Service Manual - Pure-Aire
Contents
1. contaminants and ensure proper operation Condensate automatic drains are recommended to remove water from the SFC for proper operation 1 The SFC unit has air IN and OUT connections with labels and or directional flow arrows cast right into the control element Orient the SFC unit in accordance with compressed air system flow 2 he SFC unit can be installed in any place The headers are capable of supporting the weight of the unit for either vertical or horizontal mounting Do Not support the unit from the flow control valves or the associated control piping Always use two wrenches when installing piping connections to prevent over torque stress and damage to connection when tightening 3 Install a 3 valve bypass around the SFC to allow routine maintenance and insure that compressed air will always be available for plant use A bypass can be supplied with the SFC unit as an option or can be field installed using full line size service valves As the primary design of the control valves are for precision control of positive flow conditions backpressure caused by having higher pressure on the downstream side of the SFC than the supply side should be avoided LEAK TEST Pressurize system and check the installation for leaks before starting A WARNING Air from system is not safe for human respiration breathing DISCLAIMER OF WARRANTY If this unit is used to produce breathing air OSHA 29 CFR 1910 134 specifications of the necess2. Controls valves are contaminated and or the valve internals SN EEN have Deen damaged over time 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 9 1 5 FLOW CONTROL VALVE PARTS LIST SFC 500 amp SFC 750 1 z O ke are N ugs Qoo gt D N E s Ce CA o Sese oy gt Page 10 System Flow Controller Operation Manual M SFC 10 2012 Pure Aire 1 5 FLOW CONTROL VALVE SERVICE DRAWING amp PARTS LIST SFC 500 amp SFC 750 laa Ls mw 35 etangan TI Us RmmecW T Sn TT D Sm ie Pee 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 11 2 FLOW CONTROL VALVE PARTS LIST SFC 1000 amp SFC 2000 1 4 Pilot Port lt 1 4 Gauge Port 79 e 13 s 2 a 4 SO O 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 12 2 FLOW CONTROL VALVE SERVICE DRAWING amp PARTS LIST SFC 1000 amp SFC 2000 d ak l d Es H L a pes OAI i 1 J JADMA AY ba A L e e DESCRIPTION DESCRIPTION Ce Toneriupcin In Vesp s forme sium EC INT TECTA Us wesa V MmP OOOO o eamm 0 oooO SO Pure Aii 800 274 3233 www pure aire net 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 13
3. TS Design CONC OE t IQ 4 Diagram 1 Compressed Air Recommended Installation Flow 1 cessere 5 Safety Warnings amp TT d TC 6 Hecening e Sa ee WE 7 PreSsurizalloni amp Slart UD PIOCeUUIG E 8 RR de Ee REN ee due RE TT E 9 Low Plant or Flow Control Pressure AAA 9 High Flow Control Discharge Pressure ss 9 Unstable Flow Control Discharge Pressure e llleeee ee Lieeeeen eiie nennen enean nnne anna nn nn nnns 9 1 5 Flow Control Valve Parts List SFC 500 amp SFC 750 1 c see enes eee ee eee rere e nenen n nene eee eee eee nnn nnns 10 1 5 Flow Control Valve Service Drawing amp Parts List SFC 500 amp SFC 750 11 2 Flow Control Valve Parts List SFC 1000 amp SFC 2000 55 nudo nd ad ns dd nane ENEE 12 2 Flow Control Valve Service Drawing amp Parts List SFC 1000 8 SFC 2000 13 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 3 DESIGN CONCEPT The Pure Aire System Flow Controller s SFC design consistently delivers 1 of pressure set point Most plant air systems have an ever changing fluctuation of demand and changes in plant air pressure Peak air demands will draw from the air system and tend to disrupt the air capacity The Pure Aire SFC wil
4. ary equipment and special precautions to make breathing air MUST be used or any warranties are VOID and manufacturer disclaims any liability whatsoever for loss personal injury or damage O 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 7 PRESSURIZATION amp START UP PROCEDURE This procedure is to be followed every day at start up Prior to start up check for unusual pressure drops and piping restrictions to the SFC flow controller air receiver and from the air OUT connection of the SFC to the main plant system Pressure operations and the air compressor system fluctuations may change dramatically after the SFC unit is put on line resulting in consequential events In most cases air compressor controls and set points may require adjustments During start up relief valves in the air receiver storage tank system may open Observe operation during start up e Open the 3 valve bypass around the system flow controller e Turn the ADJUSTMENT control valve to the full clockwise position this will open the SFC flow control valves The adjustment control valve will be mounted on the SFC or it can be mounted in the remote control panel if the remote control panel option is supplied purchased e While leaving the isolation valves open slowly close the bypass valve around the SFC e Turn the adjustment control valve counter clockwise slowly to dial in the desired discharge pressure Turn the SFC adjustment in small pr
