dh domnick hunter Breathing Air Purification Modules Installation, Operating & Maintenance Instructions
ARRANGEMENT DRAWINGS Section Page 1. BAM102 - BAM110 4 2. BA-DME012 to BA-DME030 6 3. BA-DME040 7 4. BA-DME050 to BA-DME060 8 5. BA-DME080 9 MAXI DRYER Section Page 1. General Description 12 2. Technical Specification 12 3. Operation of DDS Controller 13 4. DDS Heatless Control Schematic (See Figs.) 14 5. Installation 17 6. Maintenance 17 7. Known Misuse 18 8. Fault Finding 18 9. Warranty 19 MIDI DRYER Section Page Safety Warning 21 1. General Description 21 2. Technical Specification 22 3. Unpacking 23 4. Installation 23 5. Electrical Details 26 6. Operation 27 7. Maintenance 28 8. Fault Diagnosis 29 9. Known Misuse 29 10. Declaration 30 11. Warranty 31 1
PURIFIERS BAH101 Section Page 1. Installation 33 2. Service Life 35 3. Maintenance 35 PURIFIERS BAH102 - BAH106 Section Page 1. Installation 37 2. Service Life 39 3. Maintenance 39 OIL - X FILTERS Section Page 1. Declaration 41 2. Technical Specification 41 3. Installation 42 4. Maintenance 43 5. Element Replacement 44 6. Differential Pressure Gauge 46 7. Accessories 47 8. Declaration of Conformity 48 CARBON MONOXIDE MONITOR Section Page 1. General Description 51 2. Operation 51 3. Maintenance 53 Internal and external wiring looms V4 55 2
Breathing Air (Maxi) Purification Modules General Notes Flow Rate @ 7 barg 160 to 800 scfm Max.Operating Pressure 13 barg Min.Operating Pressure 4 barg Max. Inlet Temperature 50ºC Min. Outlet Temperature 5ºC Power Supply 230V. 110V. or Pneumatic Breathing Air Maxi Modules 110V Breathing Air Maxi Modules 240V Breathing Air Maxi Modules Pneumatic 3
BAM102 - BAM110 4
Technical Specification General Notes Flow Rates @ 7bar g - 24 to 176 cfm Max. Working Pressure BA-DME012-D to BA-DME040-D - 16 bar g Max. Working Pressure BA-DME050-D to BA-DME080-D- 13 bar g Min. Operating Pressure 4 bar g Recommended Max. Inlet Temperature 30 C Absolute Max. Inlet Temperature 50 C Absolute Min. Inlet Temperature 5 C Dewpoint -40 C Breathing Air Midi Purification Modules Type DDS 230V / 1PH / 50-60Hz MODEL COMP.REF. DIM DIM FLOW MAX.INLET WEIGHT INLET OUTLET OUTLET INLET A B @7bar TEMP C Kg BSP BSP FILTER FILTER BA-DME012 606033110 1045 476 24 50 37.6 1/2 3/8 0013G 0013G BA-DME015 606033120 1211 490 32 50 42.6 1/2 3/4 0040G 0025G BA-DME020 606033130 1376 490 42 50 47.6 1/2 3/4 0040G 0025G BA-DME025 606033140 1541 490 53 50 52.6 1/2 3/3 0040G 0025G BA-DME030 606033150 1707 521 65 50 57.6 1/2 3/4 0040G 0040G BA-DME040 606033160 1960 732 88 50 73.9 3/4 3/4 2X0040G 0040G BA-DME050 606033170 1750 1275 106 50 211.0 1 1 BAH101 0080G BA-DME060 606033180 1916 1275 130 50 223.8 1 1 BAH101 0080G BA-DME080 606033190 2076 1200 176 50 224 1 1 BA102 0080G Breathing Air Midi Purification Modules Type 230V / 1PH / 50-60Hz MODEL COMP.REF. DIM DIM FLOW MAX.INLET WEIGHT INLET OUTLET OUTLET INLET A B @7bar TEMP C Kg BSP BSP FILTER FILTER BA-DME012 606033210 1045 476 24 50 37.6 1/2 3/8 0013G 0013G BA-DME015 606033220 1211 490 32 50 42.6 1/2 3/4 0040G 0025G BA-DME020 606033230 1376 490 42 50 47.6 1/2 3/4 0040G 0025G BA-DME025 606033240 1541 490 53 50 52.6 1/2 3/3 0040G 0025G BA-DME030 606033250 1707 521 65 50 57.6 1/2 3/4 0040G 0040G BA-DME040 606033260 1960 732 88 50 73.9 3/4 3/4 2X0040G 0040G BA-DME050 606033270 1750 1275 106 50 211.0 1 1 BAH101 0080G BA-DME060 606033280 1916 1275 130 50 223.8 1 1 BAH101 0080G BA-DME080 606033290 2076 1200 176 50 224 1 1 BA102 0080G Breathing Air Midi Purification Modules Type 110V / 1PH / 50-60Hz MODEL COMP.REF. DIM DIM FLOW MAX.INLET WEIGHT INLET OUTLET OUTLET INLET A B @7bar TEMP C Kg BSP BSP FILTER FILTER BA-DME012 606033310 1045 476 24 50 37.6 1/2 3/8 0013G 0013G BA-DME015 606033320 1211 490 32 50 42.6 1/2 3/4 0040G 0025G BA-DME020 606033330 1376 490 42 50 47.6 1/2 3/4 0040G 0025G BA-DME025 606033340 1541 490 53 50 52.6 1/2 3/3 0040G 0025G BA-DME030 606033350 1707 521 65 50 57.6 1/2 3/4 0040G 0040G BA-DME040 606033360 1960 732 88 50 73.9 3/4 3/4 2X0040G 0040G BA-DME050 606033370 1750 1275 106 50 211.0 1 1 BAH101 0080G BA-DME060 606033380 1916 1275 130 50 223.8 1 1 BAH101 0080G BA-DME080 606033390 2076 1200 176 50 224 1 1 BA102 0080G 5
BA-DME012 to BA-DME030 6
BA-DME040 7
BA-DME040 to BA-DME060 8
BA-DME080 9
dh domnick hunter DESICCANT AIR DRYER HEATLESS Dewpoint Dependant Switching Installation Operating & Maintenance Instructions
SAFETY WARNING! Do not operate the dryer until the instructions in the operation section of this manual have been read and understood by all personnel concerned. It is essential that personnel employ safe working practices and observe all related regulations and legal requirements for safety when operating the dryer. When handling, operating or carrying out maintenance on the dryer, personnel must employ safe engineering practices and observe all relevant local health and safety requirements and regulations. The attention of UK users is drawn to the Health and Safety at Work Act 1974, and the Institute of Electrical Engineers Regulations. Most accidents which occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules or precautions. An accident can often be avoided by recognising a situation that is potentially hazardous. Improper operation or maintenance of the dryer could be dangerous and result in an accident causing injury or even death. domnick hunter can not anticipate every possible circumstance which may represent a potential hazard. The WARNINGS in this manual cover the most common potential hazards and are therefore not all-inclusive. If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended by domnick hunter he must ensure that the dryer will not be damaged or made unsafe and that there is no risk to persons or property. IMPORTANT Safety Signs Operations or procedures involving specific hazards which could cause injury or death if precautions are not heeded, are identified by the following symbols which are displayed on the desiccant air dryer to indicate potential danger points. WARNING: RISK OF DANGER CAUTION: RISK OF ELECTRIC SHOCK CAUTION: RISK OF HIGH PRESSURE IT IS STRONGLY RECOMMENDED THAT THE INSTALLATION AND OPERATING INSTRUCTIONS ARE READ THOROUGHLY BEFORE PROCEEDING ANY FURTHER. PLEASE NOTE: YOUR WARRANTY MAY BE INVALIDATED IF THE EQUIPMENT HAS NOT BEEN INSTALLED, COMMISSIONED OR MAINTAINED BY domnick hunter OR ITS APPROVED AGENTS. 11
