and/or grease.

• Per gure 4.11, insert hygrometer into the hygrometer sample block and turn to clockwise to tighten. Tighten lightly with adjustable spanner.

• Fit hygrometer DIN plug to the hygrometer and tighten screw with pozi-head screwdriver.

Figure 4.11 Attaching hygrometer

Figure 4.12 Hygrometer attached

Tools required

• Adjustable spanner

• Pozi-head screwdriver

Section 4: Mechanical Installation

Purge Orice Size Identication

• Reference gure 4.13 and the Purge Plug Identication Table.

• Each dryer is pre-set with the correctly sized purge valve for an operating pressure of 7 barg (100 psig) at point of order.

• The lettering (A through S), located on the purge valve body, indicates the orice size selected to suit the operating pressure of the dryer per the chart below.

• If the inlet pressure to the dryer will be different than the pre-set orice size, the purge valve can be adjusted.

• Most dryers use a single orice purge valve represented by the Blue and Green single letter references in the table below.

• Larger dryers may require a two or three hole purge valve as represented by the Red and Yellow two and three letter references.

• To select the correct orice size, locate the appropriate dryer model at the left side of the table and then the operating pressure at the top.

• Make sure that the correct valve body (1, 2 or 3 hole) and orice disc (01, 02, 03 or 04) has been supplied with the dryer. The discs have the number (01, 02, 03 or 04) stamped out at the top.

Purge Plug Identiﬁcation

Operating pressure

Dryer

PD0046

PD0056

PD0075

PD0090

PD0110

PD0150

PD0180

PD0220

PD0360

4 5 6 7 8 9 10 11 12 13

M K I H G F E E E D

P M L K J I H G F F

B S P M L L K I I H

C A P P N L K J I H

I E C A P M K K J I

CK M G F C B A S S P

EM CK P I G E C B A A

AFK FN DL P K H F E D C

EJP DIN CHM AFK AFK GP EM DL BJ AI

Disc

Every dryer is shipped with a purge oriﬁce set up for 7 barg (100 psig) operation. The dryer will also include the necessary purge valve components to conﬁgure the dryer to operate at any pressure from 4 barg (58 psig) to 13 barg (189 psig). For example: A PD0150 dryer will be supplied with a single hole purge assembly with an 02 purge disc installed and indexed to position F. Additional purge valve components will be included to allow the dryer to be conﬁgured to purge settings, CK, M, H, D, B, A, S, P and N.

Appropriate purge plug selection is very important for function of the dryer. Failure to comply with this may affect your warranty.

Section 4: Mechanical Installation

Figure 4.13 Purge valve assembly

Orifice Discs

Valve Body (Common to all dryers)

1 Hole Valve Stem

2 Hole Valve Stem

Valve Control Spring

M4 Screw

3 Hole Valve Stem

Valve Stem O-ring(s) (Fit into recess in Valve Stem(s))

Gasket and Valve Stem are rotated to align with index reference letters on Valve Body

Index reference letters

Purge Sealing Gasket(s)

(1, 2 or 3 hole)

Disc I.D. Number (01, 02, 03, 04)

Alignment notches

3mm allen key

Figure 4.13 Purge valve assembly

Purge Valve Assembly

• Reference gure 4.13 and the Purge Plug Identication Table on Page 20.

• Once the correct purge body (1, 2 or 3 hole) and orice disc (01, 02, 03 or 04) has been selected per the instructions on Page 20, the purge valve may be assembled.

• The index letters located on the purge valve body correspond with the selected orice sizes per the Table on Page 20.

• Place the appropriate orice disc onto the valve body, taking care to align the notches. The disc will only t in one position.

• Place the valve stem O-ring(s) into their corresponding recesses on the back of the valve stem.

• Align the holes in the purge sealing gasket with the corresponding holes in the valve stem.

• Rotate the valve stem assembly so that the correct orice letters align with the notches corresponding to the holes (1, 2 or 3) in the valve stem.

• Press the assembly together and fasten with the M4 screw.

• Double check to make sure that the open orice holes correspond with the correct orice selection as identied earlier.

Section 5: Electrical Installation

Electrical Installation

PRODRY Controller power supply options

Models PD0046 - PD0360

• The dryer is designed to operate on either AC or DC supply voltage dependant on controller option.

• Electrical wiring must comply with local regulations.

Voltage requirements must be conrmed to be within the specication on the dryers rating plate.

• Ensure only one power source is connected at any one time and is connected to the correct socket as shown in

gures 5.1 (LED Controller) and 5.2 (DMC Controller).

• The LED and DMC controller require a earth to be connected within the DIN connector.

• The cable selection must suit local installation regulations and be appropriate to power consumption

as shown in the Controller specication tables on pages

23 and 24.

PRODRY Recommended power cable specications

Controller Type

24VDC DMC 3

110/230VAC LED 3

Number of cores

Cross Sectional

Area / AWG

0.75mm2 / 18 AWG

Recommended

Max. Length

3 Metres

Type

SJOW for Thermoset cable types

SVT and SJT for Thermoplastic cable types

Standard

Compliance

IEC 60227

IEC 60245

Section 5: Electrical Installation

PIN OUTPUT

Earth

INPUT

L1 (110 VAC or 220 VAC*)

* Unit voltage rating must match supply voltage.

** Supplied from factory with jumper in female DIN between pins 1 and 2.

POWER SUPPLYENERGY MANAGEMENT / ALARM

INPUT

N.C.

Energy Management Connections**

Alarm Connections

5VDC (+)

N.O.

12-24VDC

Section 5: Electrical Installation

Figure 5.1: LED Controlle r electrical connections

LED Controller Speciﬁcations

Ambient temperature 1.5°C to 50°C (35°F to 122°F)

Max. relative humidity 80% up to 31°C (88°F), decreasing linearly to 50% RH at 50°C (122°F)

Input voltage range (115V LED Controller) 115V, 50–60Hz,

Mains supply voltage not to exceed ±10% of nominal

Power Rating 16W (Max)

Input voltage range (230V LED Controller) 230VAC, 50-60Hz,

Mains supply voltage not to exceed 10% of nominal

Power Rating 16W (Max)

Protection class IP65

Transient over voltage IEC 60664 Class II

Pollution degree 2, IEC 60664

A circuit breaker or switch must be installed near the dryer. This should be easy to reach and shall be certiﬁed according to EN60947-1 and EN60947-3. The switch or circuit breaker shall be marked as the disconn ecting device for th e dryer and needs to be marked with on and positions.

Outp ut connections do not provide isolation from the mains connect ors and in terconnecting wiring must meet EN61010-1:2001 requireme nts for reinforced insulation.

LED Controller Speciﬁcations

Ambient temperature 5°C to 50°C (35°F to 122°F)

Input voltage range (115V LED Controller) 115V, 50–60Hz,

Input voltage range (230V LED Controller) 230VAC, 50-60Hz,

Protection class IP65

A circuit breaker or switch must be installed near the dryer. This should be easy to reach and shall be certiﬁed according to EN60947-1 and EN60947-3. The switch or circuit breaker shall be marked as the disconnecting device for the dryer and needs to be marked with on and off positions.

Figure 5.1: LED Controller electrical connections

Output connections do not provide isolation from the mains connectors and interconnecting wiring must meet EN610101:2001 requirements for reinforced insulation.

Mains supply voltage not to exceed ±10% of nominal

Mains supply voltage not to exceed 10% of nominal

Power Rating 16W (Max)

Section 5: Electrical Installation

24VDC (-)

Not used

N.O.

Not used

Not used Not used

Not used

Not used Not used

Earth

PININPUT

INPUT

OUTPUT

V.F.* OUTPUT

24VDC (+)

24 VDC (+)

24 VDC (-)

Signal (Hyg Pin 1)

Hygrometer Pin 2

Hygrometer Pin 3

24VDC (+)

* Volt Free

12-24VDC

OUTPUT

24VDC (-) Remote Valve Pin 2

24VDC (+) Remote Valve Pin 1

INPUT

POWER SUPPLY

HYGROMETER

ENERGY MANAGEMENT

ALARM

REMOTE DRAIN VALVE

Section 5: Electrical Installation

Figure 5.2: DMC Controller electrical connections

DMC Controller Speciﬁcations

Ambient temperature1.5°C to 50°C (35°F to 122°F)

Max. relative humidity 80% up to 31°C (88°F), decreasing linearly to 50% RH at 50°C (122°F)

Input voltage range (24VDC DMC Controller)

24VDC

Power Rating 16W (Max)

Protection class IP65

Transient over voltage IEC 60664 Class II

Pollution degree 2, IEC 60664

A circuit breaker or switch must be in stalled near the dryer. This should be easy to reach and shall be certiﬁed according to EN60947-1 and EN60947-3. The switch or circuit breaker shall be marked as the disconnecting device for th e dryer and needs to be marked with on and

positions.

