Please complete the following information at the time of installation found on the rating label on the upper right hand side of dryer.

Transcription

1 PROS F D D F OS R P P R O S F D

2 The product to which this manual refers must not be supplied, installed, used, operated or serviced until contents of manual has been fully read and understood by all relevant personnel. Please complete following information at time of installation found on rating label on upper right hand side of dryer Model Number Serial Number Regulated Inlet Pressure Filtration present with Dryer Inlet Flow of Dryer Supply Voltage

3 Contents Safety 5 Safety Guidelines 5 Symbols 6 General Description 7 Function of Dryer 7 Controller Options 7 Package Contents 8 Primary Components 9-0 Technical Data Environmental Conditions Dimensional Specifications Sizing 4 Mechanical Installation 4 Orientation 6 Configuration of inlet /outlet ports 7 Connecting pre-filter to dryer 8 Connecting optional pre-filter drain valve 8 Installing hygrometer (DMC models only) 9 Configuring purge orifice 0 5 Electrical Installation PRODRY Controller power supply options PRODRY Recommended power cable specifications LED Controller specifications DMC Controller specifications 4 How to wire a DIN connector 5 Alarm connection details 6

4 6 Operation 7 Background / Function of Dryer 7 Detailed operational description - LED Controller 7 Detailed operational description - DMC Controller 7 Start-up procedure 8 Shut-down procedure 8 Operational schematics 9 7 Energy Management 5 Overview 5 Developing a purge control strategy 5 Using a manual switch for purge control 5 Using a standard pressure switch for purge control 6 Using an electronic pressure switch for purge control 7 Using a hygrometer and process controller for purge control 8 Making connections between a switching device and dryer EM contact 9 8 Maintenance 40 9 Spares Information 4 Service kits 4-4 Accessory kits Component Parts 46 Troubleshooting 50 Warranty 56 Declaration of Conformity 57

5 Section : Safety Safety The following safety guidelines must be strictly observed. Leave this manual at place of installation of product. It is essential that only Walker Filtration or it s appointed agents carry out maintenance and servicing work. Users, maintenance and servicing personnel must be familiar with: Accident prevention regulations. Safety information (general and specific to unit). Safety devices of unit. Measures to be taken in case of an emergency. Allow only suitably trained persons to be involved with installation, start-up, operation, servicing and maintenance of product. It is responsibility of installer to ensure that pipe work to and from dryer is suitable, in accordance with applicable legislation and subject to inspection and testing prior to being put into service. All piping must be adequately supported. Before carrying out any maintenance or servicing work unit must be taken out of operation. Users and ors will be exposed to risk if work is carried out whilst unit is running. This means electrical disconnection plus isolation from compressed air supply and full depressurisation. Only trained and competent persons familiar with electrical requirements of unit as laid out in this manual and electrical safety rules and regulations should be allowed to carry out work on electrical components and power supply to unit. When carrying out any work on unit, use only correctly sized appropriate tools in good condition. Only use original spare parts and accessories from manufacturer. There is no guarantee that non-original parts have been designed and manufactured to meet safety and operational requirements of unit. Walker Filtration assume no liability for any equipment malfunction resulting from use of non-approved parts. If carrying out installation work above head height, use suitable and safe working platforms or or means of working access. Do not make any constructional changes to product. Any changes or modifications may only be carried out by manufacturer, Walker Filtration. Any faults or defects that could affect safety must be put right fully before using unit. Used items and materials must be disposed of in correct manner, complying with local laws and regulations, in particular desiccant cartridge. 5

6 Section : Safety Figure.: Definition of symbols Manual Handling Risk of Danger Risk of High Pressure Risk of Electric Shock Warning As with all areas of workplace, Health and Safety is of great importance and must be given due care and attention. While working with this equipment, manual handling regulations must be considered and adhered to. Full advice, support and guidance should be detailed in your Health and Safety Policy and Manual Handling guide, please take time to familiarise yourself with se documents. The Manual Handling Operations Regulations apply to a wide range of manual handling activities, including lifting, lowering, pushing, pulling or carrying. We ask every person handling this product to take responsibility for ir own Health and Safety and Health and Safety of ors around m. If you feel re is a significant risk, you must take steps to eir remove risk altoger, or reduce risk prior to carry out activity. If you need furr support or guidance with this, please consult your line manager or HR Department. There are safe systems of work and correct procedures in relation to manual handling, please consult se documents available within workplace. We ask everyone handling this product to: Follow appropriate systems of work laid down for ir safety. Make proper use of any equipment provided for ir safety. Inform company if y identify hazardous handling activities. Take care to ensure that ir activities do not put ors at risk. If in doubt, please seek furr advice and ensure you always follow correct procedures and guidance. For more information please see our Health and Safety manual attached. Equipment Protected by Double Insulation Important Note A amp fuse should be fitted as per wiring diagram. 6

7 Section : General Description General Description Figure.: LED Controller Controller Options This manual is valid for following dryer models PD0046 PD0056 PD0075 PD0090 PD00 PD050 PD080 PD00 PD000 PD060 Function of Dryer PRODRY is designed to provide a smooth, controlled and uninterrupted delivery of dry compressed air. Wet air passes through a pre-filter and travels down to bottom valve assembly. The air is n fed through bottom of desiccant bed and moves through high performance desiccant until it becomes dry. On exit from desiccant cartridge, air is passed through outlet valve assembly. During this process, dryer control system cycles process air between two desiccant towers. While one tower is on stream removing water vapour, or is being carefully depressurised in preparation for regeneration. The desiccant bed is regenerated by expanding a small amount of dry process air, or purge air, through saturated desiccant. Purge air passes to atmosphere through silencer, which is fitted to an exhaust valve. The tower is n repressurised, with control system assuring each tower is at full operational pressure prior to changeover. This ensures a reliable and efficient operation. The air stream is switched and cycle repeats on a continuous basis. Features: Supplied as standard controller Microcontroller based design Available in 5V or 0VAC Energy Management Feature (EM) Alarm Outputs Figure.: DMC Controller Controller Options Features: Dewpoint Hold (-40) Dryer Dewpoint -4 PDP Hours Run 4 Service History # 0 (Optional) full feature controller PLC based design 4VDC only Includes Hygrometer Energy Management Feature (EM) Alarm Outputs Selectable output dewpoint levels (-0 C, -40 C, -74 C) Engages Dewpoint Hold during periods of low demand resulting in energy savings up to 8%. 7

8 Section : General Description Package Contents The dryer is delivered in protective packaging. Take care when transporting, loading and unloading unit. The package contains following items (refer to figure.):. Dryer unit. Instruction manual (including certificate of conformity). Power connector 4. Purge Kit Figure.: Package contents (All dryer models) Controller Options Instruction manual (including certificate of conformity) Note: All dryers come equipped with eyebolts to facilitate removing dryer from it s crate. Simplex dryers include one eyebolt and duplex models include two. 4 Note: All dryers include spare orifice components to allow dryer to be modified from factory 7 barg (00 psig) pressure setting to any pressure within specified operating range. The internal purge valves within models PD046 & PD056 can be modified to suit all pressure settings whilst models PD0075 to PD060 require additional components (which are supplied with dryer). Figure.4: Optional Items for DMC Dryer 5 Hygrometer Sample Block (Installed into top valve block) 6 Hygrometer Figure.5: Optional Items for DMC Dryer Controller Options 7 Pre-filter drain valve 8

9 Section : General Description Figure.6: Primary Components (Simplex Models PD PD080) 4 5 b DMC Models a LED Models DMC Models Front panel a. LED controller b. DMC controller. Top trim cover 4. Extrusion cover 5. Top extrusion tower plug 6. Tower spring 7. Desiccant cartridge 8. Extrusion tower 9. Top manifold assembly 0. Pre-filter (Optional). Downpipe. Exhaust silencer. Bottom manifold assembly 4. Dryer stand 5. Bottom extrusion tower plug 6. Tower circlip 7. Bottom trim cover 8. Hygrometer sample block* 9. Hygrometer* * DMC models only 9

10 Section : General Description Figure.7: Primary Components (Duplex Models PD00 - PD060) DMC Models b DMC Models Front panel a. LED controller b. DMC controller. Top trim cover 4. Extrusion cover 5. Top extrusion tower plug 6. Tower spring 7. Desiccant cartridge 8. Extrusion link 9. Extrusion tower 0. Top manifold assembly. Pre-filter (Optional). Downpipe. Exhaust silencer 4. Bottom manifold assembly 5. Bottom manifold support clip 6. Dryer stand 7. Bottom extrusion tower plug 8. Tower circlip 9. Bottom trim cover 0. Hygrometer sample block*. Hygrometer* * DMC models only 0

11 Section : Technical Data Technical Data Environmental Conditions All dryers are designed to be safe under following conditions: Indoor use Altitude up to,000m Ambient temperature 5 C (4 F) to 50 C ( F) Mains supply voltage fluctuations not to exceed +/- 0% of nominal For operation extended from above conditions, please contact Walker Filtration. Excessive vibrations from external sources may cause failure of this product. Rated Conditions Measurement Performance Inlet pressure 7 barg 0.5 psig Inlet temperature 5 C 95 F Relative humidity of air at inlet 95% Pressure dewpoint, standard version -40 C -40 F Specified Limitation for Operation Measurement Performance Maximum inlet air pressure barg 88.5 psig Minimum inlet air pressure 4 barg 58 psig Maximum ambient air temperature 50 C F Minimum ambient air temperature 5 C 4 F Pressure dewpoint (LED & DMC Controller) -0 C to -74 C -4 F to -00 F Electrical supply voltage (LED Controller) Electrical supply voltage (DMC Controller) 5 VAC or 0 VAC 4 VDC

