17-110-0120 - D2 Series Dryer User Manual.indd
Contents
1. Dryer Top Cover Controller Display Unit Front Shroud Air Outlet Air Inlet NDL 060 090 Air Inlet NDL 100 130 ral Dryer Column Silencer Box 17 110 0120 Page 9 nano purification solutions 8 System Layout 8 1 Typical installation NDL 060 090 OUTLET 0 1u m OR BETTER COALESCING FILTER INLET AIR QUALITY AIR QUALITY TO 50 8573 122001 PARTICLES CLASS 1 OR BETTER OWL CLASS 2 OR BETTER WATER CLASS 6 OR BETTER IF SPECIFIED INLET AIR QUALITY CLASS WATER 15 ACHIEVED NO INLET FILTRATION REQUIRED SEPARATOR OUTLET AIR QUALITY HO EXTERNAL DUST FILTER REQUIRED DUST FILTER TO 50 8573 17 CLASS 2 BUILT INTO THE DRYER INLET nm In l l Il 1 ii il i k imi INLET FILTRATION 8 2 Typical installation NDL 100 130 OUTLET 0 1 um OR BETTER COALESCING FILTER INLET AIR QUALITY AIR QUALITY TO 50 8573 122001 PARTICLES CLASS 1 OR BETTER L CLASS 2 OR BETTER WATER CLASS 6 OR BETTER IF SPECIFIED INLET AIR QUALITY CLASS WATER 15 ACHIEVED NO INLET FILTRATION REQUIRED SEPARATOR OUTLETAIR QUALITY HO EXTERNAL DUST FILTER REQUIRED DUST FILTER TO EO 8573 1 CLASS 2 BUILT INTO THE DRYER INLET 0 i mut A 1 M l i Fi d INLET FILTRATION IMPORTANT It is essential that the system into which the dryer is installed is fitted with a pressure limiting relief device This device should be be tween the compressor and the dryer The devi2. 101010 PURIFICATION SOLUTIONS PURIFICATION SOLUTIONS EM 0103 HEATLESS DESICCANT AIR DRYER 17 110 0120 nano purification solutions Contents 1 General information 1 1 Document introduction 1 2 Support and Manufacturers details O PS e cU ie n 10 11 12 13 Page 2 1 3 Warranty Guidelines 1 4 Packaging General safety 2 1 Intended Use 2 2 Personnel 2 3 Safe Handling Technical Description Technical Specification Product Contents Product Dimensions Equipment Overview System Layout 8 1 Typical Installation NDL 060 090 8 2 Typical Installation NDL 100 130 8 3 Site Location Electrical Installation Dryer Operation 10 1 Dryer remote control if required 10 2 Dryer Start up 10 3 Monitoring dryer performance Energy saving option 10 4 Shutdown procedure Maintenance 11 1 Maintenance guidelines 11 2 Cleaning 11 3 Daily checks Servicing 12 1 Guidelines 12 2 Procedures 12 3 Additional Kits Troubleshooting Page G CC 00 O 10 10 11 12 13 13 14 15 15 16 16 16 16 17 17 18 18 19 17 110 0120 1 General Information This manual is copyrighted all rights reserved It may not in whole or in part be copied photocopied reproduced translated or reduced to any electronic medium or machine readable form without prior consent in writing from nano purification solutions It may not be distributed through the internet
3. PURITY AIR DRYER HOURS RUN 0000 COLUMN A ONLINE DISPLAY PANEL HOURS RUN DEWPOINT COLUMN ONLINE OPERATION LED ILLUMINATED WHEN IN OPERATION 12 4 Shutdown Procedure e Close the inlet and outlet valves ensure the dryer is isolated from the compressed air supply source A The dryer will still be pressurized In order to depressurize the dryer e Cycle the dryer at least twice to ensure the dryer exhausts and is completely depressurized e When fully depressurized the clicking of the exhaust valves will be heard but no air exhausted e When the dryer is fully depressurized isolate from the power supply 17 110 0120 Page 15 nano purification solutions 11 Maintenance Maintenance operations should only be carried out by authorized suitably trained personnel 11 1 Maintenance Guidelines e Maintenance operations only to be conducted when the system has been shut down and fully depressurized All connections must be undone with care paying particular attention to the areas that become pressurized not modify or adjust the control settings e Only certified npsi approved replacement parts to be used e Always check all connections for leakage and secure seating e Ensure all loose parts are removed or secured to the dryer before operation 11 2 Cleaning Clean the equipment with a damp cloth only and avoid excessive moisture around any electrical sockets If re