Output co nnections do no t provide isolation from the mains connectors and in terconnecting wiring must meet EN61010-1:2001 requireme nts for reinforced insulation.

1-green control 2-blue 3-red

1-brown 2-blue

DMC Controller Speciﬁcations

Ambient temperature 5°C to 50°C (35°F to 122°F)

Input voltage range (24VDC DMC Controller) 24VDC

Protection class IP65

Figure 5.2: LED Controller electrical connections

A circuit breaker or switch must be installed near the dryer. This should be easy to reach and shall be certiﬁed according to EN60947-1 and EN60947-3. The switch or circuit breaker shall be marked as the disconnecting device for the dryer and needs to be marked with on and off positions.

Output connections do not provide isolation from the mains connectors and interconnecting wiring must meet EN610101:2001 requirements for reinforced insulation.

Power Rating 16W (Max)

Section 5: Electrical Installation

20 mm

3 mm

Outer insulation

must extend

through grommet

to ensure that

IP65 specification

is met

Gasket

Insert

Case

Grommet

Washer

Cable

Cable Gland

How to wire a DIN connector

Models PD0046 - PD0360

• Locate the DIN connector on the back of the controller.

• Remove the screw completely from the centre of the connector.

• Remove the blanking plug, if present, from the connector and discard.

• Insert a small at screwdriver into the small recess at the edge of the insert, pry the insert out of the DIN

connector’s outer shell per gure 5.3.

• Per gure 5.4, slip cable end through DIN connector’s cable gland, washer, grommet and out through the front of the DIN connector case.

Cable diameter should be no greater than 6mm (1/4”). Larger diameters do not ﬁt well into the cable gland of the DIN connectors.

Cable should be round as rectangular cable or ribbon cable will not seal properly in DIN connectors grommet.

• Strip the outer insulation of the cable back approx

20mm (3/4”).

• Strip the conductor insulation back approx 3mm (1/8”).

• Insert conductors into appropriate pins of insert. Tighten retaining screws securely.

• Determine which direction the cable gland should point.

• Carefully pull the cable back through the case until the insert snaps back into place. Take care to work the wires around the retaining screw hole as they can become fairly easily pinched.

• Plug the DIN connector back onto the appropriate electrical connection on the back of the dryer’s

controller per gure(s) 5.1 and 5.2. Take care to make

sure that sealing gasket is in place.

The male ground pin is slightly wider than pins 1 & 2. Take care to ensure that the female connector is oriented correctly.

Figure 5.3: DIN connector

Figure 5.4: DIN connector for LED and DMC Controller

Section 5: Electrical Installation

LED Controller

Pin 3

DC Power

Supply

(Field Installed)

Remote Visual or Audible Indicator (Field Installed)

-VDC

+VDC

LED Controller

Pin 3

Pin 1

Pin 2

DMC

Controller

DC Power

Supply

(Field Installed)

Remote Visual or Audible Indicator (Field Installed)

-VDC

+VDC

+24VDC

-24VDC/COM

Remote Visual or Audible Indicator (Field Installed)

Alarm connection details

Models PD0046 - PD0360

• To enable the alarm facility, it is recommended that a suitable cable is brought into the controller via the rear panel with a grommet. An external power source is required.

• Per Figures 5.5 (LED Controller) or 5.6 (DMC Controller), connect the switching pole of an externally powered alarm indication device to the corresponding terminals of the controller’s alarm output.

For details regarding wiring of female DIN connector refer to “How to wire a DIN connector” on page 25.

Hirschmann GDS 207 industrial std DIN connector

Alarm Contact Rating (LED Controller) 3.0 AMPS 28VDC

Alarm Contact Rating (DMC Controller) 0.5 AMPS 24VDC

Alarm Connection Details

or equivalent

Fig 5. 5 Alarm contact connections (LED Controller)

Fig 5.6 Alarm contact connections (DMC Controller)

Section 6: Operation

Detailed Operational Description - DMC Controller

•

Figure 6.1: Dewp oint selection switch cont rol

Range 2: -40° (-40°F)

Required outlet pressure dewpoint:

Purge turn on value:

Range 3: -74°C (-100°F)

Required outlet pressure dewpoint:

Purge turn on value:

DMC Controller operates on a standard timed cycle as detailed

Operational status is displayed in text form on the LCD display.

Range 1: -20°C (-4°F)

Required outlet pressure dewpoint:

Purge turn on value:

-20°C (-4°F)

-23°C (-9.4°F)

-21°C (-5.8°F)

-40°C (-40°F)

-43°C (-45.4°F)

-11°C (-41.8°F)

-74°C (-100°F)

-76°C (-104.8°F)

-74°C (-100 °F)

When installed, a hygrometer allows the DMC controller to shut

selectable dewpoint ranges. The ranges are controlled by a

switch located on the upper back side of the DMC controller as

Operation

Background / 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

Purge air passes to atmosphere through the silencer, which is

tted to an exhaust valve. The chamber is then repressurised,

with the control system assuring each chamber is at full operational pressure prior to changeover.

This ensures a reliable and efcient operation. The air stream is

switched and the cycle repeats on a continuous basis.

Detailed Operational Description - LED Controller

• Refer to detailed operational schematics, gure(s)

6.3 - 6.8.

• LED Controller operates on a standard timed cycle as detailed in Figures 6.3 through 6.8.

• Panel LED’s illuminate to indicate various service warnings, refer to Troubleshooting in Section 11 for

specic details.

• To reduce purge loss during periods of low and / or no air demand the Energy Management feature may be utilised. A detailed description is given in Section 7.

• For remote indication of any faults, the Alarm Contacts may be utilised to send a signal to a light or remote service panel. Further details are given on page 26.

Detailed Operational Description - DMC Controller

• Refer to detailed operational schematics, gure(s) 6.3

- 6.8.

• DMC Controller operates on a standard timed cycle as detailed in Figures 6.3 through 6.8.

• Operational status is displayed in text form on the LCD display.

• When installed, a hygrometer allows the DMC controller to shut off the purge when the outlet dewpoint is within one of three selectable dewpoint ranges. The ranges are controlled by a switch located on the upper back side of

the DMC controller as detailed in gure 6.1.

• Range 1: -20°C (-4°F) Required outlet pressure dewpoint: Purge shut off value: Purge turn on value:

• Range 2: -40° (-40°F) Required outlet pressure dewpoint: Purge shut off value: Purge turn on value:

• Range 3: -74°C (-100°F) Required outlet pressure dewpoint: Purge shut off value: Purge turn on value:

Figure 6.1: Dewpoint selection switch control

-20°C (-4°F)

-23°C (-9.4°F)

-21°C (-5.8°F)

-40°C (-40°F)

-43°C (-45.4°F)

-41°C (-41.8°F)

-74°C (-100°F)

-76°C (-104.8°F)

-74°C (-100°F)

If the hygrometer is not installed, the DMC controller will default to the standard timed cycle of operation.

Section 6: Operation

•

Please note that the Energy Management feature should

not be used when a hygrometer is installed in the dryer.

• If not utilising a hygrometer, purge loss may be reduced during periods of low or no air demand the Energy Management Feature (EM) may be utilised. A detailed description is given in Section 7.

Please note that the Energy Management feature should not be used when a hygrometer is installed in the dryer.

• For remote indication of any electrical faults, the Alarm Contacts may be utilised to send a signal to a light or remote service panel. Further details are given on page 26.

• An optional pre-lter drain solenoid valve is available for the DMC controller. When installed per gure

4.10, the drain will open for 2 seconds at the beginning of each cycle. Operational schematic, gure

6.8 provides additional detail.

Figure 6.2: Typical installation

Start-up procedure

• Refer to gure 6.2

• Close valves A, B, C and D.

• Switch on compressor.

• Open valve A slowly.

• Check there are no leaks from the dryer

• Switch on electric power, the panel will display the operational features.

• The dryer will enter standard cycle mode.

On initial commissioning, only run the dryer for a minimum of 6 hours to ensure dewpoint is adequate.

• Open valve B slowly.

Shut-down Procedure

• Close valve B.

• Close valve A.

• Leave dryer running for 15 minutes to fully depressurise.

• Switch off all electrical power to the dryer.

