6. service `b` instructions
Contents
1. DESICCANT CARTRIDGES DRYER COLUMN CONTROLLER DRYER SHROUD BOTTOM MANIFOLD ASSEMBLY SILENCER i BOX 10 0 IA EXHAUST VALVE Q INLET VALVE Page 5 2 1 PRODUCT ASSEMBLY MODELS NDL 100 TO NDL 130 COVER OUTLET TOP Wis s MANIFOLD ASSEMBLY 2 DESICCANT CARTRIDGES DRYER DRYER lt coLumN DRYER SHROUD INLET BOTTOM MANIFOLD ens ASSEMBLY a ENCES EXHAUST VALVE VALVE BLOCK DRYER LEGS INLET BLOCK Page 6 3 RECOMMENDED TOOLS The following tools will be required to service the dryer TERMINAL SCREW DRIVER ALLEN KEY 3mm ALLEN KEY 4mm ALLEN KEY 6mm ALLEN KEY 8mm TORQUE WRENCH 8 60NM TORQUE SOCKET 6mm TORQUE SOCKET 8mm 20mm PIN SPANNER BEARING PULLER 4 DRYER SHUT DOWN PROCEDURE Before performing any maintenance or service operations on this product ensure the product is isolated from the compressed air supply and fully depre2. the inlet control valves See Figure 1 Day VALVE BLOCK 3 Remove the 6x M8 socket head cap screws and 6x washers g from the inlet block to release both the valve block and inlet block from the bottom manifold and from each other See Figure 2 2x O RINGS 4 Remove and discard the 2x O rings from the inlet block and INLET BLOCK replace them from the service kit See Figure 2 6x M8 HEAD CAP SCREWS Figure 2 Page 12 6 1 SERVICE B INSTRUCTIONS REPLACING INLET VALVES NDL 100 TO NDL 130 ONLY Every 24 000 hrs or 4 Years VALVE RIDGE DETAILS FLOW DIRECTION ARROW INLET VALVES Figure 4 SPILL PORT NOTE The spill ports are 1 5mm holes within the valve block Figure 5 Figure 3 5 Remove the inlet valves from the valve block by pushing them out See Figure 3 6 Discard the old inlet valves 7 Insert the new inlet valves into the valve block ensuring the flow direction arrow is pointing as shown and the valve ridge details cover the spill port See Figures 4 amp 5 8 Replace the 6x M8 socket head cap screws and 6x washers and tighten at a torque setting of 20Nm See Figure 2 9 Reattach the solenoid plugs and the screw to complete the assembly See Figure 1 When service A is complete reset the dryer refer to page 18 Page 13 6 2 SERVICE B INSTRUCTIONS REPLACING INLET CONTROL AND EXHAUST VALVES NDL 10
3. 1 olO D Series HEATLESS COMPRESSED AIR DRYER NDL 060 30 NDL 070 T NDL 080 1 NDL 090 NDL 100 NDL 110 NDL 120 NDL 130 B 30S Sas 0 0s i CE CE MAINTENANCE amp SERVICE MANUAL www n psi com GENERAL INFORMATION Copyright 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 or computer bulletin board systems without prior consent from nano purification solutions 2012 nano purification solutions Heatless Desiccant Air Dryer D Series1 060 130 Service Manual Models NDL 060 070 080 090 100 110 120 130 Including ES Model Document number n psi D1 060 130 OM US 01 Issue 001 Document Introduction This manual provides manufacturers prescribed procedures for the maintenance and service procedures for a nano purification solutions compressed air dryer The procedures illustrated in this document are only to be performed by authorised personnel For further information regarding the procedures outlined in this document contact nano purification solutions before proceeding
4. VALVE STEM Page 10 Figure 2 Figure 3 6 SERVICE B INSTRUCTIONS REPLACING INLET CONTROL AND EXHAUST VALVES NDL 060 TO NDL 090 Every 24 000 hrs or 4 Years 11 118 VALVE DIAPHRAGM VALVE SP i s M5 SOCKET HEAD SCREWS N gt Figure 4 4 Remove the 16x M5 socket head screws and the 16x spring washers and discard them Remove and discard the exhaust valve bodies from the bottom manifold See Figure 4 5 Remove and discard the 4x diaphragms from the bottom manifold See Figure 4 6 Replace the 4x diaphragms and 4x exhaust valves from the service kit and replace the 16x M5 socket head screws and spring washers from the service kit and tighten to a torque setting of 6Nm See Figure 4 NOTE Refer to the page 20 and follow the correct tightening sequence 7 Reattach the 4x solenoid coils and 4x solenoid plugs See Figure 1 When service B is complete reset the dryer refer to page 18 Page 11 6 1 SERVICE B INSTRUCTIONS REPLACING INLET VALVES NDL 100 TO NDL 130 ONLY Every 24 000 hrs or 4 Years INLET CONTROL VALVES J SCREW lt A Figure 1 1 Ensure the dryer is shut down and fully depressurised before attempting any maintenance work See page 7 2 Remove the screws and BOTTOM release the solenoid plugs from MANIFOLD
