ZANDER HDK 400/100, HDK 80/100, HDK 600/100, HDK 50/250, HDK 80/250 Operating Instructions Manual

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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.

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

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.

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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.

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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

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!

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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.

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 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

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

Transportation, installation and storage

Danger due to incorrect transportation!

The dryer must be transported by authorized and qualified specialist personnel only. During transportation all applicable national regulations for accident prevention must be complied w ith. Otherwise there is a risk of personal injury.

 Only use suitable and technically perfect lifting gear with a sufficient carrying

capacity.

 During transportation the dryer must be carefully secured against falling over.

The manufacturer will not be liable for any damage caused by incorrect storage or incorrect transportation. Please note therefore the following instructions as well as the storage instructio ns on page 26.

Information on transportation packaging

Depending on the type of transportation, the dryer is delivered in different types of packaging:

 All transportation types: the apertures of the dryer are closed off by means of

plugs.

 In additio n, when transportation is effected by air: the dryer is packaged in a

wooden box.

 In additio n, when transportation is effected by ship: the dryer is packaged in a

film material and in a wooden box.

If the packaging is undamaged

► The undamaged packaging should be removed only at the final installation

site, as it offers protection against any weather influences.

What to do in the case of transport damage occurring?

► Check whether only the packaging or the dryer itself were damaged.

► If any damage is found, please contact the manufacturer immediately to file a

damage report. The telephone number is found on page 9.

Warning!

A damaged dryer must not be taken into operation! Damaged components may lead to functional faults and possibly cause further damage.

HDK350_EN_01_2005-05-10 23

Transporting and installing the dryer

Requirements for the installation site

The conditions at the installation site have a large influence on the functional capability of the dryer and the service life of the drying agent. In order to ensure a mode of operation, which is as co ntinuous as possible, and low maintenance, the installation site must meet the following requirements:

 The installation site must be located within a building - protected against

humidity. For outside installation (option) the instructions on page 20 must be complied with.

 The ambient temperature must not drop below +1 °C (33,8 °F). If necessary,

an auxiliary heater is to be provided (for information on the auxiliary heater, see page 21).

 When selecting the installation site, it should be taken into account that the

noise emission of the dryer can exceed 95 dB(A) temporarily (for further information on the noise emission, see also page 16).

 The installation area must be level, firm and free of vibrations. It must have

the necessary carrying capacity for the weight of the dryer. The weight of the dryer is specified in the technical data section of the annex.

 The dryer should be installed with

sufficient spacing at the top, sides, and rear, in order to be able to carry out maintenance work and change the dryi ng age nt witho ut any hi ndra nces (see figure).

If in doubt, the installation site must be inspected by specialists. If you have any queries in this regard, please contact the manufacturer (for details see page 9).

Transportation using lifting or forklift trucks

Warning against damage to property!

The dryer is delivered on a transportation pallet.

Necessary spacing at the top and sides

= min. 1 m

Therefore, always transport the dryer on a lifting or forklift truck.

24 HDK350_EN_01_2005-05-10

► Secure the dryer on the lifting

or forklift truck against sliding movements.

► Transport the dryer to its

installation site.

Transportation, installation and storage

Dryer on transportation pallet

Installing and anchoring

Installing

► Remove the packaging of the dryer.

► Attach suitable lifting gear to the stand profiles and cross beams.

Risk of tilting!

The dryer should only be transported in an upright position. However, this means that the centre of gravity of the unit is located in the upper half of the dryer, so that there is a serious risk that the unit might topple over.

When attaching the dryer to the lifting gear, observe its centre of gravity!

► Position the dryer at its installation site.

HDK350_EN_01_2005-05-10 25

Storing the dryer

Anchoring the dryer

The upright stand profiles of the dryer are provided with pre-drilled anchorage bores.

► Use suitable attachment material to anchor

the dryer to the floor (see figure).

► In the case of vibrating floors: place the dryer

on suitable vibratio n dampers.

Bores at the foot of the dryer

Storing the dryer

If the dryer is to be stored for an extended period of time, the storage location must me et t he follo wi ng co nditions:

 The dryer must not be stored in the open air.

 The storage room must be dry.

 The storage room must be free from dust or the dryer must be covered by a

protective sheet.

 The storage room must have an ambient temperature of at least +1 °C

(33,8 °F).

In order to store the dryer proceed as follows:

► Take dryer o ut of operation as described on page 43.

► Ensure that the compressed air inlet valve installed by the owner, and the

installed compressed air outlet valve installed by the owner, are both closed, and that the dryer is depressurised.

► Disconnect dryer from the compressed air system.

► Disconnect the dryer from the electrical power supply and all external lines.

► Use film material or similar to close the compressed air inlet apertures and

compressed air outlet apertures on the dryer in order to protect them against contamination.

► If possible cover dryer with a protective sheet.

The dryer can now be stored for long periods.

26 HDK350_EN_01_2005-05-10

Note:

If you w ish to take the dryer back into service after an extended period of storage, please proceed as described for its first commissioning and start-up (see page 37).

Store drying agents

► Do not store drying agents in the open air.

► Protect drying agents against humidity.

Transportation, installation and storage

HDK350_EN_01_2005-05-10 27

Preconditions for installation

Installation

Only authorized and qualified specialist personnel may carry out work on pipes and electrical systems.

As soon as the dryer has been set up at its installation location, you can install the compressed air infeed and outlet lines make the electrical connections.

Preconditions for installation

For a correct installation the following preco nditions must be met on the part of the owner.

 Connections and lines for the infeed and outfeed of compressed air must be

provided.

 A compressed air inlet valve as well as a compressed air outlet valve must

be installed by the owner, so that the dryer can be installed and maintained in a depressurised condition (see also the installation example on page 29).

 All pipes, co uplings, and connections must have the correct diameter and

match the operating pressure.

Hazard caused by exceeding the limit values!

A safety device must be prov ided in order to protect against the maximum permissible operating pressure from being exceeded.

The data required to meet these preconditions are contained in the technical documentation attached in the annex.

Warning!

If the above preconditions are not complied with, a safe operation of the dryer cannot be assured. Also, the functionality of the dryer may be detrimentally affected.

Connect piping

In order to ensure that the dryer operates optimally, the dryer must be assembled into the compressed air system free of all stresses.

► Ensure before connection that all infeed and outfeed compressed air lines

and valves are clean and undamaged.

► Check the bolt connections and retighten if necessary, as they co uld have

worked loose during transportation.

► Remove plugs on the pressure inlet and outlet.

28 HDK350_EN_01_2005-05-10

Installation

All piping must be free from any stress and tension whatever!

Pipes subject to stress may burst due to the load placed on them during operation. T his may cause damage to property and personal injury.

► Use steel pipes to connect the dryer to the compressed air system.

The following figure shows an installation example.