Under no circumstances must compressed air be allowed to ﬂow through the dryer following switch off of electrical power. This will result in terminal failure of the desiccant cartridges and regeneration will not be possible.

Section 6: Operation

Figure 6.3: Initial Pressurisation (Power Off)

• With power off to the dryer, both towers pressurise to line pressure. All valves remain closed and the dryer remains air tight (with the exception of a small bleed of air from the hygrometer sample block).

• Note: Any air owing through dryer, passes through both towers.

Section 6: Operation

Figure 6.4: Stage 1: Left Tower Purging, Right Tower Drying

• After an initial 40 second delay, the left solenoid valve opens allowing the left exhaust shuttle valve to open. Air rushes from the left tower out the silencer as it depressurises. For 120 seconds, a bleed of dry air from the outlet of the on-stream (right) tower

is directed through the left purge orice and down through the left tower to regenerate the off stream (left) desiccant bed.

Section 6: Operation

Figure 6.5: Stage 2: Repressurisation

• At the completion of Stage 1, the left solenoid closes and the left tower repressurises for 25 seconds.

• Note: Any air owing through dryer, passes through both towers.

Section 6: Operation

Figure 6.6: Stage 3: Left Tower Drying, Right Tower Purging

• At the completion of Stage 2, the right solenoid valve opens allowing the right exhaust shuttle valve to open. Air rushes from the right tower out the silencer as it depressurises. For 120 seconds, a bleed of dry air from the outlet of the on-stream

(left) tower is directed through the right purge orice and down through the right tower to regenerate the off stream (right)

desiccant bed.

Section 6: Operation

Figure 6.7: Stage 4: Repressurisation

• At the completion of Stage 3, the left solenoid closes and the left tower repressurises for 25 seconds.

• Note: Any air owing through dryer, passes through both towers.

Section 6: Operation

INLET

OUTLET

Purge

Control

Non-Return

Valve

Purge Control Non-Return Valve

To Drain Point

OFF

Wet

Purge

Dry

OFF

SV 2

(Right Solenoid Control Valve)

LEGEND:

SV 1

(Left Solenoid Control Valve)

OFF

DV 1

(Prefilter Drain Solenoid Valve)

Seconds: 0 120 154 274308

Alternate Outlet Position

Alternate Inlet Position

RX-1

After Filter

2 Seconds

RESET

Standard Running Mode

Hours Run 456

Service History # 0

Left

Solenoid

Control Valve

Silencer Silencer

Right

Solenoid

Control Valve

LED

Controller

DMC

Controller

XA Pre-Filter

DV1 Optional

Drain Valve

(Optional on

DMC Models Only)

Left Tower

Pressure Gauge

Right Tower

Pressure Gauge

Left Desiccant Tower

Right

Desiccant

Tower

Hyg

Sample

Cell

Optional Hygrometer

(DMC Models Only)

TIMING CHART:

SV1 SV2

Figure 6.8: Drain Valve Activation

• At the completion of Stage 4, the dryer moves back to Stage 1.

• The drain valve opens at the beginning of the cycle (Stage 1) for a period of 2 seconds.

Section 7: Energy Management

Fig 7. 1 Manu al switch purge contro l (LED Controller)

The following schemati

er an overview

of the devices mentioned as they might be connected for use in

details d er between device ma nufacturers, so in all cases th e

N.C.*

Manual Switch

(Field Installed)* Normally Closed, open to turn purge off

LED Controller

Pin 1

(Puts out +5 VDC signal)

Pin 2

Signal Out to Switch

Signal Back

Fig 7. 1 Manu al switch purge contro l (LED Controller)

The following schemati

er an overview

of the devices mentioned as they might be co nnected for use in

details d er between device manufacturers, so in all cases the

N.C.*

Manual Switch

(Field Installed)* Normally Closed, open to turn purge off

LED Controller

Pin 1

(Puts out +5 VDC signal)

Pin 2

Signal Out to Switch

Signal Back

Fig 7.2 Ma nual switch purge contro l (DMC Controller)

N.O.*

Signal Out to Switch (+24 VDC)

Manual Switch

(Field Installed)* Normally open, close to turn off purge

Pin 1

Pin 2

Signal Out to Switch

Signal Back

DMC

Controller

Energy Management

Please note that the Energy Management feature should not be used when a hygrometer is installed in the dryer.

Overview

Regenerative dryers must expel a portion of the process air in order to free themselves of accumulated moisture. During periods of low air demand, however, this air loss is not necessary and is therefore undesirable. In many cases, the compressor runs almost continuously in order to keep up with the dryer’s purge loss.

All Walker Filtration dryers are equipped with an Energy Management feature that allows the purge to be shut off during periods of low or no demand. The dryer controller

is tted with a set of eld accessible contacts, that can be

employed to shut off the solenoid valves which control the purge function of the dryer, therefore eliminating any air loss from the dryer.

Developing a Purge Control Strategy

In order to utilise this function, the operator must provide a switching system that provides acceptable logic to indicate to the dryer that there is little or no air demand. On the following pages, some examples of commonly used switching systems are provided in ascending order of complexity.

Using a Manual Switch for Purge Control

The simplest of arrangements, a manual switch may be employed to shut the purge off when the air downstream of the dryer is not being used. Commonly used on point of use systems. For example, if the dryer is only used to supply air of

an appropriate dryness to a specic machine or application,

the dryer will only be required when the machine is in use and may be shut off either manually or possibly via extra contacts

provided in the machine’s on/off switch.

It is extremely important to understand that the purge may only be shut off during periods of low or no demand. This

feature, if used otherwise, can result in permanent damage to the desiccant beds resulting in loss of drying capacity and possibly mechanical failure. The cartridges must not be allowed to become fully saturated at any time.

The following schematic ( Fig 7.1) offers an overview of the devices mentioned as they might be connected for use in

controlling a dryer’s purge function. Please note that specic

details differ between device manufacturers, so in all cases the

manufacturer’s specications should be adhered to.

Fig 7. 1 Manual switch purge control (LED Controller)

Fig 7.2 Manual switch purge control (DMC Controller)

Section 7: Energy Management (LED Controller)

Fig 7. 3 Standard pressure switch purge contro l (LED Controller)

Pressure Switch

(Field Installed)* Normally Closed, open to turn purge off

LED Controller

Pin 1

(Puts out +5 VDC signal)

Pin 2

Signal Out to Switch

Signal Back

N.C.*

N.O.

Fig 7. 3 Standard pressure switch purge contro l (LED Controller)

Pressure Switch (Field Installed)* Normally Closed, open to turn purge off

LED Controller

Pin 1

(Puts out +5 VDC signal)

Pin 2

Signal Out to Switch

Signal Back

Fig 7.4 Standard pressure switch purge contro l (DMC Controller)

(Field Installed)* Normally open, close to turn off purge

Pin 1

Signal Out to Switch (+24 VDC)

Pin 2

Signal Out to Switch

Signal Back

DMC

Controller

N.C.*

N.O.

N.C.

N.O.*

Pressure Switch

Using a Standard Pressure Switch for Purge Control

Many compressors come equipped with pressure switches with extra contacts that can be utilised to switch off the dryer’s purge when the compressor is in an unloaded state.

Unfortunately, many of these switches have signicantly large

dead bands (difference between the load (on) and unload (off) settings that in most cases cannot be altered). The amount of air that can pass downstream, through the dryer, while the compressor is unloaded must be taken into consideration as it

can be signicant, especially if there is a large dead band and/

or large wet receiver.

Often, a stand-alone pressure switch is a better option as it allows the user to adjust it independently from the compressor’s pressure switch. When selecting a stand-alone pressure switch, the smaller the dead band the better.

When using a stand-alone pressure switch, the dryer is wired into the normally closed (LED Controller) or normally open (DMC Controller) contacts on the pressure switch. When the switch is actuated (at 100 psig in the example), the purge shuts off until the pressure switch deactuates (at 95 psig in example). The point at which the switch deactuates, may be adjusted to suit the system.

If it is determined that the dewpoint drops to an unacceptable level, the deactuation point must be increased. Please note that with most standard pressure switches, the dead band is

xed such that the activation and deactuation points move

together.

It is extremely important to understand that the purge may only be shut off during periods of low or no demand. This feature, if used otherwise, can result in permanent damage to the desiccant beds resulting in loss of drying capacity and possibly mechanical failure. The cartridges must not be allowed to become fully saturated at any time.

Figures 7.3 and 7.4 offer an overview of the devices mentioned as they might be connected for use in controlling

a dryer’s purge function. Please note the specic details

differ between device manufacturers, so in all cases the

manufacturer’s specications should be adhered to.