12 Section : Technical Data PD PD060 Section Section : Technical : Technical Data PD0046 Data PD PD060 - PD060 Dryer Pipe Inlet flow rate* Inlet flow Inlet rate*flow rate* DryermodelDryer Pipe size Pipe Nm³/hr SCFM A model model size Nm³/h size SCFM A Nm³/h SCFM PD0046 PD0056 PD0075 PD0090 PD00 PD050 PD080 PD00 PD000 PD060 ½ ½ ½ ½ ½ (5.8) AB Dimensions mm (inches) Dimensions Dimensions mm (inches) mm (inches) B C D E BC CD DE 80 (5) 0 (.) 76 () 50 () EF Weight No. of Recommended Filter model Filter pipe size No.cartridges of No. Recommended of Filter Recommended Filter F WeightKg Weight cartridges Kg cartridges Filter model Filter model pipe size pipe size FKg 600 (.6) (9) 7580(5) (9) () 76 50() () () (7.6) 700 (7.6) (5) (.) 076 (.) (5.6) 80 (5) 0 (.) 76 () 50 () 850 (.5) ( (5) (5.6 () 76 50() () () (.5) 850 (.5) (5) (.) 0 76 (.) (40.5) 80 (5) 0 (.) 76 () 50 () 000 (9.4) (40.5) 00 (40.5) 0 () 76 50() () () (9.4) 000 (9.4) 75 80(5) 80(5) (.) 076 (.) (49.6) 80 (5) 5 (.8) 76 () 50 () 700 (7.6) (49.6) 60 (49.6) 0 76 () 76 50() () () (7.6) 700 (7.6) (5) 80(5) (.) 0 (.) (6.8) 80 (5) 5 (.8) 76 () 50 () 850 (.5) (6.8) 595 (6.8) 0 76 () 76 50() () () (.5) 850 (.5) (5) 80(5) (.) 0 (.) (7.6) 80 (5) 5 (.8) 76 () 50 () 000 (9.4) (7.6) 845 (7.6) 0 76 () 76 50() () () (9.4) (9.4) (5) 80(5) (.) 0 (.) (49.7) 80 (5) 490 (9.) 76 () 6 (.4) 700 (7.6) ½ (49.7) 6 (49.7) 490 () 76 6 () (.4) (.4) (7.6) 700 (7.6) (5) 80(5) (9.) (9.) (6.8) 80 (5) 490 (9.) 76 () 6 (.4) 850 (.5) (6.8) 596 (6.8) () 76 6 () (.4) (.4) (.5) 850 (.5) (5) 80(5) (9.) 490 (9.) (7.6) 80 (5) 490 (9.) 76 () 6 (.4) 000 (9.4) ½ 6 A058XA (5.8) 65580(5) (5.8) 0 76 () 76 50() () () (.6) 600 (.6) 50 80(5) (.) 0 (.) 75 (9) 80 (5) 0 (.) 76 () 50 () 700 (7.6) ½ ½ A059XA A059XA ¾ A08XA 4 A09XA 4 8 A8XA ¼ A59XA ½ F B F E F B F E D C E D C E C D C D A A ½ Models PD00-PD060 Models PD00-PD060 B B ¼ ½ 6 ½ (7.6) 845 (7.6) 490 () 76 6 () (.4) (.4) (9.4) (9.4) A59XA A59XA ½ 80(5) 80(5) (9.) (9.) * Stated flows are for an inlet pressure of 7 barg (00 psig) with reference to 0 C (68 F), barg (abs.), 0% relative water vapour pressure. For flow at or pressures, temperatures and dewpoints apply correction factors on page. * Stated flows * Stated are for flows an inlet are for pressur aneinlet of 7pressur barg e(00 of psig) 7 bargwith (00 reference psig) withtoreference 0 C (68 F), to 0 C barg (68 F), (abs.), barg 0% relative (abs.), 0% water relative vapour water pressure. vapourfor pressure. flow at For or flow at or pressures, apply pressures, appropriate apply appropriate correction factors, correction terms factors, and dewpoint. terms and dewpoint. Models PD0046-PD080 Models PD0046-PD080 A8XA 8 ½ ¾ A079XA 4 ½ ½ ½ A078XA ½ ½ ½ A A PRODRY PD0046 PRODRY-PD0046 PD060-Instruction PD060 Instruction Manual Manual Walker Filtration Walker Filtration

13 Section : Technical Data PD PD060 Dryer correction factors Operating pressure (PCF) barg psig Correction factor Temperature (TCF) Celcius C Farenheit F Correction factor Pressure dewpoint (DCF) Celcius C Farenheit F Correction factor PRODRY Sizing Example To correctly select PRODRY model suitable for your application following information is required: Minimum Inlet Pressure, Maximum Inlet Temperature, Maximum Compressor Inlet Flow and Required Pressure Dewpoint (PDP). Requirements Maximum compressor inlet flow 56 scfm - Actual minimum inlet pressure to dryer Correction Factor 6 barg PCF = 0.87 Maximum inlet temperature 5 C (77 F) TCF =. Pressure dewpoint (PDP) -74 C (-00 F) DCF = 0.77 Corrected dryer flow rate Appropriate Dryer Size Inlet flow rate PCF x TCF x DCF = 56 = (0.87 x. x 0.77) 69.7 scfm (8 Nm³/hr) Dryer model is selected based on corrected flow rate, i.e. PD0075. Technical notes. Pre-filtration, including a water separator is essential to maintain dryer performance.. An appropriate Water Separator must be installed. If bulk water enters adsorption dryer it can cause heat expansion to desiccant, substantial rise in dryer differential pressure, lead to poor outlet dewpoint, and cause potential dryer failure.. Walker Filtration recommends fitting an RXA dust filter to outlet. 4. Call your nearest Walker Filtration sales team for furr information.

14 Section 4: Mechanical Installation Mechanical Installation Figure 4.: Typical installation C XA WS X XA RXA To prevent back flow into dryer a non-return valve should be placed in-line, downstream of dryer. This is essential when more than one dryer is used in a single application. Figure 4.: Level ground 4

15 Section 4: Mechanical Installation Figure 4.: Location Figure 4.4: Hard piped installation Figure 4.5 Exposure to heat O Max 50 Max C ( 50OCOF) (OF) O Max 50O50 C O( F)OF) Max C ( O O O C ( F) Max 50OCMax (50 F) >Max>Max 50OC ( 50OCOF) (OF) O >Max 50O50 C O( F)OF) >Max C ( O O O O C ( F) >Max 50>Max C (50 F) 5

16 Section 4: Mechanical Installation Figure 4.6: Drainage (all tubing should be secured up to point of drain to prevent whipping during discharge) Orientation Figure 4.7: The PRODRY range of dryers is designed to operate in both vertical and horizontal orientation. 6

17 Section 4: Mechanical Installation Re configuration of inlet / outlet ports PD0046 PD060 models Dryer can be reconfigured to interchange position of inlet and outlet ports as per figure 4.8. PRODRY has two inlet ports (A and B) and two outlet ports (C and D). Eir (A or B) can be used for inlet and (C or D) for outlet. Make sure un-used ports are blanked off with provided pressure plugs. Figure 4.8: Inlet/outlet ports D B C A Any of two outlet ports can be used on occasion. Please ensure flow at outlet should not exceed specification. Please adhere to regional regulations. It is strongly advised to connect a non-return valve to outlet port of dryer. Only use one inlet port at any one time Tools required Adjustable spanner Ratchet with 7mm Hexagonal connection (PD PD080) Ratchet with Hexagonal connection (PD00 - PD060) Ensure original seals are in place. Check dryer is leak-free prior to operation. 7

18 Section 4: Mechanical Installation Section 4: Mechanical Installation Fig ure 4.9 : Conn ecting a pre- filte r Figure 4.9: Connecting a pre-filter Connecting pre-filter to dryer Section 4: Mechanical Installation PD0046 PD060 models s Attach pre-filter (purchased separately) utilising a pipe nippleand/or pipe adapter. Pipe away condensate with tubing from drain outlet. Ensure condensate is drained into an oil/water separator. Fit any furr filtration and/or ancillary equipment. Pre-filter is typically supplied with an autodrain installed in bowl drain port. On DMC models, this can. be replaced with a solenoid drain valve which is an All sold tubing should be secured up to point of drain to optional extra separately. Fig ure 4.9 : Conn ecting a pre- filte r s prevent whipping du ring discharge. All tubing should be secured up to point of drain to prevent whipping during discharge.. All tubing should be secured up to point of drain to prevent whipping du ring discharge. It is recommended that a bypass line including XA filter is installed, as per figure 4.. Fig ure 4.0 : Co nn ecting filte r dr ain Available on DMC models only. Connecting optional pre-filter drain valve. Install optional solenoid drain valve onto pipe adapter(s) FigureFig4.0: Connecting filterfilte drainr dr ain ure 4.0 : Co nn ecting etched into side of drain valve body. Available onavailable DMC models only.models only. on DMC If necessary, remove existing autodrain from separator. Ensure condensate is drained intovalve an oil/water pre-filter.. Install optional solenoid drain valve onto pipe adapter(s) Install pipe adapter into pre-filter drain port. etched into drain side ofvalve drain Install optional solenoid ontovalve pipebody. adapter(s) All tubing should be secured up to drain point of drain to Pipe awayow condensate with from outlet. taking care to note direction astubing indicated by arrow preventcondensate whipping isdudrained ring discharge. into an oil/water separator. etched into Ensure side of drain valve body. Pipe away condensate with tubing from drain outlet. Ensure condensate is drained into an oil/water separator. All tubing should be secured up to point of drain to Pipe away condensate with tubing from drain outlet. prevent whipping du ring discharge. All tubing should be secured up to point of drain to prevent whipping during discharge. PRODRY PD PD060 Instruction Manual Walker Filtration PRODRY PD PD060 Instruction Manual Walker Filtration 8 8 8

19 Section 4: Mechanical Installation Installing hygrometer (DMC models only) Figure 4. Hygrometer attached PD0046 PD060 models Remove hygrometer from packaging. Carefully remove plastic cover from sensor. Do not touch white sensor tube. Hygrometer sample block is pre-installed in dryer s top manifold assembly. Remove cover from threaded port. Confirm threads on hygrometer sample block are clean and free from any dirt, water, cutting lubricant, liquid thread sealant, oil and/or grease. Per figure 4., insert hygrometer into hygrometer sample block and turn to clockwise to tighten. Tighten lightly with adjustable spanner. Fit hygrometer DIN plug to hygrometer and tighten screw with pozi-head screwdriver. Figure 4. Attaching hygrometer Hygrometer DIN Plug Hygrometer Hygrometer Silencer Setting Hygrometer Sample Block Open full turns = 5Nl/min Tools required Adjustable spanner Pozi-head screwdriver 9