Compressed air system Item Component

1 Entry, humid air

2 Compressed air inlet

valve, owner end

3 Upstream filter

4Dryer

5 Downstream filter

6 Compressed air outlet

valve, owner end

Example of an installation

► The connection lines for the upstream filter (3) are to be installed at a slight

incline in the direction of the upstream filter.

► One shutdown valve each (2, 6) is to be installed at the compressed air inlet

and outlet ends of the dryer.

Installing the electrical connection

Warning against electrical voltage

Only qualified specialist personnel may carry out w ork on the electrical system!

7 Outlet, dry air

Installing the supply cable

The components of the dryer have been connected to the control cabinet at the factory. You only need to connect the control cabinet to the electrical supply cable.

The switchbox is provided with a connector where electrical power must be connected.

HDK350_EN_01_2005-05-10 29

Installing the electrical connection

► Ensure that the cross-section of the electrical supply cable corresponds to

the power rating of the dryer and the electrical voltage provided by the customer.

► Make the electrical supply cable to the dryer voltage-free.

► Secure the electrical supply cable to the dryer against switch-on.

► Undo bolt (1) on the connector and

withdraw connector with seal from the switchbox.

► Use a suitable tool to remove the

terminal bloc k from the connection box.

► Undo the PG union and pull the cable

through the aperture (3). The exposed phase ends should not be longer than 35 mm max.

► Now make the cable connectio n as

follows:

— Earth

— L1 to terminal 1

— N to terminal 2

to terminal PE

Terminal 3 is not used.

► Fit terminal block into the connector and use bolt to remount the connector

with seal on the switchbox.

► In all phases the dryer must be protected against short circuits by means of

fuses.

► In order to relief cable strain, re-tighten the PG union.

Connecting the external signalling lines

For compressor synchronisation

The control system is equipped with a digital input that ensures that the dryer can only be operated while the compressor is on.

If the compressor is switched off, the regeneratio n process started in one of the chambers is however completed. Subsequently, the respective expansion valve is automatically closed. In standby mode, the control system remains switched on, and the economy cycle LED is on. The dryer is now ready for the next switching procedure, which takes place as soon as the compressor is switched on again.

Connect electrical cable to device

adapter

To install the external line, proceed as follows:

► Connect the signalling line to the potential-free busbar connection of the

compressor to terminals 1 and 2 on the control board (s ee circuit diagram).

30 HDK350_EN_01_2005-05-10

For operation monitoring system (optional)

Operators have the option to connect the dryer to a fault signalling system, connecting the respective line to a potential-free operation signalling contact. With this option, the following statuses and events can for example be transmitted to a remote control room:

 Dryer on (contact made)

 Power supply disconnected (no contact)  Dewpoint alarm (only with dewpoint-sensing control option, no contact)

To install the external lines, proceed as follows:

► Connect the lines of the fault signalling system to relay K5 (see circuit

diagram).

Check bolt connections

Before the initial start-up:

► Check all unions and bolt connections as well as the terminals in the control

cabinet for secure seating; re-tighten if necessary.

Installation

HDK350_EN_01_2005-05-10 31

Requirements for initial start-up

Start-up

Warning!

The dryer must be taken into operation by trained personnel only! Untrained personnel does not have the required know ledge. Such personnel might cause serious faults.

Note:

You can order the initial commissioning and start-up from the manufacturer and have your personnel trained by the manufacturer. For telephone number, see page 9.

 Carry out all prescribed tests and checks.

 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.

Requirements for initial start-up

For the first start-up the following preconditions must have been met:

 The pipe system is free from

— scales

— thread abrasions

— welding beads and

— o ther co ntami nati ons.

 All shutdown valves of the compressed air inlet and outlet valves installed by

the owner are closed.

 The dryer is correctly sited and installed.

Checks before start-up

Ensure that

 all pipe, cable and bolt connections on the dryer have been retightened,

 no pipes chafe against body edges,

 all mountings are perfectly secure,

 the electrical connections are in safe contact and in good condition,

 owner-end and pressurised parts such as safety valves or other devices are

not blocked up by dirt or paint,

 all compressed air system parts which are pressurised (valves, hoses etc.)

are free from wear symptoms and defects.

32 HDK350_EN_01_2005-05-10

Setting times of the operating phases

In its standard version the dryer is delivered with a time-dependent co ntrol system. The phase sequence occurs in a fixed cycle.

With the optional dewpoint-sensing control, the dryer can also be operated at variable cycles (depending on the dewpoint).

The following table provides information on the duration of the individual phases.

Phase duration Fixed cycle Variable cycle

Adsorption 10 min 60 min, ma xi mu m

Regeneration, total 10 min 10 min

− of which: expansion time

− of which: dehumidification time

− of which: pressure build-up

Standby — ~ 50 mi n, ma xi mu m

Start-up

~ 0.2 min ~ 0.2 min

~ 8 min ~ 8 min

~ 2 min ~ 2 min

Overview of operating and control elements

ON/OFF switch

The ON/OFF switch (2) is located to the side of the control cabinet and above the mains plug (1, see figure):

 If it is set to 0, the power supply is disconnected and the dryer is switched off.

The main and expansion valves are normally closed. This ensures that the main flow direction is blocked when the dryer is switched off.

 If the switch is set to I, the dryer is switched

on and begins to operate in fixed cycle mode (i.e. time-controlled).

 If the switch is set to position II, the dryer is

switched on and begins to operate

— with compressor synchronisation

— in variable cycle mode (i.e. dew-point-

controlled).

Position II is only relevant for operation with the optional regeneration gas return system

for compressor synchronisation and/or dewpoint-sensing control.

Control cabinet with ON/OFF switch

HDK350_EN_01_2005-05-10 33

Overview of operating and control elements

Display panel

The display panel at the switchbox is equipped with LEDs (light emitting diodes) and a digital display, i ndicating the operating status of the dryer:

LED Power (1)

LED is on when dryer is switched on.

Display panel at the switchbox

Flow diagram (2)

The current operati ng phases of the dryer are indicated by means of 4 LEDs:

Vessel B1: Vessel B2:

Regeneration 1 Regeneration 2

Adsorption 1 Adsorption 2

Depending on the operating phase, the following LEDs might be on simult aneo usly:

Adsorption B1 and regeneration B2 or regeneration B1 and adsorption B2.

34 HDK350_EN_01_2005-05-10

Start-up

Digital display (3)

The digital display shows the individual programme steps and the respective remaining time. For details regarding the sequence of the individual processing steps and their duration, please refer to the logic control diagram, page 68.

Display Explanation

2 215

Default display: The figure to the left indicates the current processing step; the figure to the right shows the remai ning time in seconds.

In this example, step 2 is bei ng completed, whereby there are 215 seconds remaining.

SEr.

After 8000 operating hours, "SEr." (service) is displayed for periods of 1 minute, alternating with the default display.

Notify the service personnel of the manufacturer, as a routine service is now due.

– 25

With the dewpoint-sensing control option, the display shows the currently measured dewpoint instead of the default data. T he range of display is -100 °C (-148 °F) to +20 °C (68 °F). If the measured dewpoint exceeds the preset alarm limit (5 °C (41 °F) above the switchover value), the displayed dewpoint value is flashing.