5. cing To restart follow the PRESSURIZATION amp START UP PROCEDURE A WARNING ALWAYS REMOVE ALL PRESSURE AND DISCONNECT ALL POWER BEFORE SERVICING UNIT 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 8 TROUBLE SHOOTING GUIDE LOW PLANT OR SFC FLOW CONTROL PRESSURE REMEDY Verify the operations of all the air compressors in the system are operating correctly Make adjustments or repairs to the compressors The pneumatic control tubing is leaking or damaged Repair the leak Adjustment control valve is defective Replace the ACV and inspect all of the valves Check the control valves for contamination If Controls have stuck in the closed position necessary clean and perform annual service HIGH SFC FLOW CONTROL DISCHARGE PRESSURE REMEDY Bypass valve is open Make adjustments or repairs Adjustment control valve is defective Replace the ACV and inspect all of the valves Controls have stuck in the OPEN position Check the control valves for contamination If necessary clean and perform annual service UNSTABLE SFC FLOW CONTROL DISCHARGE PRESSURE REMEDY The inlet air pressure is within 2 to 4 psi of the discharge air pressure set point Make adjustments or repairs to the compressors The pneumatic control tubing is leaking or damaged This line should be bubble tight Repair the leak Adjustment control valve is defective Replace the ACV and inspect all of the valves
6. essure changes allowing the system to stabilize between adjustments Failure to adjust the SFC in this manner may result in a system pressure drawdown The AIR OUT gauge displays discharge pressure of the SFC unit Maximum inlet pressure is shown on the SFC nameplate Maximum regulating pressure is 5 psi below the lowest operating compressor inlet pressure NOTE If the instrument air or adjustment controls air pressure is disconnected the control valves will close OPTIONAL REMOTE CONTROL PANEL e Mount the control panel where most convenient for the operator The appropriately labeled connections are on the control panel Do not exceed 150 feet from the SFC header to the control panel Consult factory for greater distances e Pilot air tubing between the SFC piping header and the control panel is 14 OD and must be bubble tight See the general arrangement drawing for control panel pneumatic connections e LEAK TEST Pressurize system and check the installation for leaks before starting SHUTDOWN PROCEDURE ISOLATION amp DEPRESSURIZATION The following should be completed if the SFC is being shut down for a weekend shift e Slowly isolate the SFC with the manual bypass open and the inlet outlet isolation valves closing e Open the bypass valve to allow process flow to continue downstream then close the SFC outlet isolation valve e Atthis time the SFC is isolated and can be depressurized for servicing e Leave drain valves open while servi
7. l show a direct compressed air system improvement when installed in conjunction with an adequate supply side storage tank The system will utilize the new supply side storage tank installed with the compressors operating at an appropriately set control pressure and the SFC will deliver the desired plant air pressure set point Peak air consumptions will be drawn from storage and less compressor HP will be required for peak events Install the flow control system at the intermediate point of the compressed air system Install downstream from the filtration drying equipment amp air receiver storage and upstream from the main piping distribution system The flow controller constantly monitors air pressure as it is delivered to production and releases air from the receiver storage as needed to maintain a continuous stable air pressure supply 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 4 DIAGRAM 1 COMPRESSED AIR RECOMMENDED INSTALLATION FLOW Aftercooler Water Separator Removes 66 molature b 4 E Ka X E g Ar Compressor pros By Cent Drain Valve fm 7 Minimum Pipe Sizing Recommendation in Compressor Room Maximum CFM Note Based on 60 Ft Sec Velocity Standard steel pipe Minimum mpe Sizing Recommendation in Plant Pe smem S TS XT 1 350 4 000 1 640 4 900 Note Based on 0 5 a A per 100 feet Standard steal pee io Le Flow Controller Page 5 Syste