1. GENERAL DESCRIPTION The adsorptive capacity of the desiccant within the dryer is essentially constant whereas the moisture loading and the air flow through the dryer are continuously varying. In order to maintain the specified air quality downstream of the dryer, it has to be sized for the worst case conditions, namely lowest pressure, highest flow and highest inlet temperature. These conditions may only occur for a small part of the service life of the dryer, for example, the highest inlet temperatures may only be present during the summer months. This means that the moisture loading on the desiccant beds is below the dryer s capacity for much of its service life e.g. quiet periods in between shifts usually have lower air supply requirements. To gain access to this adsorptive capacity, a moisture sensor is fitted which monitors the downstream dewpoint, this system is known as Dewpoint Dependent Switching (DDS). This interrupts the normal sequence of the controller which then instructs the dryer to change over only when the desiccant has adsorbed moisture to its capacity. This effectively elongates the drying cycle. However, as regeneration has been optimised for a fully laden desiccant bed, this remains of constant duration resulting in a period of zero energy consumption; purging is discontinued. In this way energy savings are obtained when compared to the operation of a fixed cycle, without sacrificing the resulting air quality. Dewpoint Dependent Switching (DDS) is available in two variants, with or without dewpoint monitoring display. This manual describes the operation of and equipment used in the DDS system only, and should be used in conjunction with the standard PNEUDRI I.O.M.I. 2. TECHNICAL SPECIFICATION MODEL Code Suffix Pressure Dewpoint Controls Electrical Supply Dewpoint Display Analogue Output Alarm Output Indicators WITH DEWPOINT DISPLAY DS -40 C Cam Timer fitted with full Hygrometer 240V 1ph 50Hz 110V 1ph 60Hz Digital LCD 4 to 20 ma linear (Max Load 800Ω) 0 to 1V linear Volt free contact; rated 2A 240 Vac or 30 Vdc Power On Dewpoint Switching Active Dewpoint Alarm WITHOUT DEWPOINT DISPLAY DS-ND -40 C Cam Timer fitted with PCB 240V 1ph 50Hz 110V 1ph 60Hz None 1 to 6V non-linear Volt free contact; rated 2A 240 Vac or 30 Vdc Power On Dewpoint Switching Active Dewpoint Alarm 12
3. OPERATION OF DDS CONTROLLER 1. INTRODUCTION The Dewpoint Switching Systems with and without dewpoint display options incorporate two relays designated Alarm 1 and Alarm 2. These relays are preset by domnick hunter and are configured such that Alarm 1 controls the dewpoint switching function and Alarm 2 operates the fault and remote alarm functions. Alarm 1 is configured HI normally closed, and Alarm 2 is configured HI normally closed. The HI function causes an alarm signal to be generated when a high moisture content (i.e. wet dewpoint) is encountered. 2. OPERATION OF DEWPOINT DEPENDENT SWITCHING References should be made to Figure 1 (PCB option without dewpoint display) and Figure 2 (Hygrometer Display). Alarm 1 on both options controls the activation of the Dewpoint Dependent Switching. When the dryer outlet dewpoint is wetter than the set point for Alarm 1, an alarm signal is generated. Consequently the normally closed contact of the Alarm 1 relay opens and the cam timer relay coil is de-energised, the normally closed contact of the cam timer relay remains closed and the cam timer operates. Conversely, when the outlet dewpoint of the dryer becomes drier than the set point for Alarm 1, an alarm signal is not generated, and the normally closed Alarm 1 relay contact closes. The cam timer coil becomes energised causing the normally closed contact of the cam timer relay to open, thereby stopping the cam timer and producing a period of zero energy consumption. This will only occur when the offline bed has been fully regenerated and repressurised. 3. OPERATION OF ALARM (FAULT) FUNCTION Alarm 2 on both options controls the activation of the fault alarm function. When the dryer outlet dewpoint is wetter than the set point for Alarm 2 an alarm signal is generated which opens the normally closed contact of the Alarm 2 relay. This causes the fault alarm relay coil to become de-energised, the normally closed contact of the fault alarm relay closes and the alarm lamp illuminates. Conversely, when the outlet dewpoint of the dryer becomes drier than the set point for Alarm 2 an alarm signal is not generated. Consequently the normally closed contact of the Alarm 2 relay remains closed and the fault alarm relay coil becomes energised. The normally closed contact of the fault alarm relay opens, and the alarm lamp does not become illuminated. 4. FAILURE MODES Should a fault develop on the system the normally closed contacts on the cam timer relay and fault alarm relay close, thereby allowing continued operation of the cam timer and illuminating the alarm lamp. In addition a pair of volt free contacts are provided which open on alarm, these may be used to provide remote indication that a fault has occurred. In the event of a power failure (i.e. transformer fault or blown fuse) the normally closed contacts of the fault alarm relay will close thereby activating a remote alarm. The remote alarm contacts are rated at 240Vac and any external equipment or remote indicators should not exceed this level. 5. INDICATION OF DRYER DEWPOINT A voltage output (1-6V) corresponding to the dewpoint being monitored by the hygrometer sensor may be taken from the PCB on the non-display option and this may be used to indicate the dryer dewpoint. However this output is non-linear and direct conversion to a dewpoint value requires the linearisation data for the sensor version used (available on request). If the full display hygrometer is fitted, a linear 4 to 20 ma (max load 800Ω) and linear 0 to 1V analogue outputs are available. 13
4. DDS HEATLESS CONTROL SCHEMATIC FIG. 1 PCB Option Without Dewpoint Display 14
FIG. 2 Hygrometer Display 15
FIG. 3 Pneumatic Schematic 16