4. all relevant A national safety regulations must be complied with relating to pressurized and electrical systems 2 1 Intended use of the Product The dryer is exclusively intended for the treatment of compressed air which is free from bulk water oil and solid matter constituents The product should be located within a building and protected The dryer must be operated only in accordance with the data on the rating plate Any operations that do not comply with those stated on the product rating label will render the warranty void This product is only designed to operate at pressures of between 58 232 psig 4 16 barg is not suitable for pressures in excess of 232 psig 16 barg IMPORTANT It is essential that the system into which the dryer is installed is fitted with a pressure limiting relief device This device should be be tween the compressor and the dryer The device must be set to prevent the maximum working pressure of 232 psig 16 barg from being exceeded No modifications must be made to the product Any modifications may reduce the operational safety of the product and invalidate the manufacturer s warranty This could potentially result in damage to the product and serious personal injury 2 2 Personnel Only authorized competent and trained personnel are permitted to work on this product This user guide is intended solely for such personnel and is to be used only as a reference it should not be used to
5. Hz Input Current 1 3 0 8A 115 23 OVAL Controller Back Plate Es ib v ib el 382881 du E O 2500 7 ITI J 12 17 110 0120 10 Dryer Operation 10 1 Dryer Remote Control if required To set up for remote control eco mode Remove the link between pi fab pins 1 and 4 2 in the electrical connector plug A zero volt a switching signal from the remote control needs V US to be connected between pins 1 and 4 4 e When the connection is made the dryer will operate normally If the connection is broken i e the dryer has been remotely switched off the dryer will also stop cycling and go into standby mode displaying STANDBY on the display 6 Pin Electrical Connector Configuration COMPRESSOR Under no circumstances should external voltage current be applied to pins 1 and 4 damage to the controller will occur negating the warranty General Alarm Output e Pins 2 amp 30n the electrical connector provide a zero volt alarm output for customer control panel indication These pins are connected to a relay within the controller which will close when service dewpoint optional and pressure alarm optional conditions arise 17 110 0120 Page 13 nano purification solutio
6. control settings e Only certified npsi approved replacement parts to be used e Always check all connections sealing faces for cleanliness and secure seating prior to assembly e Ensure all components are refitted to the product before operation e Ensure the dryer is left operating in a safe working condition after completion of maintenance 17 110 0120 Page 17 nano purification solutions 12 2 Service Procedures A dryer service should take place every 2 years or 12 000 hours of operation whichever occurs first Service kits are available which include replacement desiccant cartridges seals and valves Please contact the manufacturer or distributor for service kit information e Service A 12 000 hours or every 2 years service Replace desiccant cartridges 060 F 130 F Heplace all gaskets and seals removed while servicing the dryer included in relevant service kits e Service B 24 000 hours or every 4 years service Service as above exhaust valves EVK130 Replace check valves CVK130 Replace ICF valves IVFO90 IVF 130 Replace Pilot valves PVK130 NDL 100 130 Only e Service C 6 000 hours or every 1 year service Dewpoint sensor calibration service NSK 0130 ES MODELS ONLY SERVICE A MODEL Without Pre tilter Element SERVICE SERVICE C With Pre filter Element NDK 060 NDL 060 NDK 060 F IVK090 EVK130 CVK130 NSK 0130 NDK 070 NDL 070 NEU
7. or computer bulletin board systems without prior consent from nano purification solutions 2012 nano purification solutions Product Series 2 Desiccant Air Dryer Document number 17 110 0120 Issue 002 1 1 Document Introduction This manual provides factory prescribed installation and maintenance procedures for a nano purification solutions compressed air dryer The procedures illustrated in this document are only to be performed by authorized personnel For further information regarding the procedures outlined in this document contact nano purification solutions before proceeding Head this document carefully before attempting to install or operate the dryer This document should be permanently available at the dryer installation site and be kept in an easily accessible place alongside the dryer 1 2 Support Manufacturers Details nano purification solutions nano porous solutions limited 11330 Vanstory Drive Dukesway Team Valley Trading Estate Huntersville NC 28078 Gateshead Tyne and Wear USA United Kingdom NE11 OPZ Telephone 704 897 2182 Telephone 44 0 191 497 7700 Fax 704 897 2183 Fax 44 0 191 497 7709 Internet WWW n psi com Internet WWW n psl com E mail support n psi com E mail info n psl com Annotations CAUTIONS indicate any situation or operation that may result in potential damage to the product injury to the user or render the product unsafe sma NOTES highlight importan
