Service package PDAD- -SP-12000 (en) Assembly instructions 8068819 1701d [8068821]
Original instructions Installation and commissioning are to be carried out only by qualified personnel in accordance with the assembly instructions. 2 Festo PDAD- -SP-12000 1701d
Table of contents 1. Introduction... 4 2. Safety... 5 3. Decommissioning... 7 4. Replacing the desiccant cartridges... 8 5. Commissioning... 12 6. Resetting the controller... 13 Festo PDAD- -SP-12000 1701d English I 3
1. Introduction For all available product documentation www.festo.com/pk These assembly instructions describe all the activities that need to be carried out to service the adsorption dryer. You must carry out the activities in the following order: 1. Decommissioning 2. Replacing the desiccant cartridges 3. Commissioning 4. Resetting the controller Further information about the adsorption dryer PDAD can be found in the operating instructions which accompany the device. Scope of delivery of the service package PDAD-09/13/22/51/73 2 desiccant cartridges 4 plastic discs 6 O-rings, large 4 O-rings, small 1 reset disc PDAD-100 4 desiccant cartridges 8 plastic discs 12 O-rings, large 8 O-rings, small 1 reset disc 4 Festo PDAD- -SP-12000 1701d. English
2. Safety Festo expressly excludes any liability or responsibility for damages and/or injuries which result from violation of these assembly instructions. The service package may only be used for its intended purpose. The parts of this service package are to be used to change the desiccant cartridge in the adsorption dryer PDAD. The following symbol indicates a possible hazard. Where such hazards arise, the appropriate measures must be taken in order to reduce the risk for the user or operator of the product. Caution: Source of danger Note on Pressure Equipment Directive Classification of the dryers in pressure equipment categories Type PDAD-09 PDAD-13 PDAD-22 PDAD-51 PDAD-73 PDAD-100 Category I I I I II II Notes on commissioning and maintenance Vibrations can cause fatigue in the material and can decrease the endurance limit of the adsorption dryers and mounting components. Protect adsorption dryers and mounting components against mechanical vibrations. Commissioning and the intervals for periodic inspections are subject to the applicable national regulations. When carrying out maintenance work, inspect components visually for damage. Replace the device if necessary. Festo PDAD- -SP-12000 1701d English I 5
The following mandatory safety regulations need to be strictly adhered to: Maintenance personnel must be aware of the following information: Accident prevention regulations Safety information (general and device specific) Device safety equipment Measures to be taken in an emergency It is the installer's responsibility to ensure that the cables to and from the dryer are suitable for the task, correspond to the applicable laws and have been subjected to a visual check and tests before commissioning. All cables must be fixed in an appropriate manner. The device must be decommissioned before carrying out any maintenance or repair work. Operators and other personnel are exposed to a risk if work is carried out on a running device. Decommissioning the device means disconnecting it from the power supply and compressed air supply and ensuring the pressure is completely reduced. Only use accessories and spare parts from the manufacturer. There is no guarantee that non-original spare parts are designed and manufactured to correspond to the safety and operating requirements of the device. Festo takes no liability for device faults which result from the use of unapproved spare parts. Do not make any design changes to the product. Changes and modifications may only be carried out by Festo. All faults or defects which could impair safety must be fully eliminated before using the device. Used objects and materials must be correctly disposed of in line with the local laws and conditions. This applies in particular to the desiccant cartridges. 6 Festo PDAD- -SP-12000 1701d. English
3. Decommissioning 1. If a bypass line has been installed, open valve C and D. Make sure that the air flowing through the bypass is not dried out. 2. Close valve B. 3. Close valve A. 4. Leave the dryer to run for 15 minutes to ensure the pressure is completely reduced. 5. Disconnect the device from any power supply. O C D B The desiccant cartridges can fail. Ensure that there is no compressed air in the adsorption dryer during longer interruptions to the power supply. Festo PDAD- -SP-12000 1701d English I 7