5. INSTALLATION 1 2 3 4 A 5 6 7 B C Rear View of Control Box 1) Hygrometer Power Connection 2) Power Connection 3) Remote Alarm (where fitted) (Display Variant) Hygrometer Sensor (PCB Variant) 4) Indicator Lights 5) Solenoid Side A 6) Solenoid Side B 7) Hygrometer Alarm Cable A) Constant Pressure B) Column Pressure Side A (with display option only) C) Column Pressure Side B 5.1 REMOTE OUTPUTS Two remote outputs are available. The first is a remote alarm which provides fault indication via the volt free contacts (and the normally open contact on the fault alarm relay). The second is an analogue voltage output which may be taken from the hygrometer display or PCB board on the non-display option to remotely indicate the dryer dewpoint. 6. MAINTENANCE The controller is designed to be maintenance free, however, if required, periodic replacement of the AA0003G filter element upstream of the sensor may be undertaken, in addition to annual recalibration of the hygrometer sensor. If any other maintenance or repair work is deemed to be required, please contact domnick hunter, or a domnick hunter approved distributor. 17
7. KNOWN MISUSE (Please ensure that the following situations do not occur in your installation) * Tampering with the controller. * Disconnection of hygrometer sensor. * Kinking of pneumatic tubing * Tampering with hygrometer settings. * Operation of dryer whilst the ON/OFF switch is in the OFF position. * Power not connected to the controller 8. FAULT FINDING VISUAL INDICATION Cam timer not running Warning lamp illuminated Power on lamp not illuminating Dewpoint Switching inoperative Energy saving lamp not illuminating Dryer always in Dewpoint Switching mode Hygrometer display permanently indicates -80 Dryer never in Dewpoint Dependent Switching mode PROBABLE CAUSE Power failure Dryer in DDS mode Controller fault Cam timer fault Hygrometer sensor fault Dewpoint wetter than set point for Alarm 2 Controller fault Hygrometer settings incorrect Blown bulb No incoming power Dewpoint wetter than set point for Alarm 1 Controller fault Loss of pneumatic signals to controller Bulb blown Dryer not in Dewpoint Switching mode Dewpoint Switching Inoperative Dewpoint dryer than DDS setpoint Sensor fault (open circuit) Controller fault Dewpoint dryer than -80 C Sensor fault (open circuit) Controller fault Dewpoint wetter than set point for Alarm 1 Alarm fault active Controller fault Loss of pneumatic signal to controller CHECK Is power lamp on? Incoming supply present? Fuses intact? Is dewpoint dryer than set point for Alarm 1? Use service engineers sensor simulator to simulate wet dewpoint Use service engineers sensor simulator to simulate dry dewpoint Bulb intact? Incoming supply present? Fuses intact? Simulate dry dewpoint using service engineers sensor simulator Kinking of pneumatic tubing, air leakage Bulb intact? Is dewpoint wetter than set point for Alarm 1 (use service engineers sensor simulator) As above Simulate wet dewpoint using service engineers sensor simulator Simulate wet dewpoint using service engineers sensor simulator Use service engineers sensor simulator to simulate dry dewpoint Is Dewpoint wetter than set point for Alarm 2 Kinking or leaks from pneumatic tubing REMEDY Check for incoming supply, replace fuses if blown If Dewpoint drier than set point then DDS is functioning correctly. If not call service engineer Call service engineer Call service engineer Call service engineer Call service engineer Call service engineer Call service engineer Replace if necessary Replace fuses if blown If fault persists call service engineer Call service engineer Call service engineer Rectify kinking of tube if possible, otherwise call service engineer Replace if necessary Call service engineer Call service engineer Call service engineer Call service engineer Call service engineer Call service engineer Call service engineer Call service engineer Call service engineer If not, call service engineer Call service engineer Rectify kinking or leaks from tube if possible, otherwise call service engineer 18
9. WARRANTY This warranty applies to dryers and associated pre-filters (the Equipment) manufactured and supplied by domnick hunter. Use of the dryer without the recommended genuine domnick hunter manufactured filtration or genuine parts, will expressly invalidate the warranty. Should the Equipment by defective as to materials or workmanship, domnick hunter warrants that it will remedy such defect for a period of 12 months from the date of despatch. Where the Equipment is a desiccant dryer, the warranty period will be 12 months from the date of commissioning or 18 months from date of despatch, whichever is the earlier, provided such commissioning is carried out by domnick hunter or it s authorised agent. In the case of Equipment other than a desiccant dryer, the warranty period shall commence from the date of despatch. Should any defect occur during the warranty period and be notified in writing to domnick hunter or it s authorised agent within the said period, domnick hunter will, at it s sole option, remedy such defects by repair or by provision of a replacement part, provided that the Equipment has been used strictly in accordance with the instructions provided with each item of the Equipment and has been stored, installed, commissioned, operated and maintained in accordance with such instruction and good practice. domnick hunter shall not be under any liability whatsoever under the warranty if, before giving notification in writing to domnick hunter as aforesaid, the Customer or any third party meddles, interferes, tampers with or carries out any work whatsoever (apart from normal maintenance as specified in the said instructions) in relation to the Equipment or any part thereof. Any accessories, parts and equipment supplied by domnick hunter but not manufactured by domnick hunter, shall carry whatever warranty the manufacturer has given domnick hunter provided it is possible for domnick hunter to pass on such warranty to the Customer. To claim under the warranty, the goods must have been installed and continuously maintained in the manner specified in the Installation, Operating and Maintenance Instruction (I.O.M.I.). Our Product Support Engineers are qualified and equipped to assist you in this respect. They are also available to make repairs that may become necessary in which event they will require an official order before carrying out the work. If such work is to be the subject of warranty claim, the order should be endorsed for consideration under warranty. Any substitution of parts not manufactured or approved by domnick hunter will expressly invalidate the warranty. 19
dh domnick hunter MIDI PLUS HIGH EFFICIENCY COMPRESSED AIR DRYERS USER GUIDE