Fig 7. 3 Standard pressure switch purge control (LED Controller)

Fig 7.4 Standard pressure switch purge control (DMC Controller)

Section 7: Energy Management

signal)

Using an elec tronic pressure switch for purg e cont rol

The best choice if using a pressure switch is to select an electronic programmable type pressure switch which is effectively a pressure transmitter an d process controller

a standard pressure switch, an electronic programmable pressure switch can be setup to provide a much more customised operation. Typically, the dead band can be reduced or eliminated so that an immediate reaction to

It is extremely important to understand that th e purge may

only be shut

during periods of low or no demand. Th is feature, if used otherwise, can result in permanent damage to the desiccant beds resulting in loss of drying capacity and possibly mech anical failure. Th e cartridges must not be allowed to become fully saturated at any time.

an overview of the devices

mentioned as they might be connected for use in controlling

d er between device manufacturers, so in all cases the

Se ctio n 7: Energy Management

This setup is for example only. This conﬁguration can be amended, depending on application.

SYSTEM PRESSURE (psig)

PURGE ON (switch deactivated) PURGE ON (switch deactivated)

PURGE OFF (switch activated)

PURGE OFF

OFF

105

100

ADJUST TO SUIT SYSTEM

(pressure switch deactivation point)

Fig 7.5 Pressu re switch setting

DC Power

Supply

-VDC (COM)

+VDC

Output

COM

Electronic

Pressure Switch

Relay

N.C.*

Figure 7.6 Electr onic press ure switc h f or purge co ntro l (LED Cont)

Figure 7.7 Electr onic pressure switch for purge co ntro l (DMC Cont)

* Normally open, close to turn off purge

Pin 1

Pin 2

Signal Out to Switch (+24VDC)

DMC

Controller

* Normally Closed, open to turn purge off

Signal Back

DC Power

Supply

-VDC (COM)

+VDC

Output

COM

Electronic

Pressure Switch

Relay

N.O.*

Signal Back

LED Controller

Pin 1

(Puts out +5 VDC signal)

Pin 2

signal)

only be shut

an overview of the devices

mentioned as they might be connected for use in controlling

d er between device manufacturers, so in all cases the

This setup is for example only. This conﬁguration can be amended, depending on application.

PURGE OFF

ADJUST TO SUIT SYSTEM

Figure 7.7 Electr onic pressure switch for purge co ntro l (DMC Cont)

* Normally open, close to turn off purge

Pin 1

Pin 2

Signal Out to Switch (+24VDC)

DMC

Controller

DC Power

Supply

-VDC (COM)

+VDC

Output

COM

Electronic

Pressure Switch

Relay

N.O.*

Signal Back

signal)

Se ctio n 7: Energy Management

SYSTEM PRESSURE (psig)

PURGE ON (switch deactivated) PURGE ON (switch deactivated)

PURGE OFF (switch activated)

PURGE OFF

OFF

105

100

ADJUST TO SUIT SYSTEM

(pressure switch deactivation point)

Fig 7.5 Pressu re switch setting

Figure 7.5: Typical installation

Using an Electronic Pressure Switch for Purge Control

The best choice if using a pressure switch is to select an electronic programmable type pressure switch which is effectively a pressure transmitter and process controller

built into one device. While signicantly more costly than

a standard pressure switch, an electronic programmable pressure switch can be setup to provide a much more customized operation. Typically, the dead band can be reduced or eliminated so that an immediate reaction to

system pressure in system indicating air ow, can

be obtained.

Figure 7.6 Electronic pressure switch for purge control (LED Controller)

Figures 7.6 and 7.7 offer an overview of the devices mentioned as they might be connected for use in controlling

a dryer’s purge function. Please note that specic details

differ between device manufacturers, so in all cases the

manufacturer’s specications should be adhered to.

This setup is for example only. This conﬁguration can be amended, depending on application.

Figure 7.7 Electronic pressure switch for purge control (DMC Controller)

Section 7: Energy Management

Process Controller

Dewpoint

Transmitter

Relay

Signal

+VDC

COM

N.C.*

Figure 7.8 : Process controller & hygrometer (LED Controller)

DC Power

Supply

-VDC (COM)

+VDC

COM

Signal In

Signal Out

* Normally Closed, open to turn purge off

Signal Back

Signal Out

LED Controller

Pin 1

(Puts out +5 VDC signal)

Pin 2

Process Controller

Dewpoint

Transmitter

Relay

Signal

+VDC

COM

N.C.*

Figure 7.8 : Process controller & hygrometer (LED Controller)

Figure 7.9 : Process controller & hygrometer (DMC Controller)

DC Power

Supply

-VDC (COM)

+VDC

COM

Signal In

Signal Out

* Normally Closed, open to turn purge off

Signal Back

Signal Out

LED Controller

Pin 1

(Puts out +5 VDC signal)

Pin 2

Process Controller

Dewpoint

Transmitter

Relay

Signal

+VDC

COM

N.O.*

DC Power

Supply

-VDC (COM)

+VDC

COM

Signal In

Signal Out

Signal Back

Signal Out

Pin 1

Pin 2

Signal Out to Switch (+24VDC)

DMC

Controller

* Normally open, close to turn off purge

Using a hygrometer and process controller for purge control

The best option for purge control if the delivered dryness (pressure Dewpoint) of the air from the dryer is critical. If the air is deemed dry enough, than the purge can be shut off until the air’s moisture starts to climb. If the purge is turned off, care must be taken to ensure that the desiccant beds are not allowed to wet out too far before the purge is turned back on. Also, after turning the purge back on, the air’s pressure Dewpoint may increase a bit before starting to drop again. This should be taken into consideration to ensure that the air

ow remains sufciently dry.

Figures 7.8 and 7.9 offer an overview of the devices mentioned as they might be connected for use in controlling

a dryer’s purge function. Please note that specic details

differ between device manufacturers, so in all cases the

manfacturer’s specications should be adhered to.

Making connections between a switching device & dryer Energy Management contact

Cable / Wire Selection Criteria:

Selected wire should have:

At least 2 conductors. More conductors can be useful in the case of a conductor break. Conductors can be swapped without having to run new cable.

• A conductor gauge of no greater than 18 awg is

• An outside diameter of no greater than 6mm (1/4”).

• An insulation type compatible with the environment that

recommended to t comfortably into the DIN connector

insert.

Larger diameters do not t well into the cable gland of the EM DIN connectors.

it will be run in.

Figure 7.8: Process controller & hygrometer (LED Controller)

Figure 7.9: Process controller & hygrometer (DMC Controller)

This setup is for example only. This conﬁguration can be amended, depending on application.

Section 7: Energy Management

Figure 7.11 : Connecting to EM port (LED Controller)

LED Controller

EM Port

Figure 7.11 : Connecting to EM port (LED Controller)

DMC

Controller

LED Controller

EM Port

Figure 7.12 : Connecting to EM port (DMC Controller)

EM Port

Figure 7.11 : Connecting to EM port (LED Controller)

Figure 7.13 : Din co nnector for LED and DMC Controller

DMC

Controller

LED Controller

EM Port

Figure 7.12 : Connecting to EM port (DMC Controller)

EM Port

20 mm

3 mm

Outer insulation

must extend

through grommet

to ensure that

IP65 specification

is met

Gasket

Insert

Case

Grommet

Washer

Cable

Cable Gland

Se ctio n 7: Energy Management

Making connections between a switching device and dryer Energy Management contact.

• check continuity at the dryer end before connecting to the dryer. Make sure that the co ntacts on the switch are normally closed for the LED Controller and normally open for the DMC Controller. Pi n 1 of the dryer EM co nnection puts out a 5 VDC signal on the LED Controller and 24VDC on the DMC Controller. Take care to ensure that the contacts on the switching device are ‘dry’ and free of any voltage which could harm the dryer controller.

•Locate the DIN connector on the ba ck of the controller (Figure(s) 7.11 and 7.12).

•Remove the screw completely from the centre of the connector.

•Remove the blanking plug from the connector and discard.

of the insert, pry the insert out of the DIN connectors outer shell per

ure 7.10.

•

•For LED Controller, remove the jumper wire which is between plug 1 and 2 and di scard.

•Slip cable en d through DIN connector’s cable gland, washer, grommet and out through the front of the DIN connector case.

•Strip the outer insulation of the cable back a

pprox 20mm

(3/4”).

•Strip the conductor insulation back approx 3mm (1/8”).

•If possible using a meter, ve rify the switch function.

•Insert conductors into pins 1 & 2 of insert. Tighten retaining screws securely.