8. replace conventional training 2 3 Safe Handling Please ensure the relevant safe engineering practices and handling procedures are employed when handling installing and operating this product Ensure that the equipment is depressurized and electically isolated prior to carrying out any of the scheduled maintenance instructions specified within this user guide A suitable lifting aid must be used to minimize the risk of physical injury or damage to the product In no circumstances must a damaged product be used in operation Using damaged products can lead to irreparable functional faults or cause serious physical harm 17 110 0120 Page 5 nano purification solutions 3 Technical Description The n psi dryer uses the pressure swing adsorption principle of drying compressed air utilizing two identical columns each containing a hygroscopic desiccant bed Inlet filtration removes water oil aerosols and particles Inlet filtration supplied separately Wet air enters the dryer through the inlet valve and is directed into one of the columns Each column contains a densely filled desiccant cartridge Air then passes through the desiccant cartridge where any remaining moisture is adsorbed Simultaneously a small amount of dry filtered air is counter flowed down through the other desiccant cartridge and exhausted to atmosphere removing the moisture and regenerating the desiccant bed The dryer controller periodically switche
9. IVK090 EVK130 CVK130 NSK 0130 NDK 080 080 MM EP IVK090 EVK130 CVK130 NSK 0130 NDK 090 090 EINE IVK090 EVK130 CVK130 NSK 0130 NDL 100 100 IVK130 EVK130 CVK130 PVK130 NSK 0130 NDK 100 F ii i 110 110 IVK130 EVK130 CVK130 PVK130 NSK 0130 NDK 110 F ki M 120 120 IVK130 EVK130 CVK130 PVK130 NSK 0130 NDK 120 F ki ii ki NDL 130 NDK 130 IVK130 EVK130 CVK130 PVK130 NSK 0130 NDK 130 F ki 12 3 Additional Kits Wall Mounting kit NMK 130 2 x Additional brackets supplied to support the dryer when wall mounting ES Upgrade Kit Converts a standard dryer to an Energy saving model Please refer to the Series 2 Dryer service guide for instruction regarding carrying out a service Page 18 17 110 0120 13 Troubleshooting 1 Insufficient inlet pressure 1 Inlet pressure min 58 psig 4 barg If not adjust inlet presure settings 2 Electrical Fault 2 Ensure the power is on and the dryer control panel is illuminated check the dryer is cycling correctly 3 Moist or contaminated 3 Eliminate the cause of contamination Replace desiccant Poor dew point desiccant cartridges do not re use performance 4 high air consumption 4 Ensure the performance of the dryer matches the required system air consumption 5 Excessive inlet air temperature 5 Check against technical specification 6 Insufficient p
10. ce must be set to prevent the maximum working pressure of 232 psig 16 barg from being exceeded Page 10 17 110 0120 8 3 Site Location When selecting an installation site for the dryer ensure the following conditions are met e Installation site should be located indoors on a flat surface protected from the weather and other harmful conditions e he ambient temperature must not drop below 33 8 1 or exceed 122 F 50 C e The installation site should be level and able to support the weight of the product e Ensure sufficient soace around the product to allow access for operation and maintenance e Take into account the noise generated by the dryer exhausting while in use when considering location Do not attempt to wall mount dryer without wall bracket kit Note Floor and wall mounting bolts not supplied Additional wall mounting brackets supplied separately 17 110 0120 Page 11 nano purification solutions 9 Electrical Installation Mains Power Connection Supplied with 3 meters of cable If the cable needs to be replaced Disconnect from mains supply Unscrew the 4 x M5 cap head screws in order to remove the dryer top cover Slide 2 x door latch pins together to allow the dryer front shroud to swing open on the hinge This will expose the controller back plate and power connection as shown in figure 8 A Electrical Power Requirements Supply 88 VAC 264 VAC 47 63