SAFETY WARNING! Do not operate the dryer until the instructions in this manual have been read and understood by all personnel concerned. When handling, installing or operating, personnel must employ safe engineering practices and observe all related regulations, health and safety procedures, and legal requirements for safety. Most accidents that occur during the operation and maintenance of machinery are the result of failure to observe basic safety rules and procedures. Accidents can be avoided by recognising that any machinery is potentially hazardous. domnick hunter can not anticipate every possible circumstance which may represent a potential hazard. The WARNINGS in this manual cover the most known potential hazards, but by definition cannot be all inclusive. If the dryer user employs an operating procedure, item of equipment or a method of working which is not specifically recommended by domnick hunter the user must ensure that the dryer will not be damaged or made a potential hazard to persons or property. IMPORTANT DME Facia Caution: Power Risk of Electric Shock Attention Power on LED ECO (DDS) LED PLEASE NOTE THAT YOUR WARRANTY MAY BE INVALIDATED IF THE EQUIPMENT HAS NOT BEEN INSTALLED, COMMISSIONED OR MAINTAINED BY domnick hunter OR A domnick hunter APPROVED AGENT. 1. GENERAL DESCRIPTION The MIDI PLUS range of compressed air dryers are designed to remove moisture from compressed air by utilising state of the art technology to obtain dewpoints of -40 o C, and by appropriate de-rating, -70 o C. The MIDI PLUS range of dryers have been designed to require minimal maintenance and can be installed virtually anywhere. The MIDI PLUS dryer consists of an inlet and an outlet manifold joined together with an aluminium column. The column has twin internal chambers both filled with desiccant material. During operation one chamber is on-line (drying) while the other is regenerating, using the Pressure Swing Adsorption (PSA) process. Pressure Swing Adsorption (PSA) A small percentage of dried air is taken from the dryer output flow and is used to regenerate the saturated chamber by expanding the dried air from line pressure to atmospheric pressure. During this process, the moisture is physically removed from the regenerating chamber and vented to atmosphere through the exhaust silencers. Dewpoint Dependent Switching (DDS) - Optional If DDS is fitted, this will adjust the dryers cycle in line with the moisture loading placed upon it, by constantly monitoring the processed air moisture content. Also available as a retrofit to all DME dryer models. 21
4 7 KEY 1 By-pass Valve 2 Inlet Valve 3 Inlet Filter 4 By-pass Line 5 Outlet Valve 6 Outlet Filter 7 Outlet Sight Glass 8 Pressure Gauges 9 Control Box 10 Feed Line (Optional with Dewpoint Dependent Switching) 1 IN 3 8 2 5 6 10 OUT 9 2. TECHNICAL SPECIFICATION Type Heatless Model DME Operating flow range 14 cfm - 299 cfm ( 0.4m 3 /min - 8.47 m 3 /min ) Dewpoint: Nominal -40 o C (-40 o F) Optional -70 o C (-94 o F) Air quality : inc filtration (dirt. water. oil) SO 8573.1 Class 1.2.1. Class 1.1.1 Optional Maximum operating pressure DME012 to DME040 16 Bar(g) (232 psig) DME050 to DME080 13 Bar(g) (188 psig) Minimum operating pressure 4 Bar(g) (58 psig) Maximum inlet temperature 50 o C (122 o F) Minimum inlet temperature 5 o C ( 41 o F) Regeneration Pressure Swing Adsorption (PSA) Nominal pressure drop across desiccant bed 140 mbar (g) (2 psi g) Standard electrical supply ( ± 10% ) 230 VAC. 1phase. 50/60 Hz (Others on request) 110 VAC. 1phase. 50/60 Hz Controls Electronic Control Timer Noise level <75 db (A) Media Desiccant Material Column High tensile extruded aluminium. Inlet/Outlet head Pressure die cast high tensile aluminium. Finish Alocrom anti-corrosion protection and dry powder epoxy painted. Construction Column snow storm filled with desiccant material and contained between the inlet and outlet head using high tensile bolts. 22
3. UNPACKING Every care is taken during product packaging by domnick hunter. It is advisable after carefully unpacking the dryer to carry out a thorough visual inspection of the unit for any signs of transit damage incurred after leaving our factory. If any damage is found please report this immediately to the carrier and the distributor involved (if applicable), or directly to domnick hunter ltd. 4. INSTALLATION (Refer to figure 1) 1. General Care must be taken to ensure that the dryer is not subject to flows (even peaks) in excess of the dryers rated capacity. The dryer must be vertical, and level, with the inlet at the bottom. Position the dryer to allow safe maintenance and operation. The dryer can be free standing or secured to the floor via the fastener points provided in the base. The purge air flow is factory set for 6 Bar g (87 psi g) minimum system pressure. Should your minimum pressure be lower, the purge air flow must be reset by trained domnick hunter personnel to maintain specified dewpoint. Suitably rated pipework and connections must be used during installation. All pipework must be secure and safely positioned. If required the exhaust assembly can be piped away, remote from the dryer. DME012 to DME040 range Two inlet port connections are available. Only remove the fitted sight glass from the port chosen as the inlet to the dryer. Two outlet port connections are available. Only remove the fitted sight glass from the port chosen as the outlet side from the dryer. Note: The remaining sight glass will adsorb moisture from the atmosphere and require replacing if the outlet head is not piped up immediately. DME050 to DME080 range One port is available for the inlet to the dryer. One port is available for the outlet from the dryer only. Remove the fitted plug. Note: The sight glass will adsorb moisture from the atmosphere and require replacing if the outlet head is not piped up immediately. Dewpoint Dependent Switching (DDS) - Optional The DDS system requires a sampling point to be inserted in the pipework at the outlet of the dryer, downstream of the after-filter but before the isolation valve. P.T.F.E. tubing must be used to link the sampling point to the 4mm push-in connector of the DDS system on the dryer. 2. Filtration domnick hunter inlet and outlet filtration must be fitted to the dryer, e.g. WS (optional), AO (recommended), an AA grade pre-filter and an AR grade after-filter are essential. All filtration must be installed using the practices described in the User Guide supplied with the filters. 23