With the optional dewpoint-sensing control, the following error messages might be displayed:

Display Cause

+20

999

sens

–999

LED Economy cycle (4)

This LED is only relevant in units that are equipped with the optional

regeneration gas return for compressor synchronisation and/or dewpoint- sensing control. The LED is o n, if the dryer is switched on but does not need

regeneration air (standby phase):

 with compressor synchronisation: if the compressor is switched off and/or

 if the dryer is set to variable cycle mode (dewpoint-co ntrolled operation).

Vessel pressure gauge

On both vessels, pressure gauges are fitted which show the operating overpressure. The operating overpressure indicates the operating phase of the relevant vessel:

 Upper measuring range limit exceeded

 Dewpoint sensor defective

 Dewpoi nt senso r not powered

 Cable defective or disconnected

 Sensor defective

HDK350_EN_01_2005-05-10 35

Emergency shutdown

 During adsorption the pressure gauge should indicate the nomi nal operating

overpressure.

 During regeneration the indication of the pressure gauge on the regenerating

vessel

— should decrease in the expansion phase from operating overpressure to

0 bar overpressure,

— indicate an overpressure of 0 bar i n the dehumidification phase.

With an increasing duration of operation, a higher overpressure can be indicated during regeneration. This overpressure during regeneration is also designated as dam pressure.

 The dam pressure should not exceed 0.3 bar, otherwise read the instructions

on page 48.

 During the pressure build-up phase the indication on the pressure gauge

should again rise to operating overpressure level.

Pressure reducer with manometer

The pressure reducer is used to control the regeneration air. By default, it is set to 8 bar. The manometer attached to the pressure reducer allows operators to check the pressure settings.

Emergency shutdown

In the event of an emergency, shut down the dryer as described in chapter Depressurising and shutting down the dryer, page 43.

Start up dryer

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!

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.

 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).

36 HDK350_EN_01_2005-05-10

 Only operate the dryer within the permissible limits. By operating the dryer i n

conditions for which it has not been designed, functional faults may be caused.

 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.

Open compressed air supply and switch on dryer

For start-up, please proceed in the sequence shown here.

► Ensure that the compressed air inlet and outlet valves installed by the owner

are closed (see installation example on page 29).

► Ensure that the compressed air system upstream of the dryer is pressurised.

If necessary, pressurise (switch on compressor).

Start-up

Slowly open compressed air inlet valve!

Avoid sudden pressure build-up in any circumstance! If pressure builds up too fast, this may cause damage to the dryer. T herefore, the compressed air inlet valve must alw ays be opened quite slowly!

► Slowly open the compressed air inlet valve, installed by the owner, upstream

of the dryer.

► Switch on dryer: to this end, set the ON/OFF

switch to I.

ON/OFF switch

If the dryer is taken into operation for the first time, or after a change of drying agent, the following i ntermediate step is meaningful. In the case of a restart situation, the following intermediate step can be skipped.

Operating the dryer for the first time (or after a change of drying agent) separately

Depending on the transportation and storage conditions, the drying agent in the vessels can already be loaded with humidity from the environment. At each first start-up it makes sense therefore to operate the dryer from some time separately from the compressed air system. This causes the drying agent in each vessel to be regenerated repeatedly and thus to be prepared optimally for the take-up of humidity.

HDK350_EN_01_2005-05-10 37

Start up dryer

Note:

Depending on the pressure dew point to be achieved, we recommend to operate the dryer at first start-up without compressed air consumption:

 for at least 4 hours at a pressure dew point of –25 to –40 °C or

 for approx. 3 to 5 days at a pressure dew point of –70 °C.

If you wish to take the dryer into operation in accordance with our recommendation, proceed as follows:

► Ensure that the compressed air outlet valve installed by the owner is closed.

► Keep the compressed air outlet valve closed for the time period

recommended above.

Then the dryer can be taken into service in the compressed air system as described in the following sectio n:

Operate dryer immediately in the compressed air system

► Ensure that the compressed air system downstream of the dryer is

pressurised or that a start-up device (option, see page 20) was installed into the compressed air system directly downstream of the dryer. The importance of this increases with the size of the compressed air system downstream of the dryer. Smaller compressed air systems can be pressurised also by means of compressed air fed through the dryer.

Slowly open compressed air outlet valve!

Avoid a sudden drop in pressure in any circumstance! If pressure drops too fast, this may cause damage to the dryer. T herefore, the compressed air outlet valve must always be opened quite slowly!

► Slowly open the compressed air outlet valve installed by the owner. Observe

the vessel pressure gauge of the pressurised vessel. The pressure should not drop below the operating pressure (if poss.). If necessary, keep the compressed air outlet valve in a slightly open position until the compressed air system downstream of the dryer has filled up completely; only then should the valve be opened fully.

The dryer has then be taken into operation within the compressed air system.

In the event of a fault

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 section Depressurising and shutting down the dryer on page 43).

Then proceed as follows:

Remedy fault

► Look up possible cause of the fault, and how to remedy the same, in the

table on page 56.

► Remedy fault.

38 HDK350_EN_01_2005-05-10

► Repeat the start-up procedure.

Changing cycle mode (optional)

When can I change cycle mode?

If the dryer has been successfully commissioned and is equipped with one of the following options:

 regeneration gas return for compressor synchronisation or

 dewpoint-sensing control

it can be set to economy cycle mode.

When should I change cycle mode?

Cycle changes should be made during the pressure build-up phase and prior to switchover; during this phase, the pressure in both vessels is just below operating pressure so that a fast pressure build-up is prevented when the vessels are switched.

During this period, only the adsorptio n LED is on in the diagram, and the digital display s hows step 4 or step 9 for the duration of 1 minute (see logic control diagram; not displayed with dewpoint sensing).

Start-up

Which cycle modes can I choose?

If the dryer is connected to a compressor synchronisation system and is equipped with the dewpoint-sensing control option, these two optional devices

can only started together. The compressor synchronisation has thereby precedence over the dewpoint-sensing control.

With regeneration gas return for compressor synchronisation (optional)

If compressor synchronisation is enabled, the dryer can only be operated in conjunction with the compressor. As soon as the compressor is switched off, the dryer is automatically set to standby mode.

The installed regeneration gas return ensures however that a regeneration cycle started in one of the vessels is completed. Subsequently, the respective expansion valve is closed. In standby mode, the control system remains on, and the dryer is ready for the next switchover, which is made as soon as the compressor is switched on.

With dewpoint-sensing control (optional)

Dryers equipped with dewpoi nt-sensi ng control operated in variable cycle mode, based on the measured dewpoint of the dried air at the compressed air outlet. As soon as a certain dewpoint is reached, as the drying agent in the absorbing vessel is saturated, the vessels are switched.

The dewpoint at which a switchover is made is preset at the factory.

