ZANDER HDK 400/100, HDK 80/100, HDK 600/100, HDK 50/250, HDK 80/250 Operating Instructions Manual
...
High Pressure Dryer
HDK
50/100-600/350
Operating Instructions
Issue 05-2005/EN
Declaration of Conformity
ZANDER Aufbereitungstechnik GmbH & CO KG
Im Teelbruch 118
D – 45219 Essen Kettw ig
hereby declares with sole responsibility, that the products
high pressure dryer
series HDK 18/25 to 600/420
assembly type: assembly acc. to Art. 3 No. 2.2,
which this declaration refers to, conform to Directive 97/23/EC and were
subjected to a conformity assessment according to Annex III Modules B + D (for
assembly assessment).
For the assembly, the EC type approval certificate SIG 0272175/1 by Lloyd’s
Register Quality Assurance GmbH, Hamburg, is available.
The quality assurance system is monitored by the service provider stated below
Lloyd’s Register Quality Assurance GmbH (identification number 0525)
Mönckebergstraße 27, D - 20095 Hamburg.
The assembly consists of pressure appliances according to the classification list
(attached to the technical documentation provided by the manufacturer).
The following standards / technical specifications were used:
harmonized standards: DIN EN 292-1, DIN EN 292-2, DIN EN 1050,
DIN EN 50081, DIN EN 50082, DIN EN 60204
The following other EC directives were used:
98/37/EC
89/336/EEC
73/23/EEC
Signature
Dr. Walter Steudle
Managing Director
Machine passport
Type designation HDK
Order no.
Project no.
Build no.
Vessel no.
Vessel no.
Year of manufacture 2005
Issue date of these operating instructions 2005-05 EN
It is the responsibility of the owner,
to enter for the first time any appliance data not stated above,
to keep these appliance data up to date.
The above-stated appliance data provide for a clear identification of the dryer and
its components, and significantly facilitate any service measures.
Further important data on the dryer such as the details on the permissible
operating pressure and the electrical connection are found on the type plate (for
position of the type plate see page 12).
Table of contents
General information................................................................................................9
Manufacturer's details................................................................................................................. 9
Details on the dryer................................................................................................................... 10
About these operating instructions........................................................................................... 11
For your own safety..............................................................................................12
Signs, instruction plates and danger zones at the dryer.......................................................... 12
Intended use of the dryer.......................................................................................................... 14
General safety notes................................................................................................................. 14
Safety notes on specific operating phases............................................................................... 15
Technical product description ............................................................................18
Summary drawing..................................................................................................................... 18
Function description.................................................................................................................. 19
Available options....................................................................................................................... 20
Transportation, installation and storage ...........................................................23
Information on transportation packaging.................................................................................. 23
What to do in the case of transport damage occurring?.......................................................... 23
Transporting and installing the dryer........................................................................................ 24
Installing and anchoring............................................................................................................ 25
Storing the dryer ....................................................................................................................... 26
Installation..............................................................................................................28
Preconditions for installation..................................................................................................... 28
Connect piping .......................................................................................................................... 28
Installing the electrical connection............................................................................................29
Start-up ...................................................................................................................32
Requirements for initial start-up ...............................................................................................32
Setting times of the operating phases...................................................................................... 33
Overview of operating and control elements............................................................................ 33
Emergency shutdown............................................................................................................... 36
Start up dryer ............................................................................................................................ 36
Changing cycle mode (optional)............................................................................................... 39
Monitoring dryer operation..................................................................................41
With dewpoint-sensing control (optional) ................................................................................. 41
Shutdown and restart dryer.................................................................................42
Mains power failure................................................................................................................... 42
HDK350_EN_01_2005-05-10
Emergency shutdown............................................................................................................... 43