•Determine which direction the cable gland should point.

•Carefully pull the cable back through the shell until the insert snaps back into place. Take care to work the wires around the retaining screw hole as they can become fairly easily pinched.

•Plug the DIN connector back onto the dr yer’s EM co nnection taking care to make sure that sealing gasket is in place.

Figure 7.10: DI N conn ecto r

Figure 7.11 : Connecting to EM port (LED Controller)

Figure 7.13 : Din co nnector for LED and DMC Controller

DMC

Controller

LED Controller

EM Port

Figure 7.12 : Connecting to EM port (DMC Controller)

EM Port

The male ground pin is slightly wider than pins 1 & 2. Take care to ensure that the female connector is oriented corectly.

20 mm

3 mm

Outer insulation

must extend

through grommet

to ensure that

IP65 specification

is met

Gasket

Insert

Case

Grommet

Washer

Cable

Cable Gland

Making connections between a switching device and dryer Energy Management contact.

• Make the connection at the switch end rst. This way you can check continuity at the dryer end before connecting to the dryer. Make sure that the contacts on the switch are normally closed for the LED Controller and normally open for the DMC Controller. Pin 1 of the dryer EM connection puts out a 5 VDC signal on the LED Controller and 24VDC on the DMC Controller. Take care to ensure that the contacts on the switching device are ‘dry’ and free of any voltage which could harm the dryer controller.

• Locate the DIN connector on the back of the controller

• Remove the screw completely from the centre of the

• Remove the blanking plug from the connector and

• Insert a small at screwdriver into the small recess at

• For LED Controller, remove the jumper wire which is

(Figure(s) 7.11 and 7.12).

connector.

discard.

the edge of the insert, pry the insert out of the DIN connectors outer shell per gure 7.10.

between plug 1 and 2 and discard.

• Slip cable end through DIN connector’s cable gland,

washer, grommet and out through the front of the DIN

connector case.

• Strip the outer insulation of the cable back approx 20mm

(3/4”).

• Strip the conductor insulation back approx 3mm (1/8”).

• If possible using a meter, verify the switch function.

• Insert conductors into pins 1 & 2 of insert. Tighten retaining screws securely.

• Determine which direction the cable gland should point.

• Carefully pull the cable back through the shell until the insert snaps back into place. Take care to work the wires around the retaining screw hole as they can become fairly easily pinched.

• Plug the DIN connector back onto the dryer’s EM connection

Figure 7.10: DIN connector

The male ground pin is slightly wider than pins 1 & 2. Take care to ensure that the female connector is oriented correctly.

Figure 7.11: Connecting to EM port (LED Controller)

Figure 7.12: Connecting to EM port (DMC Controller)

Figure 7.13: Din connector for LED and DMC Controller

Section 8: Maintenance

Maintenance

Information

All maintenance information is provided in service / maintenance leaets. These leaets are provided with each serviceable item / kit showing how to carry out the change-out component. The service leaet part numbers are shown

below:-

04 1220 001 01 (Desiccant Cartridge service leaet)

04 1220 002 01 (Purge Orice disc service leaet)

04 1220 003 01 (Exhaust Silencer service leaet)

04 1220 004 01 (Main Shuttle service leaet)

04 1220 005 01 (Exhaust Shuttle service leaet)

Service Intervals / Applicable Service Kits

Pre- Filter Element Every 1 year or 6000 hours

Exhaust silencer Every 1 year or 6000 hours

Desiccant cartridges Every 2 years or 12000 hours

Main shuttle Every 4 years or 24000 hours

Exhaust shuttle Every 4 years or 24000 hours

Solenoid valves Every 4 years or 24000 hours

Purge orice Every 4 years or 24000 hours

Important information.

Ensure shutdown and start-up procedures are followed prior to carrying out any maintenance work on the dryer.

Walker Filtration will not accept responsibility for physical injury, damage or delays caused by failure to observe the instructions in this manual and manuals provided with your equipment.

Section 9: Spares Information

Service kits

6,000 hour, Silencer Service kit

Dryer Model Kit Part Number Description Change-Out Period

PD0046 - PD0360 PD3SK01

Silencer Kit (Kit includes (2) silencers; reference gure 10.2)

12,000 hour, Desiccant Cartridge & Silencer Service Kit

Dryer Model Kit Part Number Description Change-Out Period

PD0046 PDSK0046-12000

PD0056 PDSK0056-12000 12,000 Hours or 2 Years

PD0075 PDSK0075-12000 12,000 Hours or 2 Years

PD0090 PDSK0090-12000 12,000 Hours or 2 Years

PD0110 PDSK0110-12000 12,000 Hours or 2 Years

PD0150 PDSK0150-12000 12,000 Hours or 2 Years

PD0180 PDSK0180-12000 12,000 Hours or 2 Years

PD0220 PDSK0220-12000 12,000 Hours or 2 Years

PD0300 PDSK0300-12000 12,000 Hours or 2 Years

PD0360 PDSK0360-12000 12,000 Hours or 2 Years

12,000 Hour Desiccant Cartridge and Silencer Kit

(Kit includes desiccant cartridges and associated

seals, and silencer service kit;

reference gures 10.2, 10.3 and 10.4)

12,000 hour, High Performance Desiccant Cartridge & Silencer Service Kit - for use where -74°C (-100°F) dewpoint is required

Dryer Model Kit Part Number Description Change-Out Period

PD0046 PDSK0046BA-12000

PD0056 PDSK0056BA-12000 12,000 Hours or 2 Years

PD0075 PDSK0075BA-12000 12,000 Hours or 2 Years

PD0090 PDSK0090BA-12000 12,000 Hours or 2 Years

PD0110 PDSK0110BA-12000 12,000 Hours or 2 Years

PD0150 PDSK0150BA-12000 12,000 Hours or 2 Years

PD0180 PDSK0180BA-12000 12,000 Hours or 2 Years

PD0220 PDSK0220BA-12000 12,000 Hours or 2 Years

PD0300 PDSK0300BA-12000 12,000 Hours or 2 Years

PD0360 PDSK0360BA-12000 12,000 Hours or 2 Years

12,000 Hour High Performance Desiccant Cartridge

(Kit includes High Performance desiccant cartridges and

associated seals, and silencer service kit;

and Silencer Kit

reference gures 10.2, 10.3 and 10.4)

6,000 Hours or 1 Year

12,000 Hours or 2 Years

18,000 hour, Silencer Service kit

Dryer Model Kit Part Number Description Change-Out Period

PD0046 - PD0360 PD3SK01

Silencer Kit (Kit includes (2) silencers; reference gure 10.2)