HDK350_EN_01_2005-05-10 39

Changing cycle mode (optional)

How do I change cycle mode?

► Wait until the dryer has reached the pressure build-up phase (phase prior to

switchover). One LED for Adsorption B1/B2 is on in the flow diagram.

► Set the ON/OFF switch to position II.

The programme continues the cycle.

ON/OFF switch

40 HDK350_EN_01_2005-05-10

Monitoring dryer operation

The dryer operates fully automatically. However, you should carry out the regular checks described in the Chapter Maintenance and repair of the dryer.

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!

With dewpoint-sensing control (optional)

Monitoring dryer operation

Display of dewpoint

If the dryer is equipped with a dewpoint-sensing control system, the digital display at the front of the switchbox shows the currently measured dewpoint. The range of display is –100 °C (-148 °F) to +20 °C (68 °F).

If the set dewpoint is exceeded, the system automatically completes a switchover between the vessels. The dewpoi nt at which a switchover is made is preset at the factory.

► After commissioning or extensive maintenance work, check the dewpoint

display at the dryer.

Under certain circumstances, the desired dewpoint is o nly reached after prolonged operation.

Error messages

If the measured dewpoint exceeds the preset alarm limit (5 °C (41 °F) above the switchover value), the displayed dewpoint value is flashing. In addition, an error message can be issued through the potential-free busbar.

Error codes and their causes:

Display Cause

+20

999

sens

–999

For instructions on how to eliminate faults, see chapter Identify and eliminate faults

HDK350_EN_01_2005-05-10 41

 Upper measuring range limit exceeded

 Dewpoint sensor defective

 Dewpoi nt senso r not powered

 Cable defective

 Sensor defective

Mains power failure

Shutdown and restart dryer

In the following cases, the dryer must be fully shut down and depressurised:

 In the event of an emergency or malfunction

 For maintenance work

 For dismantling

Risk of injury from escaping compressed air!

Never remove any parts of the dryer, or manipulate the same in any way, as long as the unit is pressurised! Suddenly escaping compressed air might cause serious injuries.

Prior to any work, release all pressure from the unit.

Mains power failure

In the event of a power failure, follow the instructions below:

In the event of a power failure, or when the dryer is switched off with the ON/OFF switch

 all main valves are closed

 all expansion valves are closed

As a result

 the pressure at the i nlet side of the dryer is increased, while the compressor

is on (until the compressor is automatically switched off by the control system),

 the pressure in the vessel (without start-up device) is reduced, as the

compressed air outlet valve is open, while compressed air is taken in from the pipeline system,

 no compressed air is fed to the downstream compressed air system.

Note:

If the unit is equipped with a compressor synchronisation system, first switch off the compressor and then w ait until the dryer has reached the standby phase before sw itching it off with the ON/OFF switch.

This ensures that the regeneration cycle is completed, and that the pressure in both vessels is at the same level.

Note:

As soon as the dryer is switched on again, the programme continues the cycle from the point at which it has been stopped.

42 HDK350_EN_01_2005-05-10

Emergency shutdown

In any emergency proceed as described in the next section.

Depressurising and shutting down the dryer

In order to make the dryer safe, follow the instructions in the next three sections:

Disconnect dryer from compressed air system

► Close the compressed air outlet valve (provided by operator).

► Close the compressed air inlet valve (provided by operator).

Depressurise dryer

► Leave the dryer on until the expansion phase in both vessels has been

completed.

During the expansion phase, the vessels are completely depressurised.

Shutdown and restart dryer

► Check the pressure i n the dryer at both vessel pressure gauges. The

pressure gauges should show value "0".

Disconnect voltage supply

► Switch off the dryer by setting the ON/OFF

switch to position 0.

If work is to be carried out on the electrical system

► Depressurise and shut down the dryer, following the instructio ns in the above

chapter.

Risk of injury due to voltage-carrying parts!

The electrical supply cable and external power lines are live even after the dryer is switched off and, in the event of body contact, may cause serious injury! Before carrying out any work on the electrical system, the electrical supply cable and all external power lines must be made voltage-free!

ON/OFF switch

► Make the electrical supply cable to the dryer voltage-free.

► Secure the electrical supply cable to the dryer against switch-on.

HDK350_EN_01_2005-05-10 43

Restart

Depending on the fittings installed by the operator and the actual pressure conditions, the unit might have to be restarted at operating pressure. The following general rules apply:

 When switched off, the dryer is blocked in the main flow direction.

 The pressure in the vessel drops (provided that the compressed air o utlet

valve provided by the operator is opened), if

— compressed air can escape to the compressed air system,

— the dewpoint-sensing control is implemented.

If compressed air system and dryer have remained at operating pressure

► Ensure that the compressed air inlet valve (provided by the operator) is open.

► Set ON/OFF switch to I. The programme

continues the cycle from the poi nt at which it was interrupted.

ON/OFF switch

lowly open compressed air outlet valve!

void a sudden drop in pressure in any circumstance! If pressure drops too

ast, this may cause damage to the dryer. Therefore, the compressed ai

utlet valve must always be opened quite slowly!

► Slowly open the compressed air outlet valve installed by the owner. Observe

The dryer is now in operatio n again and operates fully automatically.

If compressed air system and dryer have not remained at operating pressure

► If disconnected, reconnect the voltage supply of the dryer.

► Pressurise and switch on the dryer as described in the section Open

compressed air supply and switch on dryer on page 37.

The dryer is now in operatio n again and operates fully automatically.

44 HDK350_EN_01_2005-05-10

Maintenance and repair of the dryer

In order to allow maintenance work on the dryer to be carried out efficiently and without danger for maintenance perso nnel, you should comply with the following instructions.

Notes on maintenance

Warning!

Maintenance tasks may be carried out only by authorized and qualified specialist personnel, and only with the plant in a switched off and depressurised condition.

Note:

In order to ensure perfect maintenance and reliable operation w e recommend that you conclude a maintenance contract (For telephone number, see page 9).

Maintenance and repair of the dryer

When exchange or replacement parts are ordered, always state the dryer type and the build no. of the dryer. These data are found on the type plate attached to the control cabinet door.

 Carry out all maintenance work only when the plant has been shut down and

depressurised!

 Bolt connections must be undone with care! Note ram pressure values!

Otherwise emerging media may cause perso nal injury.

 Do not modify the factory settings of the control system in any way without

prior consultatio n with the manufacturer.

 Never carry out welding work on a vessel or modify the same in any way!

 Following maintenance work, always check all flange and bolt co nnections

for leakage and secure seating.

 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.

 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.

HDK350_EN_01_2005-05-10 45

Regular maintenance intervals

Note:

If a vessel has been depressurised, e.g. after completion of the expansion phase, and the pressure remains above 0 bar, the vessel is pressurised by w hat is known as ram pressure. T his might be due to

 blockage at the muffler(s),

 contamination of the dust sieves,

 spent drying agent.

