D-Series¹
Contents
1. 2 e DEW POINT PLUG T CI Figure 3 Figure 4 Page 13 8 SERVICE C INSTRUCTIONS REPLACING OR RE CALIBRATING THE DEW POINT SENSOR ES MODELS ONLY Every 6 000 hrs or 12 months 4 Remove the dew point sensor assembly by sliding the sensor bracket upwards from the dryer shroud to expose the sensor block fixing screws See Figure 4 amp 5 5 Remove the 2x fixing screws from the assembly to detach the sensor from the bracket See Figure 5 Figure 6 6 Unscrew the dew point sensor from the sensor block and replace it with the new or re calibrated sensor See Figure 7 7 Re attach the dew point sensor to the sensor bracket using the 2x fixing screws and replace the dew point sensor assembly by sliding the bracket back into the dryer shroud 8 Replace the dew point sensor plug and plug screw 9 Replace the controller cover 10 Replace the dryer top cover When service C is complete reset the dryer refer to page 15 url DEW POINT SENSOR gt F BRACKET DEW POINT SENSOR gt DEW POINT SENSOR BLOCK fe 2x SCREWS Figure 5 DEW POINT SENSOR gt DEW POINT SENSOR gt BLOCK Figure 7 Page 14 9 RE SETTING THE DRYER CONTROLLER 1 Ensure the dryer is on and running see dryer start up procedure on page 17 2 Remove the2. EXHAUST VALVES DRYER LEGS Page 5 3 RECOMMENDED TOOLS The following tools will be required to service the dryer SOCKETS 5 5mm 7mm and 17mm ALLEN KEY SOCKETS 3mm 5mm and 8mm SCREWDRIVER TORQUE WRENCH 0 10NM ALLEN KEY 4mm SPANNER 17mm SPANNER 19mm 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 de pressurised Also ensure the product is switched off and or isolated from the mains electrical power PROCEDURES e Close the inlet and outlet valves The dryer might still be pressurised In order to de pressurise 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 6 5 SERVICE A INSTRUCTIONS REPLACING DESICCANT CARTRIDGES NDL 010 to NDL 050 Every 12 000 hrs or 24 months Please refer to figure 1 1 Ensure the dryer is shut down and fully depressurised before attempting any maintenance work See page 6 1 Remove the 4x M5 dome head screws to release the top cover and lift from assembly 2 Remove the 2x M6 cap head screws as shown from the outlet top manifold
3. MU A ai f f SAL 2 GASKET DESICCANT CARTRIDGE Figure 1 Figure 2 Insert desiccant cartridge and rotate until it sits correctly within the dryer column then push downwards until you hear a click CO 5 1 SERVICE A INSTRUCTIONS REPLACING O RINGS AND NITRILE BALL WITHIN THE OUTLET MANIFOLD Every 12 000 hrs or 24 months Please refer to figure 4 1 Ensure the dryer is shut down and fully depressurised before attempting any maintenance work See page 6 2 Remove the 4x M5 dome head screws to release the top cover and lift from assembly 4x M5 DOME HEAD 3 Remove the 2x M6 x 50 and the 8x M6 x SCREWS 25 cap head screws as shown from the outlet PEE l x top manifold to release it from the assembly SCREWS 4 Remove the 4x M4 cap head screws and washers to remove the purge block from the 2x M6 x 50 CAP HEAD outlet top manifold SCREWS 5 Remove and discard the 3x O rings sat on the underside of the purge block See Figure 3 6 Insert the new O rings from the service kit provided and replace into the grooves on the underside of the purge block See Figure 3 7 Remove and discard the nitrile ball from the outlet manifold RINGS SS 8 Replace the nitrile ball from the service kit into the 3 way valve orifice 8x 6 x 25 CAP _
4. 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 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 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 19 13 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 kal PRINT SIGN NOTES Page 20 21 Page 22 pelne 11330 Vanstory Drive Huntersville NC 28078 Telephone 704 897 2182 Internet www n psi com E mail support n psi com
5. washers and release the exhaust valve bodies and diaphragms from the inlet manifold See Figures 4 amp 5 lt gt Sey M4 SPRING WASHERS M4 SOCKET HEAD SCREWS l Figure 4 i E 5 Replace the 2x diaphragms and 2x exhaust valve bodies from the service kit 6 Insert the 8x M4 socket head screws and 8x washers and tighten to a torque setting of 3Nm NOTE Refer to the page 16 and follow the correct tightening sequence When service B is complete reset the dryer refer to page 15 VALVE DIAPHRAGM EXHAUST VALVE BODY Figure 5 Page 12 7 SERVICE C INSTRUCTIONS REPLACING OR RE CALIBRATING THE DEW POINT SENSOR ES MODELS ONLY Every 6 000 hrs or 12 months 1 Ensure the dryer is shut down and fully depressurised before attempting any maintenance work See page 6 2 Remove the 4x M5 screws to release 2 the top cover and lift from assembly See Figure 1 Ka LAF AL a SAS Figure 1 3 Remove the controller top over by removing the 4x screws See Figure 2 4 Remove the plug screw and detach the plug from the sensor See Figure 3 amp 4