5. Page 20 10 DRYER START UP PROCEDURE Do not allow the dryer to flow air unless powered up switched on and cycling Resulting effect could be cartridge contamination requiring replacement cartridges Connect to mains power Connect all pipe work Ensure the inlet operating pressure parameters are between 4 16 barg Ensure the inlet air temperature is between 1 5 C 50 C Open the inlet and outlet valves Turn on electrical power to the dryer The dryer will display its status and commence normal operation When the dryer is powered up the display will show initialising dryer for approximately 20 seconds ensuring the dryer is in equilibrium state before commencing operation Page 21 11 OTHER DRYER CHECKS amp NON SERVICEABLE ITEMS 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 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 dirt from the dryer clean all surfaces that appear to have attracted unwanted contaminants Check the dewpoint sensor display where applicable If the dew point is not achieved the dewpoint 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
6. manifold See Figure 2 4 Replace the 2x diaphragms and 2x exhaust valves from the service gt kit 5 Replace the 8x M5 socket head screws and spring washers and tighten at a torque setting of 6Nm Reattach the 2x solenoid valves and 2x plugs See Figure 2 3 8 VALVE DIAPHRAGM EXHAUST VALVE NOTE Refer to the page 20 M5 SOCKET HEAD i i SCREWS and follow the correct tightening sequence Figure 2 Page 15 6 3 SERVICE B INSTRUCTIONS REPLACING OUTLET VALVES NDL 060 TO NDL 130 Every 24 000 hrs or 4 Years 8x M12 T 02 00 HEAD 5 5 MANIFOLD DU BUSH FITTING B 6 ex CIRCLIP e Figure 1 Please refer to figure 1 1 Ensure the dryer is shutdown and fully depressurised before attempting any maintenance work See page 7 2 Remove the 4x M5 screws to remove the dryer top cover 3 Remove the 8x M12 cap head screws and 8x washers to remove the top manifold from the dryer column 4 Using a pair of circlip pliers remove each circlip 5 Remove the valve seat using a pair of bearing pullers and then remove the valve 6 Remove the DU bush and replace it from the service kit 7 Replace
7. a product service MAINTENANCE GUIDELINES e Maintenance operations only to be conducted when the system has been shut down and fully depressurised All connections must be undone with care paying particular attention to the areas that become pressurised Do not modify or adjust the control settings Only certified n psl approved replacement parts to be used Always check all connections for leakage and secure seating Ensure all loose parts are removed or secured to the dryer before operation Page 22 13 TROUBLESHOOTING Insufficient inlet pressure 1 Inlet pressure min 4 barg If not adjust inlet pressure settings Electrical Fault 2 Ensure the power is on and the dryer front panel is illuminated check the dryer is cycling correctly Moist or contaminated desiccant 3 Eliminate the cause of contamination Replace cartridges Poor dew point do not re use performance Too high air consumption 4 Ensure the performance of the dryer matches the required system air consumption Excessive inlet air temperature 5 Check against technical specification Insufficient purge air 6 Purge incorrectly adjusted Consult service personnel to adjust settings Factory pre set Exhaust silencer blocked 7 Consult service personnel Controller not functioning correctly 8 Ensure the controller is powered check the on screen column status to ensure it is powering the solenoid valves during normal cycli