20 Section 4: Mechanical Installation Purge Orifice Size Identification Reference figure 4. and Purge Plug Identification Table. Each dryer is pre-set with correctly sized purge valve for an operating pressure of 7 barg (00 psig) at point of order. The lettering (A through S), located on purge valve body, indicates orifice size selected to suit operating pressure of dryer per chart below. If inlet pressure to dryer will be different than pre-set orifice size, purge valve can be adjusted. Most dryers use a single orifice purge valve represented by Blue and Green single letter references in table below. Larger dryers may require a two or three hole purge valve as represented by Red and Yellow two and three letter references. To select correct orifice size, locate appropriate dryer model at left side of table and n operating pressure at top. Make sure that correct valve body (, or hole) and orifice disc (0, 0, 0 or 04) has been supplied with dryer. The discs have number (0, 0, 0 or 04) stamped out at top. Purge Plug Identification Operating pressure Dryer PD0046 M K I H G F E E E D PD0056 P M L K J I H G F F PD0075 B S P M L L K I I H PD0090 C A P P N L K J I H PD00 I E C A P M K K J I PD050 CK M G F C B A S S P PD080 EM CK P I G E C B A A PD00 AFK FN DL P K H F E D C PD060 EJP DIN CHM AFK AFK GP EM DL BJ AI Disc Every dryer is shipped with a purge orifice set up for 7 barg (00 psig) operation. The dryer will also include necessary purge valve components to configure dryer to operate at any pressure from 4 barg (58 psig) to barg (89 psig). For example: A PD050 dryer will be supplied with a single hole purge assembly with an 0 purge disc installed and indexed to position F. Additional purge valve components will be included to allow dryer to be configured to purge settings, CK, M, H, D, B, A, S, P and N. Appropriate purge plug selection is very important for function of dryer. Failure to comply with this may affect your warranty. 0

21 Section 4: Mechanical Installation Figure 4. Purge valve assembly Index reference letters Gasket and Valve Stem are rotated to align with index reference letters on Valve Body Alignment notches Valve Body (Common to all dryers) Purge Sealing Gasket(s) (, or hole) Valve Stem O-ring(s) (Fit into recess in Valve Stem(s)) Orifice Discs Hole Valve Stem Hole Valve Stem Disc I.D. Number (0, 0, 0, 04) Alignment notches Hole Valve Stem M4 Screw Valve Control Spring Purge Valve Assembly Reference figure 4. and Purge Plug Identification Table on Page 0. Once correct purge body (, or hole) and orifice disc (0, 0, 0 or 04) has been selected per instructions on Page 0, purge valve may be assembled. The index letters located on purge valve body correspond with selected orifice sizes per Table on Page 0. Place appropriate orifice disc onto valve body, taking care to align notches. The disc will only fit in one position. Place valve stem O-ring(s) into ir corresponding recesses on back of valve stem. Align holes in purge sealing gasket with corresponding holes in valve stem. Rotate valve stem assembly so that correct orifice letters align with notches corresponding to holes (, or ) in valve stem. Press assembly toger and fasten with M4 screw. Double check to make sure that open orifice holes correspond with correct orifice selection as identified earlier.

22 Section 5: Electrical Installation Electrical Installation PRODRY Controller power supply options Models PD PD060 The dryer is designed to operate on eir AC or DC supply voltage dependant on controller option. Electrical wiring must comply with local regulations. Voltage requirements must be confirmed to be within specification on dryers rating plate. Ensure only one power source is connected at any one time and is connected to correct socket as shown in figures 5. (LED Controller) and 5. (DMC Controller). The LED and DMC controller require a earth to be connected within DIN connector. The cable selection must suit local installation regulations and be appropriate to power consumption as shown in Controller specification tables on pages and 4. PRODRY Recommended power cable specifications Controller Type Number of cores Cross Sectional Area / AWG 4VDC DMC 0.75mm / 0/0VAC LED 8 AWG Recommended Max. Length Metres Type SJOW for Thermoset cable types or SVT and SJT for Thermoplastic cable types Standard Compliance IEC 607 or IEC 6045

23 Section 5: Electrical Installation LED Controller Specifications Ambient temperature Input voltage range (5V LED Controller) Input voltage range (0V LED Controller) Protection class 5 C to 50 C (5 F to F) 5V, 50 60Hz, Mains supply voltage not to exceed ±0% of nominal Power Rating 6W (Max) 0VAC, 50-60Hz, Mains supply voltage not to exceed 0% of nominal Power Rating 6W (Max) IP65 A circuit breaker or switch must be installed near dryer. This should be easy to reach and shall be certified according to EN and EN The switch or circuit breaker shall be marked as disconnecting device for dryer and needs to be marked with on and off positions. Output connections do not provide isolation from mains connectors and interconnecting wiring must meet EN600- :00 requirements for reinforced insulation. Figure 5.: LED Controller electrical connections ENERGY MANAGEMENT / ALARM PIN OUTPUT INPUT Energy Management Connections** 5VDC (+) Alarm Connections N.C. -4VDC N.O. ** Supplied from factory with jumper in female DIN between pins and. POWER SUPPLY PIN INPUT L (0 VAC or 0 VAC*) N Earth * Unit voltage rating must match supply voltage.

24 Section 5: Electrical Installation DMC Controller Specifications Ambient temperature Input voltage range (4VDC DMC Controller) Protection class 5 C to 50 C (5 F to F) 4VDC Power Rating 6W (Max) IP65 A circuit breaker or switch must be installed near dryer. This should be easy to reach and shall be certified according to EN and EN The switch or circuit breaker shall be marked as disconnecting device for dryer and needs to be marked with on and off positions. Output connections do not provide isolation from mains connectors and interconnecting wiring must meet EN600- :00 requirements for reinforced insulation. Figure 5.: LED Controller electrical connections POWER SUPPLY PIN INPUT 4VDC (+) 4VDC (-) Not used Earth HYGROMETER PIN OUTPUT INPUT 4 VDC (+) Signal (Hyg Pin ) Hygrometer Pin 4 VDC (-) Hygrometer Pin Not used Not used ENERGY MANAGEMENT PIN OUTPUT 4VDC (+) Not used Not used INPUT N.O. Not used Not used ALARM PIN V.F.* OUTPUT INPUT N.O. -4VDC Not used Not used Not used Not used REMOTE DRAIN VALVE PIN OUTPUT INPUT 4VDC (+) Remote Valve Pin 4VDC (-) Remote Valve Pin Not used Not used * Volt Free 4

25 Section 5: Electrical Installation How to wire a DIN connector Figure 5.: DIN connector Models PD PD060 Locate DIN connector on back of controller. Remove screw completely from centre of connector. Remove blanking plug, if present, from connector and discard. Insert a small flat screwdriver into small recess at edge of insert, pry insert out of DIN connector s outer shell per figure 5.. Per figure 5.4, slip cable end through DIN connector s cable gland, washer, grommet and out through front of DIN connector case. Figure 5.4: DIN connector for LED and DMC Controller Cable diameter should be no greater than 6mm (/4 ). Larger diameters do not fit well into cable gland of DIN connectors. Cable should be round as rectangular cable or ribbon cable will not seal properly in DIN connectors grommet. Strip outer insulation of cable back approx 0mm (/4 ). Strip conductor insulation back approx mm (/8 ). Insert conductors into appropriate pins of insert. Tighten retaining screws securely. Outer insulation must extend through grommet to ensure that IP65 specification is met mm 0 mm Gasket Insert Case Grommet Washer Cable Cable Gland Determine which direction cable gland should point. Carefully pull cable back through case until insert snaps back into place. Take care to work wires around retaining screw hole as y can become fairly easily pinched. Plug DIN connector back onto appropriate electrical connection on back of dryer s controller per figure(s) 5. and 5.. Take care to make sure that sealing gasket is in place. The male ground pin is slightly wider than pins &. Take care to ensure that female connector is oriented correctly. 5

26 Section 5: Electrical Installation Alarm connection details Fig 5. 5 Alarm contact connections (LED Controller) Models PD PD060 To enable alarm facility, it is recommended that a suitable cable is brought into controller via rear panel with a grommet. An external power source is required. Per Figures 5.5 (LED Controller) or 5.6 (DMC Controller), connect switching pole of an externally powered alarm indication device to corresponding terminals of controller s alarm output. For details regarding wiring of female DIN connector refer to How to wire a DIN connector on page 5. Pin Pin DC Power Supply (Field Installed) +VDC -VDC LED Controller Fig 5.6 Alarm contact connections (DMC Controller) Remote Visual or Audible Indicator (Field Installed) Alarm Connection Details Hirschmann GDS 07 industrial std DIN connector or equivalent Alarm Contact Rating (LED Controller) Alarm Contact Rating (DMC Controller).0 AMPS 8VDC 0.5 AMPS 4VDC +4VDC -4VDC/COM Pin Pin DMC Controller Remote Visual or Audible Indicator (Field Installed) 6

27 Section 6: Operation Operation Background / Function of dryer Detailed Operational Description - DMC Controller PRODRY is designed to provide a smooth, controlled and uninterrupted delivery of dry compressed air. Wet air passes through a pre-filter and travels down to bottom valve assembly. The air is n fed through bottom of desiccant bed and moves through high performance desiccant until it becomes dry. On exit from desiccant cartridge, air is passed through outlet valve assembly. During this process, dryer control system cycles process air between two desiccant towers. While one tower is on stream removing water vapour, or is being carefully depressurised in preparation for regeneration. The desiccant bed is regenerated by expanding a small amount of dry process air, or purge air, through saturated desiccant. Refer to detailed operational schematics, figure(s) DMC Controller operates on a standard timed cycle as detailed in Figures 6. through 6.8. Operational status is displayed in text form on LCD display. When installed, a hygrometer allows DMC controller to shut off purge when outlet dewpoint is within one of three selectable dewpoint ranges. The ranges are controlled by a switch located on upper back side of DMC controller as detailed in figure 6.. Purge air passes to atmosphere through silencer, which is fitted to an exhaust valve. The chamber is n repressurised, with control system assuring each chamber is at full operational pressure prior to changeover. This ensures a reliable and efficient operation. The air stream is switched and cycle repeats on a continuous basis. Detailed Operational Description - LED Controller Refer to detailed operational schematics, figure(s) LED Controller operates on a standard timed cycle as detailed in Figures 6. through 6.8. Range : -0 C (-4 F) Required outlet pressure dewpoint: Purge shut off value: Purge turn on value: Range : -40 (-40 F) Required outlet pressure dewpoint: Purge shut off value: Purge turn on value: Range : -74 C (-00 F) Required outlet pressure dewpoint: Purge shut off value: Purge turn on value: Figure 6.: Dewpoint selection switch control -0 C (-4 F) - C (-9.4 F) - C (-5.8 F) -40 C (-40 F) -4 C (-45.4 F) -4 C (-4.8 F) -74 C (-00 F) -76 C (-04.8 F) -74 C (-00 F) Panel LED s illuminate to indicate various service warnings, refer to Troubleshooting in Section for specific details. To reduce purge loss during periods of low and / or no air demand Energy Management feature may be utilised. A detailed description is given in Section 7. For remote indication of any faults, Alarm Contacts may be utilised to send a signal to a light or remote service panel. Furr details are given on page 6. If hygrometer is not installed, DMC controller will default to standard timed cycle of operation. 7