8. m Flow Controller Operation Manual M SFC 10 2012 Pure Aire A SAFETY WARNINGS amp PRECAUTIONS e DO NOT service the system pressure flow controller associated filters or equipment while under pressure e Disconnect electrical and pneumatic power before servicing the flow controller e Eye and ear protection should always be used when working with compressed air equipment e Failures on the SFC valves and components can result in a large air loss and or high pressure loss One possible reason for failures is from a lack of maintenance NOTE Recommended maintenance schedule should be followed to minimize the chances of this occurring Relieve air pressure before servicing flow controller Always use two wrenches when installing tightening or associated equipment piping connections to prevent over torque stress and damage to connection 2 Disconnect power and Lockout Tagout LOTO 2 Always read and follow instructions before servicing before servicing flow controller system flow controller 3 NOT SAFE for human respiration breathing 3 Comply with electrical installation and service guidelines for the National Electrical Codeand the Federal State and Local Codes when working with this equipment 4 Condensate automatic drains are recommended to 4 Follow the Pressurization Procedures remove water from the SFC for proper operation 5 Secure drain lines to prevent bodily injury due to 5 Heview the operations of the automa
9. tic drains for unsecured pressurized drain lines whipping proper removal of condensate water drainage daily 6 Standard designed operations for a unit are Ambient temperature of 100 F Inlet air process temperature of 100 F Operating pressure of 100 psig Operations above or below these design specifications should be reviewed for proper application 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 6 RECEIVING AND START UP REVIEW RECEIVING amp INPSECTION Inspect SFC carefully upon arrival Uncrate and inspect for concealed damage Any damage should be notified to the freight carrier immediately on the freight bill File claims with the freight carrier immediately and notify Pure Aire s Sales Department DO NOT install operate maintain adjust or All SFC s are tested and inspected at the factory prior to shipping service this unit without thoroughly reading Improper operation will cause poor results or mechanical failures this manual from the SFC SFC LOCATION Locate the SFC in an area accessible for maintenance The area should be clean cool and well lighted Ambient temperature should be between 50 F and 100 F The SFC should have clearance on all sides for service See dimensional print for specific clearance requirements INSTALLATION See typical installation drawing Pure Aire recommends that an inline strainer be installed on the inlet side of the SFC to guard against
10. ure All Installation Operation and Maintenance Manual System Flow Controller SFC m aka wl PO SW a v ke par D miu Eur D 4 C B T RT 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 1 GENERAL INFORMATION Pure Aire is a global leader in the design and manufacturing of products for the drying and purification of compressed air and gas Our product line includes pressure flow controllers fluid coolers water separators compressed air filters refrigerated air dryers and heatless patented zero purge and heat reactivated desiccant air dryers Please review this detailed and comprehensive instruction manual for the use of Pure Aire system flow controllers SFC Operational information is supplied for the user and supporting information for the technical personnel who maintains the compressed air system It is recommended that all who operates or installs the flow controller should carefully read all sections of this manual before commencing with the installation Thank you for choosing Pure Aire to service your compressed air needs Please call if we can be of further assistance IMPORTANT Warranty registration will improve the parts availability with your Local Authorized Dealer and Service Center and extend the warranty 800 274 3233 www pure aire net 2012 Pure Aire System Flow Controller Operation Manual M SFC 10 Page 2 TABLE OF CONTEN
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