4. Replacing the desiccant cartridges Both desiccant cartridges (four in the case of the PDAD-100) must always be replaced at each maintenance interval. 1. Decommission the dryer. 2. Remove the micro filter MS6-LFM if mounted on the front of the dryer. To do this, unscrew the screws of the module connector 1. Then remove the module connector and the micro filter. When removing the filter, be careful with the flat seal and O-ring between the micro filter and dryer. These parts will be needed again for reassembly. 3. Release both mounting screws on the cover plate 2 (PZ 2) and remove the cover sheet. 4. Slightly loosen the four mounting screws of the pressure housing 3 using a hex key (SW 5). 5. Release the four mounting screws of the multiple distributor 4 (SW 5) with three full turns. 6. Remove the four mounting screws of the reservoir 3 and pull the reservoir out of the dryer. Remove the reservoir from the dryer. 7. Remove and dispose of the O-rings 5 between the reservoir and the top/ bottom valve block. 2 3 3 4 1 5 5 8 Festo PDAD- -SP-12000 1701d. English
8. Loosen the screw of the reservoir seal 6 using a hex key (SW 5). 9. Pull the entire cartridge module out of the reservoir using the handle on the lid 8. 10. Remove the lid 8 by unscrewing the screw of the reservoir seal 6. 11. Dispose of the plastic disc 7, the two large O-rings 9 and the used desiccant cartridge aa in compliance with the local waste disposal stipulations. 12. Re-assemble the cartridge module with the new desiccant cartridge aa, the two large O-rings 9 and the plastic disc 7 from the service package. Lightly screw in the screw of the reservoir seal 6. 6 8 6 7 8 9 aj 9 aa Festo PDAD- -SP-12000 1701d English I 9
13. Place the cartridge component in the reservoir. 14. Screw in the reservoir seal screw 6. The maximum tightening torque is 5 Nm. 15. Place a new O-ring ab from the service package on both the top and bottom valve block. 16. Place the reservoir in the dryer. Make sure that the reservoir is properly seated. The reservoir must fit tightly against the valve blocks. 17. Screw in the four mounting screws of the reservoir 3 until the reservoir is securely fixed. Do not yet fully tighten the screws. 18. Repeat steps 6 to 17 until all desiccant cartridges have been replaced. 6 3 ab ab 3 10 Festo PDAD- -SP-12000 1701d. English
19. Tighten the four mounting screws of the multiple distributor 4. The tightening torque is 20 Nm 20. Now, firmly tighten all mounting screws on the reservoir 3. The tightening torque is 20 Nm. 21. Fit the cover plate using both mounting screws 2. The tightening torque is 1 Nm. 22. If necessary, assemble the micro filter on the dryer (see operating instructions). 23. Put the dryer back in operation (see chapter 5. Commissioning). 24. Reset the control device with the reset disc from the service package (see operating instructions). 4 2 3 3 Festo PDAD- -SP-12000 1701d English I 11
5. Commissioning 1. Close valves A, B, C and D. 2. Switch on the compressor. 3. Slowly open valve A. Compressed air flows through the desiccant cartridge and escapes into the atmosphere via the silencer. 4. Check the dryer for leaks. O C D B POWER X Y Z POWER Z X Y 5. Switch on the power supply. All four LEDs on the display panel simultaneously flash green four times and then red four times to confirm the power supply. Observe the display panel during an entire operating cycle. The following cycle is preset in the factory and starts automatically. (i) The power supply LED POWER and reservoir LED X light up green. (ii) After 120 seconds the reservoir LED X goes out and the condensate outlet LED Z lights up green. The condensate drain valve opens for approx. two seconds. (iii) After a further 50 seconds the condensate drain LED Z goes out and the reservoir LED Y lights up green. (iv) After a further 120 seconds the reservoir LED Y goes out. (v) After a further 50 seconds the reservoir LED X lights up green. (vi) The cycle described above repeats itself (i v). 6. Reset the control device with the reset disc included in the service package (see the chapter about resetting the controller). 7. Leave the dryer to run for at least six hours in order to ensure that the correct pressure dew point is reached. 8. Slowly open valve B. 12 Festo PDAD- -SP-12000 1701d. English
6. Resetting the controller After carrying out the commissioning process the controller must be reset using the reset disc in the service package. The disc must be held for five seconds on the blue part of the display. During these five seconds the power supply LED POWER (network supply) flashes green. After a successful reset, the reservoir LED Y flashes red once as confirmation. The operating hour counter for the nine desiccant cartridges starts at 0. 1 Reservoir LED Y 2. Power LED 1 2 Festo PDAD- -SP-12000 1701d English I 13
Copyright: Festo AG & Co. KG, PO box D-73726 Esslingen, Germany Phone: +49 711 347-0 Fax: +49 711 347-2144 The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation is prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event that a patent, utility model or design patent is registered. e-mail: service_international@festo.com Internet: http://www.festo.com Original: Version: de 1701d