8. new gasket seal placing it into the gasket groove in the top manifold ensuring it is fully retained 10 Ensure both handles are folded flat 11 Replace the top manifold and secure with the 8x M12 cap head screws tightening to a torque setting of 80Nm NOTE Refer to the page 20 and follow the correct tightening sequence 12 The seal between the dryer column and top manifold should be checked for leaks prior to fitting the top cover and operating the dryer 13 Replace the dryer top cover and secure with the 4x M5 screws These screws should be hand tightened only or tightened to a torque setting of less than 1Nm If service A is complete reset the dryer refer to page 19 Page 8 22 T tt 4x M5 SCREWS COVER 8x M12 35 HEAD SCREWS TOP MANIFOLD Tr e B 0 GASKET SEAL Figure 1 0 Figure 2 Care must be taken when removing the lt desiccant cartridges not to damage the top face of the dryer column This is a sealing face Sealing face shown as the shaded area 5 1 SERVICE A INSTRUCTIONS REPLACING DESICCANT CARTRIDGES NDL 130 ONLY Every 12 000 hrs or 24 months Please refer to Service A instruction
9. the valve and valve seat from the service guide and re insert the circlip 8 Place the manifold back on top of the dryer column and insert the 8x M12 cap head screws and 8x washers and tighten at a torque setting of 80Nm NOTE Refer to the page 20 and follow the correct tightening sequence 9 Replace the top cover and insert the 4x M5 screws to secure it in place Page 16 7 SERVICE C INSTRUCTIONS ES MODELS ONLY Every 6 000 hrs or 12 months M4 SCREWS CONTROLLER CHASSIS PLATE Figure 2 Figure 1 1 SENSOR 1 Ensure the dryer is shutdown and PLUG fully depressurised before attempting any SCREW maintenance work See page 7 SENSOR 2 Remove the 4x M5 screws to remove PLUG the top cover See Figure 1 3 Release the catches located at the top and bottom of the shroud to open it See Figure s 1 amp 2 4 Remove the screw from the sensor plug and detach it from the dew point sensor assembly See Figure 3 amp 4 Figure 3 Page 17 7 SERVICE C INSTRUCTIONS ES MODELS ONLY Every 6 000 hrs or 12 months Figure 5 i Figure 7 Figure 6 5 Remove the 2x fixing screws from the controller chassis plate and releas
10. 0 TO NDL 130 Every 24 000 hrs or 4 Years VALVE GASKET INLET Figure 1 1 Remove the 6x fixing screws and 6x washers to release the inlet control valves from the valve block See Figure 1 2 Discard the valve gaskets and inlet control valves and replace from the service pack 3 Replace the 6x fixing screws and 6x washers 4 Replace the solenoid plug and screw See Figure 1 on page 12 When service B is complete reset the dryer refer to page 18 Page 14 6 2 SERVICE B INSTRUCTIONS REPLACING INLET CONTROL AND EXHAUST VALVES NDL 100 TO NDL 130 Every 24 000 hrs or 4 Years SILENCER BOX SILENCER lll HH FIXING 0 NUT S S SS RU O RING Figure 1 1 dryer is shutdown and fully depressurised before attempting any maintenance work See page 7 2 Unscrew the silencer fixing nut using a 20mm pin spanner and remove the O ring to release the box from the assembly See Figure 1 3 Remove the 8x M5 socket head screws and the 8x spring washers and remove the exhaust valve bodies and diaphragms from the inlet bottom