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3. By-pass line It is recommended that a by-pass line is installed to ensure a constant air supply, and safety, during maintenance. This allows untreated air to by-pass the dryer, at the customers discretion during dryer maintenance. The by-pass valve should only be open when the dryer is undergoing maintenance following the shut down procedure. 4. Valves Isolation valves are recommended on the inlet, outlet and by-pass lines. 5.ELECTRICAL DETAILS This only applies to electrically powered units. Competent qualified electricians must work on dryer supply circuitry. Check the rating plate for power supply requirements. Correct isolator switches must be provided at a safe and accessible point near to the dryer. The dryer must be connected with a live, neutral and earth. The live pin on the dryer has a fuse fitted. Connect power to the dryer via an IEC320 socket cord set, and retain with clip. L AC MODELS N FUSE BAY 26
6. OPERATING THE DME DESICCANT AIR DRYER Start up procedure Ensure the dryer inlet and outlet isolation valves are fully closed and that all covers on the dryer are secure. Ensure that a suitable supply of compressed air to within the dryers technical specifications is available. Turn ON external electrical isolator, the yellow power on LED should illuminate and the dryer should commence cycling. NB - all valves must be opened and closed gradually Proceed as follows Using by-pass line With the by-pass valve fully open, introduce air into the dryer by opening the inlet valve until fully open. Allow the dryer to fully pressurise to full system pressure, then open the outlet valve while simultaneously closing the by-pass valve. The dryer is now on stream. Without by-pass line Introduce air into the dryer by opening the inlet valve until fully open. Allow dryer to fully pressurise to full system pressure, then open the outlet valve. The dryer is now on stream. During operation During normal operating conditions the dryer is fully automatic and requires no further attention until shutdown. The yellow power on LED should be ON continuously. The dryer column contains two chambers of desiccant material. Whilst one chamber is drying the compressed air (adsorption) the other chamber is simultaneously undergoing regeneration (desorption). Every two minutes the chambers are reversed in function, this is the changeover point. Changeover is characterised by a immediate venting of compressed air from the chamber entering regeneration. The adsorption chamber is indicated by the relevant pressure gauge on the dryer reading full system air pressure. The desorption chamber is indicated by the relevant pressure gauge on the dryer reading virtually zero. After 1 1/2 minutes the desorption chamber repressurises to equal the adsorption chamber pressure, ready for changeover of the chambers. The pressure gauges and sight glass moisture indicator are for indication purposes only. Dewpoint Dependent Switching (DDS) - optional The DDS system operates as described above, with the following modifications. If the dryer is producing air at a better dewpoint than specified the DDS system will hold the dryer at a point just before the changeover occurs. The green ECO LED will illuminate. Both pressure gauges will read full system pressure. The dryer will resume normal operation the instant the DDS system monitors a fall in dewpoint to the specified level. The crystals in the outlet sight glass moisture indicator should be blue for correct operation, however, if these change colour to pink the dryer is producing a wetter dewpoint than required, and the cause of this must be investigated (refer to fault diagnosis table). Shut-down procedure The dryer can be shut down at any point in its cycle. 27
Using by-pass line Close the dryer outlet valve whilst simultaneously opening the by-pass valve. Close the dryer inlet valve. The air will now by-pass the dryer, allow the dryer to depressurise before isolating electrical supply, vent pressure from inlet and outlet filters using methods described in the filter User Guide. The dryer may still be pressurised if this is not done. Without by-pass line Close the dryer outlet valve. Close the dryer inlet valve Allow the dryer to depressurise before isolating electrical supply, vent pressure from inlet and outlet filters using methods described in the filter User Guide. The dryer may still be pressurised if this is not done. 7. MAINTENANCE RECOMMENDATIONS Daily Ensure yellow POWER ON LED is not flashing. Visually check crystals in sight glass moisture indicator for blue colour. Weekly Check dryer seals, fittings and pipe work for air leaks Check inlet and outlet filtration for indication of element blockage (see User Guide for Filters) Ensure correct operation of filtration condensate drainage (if applicable). The desiccant material in the dryer has a finite life dependent upon operating conditions but it will typically exceed 10,000 hours use before it needs replacing. It will also require replacing if contaminated. Care must be taken prior to any routine pipe flushing operations. The outlet sight glass moisture indicator requires replacing once the crystals are no longer blue. A service kit is available. Desiccant changes, service kits and service training courses are available for the MIDI PLUS range of dryers on request. Service kits must only be used by domnick hunter trained personnel. Only domnick hunter trained personnel can remove the covers on the dryer. 28
8. FAULT DIAGNOSIS TABLE Problem Indication Probable cause Remedy Poor Dewpoint Crystals go pink in outlet Entrained water Check pre-filtration and pre-filtration drains moisture indicator Excessive air flow demand Inlet pressure too low Check actual flow against rated flow of dryer Check for recent additions to air system Check against technical specification Excessive inlet air temperature Check against technical specification Insufficient purge air flow Factory set for 6 bar g (87 psig) system pressure. domnick hunter trained personnel to adjust Exhaust silencers blocked Contaminated desiccant Change by domnick hunter trained personnel Eliminate source of contamination. Desiccant change by domnick hunter trained personnel Electrical fault Flashing Yellow LED Hardware fault Contact domnick hunter customer services High differential pressure Pressure gauges Excessive outlet flow Check and regulate air demand Failure to purge No depressurisation Purge valve blocked or shut. domnick hunter trained personnel to adjust and poor dewpoint Exhaust