To prevent such malfunctions, regularly serv ice the dryer as described below .

The table provides an overview of the maintenance work to be carried out. The individual tasks are described in the following pages.

Maintenance interval

Component Maintenance task to be carried out

Complete dryer Carry out visual and function checks. ▲ 47

Vessel pressure gauge Check dam pressure. For a dam pressure

exceeding 0.3 bar:

– Check muffler.

– Check dust sieve.

– Check drying agent.

Upstream and downstream filters

Pressure reducer Check pressure settings; adjust , if necessary.

Upstream and downstream filters

Muffler Renew.

Dew point sensor (with optional dew point sensing-control

Check valves

Dust sieves, drying agent Renew.

Check differential pressure on the upstream and downstream filters.

Replace all filter elements.

Must be calibrated.

Clean, replace, if necessary.

daily

weekly

12 months

24 months

48 months

▲ 48

▲ 52

z 50

see page

Codes: ▲ Check. z Renew.

When carrying out any maintenance work, comply with the following safety instructions:

46 HDK350_EN_01_2005-05-10

Danger!

There is a very considerable risk of personal injury, when carrying out work on the activated and pressurised dryer.

Before commencing any maintenance tasks always shut down the dryer as described on page 43, Depressurising and shutting down the dryer!

Warning against electrical voltage!

Only qualified specialist personnel may carry out w ork on the electrical system!

Daily maintenance tasks

Maintenance and repair of the dryer

Carry out visual and function check on the complete dryer

► Check dryer for external damage or unusual noise generation.

► Duly eliminate any defects found.

If message SEr. is displayed, a routine service must be completed: ► Contact the service department of the manufacturer.

Clean dryer

► Remove any loose dust by means of a dry cloth, and, if required, also by

means of a moist and well wrung cloth.

► Clean the surfaces with a moist well wrung cloth.

Check dam pressure

If, following depressurisatio n of a vessel, e.g. after the expansion phase, the overpressure has not decreased to 0 bar, then there is a residual pressure, designated as dam pressure, in the vessel.

► Check for dam pressure: if the dryer functions correctly, the respective

pressure gauge indicates 0 bar. T hen there is no dam pressure.

If the dam pressure is greater than 0.3 bar:

► Depressurise the dryer and shut it down (see page 43).

Dam pressure can be caused by:

 a blocked muffler,

 a blocked dust sieve or

 drying agent which is too old.

The respective necessary maintenance measures are described in the following sections.

HDK350_EN_01_2005-05-10 47

Weekly maintenance tasks

Check differential pressure on the filters

► Check the differential pressure on the pressure gauge of the filter.

The differential pressure should be 0.6-0.8 bar max. If the differential pressure exceeds 0.6-0.8 bar, we recommend that you replace the filter element (see page 48). T he filter elements must be replaced in any case every year.

Check pressure settings at the pressure reducer

► At the manometer (1), check pressure

settings of the pressure reducer.

The pressure should be set to 8 bar.

► If the pressure is set to a value above or

below 8 bar, turn the thumbscrew (2) to adjust the pressure reducer settings.

Pressure reducer with manometer

Maintenance work to be completed every 12 months

Renew filter elements on the filters

The filter elements must be replaced every 12 months.

► Depressurise dryer and take out of service (see page 43).

► Remove the bottom section of the filter

housing (see figure).

► Replace filter element.

► Refit bottom section of the filter

housing: first screw on very tightly, and then unscrew by a quarter turn.

► Dispose of used filter element in

accordance with the applicable regulatio ns.

► Restart dryer (see page 44). Check

the all filters for leaks.

Open filter

48 HDK350_EN_01_2005-05-10

Renew mufflers

The dryer is equipped with mufflers. If a muffler becomes blocked, a dam pressure is generated which in extreme cases may cause the muffler to burst.

Hazard caused by blocked muffler!

Blocked mufflers can cause a dangerous overpressure to build up which may cause the mufflers to burst. Flying fragments may cause personal injury and damage to property.

Therefore, the mufflers must be replaced every 12 months and after each change of desiccant.

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

Always wear eye and ear protection, therefore, when you are in the vicinity of the dryer!

Maintenance and repair of the dryer

eyes or skin.

Renew muffler

► Depressurise the dryer and shut it down (see page 43).

► Unscrew muffler as shown in the

opposite figure.

► Replace muffler and secure it.

Undo muffler

► Restart dryer (see page 44).

HDK350_EN_01_2005-05-10 49

Maintenance work to be completed every 12 months

Recalibration of dewpoint sensor (optional)

In order to ensure accurate dewpoint measuring, we recommend recalibrating the dewpoint sensor at least every 12 months. The recalibration must be carried out by the manufacturer. This period depends however on the actual application and might thus be extended accordingly.

Dewpoint sensor (1)

Warning!

The dew point sensor is a sensitive measuring dev ice. It can be damaged if subjected to forceful vibrations or shocks. Therefore, please handle the dew point sensor w ith great care at all times.

For calibration, the pressure dewpoint sensor must be dismantled. In order to limit the impact on the dryer operation to a minimum, we recommend that you contact the manufacturer well in advance (for contact details, see page 9) and order a new dewpoint sensor. Upon receipt of your old pressure dewpoint sensor, we will issue a credit note.

After receipt of the new pressure dewpoint sensor, replace the sensor as follows:

► Hold the box of the dewpoint sensor ready.

► Release pressure from dryer and shut down the unit (see page 43).

Installing / dismantling pressure dewpoint sensor

50 HDK350_EN_01_2005-05-10

Maintenance and repair of the dryer

► Loosen the screw at the adapter (1) and disconnect signal cable with the

adapter and seal.

► Remove dewpoint sensor from the sensor cell (3) by turning the nut (2).

► Take the new dewpoint sensor (2) from the box, remove the protective caps

(4, 5) and screw it into the sensor chamber (3).

► Place seal onto sealing face; connect adapter (1) and secure it by tightening

the screw.

► If no other maintenance work is to be carried out: Restart the dryer (see

page 44).

Note:

For posting, the dewpoint sensor must be equipped w ith protective caps and placed in a solid box.

► Place the protective caps (4, 5) onto the old dewpoint sensor and pack it

properly in the box.

► Send the old dewpoint sensor to the manufacturer.

Clean or replace check valves

Check valves are wear parts and should be cleaned, or replaced, every 12 mo nt hs.

► Release pressure from dryer and shut down the unit (see page 43).

► Remove check valves from the pipe bridge by opening the threaded joints.

Observe direction of rotation for upper (1) and lower (2) pipe bridge (see figures below).

Dismantling of check valves

► Disassemble check valves and clean all parts.

► Worn or damaged check valves must be replaced.

► Remount the check valve in the pipe bridge.

► If no other maintenance work is to be carried out: Restart dryer (see page

44). Check co nnection for tightness.

HDK350_EN_01_2005-05-10 51

Maintenance work to be completed every 48 months

To complete the following maintenance tasks, yo u must dismantle the pipe bridges and the vessels. We therefore recommend that you carry out these tasks together.