Depressurising and shutting down the dryer............................................................................ 43
If work is to be carried out on the electrical system................................................................. 43
Restart ...................................................................................................................................... 44
Maintenance and repair of the dryer.................................................................. 45
Notes on maintenance.............................................................................................................. 45
Regular maintenance intervals................................................................................................. 46
Daily maintenance tasks........................................................................................................... 47
Weekly maintenance tasks....................................................................................................... 48
Maintenance work to be completed every 12 months ............................................................. 48
Maintenance work to be completed every 48 months ............................................................. 52
Identify and eliminate faults ............................................................................... 56
Summary of faults..................................................................................................................... 56
Index....................................................................................................................... 59
Annex with technical documentation................................................................ 62
Technical data .......................................................................................................................... 63
Replacement and wear parts list.............................................................................................. 65
Logic control diagram ............................................................................................................... 68
Flow diagram ............................................................................................................................ 70
Dimensional drawing ................................................................................................................ 71
HDK350_EN_01_2005-05-10
General information
Manufacturer's details
Name and address
Zander Aufbereitungstechnik GmbH & Co. KG
Im Teelbruch 118 Postfach 185524
45219 Essen 45205 Essen
Telephone ++49 (0)2054/934-0
Telefax ++49 (0)2054/934-164
Internet: www.zander.de
E-mail: info@zander.de
General information
Service and orders
Service and spare part order
Telephone ++49 (0)2054/934-180
Telefax ++49 (0)2054/934-117
You can also use these telephone numbers to order consumables such as
desiccant etc. as well as spare parts. When ordering spare parts, always state
the type and build no. of the dryer. Both are shown on the type plate of the
dryer.
HDK350_EN_01_2005-05-10 9
Details on the dryer
Details on the dryer
Standard equipment
Dryer, comprising
2 vessels, filled with desiccant
1 upstream filter
1 downstream filter
Piping and muffler
Control system
Associated documents
Operating instructions (present)
Technical documentation (see annex)
Circuit diagrams (see separate document)
Warranty notes
In the following cases, the warranty shall be void:
If aggressive media in the compressed air and in the environment cause
corrosion damage and functional faults on the dryer.
If the dryer is used without prior approval and confirmation in writi ng by the
manufacturer for purposes other than those specified in these operating
instructions or contractually agreed.
If preset parameters (e. g. on the control system etc.) are changed without
prior approval and confirmation in writing by the manufacturer.
If the dryer is transported or stored incorrectly.
If the dryer is sited and installed incorrectly.
If the dryer is repaired or maintained incorrectly.
If the dryer is operated by perso nnel that does not have the requisite
qualifications.
If modifications are carried o ut on the dryer, the manufacturer did not
approve that.
In the event of non-compliance the manufacturer will not accept any liability for
any consequential damage whatsoever.
10 HDK350_EN_01_2005-05-10
About these operating instructions
These operating instructions contain basic information on the safe useof the
dryer.
Characters and symbols used
► Work steps that you have to carry out in the sequence stated are marked by
black triangles.
Lists are marked by a small box.
Note:
These notes provide you with hints and information on the safe and
efficient handling of machines and devices.
Warning!
These safety notes w arn against damage to property and help you to avoid
such damage.
General information
Danger!
These danger notes w ith a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid serious or
life-threatening situations for yourself and/or third parties.
Target group of these operating instructions
These operating instructions are intended for all persons working on and using
the dryer. We assume that all such persons are specialist personnel, e.g. fitters
or electricians.
Operating instructions: handling
These operating instructions must be continuously available at the site where the
dryer is used. We recommend to prepare a copy and to keep the same i n a safe
and freely accessible place next to the dryer. Keep the original document in a
safe place.
HDK350_EN_01_2005-05-10 11
Signs, instruction plates and danger zones at the dryer
For your own safety
The dryer has been built in accordance with the state of the art and the
recognized technical safety regulations. Nevertheless, there is a risk of personal
injury and damage to property when the dryer is used, if
it is operated by non-qualified personnel,
not used within its intended design specifications,
is repaired or maintained incorrectly.
Note:
For your own safety and to prevent machine damage, please note the
information and safety notes in these operating instructions when
working with the dryer.
Signs, instruction plates and danger zones at the dryer
Signs and instructions
Vessel plate
Type plate of the dryer
Type plate of the filter
Front view
Please note the above plates and instructions attached to the dryer. Ensure that
they are not removed and are always readable.