28 Section 6: Operation If not utilising a hygrometer, purge loss may be reduced during periods of low or no air demand Energy Management Feature (EM) may be utilised. A detailed description is given in Section 7. Please note that Energy Management feature should not be used when a hygrometer is installed in dryer. For remote indication of any electrical faults, Alarm Contacts may be utilised to send a signal to a light or remote service panel. Furr details are given on page 6. An optional pre-filter drain solenoid valve is available for DMC controller. When installed per figure 4.0, drain will open for seconds at beginning of each cycle. Operational schematic, figure 6.8 provides additional detail. Figure 6.: Typical installation C D A B Start-up procedure Shut-down Procedure Refer to figure 6. Close valves A, B, C and D. Switch on compressor. Open valve A slowly. Check re are no leaks from dryer Switch on electric power, panel will display operational features. The dryer will enter standard cycle mode. On initial commissioning, only run dryer for a minimum of 6 hours to ensure dewpoint is adequate. Close valve B. Close valve A. Leave dryer running for 5 minutes to fully depressurise. Switch off all electrical power to dryer. Under no circumstances must compressed air be allowed to flow through dryer following switch off of electrical power. This will result in terminal failure of desiccant cartridges and regeneration will not be possible. Open valve B slowly. 8

29 Section 6: Operation Figure 6.: Initial Pressurisation (Power Off) With power off to dryer, both towers pressurise to line pressure. All valves remain closed and dryer remains air tight (with exception of a small bleed of air from hygrometer sample block). Note: Any air flowing through dryer, passes through both towers. 9

30 Section 6: Operation Figure 6.4: Stage : Left Tower Purging, Right Tower Drying After an initial 40 second delay, left solenoid valve opens allowing left exhaust shuttle valve to open. Air rushes from left tower out silencer as it depressurises. For 0 seconds, a bleed of dry air from outlet of on-stream (right) tower is directed through left purge orifice and down through left tower to regenerate off stream (left) desiccant bed. 0

31 Section 6: Operation Figure 6.5: Stage : Repressurisation At completion of Stage, left solenoid closes and left tower repressurises for 5 seconds. Note: Any air flowing through dryer, passes through both towers.

32 Section 6: Operation Figure 6.6: Stage : Left Tower Drying, Right Tower Purging At completion of Stage, right solenoid valve opens allowing right exhaust shuttle valve to open. Air rushes from right tower out silencer as it depressurises. For 0 seconds, a bleed of dry air from outlet of on-stream (left) tower is directed through right purge orifice and down through right tower to regenerate off stream (right) desiccant bed.

33 Section 6: Operation Figure 6.7: Stage 4: Repressurisation At completion of Stage, left solenoid closes and left tower repressurises for 5 seconds. Note: Any air flowing through dryer, passes through both towers.

34 Section 6: Operation Figure 6.8: Drain Valve Activation At completion of Stage 4, dryer moves back to Stage. The drain valve opens at beginning of cycle (Stage ) for a period of seconds. Left Tower Pressure Gauge Optional Hygrometer (DMC Models Only) Right Tower Pressure Gauge Purge Control Non-Return Valve Hyg Sample Cell A Purge Control Non-Return Valve Alternate Outlet Position RX- After Filter OUTLET INLET XA Pre-Filter Alternate Inlet Position DV Optional Drain Valve (Optional on DMC Models Only) Left Desiccant Tower To Drain Point SV Left Solenoid Control Valve A LED Controller SV Right Solenoid Control Valve A Right Desiccant Tower Standard Running Mode - Hours Run 456 Service History # 0 Silencer DMC Controller Silencer TIMING CHART: LEGEND: SV (Left Solenoid Control Valve) ON OFF Wet SV (Right Solenoid Control Valve) DV (Prefilter Drain Solenoid Valve) Seconds: ON OFF Seconds ON OFF Purge Dry 4

35 Section 7: Energy Management Energy Management Overview Please note that Energy Management feature should not be used when a hygrometer is installed in dryer. Regenerative dryers must expel a portion of process air in order to free mselves of accumulated moisture. During periods of low air demand, however, this air loss is not necessary and is refore undesirable. In many cases, compressor runs almost continuously in order to keep up with dryer s purge loss. All Walker Filtration dryers are equipped with an Energy Management feature that allows purge to be shut off during periods of low or no demand. The dryer controller is fitted with a set of field accessible contacts, that can be employed to shut off solenoid valves which control purge function of dryer, refore eliminating any air loss from dryer. Developing a Purge Control Strategy feature, if used orwise, can result in permanent damage to desiccant beds resulting in loss of drying capacity and possibly mechanical failure. The cartridges must not be allowed to become fully saturated at any time. The following schematic ( Fig 7.) offers an overview of devices mentioned as y might be connected for use in controlling a dryer s purge function. Please note that specific details differ between device manufacturers, so in all cases manufacturer s specifications should be adhered to. Fig 7. Manual switch purge control (LED Controller) Pin (Puts out +5 VDC signal) Pin Signal Out to Switch LED Controller N.C.* Signal Back Manual Switch * Normally Closed, open to turn purge off (Field Installed) In order to utilise this function, operator must provide a switching system that provides acceptable logic to indicate to dryer that re is little or no air demand. On following pages, some examples of commonly used switching systems are provided in ascending order of complexity. Fig 7. Manual switch purge control (DMC Controller) Signal Out to Switch (+4 VDC) Pin Pin Using a Manual Switch for Purge Control The simplest of arrangements, a manual switch may be employed to shut purge off when air downstream of dryer is not being used. Commonly used on point of use systems. For example, if dryer is only used to supply air of an appropriate dryness to a specific machine or application, dryer will only be required when machine is in use and may be shut off eir manually or possibly via extra contacts provided in machine s on/off switch. It is extremely important to understand that purge may only be shut off during periods of low or no demand. This Signal Back Signal Out to Switch * Normally open, close to turn off purge DMC Controller N.O.* Manual Switch (Field Installed) 5

36 Section 7: Energy Management (LED Controller) Using a Standard Pressure Switch for Purge Control Many compressors come equipped with pressure switches with extra contacts that can be utilised to switch off dryer s purge when compressor is in an unloaded state. Unfortunately, many of se switches have significantly large dead bands (difference between load (on) and unload (off) settings that in most cases cannot be altered). The amount of air that can pass downstream, through dryer, while compressor is unloaded must be taken into consideration as it can be significant, especially if re is a large dead band and/ or large wet receiver. Often, a stand-alone pressure switch is a better option as it allows user to adjust it independently from compressor s pressure switch. When selecting a stand-alone pressure switch, smaller dead band better. When using a stand-alone pressure switch, dryer is wired into normally closed (LED Controller) or normally open (DMC Controller) contacts on pressure switch. When switch is actuated (at 00 psig in example), purge shuts off until pressure switch deactuates (at 95 psig in example). The point at which switch deactuates, may be adjusted to suit system. If it is determined that dewpoint drops to an unacceptable level, deactuation point must be increased. Please note that with most standard pressure switches, dead band is fixed such that activation and deactuation points move toger. It is extremely important to understand that purge may only be shut off during periods of low or no demand. This feature, if used orwise, can result in permanent damage to desiccant beds resulting in loss of drying capacity and possibly mechanical failure. The cartridges must not be allowed to become fully saturated at any time. Figures 7. and 7.4 offer an overview of devices mentioned as y might be connected for use in controlling a dryer s purge function. Please note specific details differ between device manufacturers, so in all cases manufacturer s specifications should be adhered to. Fig 7. Standard pressure switch purge control (LED Controller) Pin (Puts out +5 VDC signal) Pin Signal Out to Switch Signal Back * Normally Closed, open to turn purge off LED Controller N.O. N.C.* Pressure Switch (Field Installed) Fig 7.4 Standard pressure switch purge control (DMC Controller) Signal Out to Switch (+4 VDC) Pin Pin Signal Back Signal Out to Switch * Normally open, close to turn off purge DMC Controller N.C. N.O.* Pressure Switch (Field Installed) 6