Note:

In accordance with national regulations, a pressure vessel inspection may be prescribed to be carried out at regular intervals by an independent supervisory office.

For an inspection of the pressure vessels, the drying agent must be removed as described as follows.

When inspecting the pressure vessels, it is recommended to check the condition of all fittings such as e.g. sieve bottoms and dust sieves, including gaskets. If necessary, these fittings must be cleaned or renew ed.

In the event of comprehensive maintenance or repair tasks, contact the manufacturer (see page 9).

Renew drying agent

The service life of the drying agent is usually approx. 3 to 5 years. However, in favourable installation conditions, the change of drying agent may be carried out at a substantially later date (for notes on the installation site, see also page 24). The change interval depends very significantly from the degree of contamination in the compressed air (or the quality of the compressed air upstream filters). Oil, dust, and dirt particles cover the drying agent surface and reduce its effective surface, in part quite irreversibly.

If in doubt, have a sample of your drying agent assessed by specialists. Send a sample of approx. 200 g to the manufacturer (for address, see page 9).

Note:

The vessels are equipped with dust sieves that hold back drying agent dust particles. If these dust sieves are blocked, back pressure is built up, which might affect the proper functioning of the dryer.

We therefore recommend cleaning, or replacing, the dust sieves each time the drying agent is replaced.

Comply with the following safety notes when changi ng the drying agent:

52 HDK350_EN_01_2005-05-10

Maintenance and repair of the dryer

Wear eye protection and dust mask due to increased dust generation!

When emptying the drying agent, increased dust generation may occur.

In order to avoid any eye irritations, w ear protective goggles!

In order to avoid any dust inhalation, w ear dust mask!

Risk of skidding!

If drying agent has been spilt on the floor, there is a risk of skidding caused by the drying agent beads. Therefore, spilt drying agent must always be taken up immediately.

Remove used drying agent

► Depressurise dryer and take out of service (see page 43).

► Place a suitable collecting vessel underneath the unit.

► Disconnect the control block from the upstream filter (1).

► Loosen the connection between the lower pipe bridge and the vessels (2).

► Disconnect the solenoid valve block (3).

Dismantling of the lower pipe bridge

► Remove the dust sieves from the vessels.

► Clean dust sieves with compressed air or a wire brush. If necessary, replace

the dust sieves.

► Drain drying agent into the collecting vessel. Remove all residue from the

vessels, using an industrial vacuum cleaner.

► Insert cleaned or new dust sieves.

► Reconnect all pipelines and cables.

HDK350_EN_01_2005-05-10 53

Maintenance work to be completed every 48 months

Warning!

If the dryer is not used within specifications, the drying agent can be contaminated with pollutants. Always take this into account for the environmentally safe disposal of the drying agent. The waste code numbers of the drying agent can be obtained from the manufacturer (see page 9).

► Dispose of the used drying agent in accordance with all applicable

regulatio ns.

Fill with new drying agent

Risk of falls!

The dryer must not be misused as a climbing aid! The components have not been designed for such loads and could fracture.

Only use approved climbing aids when filling the vessels.

► Loosen connection at the pressure plate (1).

► Loosen connection at the pressure reducer (2).

► Disconnect the upper pipe bridge from the vessels (3).

Dismantling of upper pipe bridge

► Remove the dust sieves from the vessels.

► Clean dust siev es with compressed air or a wire brush. If necessary, replace

the dust sieves.

► Fill the several drying agents in as separate layers (according to the technical

data in the appendix).

► If necessary, use a funnel. Take special note of the next step:

► Provide for a high bulk density in the vessel.

54 HDK350_EN_01_2005-05-10

Maintenance and repair of the dryer

Note:

To achieve an optimum bulk density, we recommend using a "snowstorm" filling pipe available from the manufacturer.

► Otherwise use a rubber hammer to tap regularly against the vessel wall

during filling or use a rod to distribute and compact the drying agent through the vessel opening.

► Repeat the process on the seco nd vessel.

► Insert cleaned or new dust sieves.

► Reconnect all pipelines.

► Restart dryer (see page 44). C heck that the connection is leak tight.

► Complete two dryer cycles, the shut down the unit.

► Replace muffler as described on page 49.

HDK350_EN_01_2005-05-10 55

Summary of faults

Identify and eliminate faults

The following table provides information on what designatory abbreviations are to be used for the various components. These designations are also found in the technical documentation.

Used abbreviation Component

B1/B2 Vessel

PDI Differential pressure gauge

PI Pressure gauge

V1, V2

V3, V4, V5, V6, V10, V11

V7, V8 Expa nsio n va lve

Summary of faults

There are different fault types. In the case of most electrical faults (e. g. short circuit, defective fuse etc.) the mai n valves close. In the case of some process faults, the dryer will continue to operate for some time. Faults o n the dryer become noticeable e.g. due to unusual noises and dam pressures.

The following table shows who is allowed to remedy a fault: the owner's specialist personnel or the manufacturer's service engineer.

Table of possible faults

Certain faults must be due to valves that are not properly opened/closed. For measures to be taken i n such cases, please refer to the bottom of the table.

Main valves

Check valves

Pressure build-up valve

56 HDK350_EN_01_2005-05-10

Fault Possible cause Remedy

Dewpoint is not reached

Operating pressure too low Increase operating pressure

Excessive differential pressure at upstream filter

Compressed air volume flow too high Reduce compressed air volume flow.

Inlet temperature of compressed air too high

Condensate trap (optional) at the upstream filter is not working properly Drying agent contaminated or out of date

Control board defective Check fuses (switchbox, supply line);

Insufficient regeneration gas Check function of valve V7/V8 and

Check differential pressure at the upstream filter; replace filter element, if necessary.

Reduce inlet temperature of compressed air or install preliminary compressed air cooler.

Check condensate trap (optional); clean or replace, if necessary. Inspect upstream filter for contamination; replace filter element, if necessary. Inspect drying agent for contamination; replace, if necessary.

replace board, if necessary.

muffler; replace filter element of muffler, if necessary.

Identify and eliminate faults

Specialised

personnel

Service technician

Pressure in vessel too low

Backpressure during regeneration too high

No pressure build-up

Excessive compressed air consumption

Dryer fails to switch over

Excessive differential pressure at upstream filter

Muffler contaminated Check muffler for contamination; clean

Valve V7/V8 does not open properly see *

Dust filters blocked Compressed pressure system

upstream from the dryer is not pressurised

Valve V1/V2 or V9 does not open properly.

Condensate trap (optional) at the upstream filter is not working properly Valve V7/V8 does not open properly see *

Compressor is switched off Check compressor synchronisation.

Power supply interrupted, cable broken.

Valve V1/V2 does not open properly see *

Error in control programme Restart programme. z Control board defective Check fuses (switchbox, supply line);

Check differential pressure at the upstream filter; replace filter element, if necessary.

or replace, if necessary.