12 HDK350_EN_01_2005-05-10
Hazard areas on the dryer
For your own safety
Hazard caused by electrical voltage
Hazard caused by overpressure
Hazard caused by sudden air ejection during
expansion
Hazard area
Warning against hazardous electrical voltage
Different parts of the dryer carry electrical current. These parts may be
connected, opened, and maintained by authorized specialist personnel only.
Warning against overpressure
The entire dryer is under pressure. Before commencing any work, the plant
must be depressurised.
Warning against sudden air ejection
When the vessels are depressurised, air flows suddenly out of the sound
absorber:
This causes a sudden loud cracking noise.
Due to particles carried in the air flow, there is a very considerable risk of
eye injury.
When working on the dryer, always wear eye and ear protection equipment.
Skid risk
When emptying and filling the vessels with drying agent, there is a risk of
skidding caused by spilt drying agent.
Symbol in
operating
instructions
HDK350_EN_01_2005-05-10 13
Intended use of the dryer
Intended use of the dryer
The dryer is exclusively intended for drying compressed air. Depending on
defined input conditions, it dries compressed air for industrial use.
The dryer is designed for compressed air, which is free from aggressive water,
oil, and solid matter constituents.
As standard, the dryer is intended to be sited within a building and protected
against the weather. When it is sited in the open air (option), the i nstructio ns on
page 20 must be complied with.
The dryer may be operated only in accordance with the data on the type plate
and in accordance with the contractual conditio ns.
Suspected misuse
The dryer must not be misused as a climbing aid! Pipes, valves, and similar
fittings have not been designed for such loads. They could fracture, tear off, or
become damaged in another way.
General safety notes
For your ow n safety, when carrying out any work on the dryer comply w ith
all applicable national safety regulations!
Personnel qualification
Only authorized and qualified specialist perso nnel may be tasked with the work
on the dryer described in these operating instructions.
Conversions and modifications
Without prior approval by the manufacturer, no conversions and modifications
must be made to the dryer! Any non-approved modifications may restrict the
operational safety of the dryer and cause damage to property or perso nal injury.
Handling drying agents
The drying agents used do not pose any risk to health. However, when filling and
emptying the vessels with drying agents, increased dust generation may occur.
Please comply with the following i nstructions:
When filling drying agents into the vessels, wear a dust mask and eye
protection!
If a spillage occurs, any spilt drying agent must be taken up immediately.
There is a risk of skidding!
14 HDK350_EN_01_2005-05-10
Safety notes on specific operating phases
Transportation and siting
Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
Carefully secure the dryer during transportation.
Start-up
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
A loud cracking noise occurs which can injure your hearing.
Particles carried in the air can injure your eyes or skin.
Always wear eye and ear protection, therefore, when you are in the vicinity
of the dryer!
For your own safety
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
Carry out all prescribed tests and checks.
The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
Before start-up, ensure that no tools or other foreign parts have been left
lying in a part of the dryer where they mi ght pose a hazard to the dryer being
started up.
Emergency shutdown
In any emergency, proceed as described in the section Depressurising and
shutting down the dryer on page 43.
Monitor operation
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
A loud cracking noise occurs which can injure your hearing.
Particles carried in the air flow act like bullets and can injure your
eyes or skin.
Always wear eye and ear protection, therefore, when you are in the vicinity
of the dryer!
HDK350_EN_01_2005-05-10 15
Safety notes on specific operating phases
Only operate the dryer within the permissible limits (see type plate). By
operating the dryer in conditions that go beyond the defined values, the dryer
is subjected to loads for which it has not been designed. This may cause
functional defects.
Loud noise generation!
During expansion the pressure is released suddenly through the
expansion valve. A loud cracking noise may occur.
Always wear ear protection, therefore, w hen you are next to the dryer
during operation.
The more po werful the dryer is, the more noise may be generated during
operation. Temporarily, the actual noise emission may even exceed
95 dB(A). T herefore, the operator must provide suitable protective equipment
(e. g. ear protection).