silencers blocked Change by domnick hunter trained personnel Outlet air flow stops Downstream pressure drops Electrical fault Contact domnick hunter customer services Yellow LED OFF Blown fuse in plug Change by competent personnel Constant depresurisation Erratic air flow from exhaust Damaged valve Change by domnick hunter trained personnel 9. KNOWN MISUSE Filters Lack of filtration. Installation of inlet filters remote from the dryer inlet head, allowing possible condensation to occur between filters and dryer. Blow down valve upstream of filters causing back flow / possible collapse of filter element. Installing filters in wrong flow direction. Opening inlet valve too quickly, causing initial high differential pressure across filter element. Differential pressure gauge/indicator fitted wrong way around giving false differential pressure reading. Combining drain pipes from filters to a single drain valve. Inlet / outlet head Pipe diameter too small. Pipework unsupported. Inlet pipework taken from low point of manifold range, allowing bulk water intrusion into the dryer. Control box/electric s Incorrect wiring configuration by user, or incorrect supply voltage. No neutral or earth wire fitted by user to dryer. Additional Items Use of non recommended componentry. Untrained / unauthorised maintenance or installation personnel used. Subsequent increase in air consumption without relation to dryer flow capacity. Purging of pneumatic system and dryer with cleaning agents that have the potential to damage desiccant material. Covers removed or loose during operation. 29
Declaration of Conformity DECLARATION OF CONFORMITY 98/37/EC GB Name of manufacturer or supplier: domnick hunter limited Full postal address including country of origin Dukesway, Team Valley Trading Estate, Gateshead, Tyne & Wear, England, NE11 0PZ Description of product Adsorption Dryer Name type or model, batch or serial number DME012, DME015, DME020, DME025, DME030, DME040, DME050, DME060, DME080. Standards used, including number, title, issue date and other relative documents EN292-1 : 1991, EN292-2 : 1991, EN50081-2:1994, EN50081-1:1992 EN50082-1:1998, EN50082-2:1995, EN61010-1:1993 Place of issue: GATESHEAD, TYNE & WEAR, ENGLAND Name of authorised representative ERIC W. BLAKIE Position of authorised representative MANAGING DIRECTOR (INDUSTRIAL DIV.) Full postal address if different from manufacturers Declaration I declare that as the authorised representative, the above information in relation to the supply/manufacture of this product, is in conformity with the stated standards and other related documents following the provisions of the 98/37/EC Directive. Signature of authorised representative: 30
11. WARRANTY This warranty applies to dryers and associated pre-filters (the Equipment) manufactured and supplied by domnick hunter. Use of the dryer without the recommended genuine domnick hunter manufactured filtration or genuine parts, will expressly invalidate the warranty. Should the Equipment by defective as to materials or workmanship, domnick hunter warrants that it will remedy such defect for a period of 12 months from the date of despatch. Where the Equipment is a desiccant dryer, the warranty period will be 12 months from the date of commissioning or 18 months from date of despatch, whichever is the earlier, provided such commissioning is carried out by domnick hunter or it s authorised agent. In the case of Equipment other than a desiccant dryer, the warranty period shall commence from the date of despatch. Should any defect occur during the warranty period and be notified in writing to domnick hunter or it s authorised agent within the said period, domnick hunter will, at it s sole option, remedy such defects by repair or by provision of a replacement part, provided that the Equipment has been used strictly in accordance with the instructions provided with each item of the Equipment and has been stored, installed, commissioned, operated and maintained in accordance with such instruction and good practice. domnick hunter shall not be under any liability whatsoever under the warranty if, before giving notification in writing to domnick hunter as aforesaid, the Customer or any third party meddles, interferes, tampers with or carries out any work whatsoever (apart from normal maintenance as specified in the said instructions) in relation to the Equipment or any part thereof. Any accessories, parts and equipment supplied by domnick hunter but not manufactured by domnick hunter, shall carry whatever warranty the manufacturer has given domnick hunter provided it is possible for domnick hunter to pass on such warranty to the Customer. To claim under the warranty, the goods must have been installed and continuously maintained in the manner specified in the User Guide. Our Product Support Engineers are qualified and equipped to assist you in this respect. They are also available to make repairs that may become necessary in which event they will require an official order before carrying out the work. If such work is to be the subject of warranty claim, the order should be endorsed for consideration under warranty. Any substitution of parts not manufactured or approved by domnick hunter will expressly invalidate the warranty. 31
dh domnick hunter CATALYST/ACTIVATED CARBON PURIFIER MODEL BAH101 USER GUIDE
1. INSTALLATION Figure 1 1. The purifier should be securely mounted on a suitable structure, which is free from vibration. It should be secured using the two Ø12 holes through the centre of the column. HEAD BOLTS GASKET PLATE OUTLET HEAD INLET HEAD 3/4 BSPP FEMALE THREADED CONNECTIONS Figure 2 2. Filtration a. Pre-filtration This must be positioned as close to the inlet as possible. domnick hunter grade AO and AA filters must be fitted upstream of the inlet to prevent contamination of the activated carbon bed. In case of extreme water contamination, a domnick hunter Water separator should also be incorporated into the system prior (upstream) to the AO filter. b. After-filtration A domnick hunter grade AR filter must be fitted downstream of the purifier to prevent activated carbon dust carryover. 33