Clean or replace dust filters.. Check whether the compressed

pressure system upstream from the dryer is pressurised. Eliminate any faults in the compressed air system.

see *

Check condensate trap (optional); clean or replace, if necessary.

Reconnect the unit to the power supply.

replace board, if necessary.

HDK350_EN_01_2005-05-10 57

Summary of faults

Fault Possible cause Remedy

No expansion in chamber

Valve V7/V8 does not open properly see *

Specialised

personnel

Service technician

Valve V7/V8 does not close properlyDryer is continuously

bled

Dryer is bled excessively Valves V1/V2, V3, V4, V5, V6 do not

* Valve fails to open or close properly

Valve V1/V2 does not close properly

close properly

Check supply voltage.

Check whether coil is properly mounted.

Inspect valve for contamination; clean or replace, if necessary.

Check voltage at cables, contacts and coils; replace, if necessary.

With dewpoint-sensing control (optional)

Fault code Description of fault Possible cause Remedy

+20

999

sens

–999

Upper measuring range limit exceeded

Dewpoint sensor defective

Sensor not powered, or cable or sensor defective

Drying capacity exceeded. Error in programme. Restart programme. z

Sensor defective or irreversibly contaminated. Sensor, sensor cable or sensor adapter defective.

See instructions for commissioning. If the drying agent is wet, replace it.

Replace sensor.

Visual inspection; check power supply (24 V to terminals 4 and 6). Replace defective component(s).

see *

Specialised

personnel

Service technician

58 HDK350_EN_01_2005-05-10

Index

Abbreviation

components.......................................................... 56

Address, manufacturer............................................... 9

Adsorption, explanation............................................ 19

air ejection

hazard .................................................................. 13

Auxiliary heater.........................................................21

Bolt connections....................................................... 28

Build no. ................................................................... 45

Changing cycle mode

explanation........................................................... 39

Check valves

maintenance interval............................................ 46

Components............................................................. 56

Compressed air.................................................. 14, 19

Compressor synchronisation.................................... 21

option ...................................................................21

Compressor synchronisation line

installation ............................................................ 30

Connection lines....................................................... 29

Connector

electrical............................................................... 30

Consumables ............................................................. 9

Control

dewpoint-sensing ................................................. 21

Control cabinet......................................................... 18

Control system

pneumatic............................................................. 21

signalling contacts................................................ 21

Conversions ............................................................. 14

Cycle

fixed...................................................................... 21

variable................................................................. 21

Cycle mode change

explanation........................................................... 39

Index

Design

paint compatible ................................................... 22

Dew point sensor

maintenance interval ............................................ 46

Dewpoint-sensing control.........................................21

Digital display

explanation...........................................................35

Documentation, technical.........................................62

Dryer

maintenance interval ............................................ 46

drying agent

service life ............................................................52

Drying agent

charging................................................................21

maintenance interval ............................................ 46

storage .................................................................27

drying agents

handling................................................................ 14

dust generation...................................................14, 53

dust mask.................................................................14

Dust sieves

maintenance interval ............................................ 46

Ear protection.....................................................16, 36

electrical voltage, hazard..........................................13

Example for installation ............................................ 29

Expansion, explanation ............................................ 19

Fabrication no.............................................................5

Factory settings........................................................16

Filter elements

maintenance interval ............................................ 46

Fixed cycle................................................................21

Flow diagram............................................................ 70

Fluid group ...............................................................64

hazard areas.............................................................13

Humidity....................................................................64

Danger notes

Danger! ................................................................11

Danger warning, maintenance ................................. 47

Date of manufacture................................................... 5

Dehumidification

explanation........................................................... 19

HDK350_EN_01_2005-05-10 59

Installation area........................................................24

Installation example..................................................29

Installation site, requirements...................................24

LEDs

explanation........................................................... 34

Liability..................................................................... 10

lifting gear .......................................................... 15, 23

Limits, permissible.............................................. 16, 37

Machine damage, prevention................................... 12

Machine passport....................................................... 5

Mains voltage........................................................... 64

Maintenance

check valves ........................................................ 51

dam pressure....................................................... 47

differential pressure ............................................. 48

drying agent ......................................................... 52

Muffler.................................................................. 49

replacement of filter element................................ 48

sensor .................................................................. 50

Maintenance contract............................................... 45

Maintenance, danger warnings................................ 47

Manometer

pressure reducer.................................................. 36

Media

aggressive............................................................ 10

Misuse...................................................................... 14

Misuse, suspected ................................................... 14

Modifications on the dryer........................................ 14

Muffler

maintenance interval............................................ 46

Noise level ............................................................... 64

Notes

safe, efficient handling ......................................... 11

On/Off switch

explanation........................................................... 33

On/Off-Switch........................................................... 18

Operating instructions.............................................. 10

safe place............................................................. 11

safety notes.......................................................... 12

target group.......................................................... 11

Operating overpressure

minimum, maximum............................................. 64

Operating pressure .................................................. 38

permissible............................................................. 5

safety device........................................................ 28

Operating signalling contact

installation............................................................ 31

Operation signalling

contact.................................................................. 21

Original replacement parts................................. 17, 45

Outside installation................................................... 20

overpressure, hazard ............................................... 13

Packaging ................................................................23

Parameters

preset ................................................................... 10

Personnel qualification........................... 10, 12, 14, 47

Power supply

interrupted............................................................ 42

Pressure build-up

explanation........................................................... 20

sudden .................................................................37

Pressure reducer

maintenance interval............................................ 46

pressure vessel.................................................. 16, 45

Programme

sequence, steps................................................... 68

Protection class........................................................ 64

Regeneration, explanation ....................................... 19

Regulations for accident prevention......................... 23

Repairs, telephone number........................................ 9

Replacement parts............................................. 17, 45

Restart

pressure conditions.............................................. 44

Safety notes ............................................................. 12

general ................................................................. 14

operating phases.................................................. 15

Warning!............................................................... 11

Safety valves...................................................... 28, 32

Service, telephone number ........................................ 9

Shutdown valves...................................................... 29

Shutting down ..........................................................43

emergency............................................................43

Signalling lines

external.................................................................30

skid risk .................................................................... 13

Skidding risk

charging drying agent........................................... 53

Snowstorm filling pipe

charging drying agent........................................... 55

Specialist personnel........................................... 11, 28

Stand profiles ........................................................... 25

Standard equipment................................................. 10

Start-up device......................................................... 20

Start-up, requirements..............................................32

Storage room

60 HDK350_EN_01_2005-05-10

Index

requirements ........................................................ 26

Supply cable, electrical ............................................29

Supply lines.............................................................. 28

Switching off............................................................. 42

symbols, explanation................................................ 13

Target group ............................................................ 11

Temperature, ambient

minimum, maximum ............................................. 64

Transport damage.................................................... 23

Type plate ................................................................12

Use, intended........................................................... 14

Use, safe .................................................................. 11

Variable cycle...........................................................21

Vessel pressure gauge

maintenance interval ............................................ 46

vibration dampers..................................................... 26

Visual inspection.......................................................47

Voltage

electrical ............................................................... 29

Warranty................................................................... 10

Waste code numbers................................................17

HDK350_EN_01_2005-05-10 61

Annex with technical documentation

This annex comprises the following information and technical documentation:

 Technical data

 Replacement and wear parts list

 Logic control diagram

 Flow diagram

 Dimensional drawing

62 HDK350_EN_01_2005-05-10

Technical data

Annex with technical documentation

Capacity* Length Height Width Weight

Type

HDK 50/100 50 635 1155 400 100

HDK 80/100 80 635 1205 400 110

HDK 140/100 115 685 1220 400 110

HDK 250/100 240 740 1350 450 144

HDK 400/100 370 810 1410 450 200

HDK 600/100 580 870 1710 450 275

HDK 50/250 80 635 1155 400 110

HDK 80/250 140 635 1205 400 115

HDK 140/250 205 685 1220 400 132

HDK 250/250 420 740 1350 450 195

HDK 400/250 655 810 1410 450 245

m3/h mm mm mm kg

100 bar

250 bar

HDK 600/250 1020 870 1710 450 375

350 bar

HDK 50/350 130 635 1155 400 110

HDK 80/350 180 635 1205 400 115

HDK 140/350 255 685 1220 400 145

HDK 350/350 520 740 1350 450 225

HDK 400/350 367 810 1410 450 280

HDK 600/350 1280 870 1710 450 415

* relative to 1 bar (abs.) and 20 °C (68 °F) at 7 bar operating pressure and a feed temperature of 35 °C (95 °F).

HDK350_EN_01_2005-05-10 63

Technical data

Type HDK 50/100–600/350

Fluid group (acc. to 97/23/EC) 2

max. operating overpressure 100/250/350 bar

min. operating overpressure 10 bar

min. ambient temperature ≥+1 °C (33,8 ° F)

max. ambient temperature ≤+50 °C (122 ° F)

Rel. humidity ≤ 60 %

Noise level : +3 dB (A) relative to free field measurement, 1 m surr.

65 – 95 dB(A)

field

Mains voltage (see type plate)

Protection class IP 65

Filling quantity Drying agent per vessel

Top MS512 80 %

Bottom Ecosorb IIa 20 %

64 HDK350_EN_01_2005-05-10

Annex with technical documentation

Replacement and wear parts list

Items see dimensio n drawing.

Type HDK 100/250/350 bar

Item Designation 50/... 80/... 140/... 250/...

1 Vessel

5 Ecosorb IIa 675010025502

6 Molecular screen MS512 675010051201

7 Dust sieve 799020002003 799020003202

2 Upstream filter G3XP G5XP G7XP G9XP

2.3 Filter element 1050 XP 211010010508 — — —

2.3 Filter element 1070 XP — 211010010706 — —

2.3 Filter element 1140 XP — — 211010011411 —

2.3 Filterelement 2010 XP — — — 211010020110

Manual drain EV05 631120008001

Condensate trap (optional)

Trap 2/250 Trap 2/400

Differential pressure gauge

HZD80, 420 bar 104000008000

104100000016 104100000018

3 Downstream filter G3V G5V G7V G9V

3.3 Filter element 1050 V 211040010500 — — —

3.3 Filter element 1070 V — 211040010700 — —

3.3 Filter element 1140 V — — 211040011410 —

3.3 Filter element 2010 V — — — 211040020110

Manual drain EV05 631120008001

Differential pressure gauge

HZD80, 420 bar 104000008000

12 Control system

95 Dew point sensor (option) 655000010001

17 Pressure reducer

21 Muffler, complete

657500010010

672200001501

HDK350_EN_01_2005-05-10 65

Replacement and wear parts list

Type HDK 100/250/350 bar

Item Designation 50/... 80/... 140/... 250/...

Valves

9 Pressure build up valve, Expansion

valves, DN 6

10 Main valve DN 12 641400023001

13 Check valve ø 16 620300001629

14 Check valve ø 8 620300000825

15 Check valve ø 8 620300000840

641400023001

Manometer

18 Vessel manometer

50-250/100 bar 50-250/250 bar 50-250/350 bar

650200032221 650200032521 650200032621

66 HDK350_EN_01_2005-05-10

Annex with technical documentation

Type HDK 100/250/350 bar

Item Designation 400/... 600/...

1 Vessel

5 Ecosorb IIa 675010025502

6 Molecular screen MS512 675010051201

7 Dust sieve 799020003202

2 Upstream filter G7XP G11XP

2.3 Filter element 1140 XP 211010011411 —

2.3 Filter element 2020 XP — 211010020208

Manual drain EV05 631120008001

Condensate trap (optional)

Trap 2/250 Trap 2/400

Differential pressure gauge

HZD80, 420 bar 104000008000

104100000016 104100000018

3 Downstream filter G7V G11V

3.3 Filter element 1140 V 211040011410 —

3.3 Filter element 2020 V — 211040020200

Manual drain EV05 631120008001

Differential pressure gauge

HZD80, 420 bar 104000008000

12 Control system

95 Dew point sensor (option) 655000010001

17 Pressure reducer

21 Muffler, complete

657500010010

672200001501

Valves

9 Pressure build up valve,

Expansion valves, DN 6

10 Main valve DN 12 641400023002

13 Check valve ø 20 620300002010

14 Check valve ø 8 620300000825

15 Check valve ø 8 620300000840

641400023001

Manometer

18 Vessel manometer

400-600/100 bar 400-600/250 bar 400-600/350 bar

650200032222 650200032521 650200032622

HDK350_EN_01_2005-05-10 67

Logic control diagram

Adsorption in B1 and regeneration in B2

68 HDK350_EN_01_2005-05-10

Regeneration in B1 and adsorption in B2

Annex with technical documentation

HDK350_EN_01_2005-05-10 69

Flow diagram

Item Designation Item Designation

1 Vessel 12 Control cabinet

2 Upstream filter 13, 14, 15 Check valves

3 Downstream filter 17 Pressure reducer

7 Dust sieve 18 Vessel manometer

9 Pressure build up valve 21 Muffler

10 Main valve

70 HDK350_EN_01_2005-05-10

Dimensional drawing

Annex with technical documentation

Dimensions (mm)

Connection G 1/2 “ G 1/2 “ G 1/2 “ G 1/2 “ G 3/4 “ G 3/4 “

Type HDK 100/250/350 bar

50/... 80/... 140/... 250/... 400/... 600/...

A 640 640 640 775 845 905 B 1155 1205 1220 1350 1410 1710

C 400 400 400 450 450 450

HDK350_EN_01_2005-05-10 71

Dimensional drawing

Items

Option

72 HDK350_EN_01_2005-05-10

ZANDER HDK 400/100, HDK 80/100, HDK 600/100, HDK 50/250, HDK 80/250 Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

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