6. HEAD SCREWS 5 9 Sit the purge block back on top of the outlet manifold and replace the 4x M4 cap head screws at torque setting of 3Nm NITRILE BALL 10 Sit the manifold assembly back on top of gt 0 the dryer column and replace the 2x M6 x 50 and 8x M6 x 25 cap head screws at a torque setting of 5Nm OUTLET TOP MANIFOLD NOTE Refer to the page 16 and follow the correct tightening sequences CAKET SS Figure 3 Figure 4 Page 8 5 2 SERVICE A INSTRUCTIONS REPLACING O RINGS NITRILE BALL AND GASKET SEAL WITHIN THE INLET MANIFOLD Every 12 000 hrs or 24 months Please refer to figure 5 1 Ensure the dryer is shut down and fully depressurised before attempting any maintenance work See page 6 2 Unclip the solenoid plug from the valve stem See Figure 2 amp 3 on page 11 3 Remove the 8x M4 cap head screws and washers from the valve block to release the exhaust valves 4 Remove the 2x M6 cap head screws to release the valve block from the inlet manifold 5 Remove and discard the 3x O rings on the underside of the valve block 6 Insert the new O rings from the service kit and replace into the grooves on the underside of the valve block See Figure 6 on page 10 7 Remove the 8x M6 cap head screws from the inlet manifold to release it from the dryer 8 Remove and discard the nitrile ball from the inlet
7. manifold 9 Replace the nitrile ball from the service kit and replace into the 3 way valve orifice See Figure 7 on page 10 10 Remove and discard the gasket seal from the underside of the inlet manifold 11 Insert the new gasket seal from the service kit into the gasket seal grooves on the underside of the inlet manifold 0 0 0 0 GASKET SEAL INLET MANIFOLD Soa B B NITRILE BALL gt ta gt D 8x M6 CAP HEAD SCREWS _ gt 1 E VALVE BLOCK _ gt 8mm ELBOW PUSH IN FITTING 2x M6 CAP HEAD SCREWS 4x M4 CAP HEAD SCREWS SOLENOID PLUGS Figure 5 Page 9 5 2 SERVICE A INSTRUCTIONS REPLACING O RINGS NITRILE BALL AND GASKET SEAL WITHIN THE INLET MANIFOLD Every 12 000 hrs or 24 months Please refer to figure 4 12 To reassemble place the valve block on top of the inlet manifold ensuring the profiles of the screw holes line up correctly 13 Sit the exhaust valves on top of the valve block ensuring the profiles of the screw holes line up correctly 14 Insert 4x M4 cap head screws through both exhaust valves and tighten at a torque setting of 3Nm Refer to the page 16 and follow the correct tightening sequence 15 Place the manifold assembly back
8. onto the dryer and insert the 2x M6 cap head screws through the valve block tightening at a torque setting of 5Nm 16 Insert the 8x M6 cap head screws into the inlet manifold and tighten to a torque setting of 5Nm Refer to the page 16 and follow the correct tightening sequence Figure 7 17 To finish the assembly reattach the solenoid plugs to the exhaust valve When service A is complete reset the dryer refer to page 15 Page 10 6 SERVICE B INSTRUCTIONS REPLACING EXHAUST VALVES NDL 010 TO NDL 050 Every 36 000 hrs or 60 months VALVE SOLENOID SOLENOID PLUG SOLENOID PLUG SCREWS pa Figure 1 LILI 1 Ensure the dryer is shut down and L L i A fully depressurised before attempting IT T TIL 1ETI a PS any maintenance work See page 6 M LUA 2 Remove the valve solenoid plugs by Je Sies removing the plug screws and pulling l a j the plug free from the solenoid See Figure 1 RETAINING CLIPS z ULII 3 Remove the valve solenoids bv unclipping the retaining clips and sliding the solenoids down and free from the valve stems See Figures 2 8 3 Figure 3 Page 11 6 SERVICE B INSTRUCTIONS REPLACING EXHAUST VALVES NDL 010 TO NDL 050 Every 36 000 hrs or 60 months 4 Remove the 8x M4 socket head screws and the 8x M4 spring
9. 3 Eliminate the cause of contamination Replace cartridges do not re use 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 Poor dew point performance 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 cyclic operation 9 Insufficient inlet pressure 9 Inlet pressure min 4 barg If not adjust inlet pressure Failure of dryer to settings cycle 10 Failure to de pressurise when 10 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 11 Outlet flow stops 11 Check inlet air supply 12 Failure to initialise dryer 12 Switch off and restart dryer Ensure dryer is pressurised Constant before powering dryer to allow dryer to initialise before depressurisation commencing operation 13 Erratic air flow from exhaust 13 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