37 Section 7: Energy Management Se ct io n 7: Energy Management Se Fig ct7.5: io np7:ressu Figure installation SeEnergy ctreioswitch n 7:Management Energy 7.5Typical setti ng Management ADJUST TO SUIT SYSTEM (pressure switch deactivation point) Fig 7.5 P ressufig re 7.5 switch setti rengswitch setti ng P ressu ADJUST TO SUITADJUST SYSTEMTO SUIT SYSTEM (pressure switch(pressure deactivation point) PURGE ON (switchpoint) deactivated) switch deactivation PURGE ON (switch deactivated) PURGE OFF ON PURGE OFF (switch activated) OFF deactivated) 05PURGE ON (switch PURGE ON (switch deactivated) ON OFF ON OFF SYSTEM PRESSURE (psig) PURGE OFF PURGE OFF (switch activated) PURGE OFF (switch activated) PURGE OFF signal) signal) SYSTEM PRESSURE (psig) SYSTEM PRESSURE (psig) 95 PURGE ON (switch deactivated) PURGE ON (switch deactivated) signal) It is extremely important to understand that purge may during periods of low or no demand. This only be shut only be shut off during periods of low or no demand. This feature, if used orwise, can result in permanent damage if during used orwise, can inorpermanent damage of low or result noofdemand. This only feature, be shutonly periods low no demand. be shutperiods to desiccant bedsduring resulting in loss of drying capacity This Using an eleusing ctronicanpressur e swit ch forepurge control electron ic pressur switch for purge control feature, if used orwise, can result incan permanent damage to desiccant beds resulting inresult lossinofpermanent drying capacity feature, ifmechanical used orwise, damage The best choice if using a pressure switch is to select an and possibly failure. The cartridges must not be The best choice if using a pressure switch is to select an to desiccant resulting in failure. loss of drying capacity and possibly mechanical The cartridges must not be to beds desiccant beds resulting in loss drying capacity electronic programmable type pressure switch which is allowed to become fully saturated at any of time. electronic programmable type pressure switch which is and possibly mechanical failure. The cartridges must not be and possibly mechanical failure. The cartridges must not be allowed to become fully saturated at any time. The bestachoice if using a pressure is to selectisanto select an The best choice if using aswitch pressure switch effectively pressure transmitter and controller effectively a pressure transmitter andprocess process controller anat overview saturated any time.ofat allowed fully to become fully saturated anydevices time. electronic programmable type pressure switch which is which is allowed to become programmable typemore pressure switch built into oneelectronic device. While significantly costly than Figures 7.6 and 7.7 offer an overview of devices mentioned as y be connected for use in controlling effectively aeffectively pressure transmitter and processand controller anmight overview ofoverview devices a pressure transmitter process controller an of devices a standard pressure switch, ananelectronic mentioned as y might be connected for use in controlling a standard pressure switch, electronicprogrammable programmable mentioned mentioned as y might use in controlling as be yconnected might befor connected for use in controlling pressure switch cancan be be setup totoprovide aamuch more a ddryer s purge device function. Please notesothat details pressure switch setup provide much more er between manufacturers, in allspecific cases a standard pressure switch, an electronic programmable a standard pressure switch, an electronic programmable customized operation. Typically, dead band can between device manufacturers, so in all cases cases customised operation. Typically, band be more pressure switch can be setup to be provide adead more d erdiffer between device manufacturers, so in all cases pressure switch can setup tomuch provide acan much d er between device manufacturers, so in all reduced or eliminated so that an immediate reaction to reduced or eliminated so that an immediate reaction manufacturer s specifications should be adhered to. customised operation. Typically, dead band bebandto customised operation. Typically, can dead can be This setup is for example only. This configuration can be system pressure in system indicating airanflow, canto reduced or reduced eliminated that an immediate reaction or so eliminated so that immediate reaction to This setup isthis for example only. This configuration canthis be configuration amended, depending on application. Thisissetup is for example be obtained. setup for example only. This only. configuration can be It is extremely important to understand that purge may amended, depending amended, depending on application. can on be application. amended, depending on application. It is extremely understand that purge It isimportant extremelytoimportant to understand thatmay purge may 80 Using an Electronic Pressure Switch for Purge Control Using an electronic pressure switch for purge control Fig ure 7.7 Electr onic press ure switc h f or p urge co ntro l (DMC Cont) Fig ure 7.6 Electr onic press ure switc h f or p urge co ntro l (LED Cont) Figure Electronic forcopurge (DMC Figure Electronic pressure switch forh purge control Controller) Electr onic press urepressure switcpress h fswitch orure p urge l urge (DMCcoCont) Fig ure Electr onic press ure switcpress f orure p urge coh ntro (LED Cont) Fig7.7 ure 7.7 Electr onic switc h ntro f or pcontrol ntro l Controller) (DMC Cont) Fig ure 7.6 Electr onic switc f (LED or pl urge co ntro l (LED Cont) Fig ure 7.7 +VDC +VDC Output +VDC COM Output +VDC COM Output COM -VDC (COM) +VDC -VDC (COM) Relay Relay +VDC(COM) -VDC DC PowerDC Power Electronic DC Power Electronic Electronic Supply Supply Pressure Switch Switch Supply Pressure SwitchPressure Relay Pin Pin DMC DMC DMC Controller Controller Controller Pin DC PowerDC Power Electronic Electronic DC Power Electronic Pressure Switch Supply Supply Pressure Switch Supply Pressure Switch Signal Back SignalSignal Back Back Relay Relay Relay N.C.* N.C.* Signal Back N.C.* Signal Back open toclosed, turn purge * Normally openoffto turn purge off Signal Back * Normally Closed, * Normally Closed, open to turn purge off PRODRY PD PD060 Manual Walker Filtration Filtration PRODRY PD0046Instruction - PD060 Instruction Manual Walker PRODRY PD PD060 Instruction Manual Walker Filtration N.O.* Output COM +VDC +VDC Output Output COM COM (Puts out +5 VDC signal) Pin +VDC +VDC (Puts out (Puts out +5 VDC +5 VDC signal) signal) +VDC -VDC (COM) Pin Signal Out to Switch (+4VDC) Signal Out to Switch (+4VDC) Pin +VDC Pin Pin Pin -VDC (COM) LED Controller Pin LED Controller LED Controller Signal Out to Switch (+4VDC) -VDC (COM) Pin Pin N.O.*N.O.* * Normally open, close to turn offclose purgeto turn off purge * Normally open, * Normally open, close to turn off purge

38 Section 7: Energy Management Using a hygrometer and process controller for purge control The best option for purge control if delivered dryness (pressure Dewpoint) of air from dryer is critical. If air is deemed dry enough, than purge can be shut off until air s moisture starts to climb. If purge is turned off, care must be taken to ensure that desiccant beds are not allowed to wet out too far before purge is turned back on. Also, after turning purge back on, air s pressure Dewpoint may increase a bit before starting to drop again. This should be taken into consideration to ensure that air flow remains sufficiently dry. It is extremely important to understand that purge may only be shut off during periods of low or no demand. This feature, if used orwise, can result in permanent damage to desiccant beds resulting in loss of drying capacity and possibly mechanical failure. The cartridges must not be allowed to become fully saturated at any time. Figures 7.8 and 7.9 offer an overview of devices mentioned as y might be connected for use in controlling a dryer s purge function. Please note that specific details differ between device manufacturers, so in all cases manfacturer s specifications should be adhered to. Figure 7.8: Process controller & hygrometer (LED Controller) Pin (Puts out +5 VDC signal) Pin Dewpoint Transmitter COM +VDC Signal Signal Back DC Power Supply -VDC (COM) +VDC Signal Out LED Controller Process Controller +VDC Signal In Signal Out Relay COM N.C.* * Normally Closed, open to turn purge off Making connections between a switching device & dryer Energy Management contact Figure 7.9: Process controller & hygrometer (DMC Controller) Cable / Wire Selection Criteria: Pin Selected wire should have: At least conductors. More conductors can be useful in case of a conductor break. Conductors can be swapped without having to run new cable. A conductor gauge of no greater than 8 awg is recommended to fit comfortably into DIN connector insert. An outside diameter of no greater than 6mm (/4 ). Larger diameters do not fit well into cable gland of EM DIN connectors. An insulation type compatible with environment that it will be run in. Signal Out to Switch (+4VDC) Pin DC Power Supply -VDC (COM) +VDC DMC Controller Process Controller +VDC Signal In Signal Out COM This setup is for example only. This configuration can be amended, depending on application. Dewpoint Transmitter COM +VDC Signal Signal Back Signal Out Relay N.O.* * Normally open, close to turn off purge 8