18,000 Hours or 3 Years

Section 9: Spares Information

Service kits

24,000 Hour, Desiccant Cartridge, Silencer, Valve & Purge Valve Service Kit

Voltage

Dryer Model Kit Part Number Description Change-Out Period

PD0046 PDSK0046-24000-S24

PD0056 PDSK0056-24000-S24 24,000 Hours or 4 Years

PD0075 PDSK0075-24000-S24 24,000 Hours or 4 Years

PD0090 PDSK0090-24000-S24 24,000 Hours or 4 Years

PD0110 PDSK0110-24000-S24 24,000 Hours or 4 Years

PD0150 PDSK0150-24000-S24 24,000 Hours or 4 Years

DMC 24VLED 115VLED 230V

PD0180 PDSK0180-24000-S24 24,000 Hours or 4 Years

PD0220 PDSK0220-24000-D24 24,000 Hours or 4 Years

PD0300 PDSK0300-24000-D24 24,000 Hours or 4 Years

PD0360 PDSK0360-24000-D24 24,000 Hours or 4 Years

PD0046 PDSK0046-24000-S115

PD0056 PDSK0056-24000-S115 24,000 Hours or 4 Years

PD0075 PDSK0075-24000-S115 24,000 Hours or 4 Years

PD0090 PDSK0090-24000-S115 24,000 Hours or 4 Years

PD0110 PDSK0110-24000-S115 24,000 Hours or 4 Years

PD0150 PDSK0150-24000-S115 24,000 Hours or 4 Years

PD0180 PDSK0180-24000-S115 24,000 Hours or 4 Years

PD0220 PDSK0220-24000-D115 24,000 Hours or 4 Years

PD0300 PDSK0300-24000-D115 24,000 Hours or 4 Years

PD0360 PDSK0360-24000-D115 24,000 Hours or 4 Years

PD0046 PDSK0046-24000-S230

PD0056 PDSK0056-24000-S230 24,000 Hours or 4 Years

PD0075 PDSK0075-24000-S230 24,000 Hours or 4 Years

PD0090 PDSK0090-24000-S230 24,000 Hours or 4 Years

PD0110 PDSK0110-24000-S230 24,000 Hours or 4 Years

PD0150 PDSK0150-24000-S230 24,000 Hours or 4 Years

PD0180 PDSK0180-24000-S230 24,000 Hours or 4 Years

PD0220 PDSK0220-24000-D230 24,000 Hours or 4 Years

PD0300 PDSK0300-24000-D230 24,000 Hours or 4 Years

PD0360 PDSK0360-24000-D230 24,000 Hours or 4 Years

24,000 hour Desiccant Cartridge, Silencer,

Valve & Purge Valve Service Kit

(Kit includes desiccant cartridges and associated

seals; reference gures 10.3 and 10.4,

silencer service kit; reference gures 10.2, and

valve body stem and all associated seals; reference

24,000 hour Desiccant Cartridge, Silencer,

(Kit includes desiccant cartridges and associated

seals; reference gures 10.3 and 10.4,

silencer service kit; reference gures 10.2, and

valve body stem and all associated seals; reference

24,000 hour Desiccant Cartridge, Silencer,

(Kit includes desiccant cartridges and associated

seals; reference gures 10.3 and 10.4,

silencer service kit; reference gures 10.2, and

valve body stem and all associated seals; reference

gures 10.6)

Valve & Purge Valve Service Kit

gures 10.6)

Valve & Purge Valve Service Kit

gures 10.6)

24,000 Hours or 4 Years

Section 9: Spares Information

Service kits

24,000 Hour, High Performance Desiccant Cartridge, Silencer, Valve & Purge Valve Service Kit For use where -74°C (-100°F) dewpoint is required

Voltage

Dryer Model Kit Part Number Description Change-Out Period

PD0046 PDSK0046BA-24000-S24

PD0056 PDSK0056BA-24000-S24 24,000 Hours or 4 Years

PD0075 PDSK0075BA-24000-S24 24,000 Hours or 4 Years

PD0090 PDSK0090BA-24000-S24 24,000 Hours or 4 Years

PD0110 PDSK0110BA-24000-S24 24,000 Hours or 4 Years

PD0150 PDSK0150BA-24000-S24 24,000 Hours or 4 Years

DMC 24V

PD0180 PDSK0180BA-24000-S24 24,000 Hours or 4 Years

PD0220 PDSK0220BA-24000-D24 24,000 Hours or 4 Years

PD0300 PDSK0300BA-24000-D24 24,000 Hours or 4 Years

PD0360 PDSK0360BA-24000-D24 24,000 Hours or 4 Years

PD0046 PDSK0046BA-24000-S115

PD0056 PDSK0056BA-24000-S115 24,000 Hours or 4 Years

PD0075 PDSK0075BA-24000-S115 24,000 Hours or 4 Years

PD0090 PDSK0090BA-24000-S115 24,000 Hours or 4 Years

PD0110 PDSK0110BA-24000-S115 24,000 Hours or 4 Years

PD0150 PDSK0150BA-24000-S115 24,000 Hours or 4 Years

LED 115VLED 230V

PD0180 PDSK0180BA-24000-S115 24,000 Hours or 4 Years

PD0220 PDSK0220BA-24000-D115 24,000 Hours or 4 Years

PD0300 PDSK0300BA-24000-D115 24,000 Hours or 4 Years

PD0360 PDSK0360BA-24000-D115 24,000 Hours or 4 Years

PD0046 PDSK0046BA-24000-S230

PD0056 PDSK0056BA-24000-S230 24,000 Hours or 4 Years

PD0075 PDSK0075BA-24000-S230 24,000 Hours or 4 Years

PD0090 PDSK0090BA-24000-S230 24,000 Hours or 4 Years

PD0110 PDSK0110BA-24000-S230 24,000 Hours or 4 Years

PD0150 PDSK0150BA-24000-S230 24,000 Hours or 4 Years

PD0180 PDSK0180BA-24000-S230 24,000 Hours or 4 Years

PD0220 PDSK0220BA-24000-D230 24,000 Hours or 4 Years

PD0300 PDSK0300BA-24000-D230 24,000 Hours or 4 Years

PD0360 PDSK0360BA-24000-D230 24,000 Hours or 4 Years

24,000 hour High Performance Desiccant

Cartridge, Silencer,

Valve & Purge Valve Service Kit

(Kit includes desiccant cartridges and associated

seals; reference gures 10.3 and 10.4,

silencer service kit; reference gures 10.2, and

valve body stem and all associated seals; reference

24,000 hour High Performance Desiccant

(Kit includes desiccant cartridges and associated

seals; reference gures 10.3 and 10.4,

silencer service kit; reference gures 10.2, and

valve body stem and all associated seals; reference

24,000 hour High Performance Desiccant

(Kit includes desiccant cartridges and associated

seals; reference gures 10.3 and 10.4,

silencer service kit; reference gures 10.2, and

valve body stem and all associated seals; reference

gures 10.6)

Cartridge, Silencer,

Valve & Purge Valve Service Kit

gures 10.6)

Cartridge, Silencer,

Valve & Purge Valve Service Kit

gures 10.6)

24,000 Hours or 4 Years

Section 9: Spares Information

Accessory kits

Solenoid Kit (Kit includes (2) solenoid control valves with attached tube ﬁttings; reference ﬁgure 10.5)

Dryer Model Kit Part Number Description

PD0046 - PD0360 PD3SKV024 24VDC Solenoid Kit

PD0046 - PD0360 PD3SKV115 115V Solenoid Kit

PD0046 - PD0360 PD3SKV230 240V Solenoid Kit

Shuttle Service Kit (Kit includes (1) control shuttle, (2) exhaust shuttles and associated seals; reference ﬁgure 10.2)

Dryer Model Kit Part Number Description

PD0046 - PD0180 PD3SKS01 Simplex Shuttle Service Kit

PD0220 - PD0360 PD3SKD01 Duplex Shuttle Service Kit

Controller kit (Kit includes (1) controller and (2) control solenoid valves with installed tube ﬁttings; reference ﬁgure 10.5)

Dryer Model Kit Part Number Description

PD0046 - PD0360 PD3CK024 24VDC Controller Complete with Valves

PD0046 - PD0360 PD3CK110 110V Controller Complete with Valves

PD0046 - PD0360 PD3CK240 240V Controller Complete with Valves

Purge Oriﬁce (complete)

Dryer Model Kit Part Number Description

PD0046

PD0056

PD0075

PD0110

PD0150 PD3PPK3 PD0150 Purge valve kit

PD0180 PD3PPK4 PD0180 Purge valve kit

PD0220

PD0300

PD0360 PD3PPK6 PD0360 Purge valve kit

PD3PPK1 PD0046 - PD0056 Purge valve kit

PD3PPK2 PD0075 - PD0110 Purge valve kitPD0090

PD3PPK5 PD0220-PD0300 Purge valve kit

Complete kit for dryers operating between 4 and 13 barg and appropriate

purge oriﬁce discs, fully assembled; reference ﬁgure 10.6

Purge disc kit (Kit includes (1) ea discs 01, 02, 03 and 04; reference ﬁgure 10.6)

Dryer Model Kit Part Number Description

PD0046 - PD0360 PD3PDK4 Purge orice disc kit

Section 9: Spares Information

Hygrometer Kit (Kit includes hygrometer only)

Dryer Model Kit Part Number Description

PD0046 - PD0360 PD3HK01 Hygrometer Kit

Drain Valve Kit (Kit includes (1) solenoid drain valve with attached female DIN connector)

Dryer Model Kit Part Number Description

PD0046 - PD0360 PD3DVS01 Drain Valve Kit

Din Plug Kit (Kit includes (1), 3 pole + ground industrial standard DIN connector)

Dryer Model Kit Part Number Description

PD0046 - PD0360 PD3DIN01 Female DIN plug kit

Power Supply Kit (Kit includes power supply and DIN connector)

Dryer Model Kit Part Number Description

PD0046 - PD0360 PD3PSK01 100-240V to 24VDC Power Supply Lead (24VDC DMC controller only)

Although the power supply is supplied separately as an accessory and meets the required CE and UL approval, it is the responsibilty of a competent person installing the equipment that all local installation regulations are adhered to.