10. 3 Remove the 8x M6 cap head screws to remove the outlet top manifold from the dryer column 4 Remove the gasket seal 5 Remove the 2x cartridges using the handle to withdraw them from the column 6 Check and clean the outlet top manifold and dryer column as required paying particular attention to the gasket sealing areas 7 Remove the new cartridges and gasket seal from the service kit provided 8 Insert the new gasket seal into the gasket groove on the underside of the outlet top manifold ensuring it is fully retained 9 Insert the 2x new desiccant cartridges and rotate until they sit correctly into place Then press down until they stop and the cartridge is below the top surface of the dryer column See Figure s 2 amp 4 10 Replace the outlet top manifold and secure with the 10x M6 cap head screws tightening to a torque setting of 5Nm Refer to the page 16 and follow the correct tightening sequence 11 The seal between the dryer column and outlet top manifold should be checked for leaks prior to fitting the top cover and operating the dryer 12 Replace the dryer top cover and secure with the 4x M5 screws These screws should be hand tightened or tightened at a torque setting of less than 1Nm Page 7 J aa E ccr AS 4x M5 DOME AT HEAD SCREWS 2 M6 _ gt HEAD SCREWS 8 X M6 CAP ejj HEAD SCREWS OUTLET MANIFOLD ey
11. 4x M5 to release the top cover See Figure 1 o 3 Place a magnet on the marked area in Figures 1 amp 2 re set area for 8 10 seconds until the controller resets See Figures 1 amp 2 4 Once re set the hours run counter will show 00000 Re set Area Figure 2 Top view with cover off Page 15 10 MANIFOLD TIGHTENING SEQUENCES NDL 010 TO NDL 050 Inlet bottom manifold Page 16 10 DRYER START UP PROCEDURE Do not allow the dryer to flow air unless powered up switched on and cycling Resulting effect A could be cartridge contamination requiring replacement cartridges e 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 e Connect the IEC power supply underneath the dryer using the retaining clip to secure in position e Open the inlet and outlet valves Turn on the dryer using the switch located underneath the front of dryer body e 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 17 11 OTHER DRYER CHECKS amp NON SERVICEABLE ITEMS DAILY CHECKS Visual and functio
12. Exhaust Valve Replacement 9 Service Instructions ES Models Only 10 Re setting the Dryer Controller 11 Manifold Tightening Sequences 12 Dryer Start up Procedure 13 Other Dryer Checks amp Non Serviceable Items 14 Troubleshooting 15 Service Record amp Notes Page 3 Page s 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 Required Service Kits Dryer Model Page 4 2 PRODUCT ASSEMBLY MODELS NDL 010 TO NDL 050 TOP COVER OUTLET TOP MANIFOLD ASSEMBLY L ae a a ee L UT TEL mA Paran AN ET aaa H DESICCANT CARTRIDGES CONTROLLER COVER TOP DRYER COLUMN CONTROLLER SILENCER DRYER SHROUD ASSEMBLY 0 So Ch 0 O zD CONTROLLER COVER BOTTOM gt W j VALVE INLET BOTTOM f 7 227 BLOCK MANIFOLD ASSEMBLY
13. f ISBN D Seriesi HEATLESS COMPRESSED AIR DRVER NDL 010 NDL 020 6 NDL 030 NDL 040 NDL 050 JE 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 010 050 Service Manual Models NDL 010 020 030 040 050 Including ES Option Document number n psi D1 010 050 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 Read this document carefully before attempting to service the dryer General Safety For your own safety when carrying out maintenance
14. nal 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 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 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 a product service MAINTENANCE GUIDELINES e Maintenance operations only to be conducted when the system has been shut down and fully depressurised e All connections must be undone with care paying particular attention to the areas that become pressurised e Do not modify or adjust the control settings e Only certified n psl 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 Page 18 12 TROUBLESHOOTING Insufficient inlet pressure 1 Inlet pressure min 4 bar 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
15. 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 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 should be made For further information please contact us at support n psi com Page 2 MANUFACTURERS DETAILS nano purification solutions 11330 Vanstory Drive Huntersville 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 010 NDL 050 5 Service A Instructions Replacing O rings Nitrile Ball and Gasket Seal 8 Service Instructions
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