Check the dryer regularly for externally visible damage and defects. Any
changes, even in its operating behavio ur, must be reported immediately to
the competent office or person.
In the event of an emergency or if a safety-relevant disruption occurs (e.g.
escaping compressed air, defective component), the dryer must be shut
down immediately as described in the sectio n Depressurising and shutting
down the dryer on page 43). The unit may only be restarted after all defects
have been eliminated.
Maintenance of the dryer and fault removal
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
Carry out maintenance work only when the plant has been shut down and
depressurised!
The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
Bolt connections must be undone with care! Note ram pressure values!
Otherwise emerging media may cause perso nal injury.
Never carry out any welding on a vessel or change the same i n any other
way!
Never use pipes and fittings as steps or holding points! The components
might fracture, or the distortions which occur may cause internal damage on
the dryer. There is a risk of injury by slipping off the components,
components breaking off, and expanding compressed air!
Never leave tools, loose parts or cloths in, at or on the dryer.
Following maintenance work always test all flange and bolt connectio ns for
leak tightness and secure seating.
16 HDK350_EN_01_2005-05-10
Only use replacement parts that are suitable for the relevant function and
meet the technical requirements stipulated by the manufacturer. This is
always the case, if you use original replacement parts only.
Disassembly and disposal
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
Dispose all parts of the dryer, the drying agent, and all other operati ng
materials in an environmentally safe way and in accordance with all current
statutory regulations. The waste code numbers of the drying agents can be
obtained from the manufacturer (for the manufacturer's address see page 9).
For your own safety
HDK350_EN_01_2005-05-10 17
Summary drawing
r
y
r
r
s
Technical product description
Summary drawing
Front view
Vessel pressure
gauge
Manomete
On/Off-Switch
Power suppl
connecto
Compressed air outlet Compressed air inlet
Downstream filte
Valve
Pressure reducer with
manometer
Control cabinet
Differential pressure
gauge
Upstream filter
Hand drain
Muffler
18 HDK350_EN_01_2005-05-10
Function description
The dryer dries the compressed air supplied by the compressor and makes it
available for industrial use.
Upstream filters clean the compressed air and remove dust, dirt, oil, and water
droplets, before the compressed air reaches the dryer. Thus, an upstream filter is
also used for extending the service life of the drying agent.
Downstream filters clean the compressed air from drying agent abrasions, before
it is fed into the compressed air system.
The two vessels contain an extremely porous drying agent by means of which
humidity is removed from the compressed air and stored just as in a sponge. The
stored humidity is then removed again from the drying agent and re-introduced
into the ambient environment.
To this end, the two vessels alternate between different operating modes. Whilst
in one vessel, compressed air is de-humidified (adsorption), in the other vessel
the humid drying agent is prepared for another charge (regeneration). These two
states, which run in parallel during compressed air preparation, are described
below.
Technical product description
Adsorption
Via a compressor, humid compressed air is supplied to the upstream filter. From
here, the compressed air flo ws upwards through the absorption vessel, which is
pressurised. In so doing, the drying agent dehumidifies the air. The dry
compressed air is supplied to the pipe network via the downstream filter.
Regeneration (running in parallel to the adsorption)
At the same time the other vess el is prepared for a renewed take-up of humidity.
This process is called regeneration.
The regeneration is subdivided into three phases: expansion, dehumidification,
and pressure build-up.
With the dewpoint-sensing control option, the regeneration phase is followed by a
standby phase.
Expansion phase
During the expansion phase the pressure in the right vessel is released via the
muffler down to ambient pressure within just a few seconds. The outflow of the
compressed air becomes noticeable due to a sudden powerful flow noise at the
muffler.
Dehumidification phase
Prior to being released into the pipe network, dried compressed air is bled by
means of an orifice plate. This separate regeneration air flow is fed through the
depressurised vessel. The humidity stored in the drying agent is taken up by the
air flow and expelled into atmosphere via the muffler.