39 Section Energy Management Se 7: ct io n 7: Energy Management Se ct io n 7: Energy Management Se ct io n 7: Energy Management Making connections between a switching device and dryer Making connections between a switching device and Energy Management contact. dryer Energy Se ct Management io n 7: Energy contact. Management Fig ure 7. : Co nnecting to EM por t (LED Controller) Figure 7.: Connecting to EM port (LED Controller) Making connections between a switching device and dryer LEDpor Controller Fig ure 7.EM : Co nnecting to EM t (LED Controller) Port Energy Management contact. Making connections between a switching and dryer check continuity at dryer end beforedevice connecting to Fig ure 7. : Co nnecting to EM por t (LED Controller) Energy MakeManagement connection at switch end first. This way you contact. LED Controller dryer. Make sure that contacts on switch are normally EM Port check can continuity at dryer end before connecting closed for LED Controller and normally open for DMC check continuity at dryer before connecting to Making connections between a switching and LED to dryer. Make sure that end contacts on device switch are dryer FigEM ureport 7. : Co nnecting to Controller EM por t (LED Controller) Controller. Pin that of EM connection puts a 5 VDC Energy Management contact. dryer. Make sure dryer contacts onand switch areout normally normally closed forled Controller LED Controller normally open signal on and 4VDC on DMC Controller. check continuity at dryer end before connecting to closed for LED Controller and normally open for DMC for Take DMC Controller. Pin ofcontacts dryer connection LED Controller care to ensure onem puts switching dryer. Make sure contacts switch are normally EM Port Controller. Pinthat of that dryer EMon connection out a 5 VDC a 5 VDC puts out signal on LED Controller and 4VDC device are dry and free of dryer any voltage which could harm closed forcheck LED Controller normally open for DMC signal on LED Controller and 4VDC onconnecting DMC Controller continuity at and end before to. on dryer DMCcontroller. Controller. TakeEM care to ensure that Controller. Pin ofake sure dryer connection puts out a 5are VDC dryer. M that contacts switching switch normally Take care toensure that contacts onon contacts switching are dry and free of any signal onon LED Controller and 4VDC on DMC Controller. DMC closed for LED device Controller open for are dry and free of any which harm device Locate DIN connector on voltage and backnormally of could controller voltage which could harm dryer controller. Takedryer care to ensure that contacts on switching Controller. dryer EM connection puts out a 5 VDC controller. (Figure(s) 7. Pin and of 7.). device aresignal dry freeled of any which could Controller on Controller and 4VDC on harm DMC. Locate DIN and connector on voltage back of controller Loc Remove completely centre of dryer atetake DINscrew connector on from back of on controller ensure that contacts switching controller. (Figure(s) 7. care andto7.). Fig ure 7. : Co nnecting to EM por t (DMC Controller) connector. (Figure(s) 7. device areand dry 7.). and free of any voltage which could harm Remove DIN screw completely centre of Locate connector on from back of controller dryer controller. (Figure(s) screw completely from connector centre ofand discard. Remove Remove blanking plug from 7. and 7.). connector. Figure portpor(dmc Controller) Fig ure7.: 7. :Connecting Co nnectingtotoemem t (DMC Controller) connector. Locate DIN connector on back of controller EM Port Remove blanking and Remove screw completely from connector centre of (Figure(s) 7.plug and from 7.). R emove blanking plug from connector and discard. of insert, pry insert out of DIN connectors outer Fig ure 7. : Co nnecting to EM por t (DMC Controller) connector. discard. R emoveure 7.0. screw completely from centre of shell per Remove Insert a small at screwdriver into small recess at Fig ure 7. : Co nnecting to EM por t (DMC Controller) EM Port blanking plug from connector and discard. connector. edge Controller, remove between offor LED insert, pry pry insert out of jumper out DINofwire connectors of insert, insert which DIN isouter R emove blanking plug from connector and discard. plugper andure and EM Port shell 7.0.discard. DMC connectors outer shell per figure 7.0. of insert, pry insert out of DIN connectors outer Controller EM Port LED LED For Controller, remove jumperwire wire which Slip cable end through DIN connector s cable gland, washer, For remove jumper which isis between shell percontroller, ure 7.0. and insert, pry insert of DINDIN connectors outer plug of and andout discard. grommet through out front of connector case. DMC between plug and and discard shell per reure For LED Controller, move jumper wire which is between Controller cable Strip outer insulation of cablecable back plug Slip cable end through DIN connector s cableapprox gland, 0mm washer, Slip end through DIN gland, and discard. andfor LED Controller, reconnector s move jumper wire which is between DMC (/4 ). and out through front of DIN connector case. grommet washer, grommet outdiscard. through front of DIN plug andand and Controller DMC Slip cable end through DIN connector s cable gland, washer, Strip Strip conductor insulation back approx mm 0mm (/8 ). Controller grommet outer insulation offront cable connector case. and out through of back DINapprox connector Slip cable end through DIN connector s cable gland,case. washer, (/4 ).outer grommet anda out through front of approx DIN connector Strip insulation of cable back 0mm case. If possible using meter, switch function. 0mm Strip outer insulation of verify cable back approx (/4 ). Strip conductor back mm (/8 ). (/4 ). 0mm Strip outerinsulation insulation of approx cable back approx Fig ure 7. : Din co nnect or for LED and DMC C ontrolle r Insert conductors into pins & of insert. Tighten retaining (/4 ). Strip conductor back approx mm (/8 ). screws securely. possible using insulation ainsulation meter, verify switch function. StripIf conductor back approx mm (/8 ). Strip a conductor insulation back approx mm (/8 ). If possible using meter, verify switch function. Fig ure 7. : Din co nnect or for LED and DMC C ontrolle r Determine direction cable gland should point. Insert conductors into pins & switch of insert. Tighten retaining Ifpossible using which a meter, verify function. Insert conductors pins & verify of insert. Tighten Ifsecurely. possibleinto using a meter, switch function. screws C arefully pull cable back through shell until insert Fig ure 7. : Din co nnect or for LED and DMC C ontrolle r retaining Insert conductors into pins & of insert. Tighten retaining securely. Fig ure 7.Din : Din co nnect for or for DMC C ontrolle r Figure 7.: connector LEDLED andand DMC Controller screws Insert conductors into pins & of insert. Tighten retaining screws Determine which direction cable gland should snaps back into place. Take care towork wirespoint. around securely. screws securely. Determine which direction gland should point. retaining screw hole as ycable can become fairly easily pinched. Determine Carefullywhich pull cable back through shell until insert direction through cable gland point. pull Determine which direction cable glanduntil should point. Carefully cable back should shell intoconnector place. Takeback careonto to work wires snaps Plug back DIN dryer s EMaround connection snaps back into place. Take care to work wires insert Carefully pull cable back through shell until insert retaining screw hole assure ythat cansealing become fairly pinched. taking care topull make gasket iseasily inuntil place. Carefully cable back through shell insert Gasket snaps back into place. Take care to work wires around around snaps retaining screw hole as y can become fairly back into place. Take care to work wires around retaining Plug DINhole connector back ontocan become dryer s EM pinched. connection screw as y can become fairly easily retaining screw hole asisy fairly easily easily pinched. ground slightly &pinched.. Insert takingthe caremale to make surepin that sealing wider gasketthan is in pins place. Take caredin to ensure female Gasket Plug connector backthat onto dryer s DIN Plugconnector connector back onto connector dryer s EMisconnection Plug DIN back onto dryer s EMEM connection Case oriented corectly. Outer insulation taking caresure to make sure that sealing isgasket is in place. taking care make in place. connection The to male ground that pin issealing slightlygasket wider than pins &. Take care to ensure that female connector is The male ground pin is wider slightlythan wider than pins The7.0 male ground pin pins &. &. Fig ure : DIN conn ecto ris slightly oriented corectly. The male ground pin is slightly wider than is care tothat ensure connector female connector Take care Take to ensure that female is oriented pins &. corectly. Take care to ensure that female oriented corectly. Fig ure 7.0 : DIN conn ectoisr oriented correctly. connector Fig ure 7.0 : DIN conn ecto r Fig ure 7.0DIN : DIN conn ecto r Figure 7.0: connector must extend through grommet Outerto insulation ensure that must extend IP65 specification Outergrommet insulation through Outer insulation is met must extend to extend ensure that must through grommet IP65grommet specification through to ensure that is met to ensure that IP65 specification IP65 specificationis met is met mm 0 mm mm mm mm 0 mm 0 mm 0 mm Gasket Insert Gasket Grommet Insert Case Insert Washer Case CaseGrommet Cable Grommet Washer Grommet Cable Gland Washer Cable Washer Cable CableCable Gland Cable Gland Cable Gland PRODRY PD PD060 Instruction Manual Walker Filtration PRODRY PD PD060 Instruction Manual Walker Filtration PRODRY PD PD060 Instruction Manual Walker Filtration PRODRY PD PD060 Instruction Manual Walker Filtration

40 Section 8: Maintenance Maintenance Information All maintenance information is provided in service / maintenance leaflets. These leaflets are provided with each serviceable item / kit showing how to carry out change-out component. The service leaflet part numbers are shown below: (Desiccant Cartridge service leaflet) (Purge Orifice disc service leaflet) (Exhaust Silencer service leaflet) (Main Shuttle service leaflet) (Exhaust Shuttle service leaflet) Service Intervals / Applicable Service Kits Pre- Filter Element Exhaust silencer Desiccant cartridges Main shuttle Exhaust shuttle Solenoid valves Purge orifice Every year or 6000 hours Every year or 6000 hours Every years or 000 hours Every 4 years or 4000 hours Every 4 years or 4000 hours Every 4 years or 4000 hours Every 4 years or 4000 hours Important information. Ensure shutdown and start-up procedures are followed prior to carrying out any maintenance work on dryer. Walker Filtration will not accept responsibility for physical injury, damage or delays caused by failure to observe instructions in this manual and manuals provided with your equipment. 40

41 Section 9: Spares Information Service kits 6,000 hour, Silencer Service kit Dryer Model Kit Part Number Description Change-Out Period PD PD060 PDSK0 Silencer Kit (Kit includes () silencers; reference figure 0.) 6,000 Hours or Year,000 hour, Desiccant Cartridge & Silencer Service Kit Dryer Model Kit Part Number Description Change-Out Period PD0046 PDSK ,000 Hours or Years PD0056 PDSK ,000 Hours or Years PD0075 PDSK ,000 Hours or Years PD0090 PDSK ,000 Hours or Years,000 Hour Desiccant Cartridge and Silencer Kit PD00 PDSK (Kit includes desiccant cartridges and associated,000 Hours or Years PD050 PDSK seals, and silencer service kit;,000 Hours or Years PD080 PDSK reference figures 0., 0. and 0.4),000 Hours or Years PD00 PDSK00-000,000 Hours or Years PD000 PDSK ,000 Hours or Years PD060 PDSK ,000 Hours or Years,000 hour, High Performance Desiccant Cartridge & Silencer Service Kit - for use where -74 C (-00 F) dewpoint is required Dryer Model Kit Part Number Description Change-Out Period PD0046 PDSK0046BA-000,000 Hours or Years PD0056 PDSK0056BA-000,000 Hours or Years PD0075 PDSK0075BA-000,000 Hours or Years PD0090 PDSK0090BA-000,000 Hour High Performance Desiccant Cartridge,000 Hours or Years PD00 PDSK00BA-000 and Silencer Kit,000 Hours or Years PD050 PDSK050BA-000 (Kit includes High Performance desiccant cartridges and associated seals, and silencer service kit;,000 Hours or Years PD080 PDSK080BA-000 reference figures 0., 0. and 0.4),000 Hours or Years PD00 PDSK00BA-000,000 Hours or Years PD000 PDSK000BA-000,000 Hours or Years PD060 PDSK060BA-000,000 Hours or Years 8,000 hour, Silencer Service kit Dryer Model Kit Part Number Description Change-Out Period PD PD060 PDSK0 Silencer Kit (Kit includes () silencers; reference figure 0.) 8,000 Hours or Years 4

42 Section 9: Spares Information Service kits Voltage DMC 4V LED 5V LED 0V 4,000 Hour, Desiccant Cartridge, Silencer, Valve & Purge Valve Service Kit Dryer Model Kit Part Number Description Change-Out Period PD0046 PDSK S4 4,000 Hours or 4 Years PD0056 PDSK S4 4,000 Hours or 4 Years PD0075 PDSK S4 4,000 hour Desiccant Cartridge, Silencer, 4,000 Hours or 4 Years PD0090 PDSK S4 Valve & Purge Valve Service Kit 4,000 Hours or 4 Years PD00 PDSK S4 (Kit includes desiccant cartridges and associated 4,000 Hours or 4 Years PD050 PDSK S4 seals; reference figures 0. and 0.4, silencer service kit; reference figures 0., and 4,000 Hours or 4 Years PD080 PDSK S4 valve body stem and all associated seals; reference 4,000 Hours or 4 Years PD00 PDSK D4 figures 0.6) 4,000 Hours or 4 Years PD000 PDSK D4 4,000 Hours or 4 Years PD060 PDSK D4 4,000 Hours or 4 Years PD0046 PDSK S5 4,000 Hours or 4 Years PD0056 PDSK S5 4,000 Hours or 4 Years PD0075 PDSK S5 4,000 hour Desiccant Cartridge, Silencer, 4,000 Hours or 4 Years PD0090 PDSK S5 Valve & Purge Valve Service Kit 4,000 Hours or 4 Years PD00 PDSK S5 (Kit includes desiccant cartridges and associated 4,000 Hours or 4 Years PD050 PDSK S5 seals; reference figures 0. and 0.4, silencer service kit; reference figures 0., and 4,000 Hours or 4 Years PD080 PDSK S5 valve body stem and all associated seals; reference 4,000 Hours or 4 Years PD00 PDSK D5 figures 0.6) 4,000 Hours or 4 Years PD000 PDSK D5 4,000 Hours or 4 Years PD060 PDSK D5 4,000 Hours or 4 Years PD0046 PDSK S0 4,000 Hours or 4 Years PD0056 PDSK S0 4,000 Hours or 4 Years PD0075 PDSK S0 4,000 hour Desiccant Cartridge, Silencer, 4,000 Hours or 4 Years PD0090 PDSK S0 Valve & Purge Valve Service Kit 4,000 Hours or 4 Years PD00 PDSK S0 (Kit includes desiccant cartridges and associated 4,000 Hours or 4 Years PD050 PDSK S0 seals; reference figures 0. and 0.4, silencer service kit; reference figures 0., and 4,000 Hours or 4 Years PD080 PDSK S0 valve body stem and all associated seals; reference 4,000 Hours or 4 Years PD00 PDSK D0 figures 0.6) 4,000 Hours or 4 Years PD000 PDSK D0 4,000 Hours or 4 Years PD060 PDSK D0 4,000 Hours or 4 Years 4