11. NDL 120 5 1 Service A Instructions Cartridge Replacement NDL 130 only 6 Service B Instructions Inlet Control amp Exhaust Valve Replacement NDL 060 NDL 090 6 1 Service B Instructions Inlet Valve Replacement NDL 100 NDL 130 Page s 4 5 6 10 11 12 13 6 2 Service B Instructions Inlet Control amp Exhaust Valves Replacement NDL 100 TO NDL 130 14 15 6 3 Service B Instructions Outlet Valve Replacement NDL 060 TO NDL 130 7 Service C Instructions ES Models Only 8 Re setting the Dryer Controller 9 Manifold Tightening Sequences 10 Dryer Start up Procedure 11 Other Dryer Checks amp Non serviceable Items 12 Troubleshooting 13 Service Record amp Notes Page 3 20 21 22 23 24 25 1 SERVICE INTERVALS The following table details the recommended service intervals for this product and the service kits to be used Recommended Service Intervals Service Type 2 Years 4 Years 6 Years 8 Years 10 Years 12 Years 12 000 Hrs 24 000 Hrs 36 000 Hrs 48 000 Hrs 60 000 Hrs 72 000 Hrs Additional For ES Models Only 1 2 3 4 5 6 7 8 9 10 11 12 Year Years Years Years Years Years Years Years Years Years Years Years C Required Service Kits Dryer Model ae Ksa ae 4 2 PRODUCT ASSEMBLY MODELS NDL 060 TO NDL 090 TOP COVER INLET OUTLET TOP MANIFOLD ASSEMBLY
12. Read this document carefully before attempting to service the dryer General Safety For your own safety when carrying out maintenance work on the dryer all relevant national safety regulations must be complied with relating to pressurised and electrical systems Only authorised competent and trained personnel should maintain the dryer this user guide is intended solely for such personnel and is to be used only as a reference it should not be used to replace conventional training CAUTIONS indicate any situation or operation that may result in potential damage to the product injury to the user or render the product unsafe lt NOTES highlight important sections of information where particular care and attention should be paid Warranty Guidelines All dryers are supplied with a 5 year manufacturer s warranty from the date of purchase The dryer should be installed operated and maintained in accordance with the manufacturer s guidelines Only genuine service parts should be used and no modifications made For further information please contact us at support n psi com Page 2 MANUFACTURERS DETAILS nano purification solutions 11330 Vanstory Blvd Huntersville NC 28078 Telephone 704 897 2182 Internet www n psi com E mail support n psi com CONTENTS Title 1 Service Intervals 2 Product Assembly 3 Recommended Tools 4 Dryer Shutdown Procedure 5 Service A Instructions Cartridge Replacement NDL 060
13. c operation 9 Controller not illuminated 9 Check power to unit amp fuse T2A 250V located at Fig 8 A 10 Insufficient inlet pressure 10 Inlet pressure min 4 barg If not adjust inlet pressure settings 11 Failure to de pressurise 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 energises 12 Outlet flow stops 12 Check inlet air supply Failure of dryer to cycle 13 Failure to initialise dryer 13 Switch off and restart dryer Ensure dryer is pressurised before powering dryer to allow dryer to initialise before depressurisation commencing operation 14 Erratic air flow from exhaust 14 Faulty or damaged valve service required Constant 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 blown Check the plug and fuse located on top of the controller back plate inside the dryer front cover Additional Items Use of non authorised components Untrained unauthorised maintenance installation personnel used Increase in air consumption without relation to the flow capacity of the dryer Purging the d
14. e the dew point sensor assembly See Figure 5 amp 6 6 Unscrew the dew point sensor from the sensor block and replace with the new or re calibrated sensor See Figure 7 7 Reattach the new or re calibrated dew point sensor and sensor block assembly to the controller chassis plate using the 2x fixing screws 8 Replace the sensor plug and screw to complete the sensor assembly See Figure 3 amp 4 9 Close the shroud and ensure the latches are in position 10 Replace the top cover and insert the 4x M5 screws These screws should be hand tightened only See Figure 1 When service C is complete reset the dryer refer to page 19 DEW POINT SENSOR SENSOR BLOCK Page 18 8 RESETTING THE DRYER CONTROLLER Page 19 CONTROLLER RESET AREA 2 a SS Figure 1 1 Ensure the dryer is on and running see dryer start up procedure on page 18 2 Place a magnet over the controller reset area shown in Figure 1 for 8 10 seconds until the dryer re sets See Figure 1 3 Once re set the hours run counter will show 00000 NOTE Magnet not included in the service kit 9 MANIFOLD TIGHTENING SEQUENCES FOR MODELS NDL 060 TO NDL 130 19 03 8 9 5 O Og 4 2 Top manifold 19 83 4 2 Bottom manifold