Master seal kit (Kit includes all seals (except purge oriﬁce seals); reference ﬁgures 10.1, 10.2, 10.3 and 10.4

Dryer Model Kit Part Number Description

PD0046 - PD0180 PD3MSKS Simplex master seal kit

PD0220 - PD0360 PD3MSKD Duplex master seal kit

Section 10: Component Parts

Component parts

Fig 10.1 To p manifold assembly

Section 10: Component Parts

Component parts

Fig 10.1 To p manifold assembly

Section 10: Component Parts

Fig 10.2 Bottom manifold assembly

5 2

Itm QtyDescription

Inlet / outlet manifold

Purge valve service plug

Purge control valve

Valve control spring

See figure 10.6

Inlet/outlet blanking plug

Hyg port blanking plug

Manifold fixing bolts

Hygrometer sample block*

* Duplex Only

DMC Only

Manifold connection O-ring

Valve service plug O-ring

11 Down tube O-ring

Included in Service / Accessory Kit

Master Seal

Duplex or

Simplex

Component parts

PD0046 - PD0360

Fig 10.1 Top manifold assembly

DMC Only

Included in Service / Accessory Kit

5 2

Fig 10.2 Bottom manifold assembly

6 11

4 3

2 12

Itm QtyDescription

Inlet / outlet manifold

Purge valve service plug

Purge control valve

Valve control spring

Inlet/outlet blanking plug

Hyg port blanking plug

Manifold fixing bolts

Hygrometer sample block*

Manifold connection O-ring

Valve service plug O-ring

11 Down tube O-ring

Itm QtyDescription

RH exhaust manifold

LH exhaust manifold

Centre shuttle manifold

Control shuttle

Exhaust control valve

Valve service plug

Silencer adapter

Manifold fixing bolt*

Duplex fixing clip

Silencer

Manifold connection O-ring

Exhaust manifold O-ring

Down tube O-ring

14 Valve Service Plug O-ring

Duplex

Included in Service / Accessory Kit

8/12

Master Seal

See figure 10.6

Valve

Service

Shuttle

Service

* 8 for Simplex / 12 for Duplex

Duplex or

Simplex

Silencer

* Duplex Only

Master

Seal

Section 10: Component Parts

0 0 0

Section 10: Component Parts

Fig 10.3 To we r assembly (Simplex)

PD0046 - PD0180

Fig 10.3 Tower assembly (Simplex)

Included in Service / Accessory Kit

ItmQtyDescription

Tower extrusion

Extrusion tower plug

Desiccant cartridge*

Cartridge pressure spring

Support circlip

Floor mounting bracket

Trim caps

Controller reset magnet

Service cap outer O-ring

Service cap inner O-ring

Desiccant

Cartridge

2/4

* Quantity varies per dryer model

Master

Seal

Section 10: Component Parts

Fig 10.4 To we r assembly (Duplex)

PD0046 - PD0180

Fig 10.4 Tower assembly (Duplex)

Included in Service / Accessory Kit

ItmQtyDescription

Tower extrusion (Front)

Tower extrusion (Rear)

Extrusion tower plug

Desiccant cartridge

Cartridge pressure spring

Support circlip

Floor mounting bracket

Trim caps

Clamp assembly

Controller reset magnet

Service cap outer O-ring

Service cap inner O-ring

Extrusion O-ring

Desiccant Cartridge

Master

Seal

Section 10: Component Parts

Fig 10.5 Controller assembl ies

ItmQtyDescription

Solenoid control valves*

LED controller

DMC controller

* Includes installed tube fittings

** Specify which controller model and/or voltage when ordering

Included in Service /Accessory Kit

Valve Service

Controller**

Solenoid

Section 10: Component Parts

Fig 10.5 Controller assembl ies

Fig 10.6 Purge valve assembly

ItmQtyDescription

Solenoid control valves*

LED controller

DMC controller

* Includes installed tube fittings

** Specify which controller model and/or voltage when ordering

Included in Service /Accessory Kit

Valve Service

Controller**

Solenoid

1/2/3

ItmQtyDescription

Purge valve body

Orifice disc (01)

Orifice disc (02)

Orifice disc (03)

Orifice disc (04)

Sealing gasket (1 Hole)

Sealing gasket (2 Hole)

Sealing gasket (3 Hole)

Valve stem O-ring

Valve stem (1 Hole)

Valve stem (2 Hole)

Valve stem (3 Hole)

M4 screw

Valve control spring

Included in Service / Accessory Kit

Purge Valve Body (1 Hole)

Purge Valve Body (2 Hole)

Purge Valve Body (3 Hole)

Purge Orifice Disc

13 14

6 7 8 129

1110

PD0046 - PD0180

Fig 10.5 Controller assemblies

Fig 10.6 Purge valve assembly

Section 11: Troubleshooting

Troubleshooting

General troubleshooting

Before specic identication of any fault is looked for, the following general points must be veried:

• Has the unit been damaged externally or are any parts missing?

• Is power being supplied to the unit?

• Was start-up carried out in accordance with the instructions in this manual?

• Are all external valves correctly set for operation?

• Do the operational conditions meet those specied at time of ordering and used for product selection?

• Did the dryer operate normally for a period of time before the problem occured?

Before calling for service assistance, please obtain dryer model and serial number from dryer speciﬁcation label.

Troubleshooting: General

Problem

Poor dewpoint

Incorrect dryer operation, won’t switch towers

Incorrect dryer operation, won’t depressurise towers

Excessive or loud purge, or purge on only one tower

Possible Cause Action

Liquid water at dryer inlet Check pre-filtration and drains

Excessive flow Check actual flow against maximum specified

Low inlet pressure Check against specification

High inlet temperature Check against specification

Incorrect purge orice size Check against specication and recongure

Silencer blocked or damaged Replace silencer

Air leaks Tighten joints or fit new seals

Desiccant life exceeded Replace desiccant cartridges

Desiccant contaminated

EM is active when air is owing

through dryer

Power to dryer off while air is owing through

dryer

Jammed shuttle valves Clean or replace shuttles

Faulted electrical components See electrical operation troubleshooting section

Jammed purge exhaust shuttle Clean or replace exhaust shuttles and solenoid valves

Blocked and/or damaged silencer Replace silencer

Jammed main control shuttle valve Clean or replace shuttles

Jammed purge exhaust shuttle Clean or replace exhaust shuttles

Faulty solenoid valve Clean or replace solenoid valve

Not utilising Energy Management feature Refer to Energy Management instructions (Section 7)

Blocked and/or damaged silencer Replace silencer and check desiccant cartridges

Damaged purge valve(s) Replace purge valve bodies

Incorrect purge orifice size Double check and select correct size

Check inlet lter and drains,

replace cartridges

Check EM wiring, DMC and/or control method used

Ensure that power is on whenever air is owing

through dryer

Section 11: Troubleshooting

Troubleshooting: Electrical

Problem

No dryer function No power supply Check supply

Dryer does not activate external alarm when display panel indicates alarm condition

Possible Cause Action

Power connected to wrong controller input Check connections with specifications

Faulty controller Replace controller

Shorted or incorrect device wiring Correct external wiring

External power not supplied Add external power source per specifications

Faulty external indication device Repair or replace device

Faulty controller Replace controller

listed in Section 5

given in Section 5

Troubleshooting: Energy Management

Problem

Dryer does not enter Energy Management when switching device is activated and/or Dryer does not enter Energy Management when EM contacts are opened.

Possible Cause Action

Shorted or incorrect device wiring Remove external wiring from the dryer’s EM

Faulty switching device Consult device manufacturer

Faulty controller output Replace controller

contacts:

• On LED controllers, dryer should enter EM mode.

• On DMC controllers, place jumper between pins 1 and 2 of EM male connector. Dryer should enter EM mode.