C. Filter Sizing It is recommended that each purifier bank has its own filtration. Filter sizes for each purifier are shown in Table 1. 5. Shut-off valves (Figure 2) should be fitted to the inlet and outlet pipework of each purifier to allow isolation for maintenance. 6. By-pass lines should be avoided whenever possible as contamination may leak through valves and by-pass filters. 7. In line valves should be opened slowly to avoid high surge flows. 8. The inlet valve should be carefully opened to pressurise the purifier, then slowly opening the outlet valve will bring the purifier on-line. Table 1 MODEL Nominal Flow Rate Dim A Pipe Recommended Filtration Filter/Dryer NL/s@ 7 scfm @ (see fig.2) conns. Inlet * Outlet ** Dryer Pipe size bar g 100 psi g mm BAH 101 61 130 535 3/4 AO-0080G/G AR-0080G/G BADME050 1 AA-0080G/G BADME060 * Grade AO - General purpose filter : particle removal down to 1 micron, maximum remaining oil content 0.5 mg/m 3 at 21 0 C. Grade AA - High efficiency filter: particle removal down to 0.01 micron, maximum remaining oil content 0.01 mg/m 3 at 21 0 C. Note - Fixing kits are available for bolting AO and AA filters together dispensing with unnecessary inter-connecting pipework for 0058G/G and 0145G/G order Fixing Kit FXK3. ** Grade AR - Dust filter: 100% particle removal down to 1 micron, 98% removal at 0.3 micron. 34
2. SERVICE LIFE The service life of the purifier is determined by the temperature of the air flowing through it. With mineral type compressor oils the expected service life of the purifier at a line pressure of 7 bar g is: 6000 hours at an air temperature of 30 0 C, and 2000 hours at an air temperature of 45 0 C. 3. MAINTENANCE 1. Replacing Activated Carbon/Catalyst To replace the activated carbon/catalyst the top head should first be removed by unbolting the head bolts (see Figure 1). The top gasket then removed. The activated carbon/catalyst may now be extracted using an industrial vacuum cleaner (the use of a suitable face mask is recommended during this operation). Replacement activated carbon/catalyst packs are available from domnick hunter (see table 2). The use of a snow storm filling device (see table 2) is essential to achieve maximum packing of new carbon/catalyst. New gasket seals should be fitted. The top head replaced and head bolts tightened in sequential manner to a torque of 25 lb.ft (34Nm). Note - Do not attempt to remove heads or replace activated carbon/catalyst whilst AC purifier is pressurised. Always check that purifier is not pressurised. Table 2 MODEL Replacement dh Comp. Gasket dh Comp. Additional Service Tool Desiccant Pack No. Seal Kit No. BAH 101 RP 101 605009772 COL. GKT. 608202114 Snow Storm Filler Note - If replacing both top and bottom heads please order 2-off of the Gasket Seal Kits. 2. Maintenance Plans domnick hunter offers service plans which are tailored to each customer s requirements. Through these plans, the service/maintenance responsibility becomes domnick hunter s. For details please contact our Service Department. 35
dh domnick hunter CATALYST/ACTIVATED CARBON PURIFIER MODELS BAH102 - BAH106 User Guide
1. INSTALLATION 1. Provision is made for lifting the purifier as a complete unit by two eye bolts located in the top of the unit (see Figure 1). Ensure that the eye bolts are screwed fully home before attempting a lift (each bank of a multibank system should be lifted separately.) 2. The purifier should be securely mounted on a suitably structured, flat and level floor or base which is free from vibration. It may be secured to the base using bolts located through the slots in the mounting feet. 3. A clearance of approximately 2 metres around the purifier and 300mm between banks allow comfortable access for maintenance. EYE BOLTS HEAD BOLTS FEMALE THREADED/FLANGED CONNECTIONS Figure 1 OUTLET FLANGE COLUMNS OUTLET MANIFOLD MOUNTING FEET MANUAL DRAIN VALVE Figure 2 4. Filtration a. Pre-filtration This must be positioned as close to the inlet as possible. domnick hunter grade AO and AA filters must be fitted upstream of the inlet to prevent contamination of the activated carbon bed. In case of extreme water contamination, a domnick hunter Water separator should also be incorporated into the system prior (upstream) to the AO filter. b. After-filtration A domnick hunter grade AR filter must be fitted downstream of the purifier to prevent activated carbon dust carryover. 37
C. Filter Sizing It is recommended that each purifier bank has its own filtration. Filter sizes for each purifier are shown in Table 1. 5. Shut-off valves (Figure 2) should be fitted to the inlet and outlet pipework of each purifier to allow isolation for maintenance. 6. By-pass lines should be avoided whenever possible as contamination may leak through valves and by-pass filters. 7. In line valves should be opened slowly to avoid high surge flows. 8. The inlet valve should be carefully opened to pressurise the purifier, then slowly opening the outlet valve will bring the purifier on-line. Table 1 MODEL Nominal Flow Rate Dim A Pipe Weight Recommended Filtration Filter/Dryer NL/s@ 7 scfm @ (see fig.2) conns. kg Inlet * Outlet ** Dryer Pipe size bar g 100 psi g mm BAH 102 132 280 521 2 66 AO-0220G/G AR-0220G/G DX104BA 2 AA-0220G/G BAH 103 198 420 628 2 90 AO-0220G/G AR-0220G/G DX105 BA 2 AA-0220G/G BAH 104 264 560 734 2 114 AO-0405G/G AR-0405G/G DX107 BA 2.5 AA-0405G/G BAH 105 330 700 840 2 138 AO-0405G/G AR-0405G/G DX108 BA 2.5 AA-0405G/G BAH 106 396 840 947 2 162 AO-0405G/G AR-0405G/G DX110 BA 2.5 AA-0405G/G * Grade AO - General purpose filter : particle removal down to 1 micron, maximum remaining oil content 0.5 mg/m 3 at 21 0 C. Grade AA - High efficiency filter: particle removal down to 0.01 micron, maximum remaining oil content 0.01 mg/m 3 at 21 0 C. Note - Fixing kits are available for bolting AO and AA filters together dispensing with unnecessary inter-connecting pipework for 0220G/G and 0405G/G order Fixing Kit FXK4. ** Grade AR - Dust filter: 100% particle removal down to 1 micron, 98% removal at 0.3 micron. 38