15. ryer 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 Do not allow the dryer to flow air unless powered up switched on and cycling Resulting effect could be cartridge contamination requiring replacement cartridges Page 23 14 SERVICE RECORD amp NOTES The following table allows the customer to document the service history of the product and to make notes related to each service DRYER SERVICE RECORD PRODUCT CODE PRODUCT SERIAL NO SERVICE TYPE SERVICED BY A B C PADE PRINT SIGN NES Page 24 Page 25 pelne 11330 Vanstory Blvd Huntersville NC 28078 Telephone 704 897 2182 Internet www n psi com E mail support n psi com Page 26
16. s on page 8 of this service guide NOTE NDL 130 dryer has 2x cartridges per side See Figure 3 REPLACING DESICCANT CARTRIDGES 1 Lift handle and remove the upper cartridges from the dryer and discard them NOTE Ensure the upper cartridges have disconnected from the cartridge joining rings and the lower cartridges before attempting to lift from the dryer 2 Remove the lower cartridges from the dryer and discard 3 Identify upper and lower cartridges from the service kit 4 Insert joining ring into the head of the lower cartridge 5 Insert lower cartridges separatey into dryer 6 Insert upper cartridges separately into dryer 7 See page 8 for reassembling top manifold Page 9 DRYER CARTRIDGE UPPER CARTRIDGE JOINING RINGS DRYER CARTRIDGE LOWER Figure 3 6 SERVICE B INSTRUCTIONS REPLACING INLET CONTROL AND EXHAUST VALVES NDL 060 TO NDL 90 Every 24 000 hrs or 4 Years 1 Ensure the dryer is shutdown and fully depressurised before attempting any maintenance work See page 7 2 Detach each of the solenoid plugs from the solenoids by removing the 4x plug screws and releasing the plugs See Figure 1 SOLENOID PLUG PLUG SCREW Figure 1 RETAINING CLIP SOLENOIDS COILS 3 Remove the solenoid coils by unclipping and sliding the coils from the valve stems See Figure s 2 amp 3
17. ssurised Also ensure the product is switched off and or isolated from the mains power PROCEDURES Close the inlet and outlet valves The dryer might still be pressurised In order to depressurise the dryer ensure the dryer is isolated from the compressed air source Cycle the dryer twice to ensure the dryer exhausts is completely depressurised When fully depressurised the clicking of the exhaust valves will be heard but no air exhausted When the dryer is fully depressurised isolate from the power supply Page 7 5 SERVICE A INSTRUCTIONS REPLACING DESICCANT CARTRIDGES NDL 060 to NDL 120 Every 12 000 hrs or 24 months Please refer to figure 1 1 Ensure the dryer is shutdown and fully depressurised before attempting any maintenance work See page 7 2 Remove the 4x M5 screws as shown to remove the dryer top cover 3 Remove the 8x M12 cap head screws and 8x washers to remove the top manifold from the dryer column 4 Discard the gasket seal 5 Lift the wire handle and remove the cartridge from the dryer column See figure 2 6 Check and clean the top manifold and dryer column as required paying particular attention to the gasket sealing faces 7 Remove the new cartridges and gasket seal from the service kit provided 8 Insert 2x new desiccant cartridges and press them down until they stop and the cartridge is below the top surface of the dryer column 9 Insert the
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