11. n Check the plug and fuse located on top of the controller back plate inside the dryer front shroud Additional Items Use of non authorized components Untrained unauthorized maintenance installation personnel used Increase in air consumption without relation to the flow capacity of the dryer Purging the dryer with cleaning agents that could damage the components or the desiccant Covers removed or loose during operation Failure to carry out a service when indicated by the dryer service light Do not allow the dryer to flow air unless powered up switched on and cycling Resulting effect could be desiccant contamination requiring replacement desiccant cartridges 17 110 0120 Page 19 101010 PURIFICATION SOLUTIONS nano purification solutions 11330 Vanstory Drive Huntersville NC 28078 USA Telephone 704 897 2182 Fax 704 897 2183 Internet www n psi com E mail support n psi com
12. ns 10 2 Dryer Start up e Ensure the dryer is securely hardwired into the power source Do not allow the dryer to flow air unless powered up switched on and cycling Resulting effect could be desiccant contamination requiring replacement desiccant cartridges e Connect all pipe work e Ensure the inlet operating pressure parameters are between 58 232 psig 4 16 barg e Ensure the inlet air temperature is between 35 F 122 F 1 5 C 50 C e Slowly open the inlet valve and allow dryer to pressurize e Turn on the power to the dryer e Open the outlet valve e The dryer will display its status and commence normal operation When the dryer is powered up the display will show initializing dryer for approximately 20 seconds ensuring the dryer is in equilibrium state before commencing operation Page 14 17 110 0120 10 3 Monitoring dryer performance Energy saving option e The dew point is displayed on the control panel When the dew point displayed is better than 54 4 F 48 C PDP the dryer will switch into economy mode and stop cycling When the dew point degrades to 43 6 F 427C the dryer will restart cycling ensuring the dew point is maintained at or better than 40 F 40 C e the dryer fails to achieve dew point falls below 22 F 307C the alarm output will be indicated on the front screen and the remote alarm output will activate SERVICE LED ILLUMINATED WHEN SERVICE REQUIRED ULTRA HIGH
13. quired a mild detergent may be used however do not use abrasives or solvents as they may cause damage 11 3 Daily Checks Visual and functional check of the dryer should be carried out daily e Check the dryer for any external damage Assess and eliminate any defects found e Ifthe red service light appears the dryer must be serviced Contact the service department and request a dryer service kit e Remove any loose dust or dirt from the dryer clean all surfaces that appear to have attracted unwanted contaminants e Check the dewpoint sensor display if installed If the dewpoint is not maintained at lt 22 F the reading on the display will alternate with dewpoint alarm every 5 seconds The no volt alarm will also activate Contact the service department and request a product service Page 16 17 110 0120 12 Servicing Maintenance operations should only be carried out by authorized competent and suitably trained personnel 12 1 Servicing Guidelines e Maintenance operations only to be conducted when the system has been shut down fully depressurized and isolated completely from the compressed air and electrical supply e Ensure the system is in a safe condition for maintenance to be carried out on e Dismantle and assemble with care paving particular attention to the areas that become pressurized e All gaskets removed during maintenance operations must be replaced with new gaskets e not modify or adjust the