• If dryer enters EM mode, correct external wiring problem

• If dryer does not enter EM mode, replace controller

Troubleshooting: Dewpoint control (DMC Controller only)

Problem

Dryer does not enter dewpoint mode Hygrometer Din plug not connected correctly

Dryer controller displaying hygrometer out of range

Possible Cause Action

to hygrometer

Demand is too high, dryer undersized Check against specification

Hygrometer not reading accurately / fouled Verify hygrometer calibration

Hygrometer failed (electrically) Replace hygrometer

Hygrometer is reading an outlet dewpoint of either +20°C or -100°C which is the maximum limits of the hygrometer

Check Din plug is tightly connected to hygrometer with the Din plug

Check hygrometer is functioning correctly and not damaged

RESET

Section 11: Troubleshooting

Troubleshooting - LED Display Status Identication

LED Identiﬁcation Function Indication Remark

N/A Power Off Power supply disconnected

Z Power On

X Left tower ‘Online’ Left tower drying

Y Right tower ‘Online’ Right tower drying

X & Y Both towers ‘Online’

RESET

One tower drying, the other tower

RESET

repressurising

X Left solenoid failure Clean or replace solenoid

RESET

Section 11: Troubleshooting

RESET

LED Number Function Indication Remark

Y Right solenoid failure Clean or replace solenoid

1 Service warning 11500 hours continuous operation

RESET

2 Service alarm 12000 hours continuous operation

1 & 2 Controller reset

N/A Power Failure Replace controller

RESET

Activated when the reset magnet

RESET

is applied

Section 11: Troubleshooting

Function Indication Remark

Full DMC message layout

Line message 1

Line message 2

Line message 3

Line message 4

Dryer functioning in standard

running mode

Dryer functioning in standard

running mode (service due)

Dryer functioning in standard

running mode (service overdue)

Energy management mode

active

Energy management mode

active (service due)

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

STANDARD RUNNING MODE

HOURS RUN XXXXX

SERVICE HISTORY # XX

STANDARD RUNNING MODE

SERVICE DUE (XXX HOURS)

SERVICE HISTORY # XX

STANDARD RUNNING MODE

SERVICE OVERDUE

SERVICE HISTORY # XX

ENERGY MANAGEMENT MODE

HOURS RUN XXXXX

SERVICE HISTORY # XX

ENERGY MANAGEMENT MODE

SERVICE DUE (XXX HOURS)

SERVICE HISTORY # XX

(500 hour countdown until 12000 hours

(12000 hours continuous operation)

(500 hour countdown until 12000 hours

Service due

continuous operation)

Service overdue

Service due

continuous operation)

Energy management mode

active (service overdue)

Line message 1

Line message 2

Line message 3

Line message 4

ENERGY MANAGEMENT MODE

SERVICE OVERDUE

SERVICE HISTORY # XX

Service overdue

(12000 hours continuous operation)

Section 11: Troubleshooting

Function Indication Remark

Dewpoint mode active (-20)

Dewpoint mode active (-40)

Dewpoint mode active (-74)

Line message 1

Line message 2

Line message 3

Line message 4

DEWPOINT MODE (-20) (-40) (-74)

DRYER DEWPOINT -XXX PDP

HOURS RUN XXXXX

SERVICE HISTORY # XX

Dewpoint mode active but dryer in standard

cycle mode

Dewpoint hold active (-20)

Dewpoint hold active (-40)

Dewpoint hold active (-74)

Dewpoint mode active (-20) –

Dewpoint mode active (-40) –

Dewpoint mode active (-74) –

Dewpoint mode active (-20) –

Dewpoint mode active (-40) –

Dewpoint mode active (-74) –

Dewpoint hold active (-20) –

Dewpoint hold active (-40) –

Dewpoint hold active (-74) –

Dewpoint hold active (-20) –

Dewpoint hold active (-40) –

Dewpoint hold active (-74) –

service due

service overdue

service due

service overdue

Hygrometer out of range

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

Line message 1

Line message 2

Line message 3

Line message 4

DEWPOINT HOLD (-20) (-40) (-74)

DRYER DEWPOINT -XXX PDP

HOURS RUN XXXXX

SERVICE HISTORY # XX

DEWPOINT MODE (-20) (-40) (-74)

DRYER DEWPOINT -XXX PDP

SERVICE DUE (XXX HOURS)

SERVICE HISTORY # XX

DEWPOINT MODE (-20) (-40) (-74)

DRYER DEWPOINT -XXX PDP

SERVICE OVERDUE

SERVICE HISTORY # XX

DEWPOINT HOLD (-20) (-40) (-74)

DRYER DEWPOINT -XXX PDP

SERVICE DUE (XXX HOURS)

SERVICE HISTORY # XX

DEWPOINT HOLD (-20) (-40) (-74)

DRYER DEWPOINT -XXX PDP

SERVICE OVERDUE

SERVICE HISTORY # XX

XXXXXXXXXXXXXXX

XXXXXXXXXXXXXXXXXXXXX

HYGROMETER OUT OF RANGE

Dewpoint hold active purge flow has been

Dewpoint mode active but dryer in standard

cycle mode (500 hour countdown until 12000

Dewpoint mode active, dryer in standard cycle

mode (12000 hours continuous operation)

Dewpoint hold active, purge flow has been

isolated – 500 hour countdown until 12000

Dewpoint hold active, purge flow has been

isolated – 12000 hours continuous operation

Check din plug and wiring connections

between hygrometer and Dryer controller

isolated

hours continuous operation)

hours continuous operation

Section 12: Warranty

Warranties and liabilities

Claims for warranty and liability concerning personal injury or material damage are excluded if they resulted due to one or more of the following factors:

• Inappropriate use

• Inappropriate application of the dryer.

• Technically incorrect installation, start-up operation or maintenance of the dryer.

• Operation of a known damaged dryer.

• Failure to observe the information given in this manual concerning all life phases of the dryer.

• Undertaking constructional or operational modications to the dryer without prior agreement with Walker Filtration.

• Inadequate monitoring and replacement of components of the dryer that are subject to wear.

• Improper completion of repairs.

• Use of non-original or non-approved parts for service or maintenance.

The warranty of this product could become void if the correct ﬁltration is not installed upstream of the dryer. It is recommended that the inlet ﬁltration upstream of the dryer consists of a WS, X1 then XA. However, it is essential that a WS followed by a XA is used

Important Note

Industrial Compressed Air Desiccant Dryers

The Walker Filtration Ltd desiccant dryer range is designed for,

warrantied and intended for use in xed industrial compressed

air applications only.

Use on non-xed installations such as :

Such additional undertakings are the responsibility of the package or system builder, installer or end user.

• marine (e.g. offshore, shipboard)

• transportable (e.g. portable air treatment units)

• non-xed (e.g. rolling stock, railway etc)

are not strictly prohibited, however use in such applications is not recommended nor endorsed as additional design features,

function testing, certication (both mechanical and electrical)

and validation may be required to satisfy relevant end user

application specic specications and/or mandatory and

non-mandatory local, national or international standards and legislation.

Section 13: Declaration of Conformity

Declaration of Conformity

2014/30/EU, 2014/35/EU, 2014/68/EU (97/23/EC)

Name of Manufacturer

Address of Manufacturer

Description of Product

Designation of Product

Standards Used

Harmonised Standards* applied where available — with alternatives speciﬁed where harmonised standards do not exist.

Notiﬁed Body

Pressure Equipment Directive (PED) Only

Conformity Assessment Module

Pressure Equipment Directive (PED) Only

Quality Assurance System

Year of Manufacture

Name of Authorised Representative

Position of Authorised Representative

Walker Filtration Ltd.

Birtley Road, Washington, Tyne & Wear, NE38 9DA, England.

PRODRY Compressed Air Desiccant Dryers

PD0046, PD0056, PD0075, PD0090, PD0110, PD0150, PD0180, PD0220, PD0300, PD0360

LVD: 2014/35/EU EN 61010-1:2010*

EMC: 2014/30/EU EN 61000-6-2:2005+AC:2005*

PED: 97/23/EC PED: 2014/68/EU (From 19-07-2016)

Lloyds Register EMEA

Notied Body No.0038

71 Fenchurch Street, London, EC3M 4BS, England

PD0046-PD0180: Cat II Module D1 [COV0310124/1] PD0220-PD0360: Cat III Module B1 [COV1611049/1]**+ D [COV1112690/1]

**Module B1 certicate issued by conformity assessment body under directive 97/23/EC and remains valid under the new directive as dened in 2014/68/EU Article 48.

ISO 9001:2008

Certicate Number LRQ 0930553 Lloyds Register Quality Assurance Ltd (LRQA)

1 Trinity Park, Bickenhill Lane, Birmingham, B37 7ES, United Kingdom

Refer to product marking

Simon Wise

CTO (Chief Technical Ofcer)

This declaration of conformity is issued under the sole responsibility of the manufacturer. I declare on behalf of Walker Filtration Ltd (the manufacturer) and as authorised representative,

that the above stated products full the requirements of the new approach directives

EN 61000-6-3:2007+A1:2011+AC:2012*

Generally in accordance with ASME VIII Division 1 Rules for Construction of Pressure Vessels

July 2016

3770B Laird Road, Unit 2 Mississauga, Ontario L5L 0A7 Tel: 800-951-0777 Fax: 905-820-3490 www.cagpurification.com

WALKER FILTRATION PROSFD, PROSFD PD0046, PROSFD PD0056, PROSFD PD0075, PROSFD PD0110 Series Manual

Specifications and Main Features

Frequently Asked Questions

User Manual