43 Section 9: Spares Information Service kits LED 0V LED 5V DMC 4V Voltage 4,000 Hour, High Performance Desiccant Cartridge, Silencer, Valve & Purge Valve Service Kit For use where -74 C (-00 F) dewpoint is required Dryer Model Kit Part Number Description Change-Out Period PD0046 PDSK0046BA-4000-S4 4,000 Hours or 4 Years PD0056 PDSK0056BA-4000-S4 4,000 Hours or 4 Years PD0075 PD0090 PD00 PD050 PD080 PD00 PDSK0075BA-4000-S4 PDSK0090BA-4000-S4 PDSK00BA-4000-S4 PDSK050BA-4000-S4 PDSK080BA-4000-S4 PDSK00BA-4000-D4 4,000 hour High Performance Desiccant Cartridge, Silencer, Valve & Purge Valve Service Kit (Kit includes desiccant cartridges and associated seals; reference figures 0. and 0.4, silencer service kit; reference figures 0., and valve body stem and all associated seals; reference figures 0.6) 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years PD000 PDSK000BA-4000-D4 4,000 Hours or 4 Years PD060 PDSK060BA-4000-D4 4,000 Hours or 4 Years PD0046 PDSK0046BA-4000-S5 4,000 Hours or 4 Years PD0056 PDSK0056BA-4000-S5 4,000 Hours or 4 Years PD0075 PD0090 PD00 PD050 PD080 PD00 PDSK0075BA-4000-S5 PDSK0090BA-4000-S5 PDSK00BA-4000-S5 PDSK050BA-4000-S5 PDSK080BA-4000-S5 PDSK00BA-4000-D5 4,000 hour High Performance Desiccant Cartridge, Silencer, Valve & Purge Valve Service Kit (Kit includes desiccant cartridges and associated seals; reference figures 0. and 0.4, silencer service kit; reference figures 0., and valve body stem and all associated seals; reference figures 0.6) 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years PD000 PDSK000BA-4000-D5 4,000 Hours or 4 Years PD060 PDSK060BA-4000-D5 4,000 Hours or 4 Years PD0046 PDSK0046BA-4000-S0 4,000 Hours or 4 Years PD0056 PDSK0056BA-4000-S0 4,000 Hours or 4 Years PD0075 PD0090 PD00 PD050 PD080 PD00 PDSK0075BA-4000-S0 PDSK0090BA-4000-S0 PDSK00BA-4000-S0 PDSK050BA-4000-S0 PDSK080BA-4000-S0 PDSK00BA-4000-D0 4,000 hour High Performance Desiccant Cartridge, Silencer, Valve & Purge Valve Service Kit (Kit includes desiccant cartridges and associated seals; reference figures 0. and 0.4, silencer service kit; reference figures 0., and valve body stem and all associated seals; reference figures 0.6) 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years 4,000 Hours or 4 Years PD000 PDSK000BA-4000-D0 4,000 Hours or 4 Years PD060 PDSK060BA-4000-D0 4,000 Hours or 4 Years 4

44 Section 9: Spares Information Accessory kits Solenoid Kit (Kit includes () solenoid control valves with attached tube fittings; reference figure 0.5) Dryer Model Kit Part Number Description PD PD060 PDSKV04 4VDC Solenoid Kit PD PD060 PDSKV5 5V Solenoid Kit PD PD060 PDSKV0 40V Solenoid Kit Shuttle Service Kit (Kit includes () control shuttle, () exhaust shuttles and associated seals; reference figure 0.) Dryer Model Kit Part Number Description PD PD080 PDSKS0 Simplex Shuttle Service Kit PD00 - PD060 PDSKD0 Duplex Shuttle Service Kit Controller kit (Kit includes () controller and () control solenoid valves with installed tube fittings; reference figure 0.5) Dryer Model Kit Part Number Description PD PD060 PDCK04 4VDC Controller Complete with Valves PD PD060 PDCK0 0V Controller Complete with Valves PD PD060 PDCK40 40V Controller Complete with Valves Purge Orifice (complete) Complete kit for dryers operating between 4 and barg and appropriate purge orifice discs, fully assembled; reference figure 0.6 Dryer Model Kit Part Number Description PD0046 PDPPK PD PD0056 Purge valve kit PD0056 PD0075 PD0090 PD00 PD050 PDPPK PDPPK PD PD00 Purge valve kit PD050 Purge valve kit PD080 PDPPK4 PD080 Purge valve kit PD00 PDPPK5 PD00-PD000 Purge valve kit PD000 PD060 PDPPK6 PD060 Purge valve kit Purge disc kit (Kit includes () ea discs 0, 0, 0 and 04; reference figure 0.6) Dryer Model Kit Part Number Description PD PD060 PDPDK4 Purge orifice disc kit 44

45 Section 9: Spares Information Hygrometer Kit Dryer Model Kit Part Number Description PD PD060 PDHK0 Hygrometer Kit (Kit includes hygrometer only) Drain Valve Kit (Kit includes () solenoid drain valve with attached female DIN connector) Dryer Model Kit Part Number Description PD PD060 PDDVS0 Drain Valve Kit Din Plug Kit (Kit includes (), pole + ground industrial standard DIN connector) Dryer Model Kit Part Number Description PD PD060 PDDIN0 Female DIN plug kit Power Supply Kit (Kit includes power supply and DIN connector) Dryer Model Kit Part Number Description PD PD060 PDPSK V to 4VDC Power Supply Lead (4VDC DMC controller only) Although power supply is supplied separately as an accessory and meets required CE and UL approval, it is responsibilty of a competent person installing equipment that all local installation regulations are adhered to. Master seal kit (Kit includes all seals (except purge orifice seals); reference figures 0., 0., 0. and 0.4 Dryer Model Kit Part Number Description PD PD080 PDMSKS Simplex master seal kit PD00 - PD060 PDMSKD Duplex master seal kit 45

46 Section 0: Component Parts Component parts PD PD060 Fig 0. Top manifold assembly DMC Only Itm Description Qty Inlet / outlet manifold Purge valve service plug Purge control valve Valve control spring Inlet/outlet blanking plug Hyg port blanking plug Manifold fixing bolts Hygrometer sample block* Manifold connection O-ring Valve service plug O-ring Down tube O-ring 8 Included in Service / Accessory Kit Master Seal Duplex or Simplex See figure 0.6 * Duplex Only Fig 0. Bottom manifold assembly Itm Description RH exhaust manifold Qty Included in Service / Accessory Kit Valve Service Shuttle Service Silencer Master Seal LH exhaust manifold Centre shuttle manifold 4 Control shuttle 5 6 Exhaust control valve Valve service plug 7 Silencer adapter Manifold fixing bolt* Duplex fixing clip Silencer 8/ Manifold connection O-ring Exhaust manifold O-ring Duplex Down tube O-ring 4 Valve Service Plug O-ring * 8 for Simplex / for Duplex 46

47 Section 0: Component Parts PD PD080 Fig 0. Tower assembly (Simplex) Included in Service / Accessory Kit 8 7 Itm Description Qty Desiccant Cartridge Master Seal Tower extrusion Extrusion tower plug Desiccant cartridge* Cartridge pressure spring /4 5 Support circlip 6 Floor mounting bracket 7 Trim caps Controller reset magnet Service cap outer O-ring Service cap inner O-ring 4 4 * Quantity varies per dryer model

48 Section 0: Component Parts PD PD080 Fig 0.4 Tower assembly (Duplex) 8 Included in Service / Accessory Kit 0 Itm Description Qty Desiccant Cartridge Master Seal Tower extrusion (Front) Tower extrusion (Rear) Extrusion tower plug 8 4 Desiccant cartridge Cartridge pressure spring Support circlip Floor mounting bracket Trim caps Clamp assembly Controller reset magnet Service cap outer O-ring Service cap inner O-ring Extrusion O-ring

49 Section 0: Component Parts PD PD080 Fig 0.5 Controller assemblies Fig 0.5 Controller assembl ies Included in Service /Accessory Kit Itm Description Qty Valve Service Solenoid Controller** Solenoid control valves* LED controller DMC controller * Includes installed tube fittings ** Specify which controller model and/or voltage when ordering Fig 0.6 Purge valve assembly Included in Service / Accessory Kit Itm Description Qty Purge Valve Body ( Hole) Purge Valve Body ( Hole) Purge Valve Body ( Hole) Purge Orifice Disc Purge valve body Orifice disc (0) Orifice disc (0) Orifice disc (0) Orifice disc (04) Sealing gasket ( Hole) Sealing gasket ( Hole) Sealing gasket ( Hole) Valve stem O-ring // 0 Valve stem ( Hole) Valve stem ( Hole) Valve stem ( Hole) M4 screw 4 Valve control spring 49

50 Section : Troubleshooting Troubleshooting General troubleshooting Before specific identification of any fault is looked for, following general points must be verified: Has unit been damaged externally or are any parts missing? Is power being supplied to unit? Was start-up carried out in accordance with instructions in this manual? Are all external valves correctly set for operation? Do operational conditions meet those specified at time of ordering and used for product selection? Did dryer operate normally for a period of time before problem occured? Before calling for service assistance, please obtain dryer model and serial number from dryer specification label. Troubleshooting: General Problem Possible Cause Action Poor dewpoint Liquid water at dryer inlet Check pre-filtration and drains Incorrect dryer operation, won t switch towers Incorrect dryer operation, won t depressurise towers Excessive or loud purge, or purge on only one tower Excessive flow Low inlet pressure High inlet temperature Incorrect purge orifice size Silencer blocked or damaged Air leaks Desiccant life exceeded Desiccant contaminated EM is active when air is flowing through dryer Power to dryer off while air is flowing through dryer Jammed shuttle valves Faulted electrical components Jammed purge exhaust shuttle Blocked and/or damaged silencer Jammed main control shuttle valve Jammed purge exhaust shuttle Faulty solenoid valve Check actual flow against maximum specified Check against specification Check against specification Check against specification and reconfigure Replace silencer Tighten joints or fit new seals Replace desiccant cartridges Check inlet filter and drains, replace cartridges Check EM wiring, DMC and/or control method used Ensure that power is on whenever air is flowing through dryer Clean or replace shuttles See electrical operation troubleshooting section Clean or replace exhaust shuttles and solenoid valves Replace silencer Clean or replace shuttles Clean or replace exhaust shuttles Clean or replace solenoid valve Not utilising Energy Management feature Refer to Energy Management instructions (Section 7) Blocked and/or damaged silencer Damaged purge valve(s) Incorrect purge orifice size Replace silencer and check desiccant cartridges Replace purge valve bodies Double check and select correct size 50