14. s columns after top end repressurization ensuring a continuous supply of dry air at constant pressure The dryer can also be controlled using a Zero Volt signal from the compressor This energy saving mode senses when the compressor is switched off and stops the dryer operation until the compressor restarts The dry air passes out through the final particulate filter lt 1micron ISO8573 1 Class 2 4 Technical Specification Specification Class 2 Water 40 F 40 C PDP Class 2 Dirt 1um ISO 8573 2 2001 Qualitv Classes Minimum working pressure 58 psig 4 barg Maximum working pressure 232 psig 16 bar Power Supply 100 240v AC 50 60Hz Minimum inlet temperature 34 7 F 1 5 C Maximum inlet temperature 122 F 50 C Ambient Temperature 34 122 F 1 50 C IP Rating IP54 NEMA 38W lt 80dB A Flow rate based on air inlet pressure of 100 psig 7 0 barg and temperature of 95 F 35 C For dryer performance at other inlet conditions or 100 F 70 C dewpoint requirements contact support n psi com All dryers should be proceeded by a coalescing filter regardless of oil or oil free applications a nano MO1 grade coalescing filter must be installed on the inlet to the dryer Page 6 17 110 0120 NZNO 5 Product Contents 1 Series 2 Compressed Air Dryer 2 Documentation o 1 x User Guide o 1 x Quick Start Guide 1 x Declaration of Conformity 3 Packaging 1 x Dryer support ba
15. se and box cover Figure 1 Contents Layout 17 110 0120 Page 7 nano purification solutions 6 Product Dimensions eu NDL 060 NDL 070 NDL 080 NDL 090 NDL 100 NDL 110 NDL 120 NDL 130 Page 8 72 91 115 153 183 229 306 Inlet Flow Rate 59 35 67 5 734 440 Connection L c INS INS INS mm mm 30 17 12 295 88 40 30 17 12 88 734 440 295 40 36 17 12 119 914 440 295 54 1 914 440 295 54 Inlet amp outlet 43 17 12 141 1089 440 295 64 49 17 12 172 1239 440 295 78 59 17 12 209 1489 440 295 95 72 1839 17 440 12 295 262 119 17 110 0120 7 Equipment Overview
16. t sections of information where particular care and attention should be paid 17 110 0120 Page 3 nano purification solutions 1 3 Warranty Guidelines All products are supplied with a 5 year manufacturer s warranty from the date of purchase when purchased with an ES Energy Saving system and installed and maintained in accordance with the manufacturers guidelines Only genuine service parts should be used and no modifications made For further information please contact nano purification solutions 1 4 Packaging All products are securely packaged in a specifically designed wooden packing box The dryer will be held in a horizontal position by wooden struts using straps to secure the product to the box base The box top cover can be removed by removing the 4 fixing screws and lifting off in one piece Damage to Packaging e Check immediately to establish whether damage has occurred to the external packaging and if the damage extends to the product inside e lf there is damage to a product contact the relevant supplier immediately In nocircumstances must a damaged product be used in operation Using damaged products can lead to irreparable functional faults or cause serious physical harm The support packing box permits longitudinal stacking however the central section of the packing box should not be considered load bearing Page 4 17 110 0120 2 General safety For your own safety when carrying out work on this product
17. urge air 6 Purge incorrectly adjusted Consult service personnel to adjust settings Factory pre set 7 Exhaust silencer blocked 7 Consult service personnel 8 Controller not functioning 8 Ensure the controller is powered check the on screen correctly column status to ensure it is powering the solenoid valves during normal cyclic operation 9 Controller not illuminated 9 Inlet pressure min 58 psig 4 barg If not adjust inlet presure settings Failure of dryer to T cycle 10 Insufficient inlet pressure 10 Check power to unit amp fuse 11 Failure to de pressurize when 11 Solenoid valve not functioning correctly if there is power cycling to the coil replace valve A correctly working valve outputs an audible click when it energizes 12 Outlet flow stops 12 Check inlet air supply 13 Failure to initialize dryer 13 Switch off and restart dryer Ensure dryer is pressurized Constant before powering dryer to allow dryer to initialize before depressurization commencing operation 14 Erratic air flow from exhaust 14 Faulty or damaged valve service required Reference to known issue Opening the inlet valve too quickly Valve should be opened slowly allowing the pressure to build up gradually Inlet outlet head pipe Diameter too small Pipe work unsupported Inlet pipe work from low point in system allowing bulk water to collect and enter the dryer Electrical controller Incorrect fuse fitted or fuse blow
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