HDK350_EN_01_2005-05-10 19
Available options
Switchover
Pressure build-up phase
After dehumidification the pressure in the regenerated hollow section vessel is
built up to operating pressure, so that the switchover from regeneration to
adsorption can take place at operating pressure level.
Standby phase (only with the dewpoint-sensing control option)
When in standby phase, the fully regenerated vessel is ready for absorption
operation. The system is switched to this vessel, as soon as the measured
dewpoint at the compressed air outlet has reached the set dewpoint value for
switchover.
When the drying agent in the adsorbing vessel has taken up a sufficient level of
humidity, then the switchover between the vessels will be effected between the
vessels. Following switchover, the above-described process is repeated, with the
adsorption and regeneration now taking place in the respective different vessel.
Available options
The following options are available for the dryer:
Start-up device
Outside installation
Auxiliary heater
Signalling contacts of control system
Regeneration gas return line for compressor synchronisation
Dewpoint-sensing control
Pneumatic control
Paint compatible design
Start-up device
A start-up device basically consists of a pressure holding device, which is located
at the rear of the dryer. The pressure holding device ensures that pressure can
build up in the dryer and adsorption take place.
It is always required when an empty compressed air reservoir or an empty
compressed air system must be filled downstream of the dryer (e.g. following
weekend shutdowns and when the pressure in the compressed air system can
frequently drop below the stated operating pressure).
The start-up device cannot be combined with the regeneration gas return line
option.
Outside installation
As standard, the dryer is not suitable for outside installation, as its functio n and
service life is influenced by the following factors:
Environmental humidity due to rain (or other deposit)
Corrosion caused by environmental humidity or a salt-containing environment
20 HDK350_EN_01_2005-05-10
Freezing of valves, cocks, flaps, and other components at low temperatures
Therefore, a planned o utside installation must always be discussed in advance
with the manufacturer to allow specific technical design measures to be provided
for the installation location.
Auxiliary heater
For installation sites with temperatures under +1 ºC (33,8 ° F), the wet side of the
dryer must be equipped with an auxiliary heater to prevent valves, cocks, flaps,
and other components from freezing up.
Signalling contacts of the control system
The control system is equipped with a digital input for the synchronised operation
with a compressor. This feature allows for synchronised and thus efficient dryer
operation with disco ntinuous compressor operation.
The control system can also be equipped with an optional operation signalling
contact with which the dryer operation can be monitored from an external device.
Dryers with the optional dewpoint-sensing control are equipped with such a
contact as standard. It is used for the transmission of operating signals and for
the output of dewpoint alarms.
Technical product description
Regeneration gas return for compressor synchronisation
Compressor synchronisation helps reduce energy costs, as the dryer can be
operated independently of the compressor.
When the compressor is switched off, the regeneration gas return ensures that
regeneration is continued, as soon as a certain compressed air volume is
reached behind the dryer.
The regeneration gas return must be adjusted to suit the installed compressed air
system. Prior to installation, please consult the manufacturer.
The regeneration gas return option cannot be combined with the optional start-up
device.
Dewpoint-sensing control
With a dewpoint-sensing control system, you can operate the dryer in fixed or
variable cycles. In the fixed cycle, switchover is effected after a fixed time period
(usually after 5 minutes). In the variable cycle, the switchover is effected in
relation to the dew point reached and the charging of the drying agent . T he
adsorption time in the variable cycle amounts to 60 minutes maximum.
Pneumatic control
A pneumatic control system can be used wherever an alternative to the electronic
control system is required, such as e.g. in explosion hazard areas.
HDK350_EN_01_2005-05-10 21
Available options
Paint compatible design
Paint shop plants impose particularly stringent requirements with regard to the
cleanliness of the compressed air, as already the minutest contaminations can
reduce the quality of the paint finish. Even minute quantities of oil and grease
containing foreign materials or solvents — above all silicones — are sufficient to
cause pits, discolorations, swelli ngs, and other contami natio ns i n t he pai nt finis h.
Dryers in a paint compatible design comprise seals and filters that are absolutely
free of grease and silicon and thus ensure a high quality of the compressed air
used for painting.
22 HDK350_EN_01_2005-05-10
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