51 Section : Troubleshooting Troubleshooting: Electrical Problem Possible Cause Action No dryer function No power supply Check supply Dryer does not activate external alarm when display panel indicates alarm condition Power connected to wrong controller input Faulty controller Shorted or incorrect device wiring External power not supplied Faulty external indication device Faulty controller Check connections with specifications listed in Section 5 Replace controller Correct external wiring Add external power source per specifications given in Section 5 Repair or replace device Replace controller Troubleshooting: Energy Management Problem Possible Cause Action Dryer does not enter Energy Management when switching device is activated and/or Dryer does not enter Energy Management when EM contacts are opened. Shorted or incorrect device wiring Faulty switching device Faulty controller output Remove external wiring from dryer s EM contacts: On LED controllers, dryer should enter EM mode. On DMC controllers, place jumper between pins and of EM male connector. Dryer should enter EM mode. If dryer enters EM mode, correct external wiring problem If dryer does not enter EM mode, replace controller Consult device manufacturer Replace controller Troubleshooting: Dewpoint control (DMC Controller only) Problem Possible Cause Action Dryer does not enter dewpoint mode Dryer controller displaying hygrometer out of range Hygrometer Din plug not connected correctly to hygrometer Demand is too high, dryer undersized Hygrometer not reading accurately / fouled Hygrometer failed (electrically) Hygrometer is reading an outlet dewpoint of eir +0 C or -00 C which is maximum limits of hygrometer Check Din plug is tightly connected to hygrometer with Din plug Check against specification Verify hygrometer calibration Replace hygrometer Check hygrometer is functioning correctly and not damaged 5

52 Section : Troubleshooting Troubleshooting - LED Display Status Identification LED Identification Function N/A Power Off Z Power On Indication Remark Power supply disconnected X Left tower Online Left tower drying Y Right tower Online Right tower drying X&Y Both towers Online One tower drying, or tower repressurising X Left solenoid failure Clean or replace solenoid 5

53 Section : Troubleshooting LED Number Function Indication Remark Y Right solenoid failure Clean or replace solenoid Service warning 500 hours continuous operation Service alarm 000 hours continuous operation & Controller reset Activated when reset magnet is applied N/A Power Failure Replace controller 5

54 Section : Troubleshooting Function Indication Remark Line message Full DMC message layout Line message Line message Line message 4 Line message STANDARD RUNNING MODE Dryer functioning in standard running mode Line message - Line message HOURS RUN XXXXX Line message 4 Line message SERVICE HISTORY # XX STANDARD RUNNING MODE Dryer functioning in standard running mode (service due) Line message - Line message SERVICE DUE (XXX HOURS) Service due (500 hour countdown until 000 hours continuous operation) Line message 4 Line message SERVICE HISTORY # XX STANDARD RUNNING MODE Dryer functioning in standard running mode (service overdue) Line message - Line message SERVICE OVERDUE Service overdue (000 hours continuous operation) Line message 4 Line message SERVICE HISTORY # XX ENERGY MANAGEMENT MODE Energy management mode active Line message - Line message HOURS RUN XXXXX Line message 4 Line message SERVICE HISTORY # XX ENERGY MANAGEMENT MODE Energy management mode active (service due) Line message - Line message SERVICE DUE (XXX HOURS) Service due (500 hour countdown until 000 hours continuous operation) Line message 4 Line message SERVICE HISTORY # XX ENERGY MANAGEMENT MODE Energy management mode active (service overdue) Line message - Line message SERVICE OVERDUE Service overdue (000 hours continuous operation) Line message 4 SERVICE HISTORY # XX 54

55 Section : Troubleshooting Function Indication Remark Dewpoint mode active (-0) or Dewpoint mode active (-40) or Dewpoint mode active (-74) Line message DEWPOINT MODE (-0) (-40) (-74) Line message DRYER DEWPOINT -XXX PDP Line message HOURS RUN XXXXX Line message 4 SERVICE HISTORY # XX Dewpoint mode active but dryer in standard cycle mode Dewpoint hold active (-0) or Dewpoint hold active (-40) or Dewpoint hold active (-74) Dewpoint mode active (-0) service due or Dewpoint mode active (-40) service due or Dewpoint mode active (-74) service due Dewpoint mode active (-0) service overdue or Dewpoint mode active (-40) service overdue or Dewpoint mode active (-74) service overdue Dewpoint hold active (-0) service due or Dewpoint hold active (-40) service due or Dewpoint hold active (-74) service due Dewpoint hold active (-0) service overdue or Dewpoint hold active (-40) service overdue or Dewpoint hold active (-74) service overdue Line message DEWPOINT HOLD (-0) (-40) (-74) Line message DRYER DEWPOINT -XXX PDP Line message HOURS RUN XXXXX Line message 4 SERVICE HISTORY # XX Line message DEWPOINT MODE (-0) (-40) (-74) Line message DRYER DEWPOINT -XXX PDP Line message SERVICE DUE (XXX HOURS) Line message 4 SERVICE HISTORY # XX Line message DEWPOINT MODE (-0) (-40) (-74) Line message DRYER DEWPOINT -XXX PDP Line message SERVICE OVERDUE Line message 4 SERVICE HISTORY # XX Line message DEWPOINT HOLD (-0) (-40) (-74) Line message DRYER DEWPOINT -XXX PDP Line message SERVICE DUE (XXX HOURS) Line message 4 SERVICE HISTORY # XX Line message DEWPOINT HOLD (-0) (-40) (-74) Line message DRYER DEWPOINT -XXX PDP Line message SERVICE OVERDUE Line message 4 SERVICE HISTORY # XX Dewpoint hold active purge flow has been isolated Dewpoint mode active but dryer in standard cycle mode (500 hour countdown until 000 hours continuous operation) Dewpoint mode active, dryer in standard cycle mode (000 hours continuous operation) Dewpoint hold active, purge flow has been isolated 500 hour countdown until 000 hours continuous operation Dewpoint hold active, purge flow has been isolated 000 hours continuous operation Line message XXXXXXXXXXXXXXX Hygrometer out of range Line message Line message XXXXXXXXXXXXXXXXXXXXX XXXXXXXXXXXXXXXXXXXXX Check din plug and wiring connections between hygrometer and Dryer controller Line message 4 HYGROMETER OUT OF RANGE 55

56 Section : Warranty Warranties and liabilities Claims for warranty and liability concerning personal injury or material damage are excluded if y resulted due to one or more of following factors: Inappropriate use Inappropriate application of dryer. Technically incorrect installation, start-up operation or maintenance of dryer. Operation of a known damaged dryer. Failure to observe information given in this manual concerning all life phases of dryer. Undertaking constructional or operational modifications to dryer without prior agreement with Walker Filtration. Inadequate monitoring and replacement of components of dryer that are subject to wear. Improper completion of repairs. Use of non-original or non-approved parts for service or maintenance. The warranty of this product could become void if correct filtration is not installed upstream of dryer. It is recommended that inlet filtration upstream of dryer consists of a WS, X n XA. However, it is essential that a WS followed by a XA is used Important Note Industrial Compressed Air Desiccant Dryers The Walker Filtration Ltd desiccant dryer range is designed for, warrantied and intended for use in fixed industrial compressed air applications only. Use on non-fixed installations such as : Such additional undertakings are responsibility of package or system builder, installer or end user. marine (e.g. offshore, shipboard) transportable (e.g. portable air treatment units) non-fixed (e.g. rolling stock, railway etc) are not strictly prohibited, however use in such applications is not recommended nor endorsed as additional design features, function testing, certification (both mechanical and electrical) and validation may be required to satisfy relevant end user application specific specifications and/or mandatory and non-mandatory local, national or international standards and legislation. 56

57 Section : Declaration of Conformity Declaration of Conformity 04/0/EU, 04/5/EU, 04/68/EU (97//EC) Name of Manufacturer Address of Manufacturer Description of Product Designation of Product Standards Used Walker Filtration Ltd. Birtley Road, Washington, Tyne & Wear, NE8 9DA, England. PRODRY Compressed Air Desiccant Dryers PD0046, PD0056, PD0075, PD0090, PD00, PD050, PD080, PD00, PD000, PD060 LVD: 04/5/EU EN 600-:00* Harmonised Standards* applied where available with alternatives specified where harmonised standards do not exist. EMC: 04/0/EU PED: 97//EC PED: 04/68/EU (From ) EN :005+AC:005* EN :007+A:0+AC:0* Generally in accordance with ASME VIII Division Rules for Construction of Pressure Vessels Notified Body Pressure Equipment Directive (PED) Only Conformity Assessment Module Pressure Equipment Directive (PED) Only Lloyds Register EMEA Notified Body No Fenchurch Street, London, ECM 4BS, England PD0046-PD080: Cat II Module D [COV004/] PD00-PD060: Cat III Module B [COV6049/]**+ D [COV690/] **Module B certificate issued by conformity assessment body under directive 97//EC and remains valid under new directive as defined in 04/68/EU Article 48. Quality Assurance System ISO 900:008 Certificate Number LRQ Lloyds Register Quality Assurance Ltd (LRQA) Trinity Park, Bickenhill Lane, Birmingham, B7 7ES, United Kingdom Year of Manufacture Name of Authorised Representative Position of Authorised Representative Refer to product marking Simon Wise CTO (Chief Technical Officer) This declaration of conformity is issued under sole responsibility of manufacturer. I declare on behalf of Walker Filtration Ltd ( manufacturer) and as authorised representative, that above stated products fulfil requirements of new approach directives July 06 57

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