2. SERVICE LIFE The service life of the purifier is determined by the temperature of the air flowing through it. With mineral type compressor oils the expected service life of the purifier at a line pressure of 7 bar g is: 6000 hours at an air temperature of 30 0 C, and 2000 hours at an air temperature of 45 0 C. 3. MAINTENANCE 1. Routine Maintenance Any build-up of carbon dust in the outlet manifold may be cleared by opening the manual drain valve (in an anticlockwise direction) located on the underside of the outlet manifold. 2. Replacing Activated Carbon/Catalyst To replace the activated carbon/catalyst the top manifold should first be removed by unbolting the head bolts (see Figure 1). The top gaskets are then removed. The activated carbon/catalyst may now be extracted using an industrial vacuum cleaner (the use of a suitable face mask is recommended during this operation). Replacement activated carbon/catalyst packs are available from domnick hunter (see table 2). The use of a snow storm filling device (see table 2) is essential to achieve maximum packing of new carbon/catalyst. New gasket seals should be fitted. The top manifold replaced and head bolts tightened in sequential manner to a torque of 25 lb.ft (34Nm). Note - Do not attempt to remove manifolds or replace activated carbon/catalyst whilst AC purifier is pressurised. Always open manual drain valve (on underside of inlet manifold) to check that purifier is not pressurised. Table 2 MODEL Replacement dh Comp. Gasket dh Comp. Additional Service Tool Desiccant Pack No. Seal Kit No. BAH 102 RP 102 605009240 GK 102 605009190 Snow Storm Filler 608200622 BAH 103 RP 103 605009250 GK 103 605009200 Snow Storm Filler 608200622 BAH 104 RP 104 605009260 GK 104 605009210 Snow Storm Filler 608200622 BAH 105 RP 105 605009270 GK 105 605009220 Snow Storm Filler 608200622 BAH 106 RP 106 605009280 GK 106 605009230 Snow Storm Filler 608200622 Note - If replacing both top and bottom manifolds please order 2-off of the Gasket Seal Kits. 3. Maintenance Plans domnick hunter offers service plans which are tailored to each customer s requirements. Through these plans, the service/maintenance responsibility becomes domnick hunter s. For details please contact our Service Department. 39
dh domnick hunter OIL-X Filters for compressed air and gasses 0009G-0620G (PF, AO, AA, ACS, AX, AR, AAR) AC-0006G-0085G User Guide
? THIS FILTER MUST BE INSTALLED AND MAINTAINED BY A COMPETENT PERSON TECHNICAL SPECIFICATION Maximum working pressure and temperature 1.5 C (35 F) 66 C (151 F) 1.5 C (35 F) 30 C (86 F) 16 bar g 232 psi with auto drain 20 bar g 290 psi AO, AA, AR with manual drain AC, ACS 41
INSTALLATION AC PF AO AA ACS PF AO AA 42
MAINTENANCE AC-0006G-0085G 0009G-0145G 0205G-0620G B B C A B C C A A B C A SEE ACCESSORIES 43
FILTER ELEMENT REPLACEMENT PF, AO, AA, ACS, AX, AR, AAR 0009G-0620G (1) ISOLATE AIR SUPPLY (2) DEPRESSURISE FILTER HOUSING (3) (4) (5) (6) (7)! 44
FILTER ELEMENT REPLACEMENT AC 0006G-0085G (1) ISOLATE AIR SUPPLY (2) DEPRESSURISE FILTER HOUSING 45
FITTING DIFFERENTIAL PRESSURE GAUGE ISOLATE AIR SUPPLY! DEPRESSURISE FILTER HOUSING 1/2AA DPG DPGL DPI 46
ACCESSORIES AUTOMATIC DRAIN No. 60864 MANUAL DRAIN No. 69203 MOUNTING BRACKET KIT FIXING KIT 0009G 0017G-0030G 0058G-0145G 0205G-0330G 0405G-0620G MBK1 MBK2 MBK3 MBK4 MBK5 0009G 0017G-0030G 0058G-0145G 0205G-0330G 0405G-0620G FXK1 FXK2 FXK3 FXK4 FXK5 0009G 0017G-0030G 0058G-0145G 0205G-0330G 0405G-0620G MAK1 MAK2 MAK3 MAK4 MAK5 SGK1 DPGL DPI DPG 47
Declaration of Conformity DECLARATION OF CONFORMITY 98/37/EC GB Name of manufacturer or supplier: domnick hunter limited Full postal address including country of origin Dukesway, Team Valley Trading Estate, Gateshead, Tyne & Wear, England, NE11 0PZ Description of product OIL-X FILTERS FOR COMPRESSED AIR AND GASSES Name type or model, batch or serial number PF, AO, AA, ACS,AX, AR, AAR-0009G-0620G AC-0006G-AC-0085G Standards used, including number, title, issue date and other relative documents EN292-1:1991 EN 292-2:1991 Place of issue: GATESHEAD, TYNE & WEAR, ENGLAND Name of authorised representative ERIC W. BLAKIE Position of authorised representative MANAGING DIRECTOR (INDUSTRIAL DIV.) Full postal address if different from manufacturers Declaration I declare that as the authorised representative, the above information in relation to the supply/manufacture of this product, is in conformity with the stated standards and other related documents following the provisions of the 98/37/EC Directive. Signature of authorised representative: 48
dh domnick hunter CARBON MONOXIDE MONITOR Installation, Operating & Maintenance Instructions
CO MONITOR GENERAL DETAILS Sample/test Gas Inlet LED Display Test Button MODE Electrical Connection From Transformer UP DOWN ENTER PPM CO 80mm (3.15") 90dba Alarm Horn 160mm (6.30") 85mm depth (3.35") Exhaust Gas Remote Alarm Connection 50
CARBON MONOXIDE MONITOR 1. GENERAL DESCRIPTION 1.1 The ANOLOX 3050 instrument is designed to measure and indicate the concentration of Carbon Monoxide (CO) in the gas sample presented to its input port. The range of measurement can be specified by the user, but the present design is configured for 0 to 50ppm with a resolution of approximately 0.3ppm. 1.2 CO concentration is measured using an electro-chemical sensor the electrical signal is then passed to a microprocessor, which carries out the following functions : a. Linearisation of the signal using calibration constants. b. Conversion of the signal into a form, suitable for the instrument display. c. Monitoring for an alarm condition with reference to a pre-set level. d. Provide facilities for audible and visual gas alarms. e. Provide simple means of user calibration. f. Provide authorised personnel access to change the alarm set-point. g. Carry out continuous monitoring of the battery condition and warns when low. 2. OPERATION 2.1 SWITCHING ON When the instrument is first switched on, it carries out a self test procedure and during this operation, the display will show the word TEST. This procedure takes about 5 seconds and also allows a period for the electro-chemical sensor to stabilise. After this time, the instrument is ready to monitor the input gas. 2.1.1 Carbon monoxide concentration in the input sample is indicated on the 4 Digit LCD display. 2.2 GAS ALARM 2.2.1 As long as the measured CO concentration remains below the pre-set alarm level (see 2.2.4), the relay will be energised and the normally open contact will be connected to the common contact. The alarm LED and audible alarm will be inactive. 2.2.2 If the CO concentration exceeds the pre-set alarm level, then the following actions will take place : a. The relay will de-energise resulting in the common contact connecting to the normally closed contact and breaking the connection to the normally open contact. b. The alarm LED will be turned on. c. The audible alarm will be activated. 2.2.3 These conditions will prevail until the measured CO concentration drops 1ppm below the alarm set-point. 2.2.4 The alarm set-point value depends on local health and safety regulations and varies depending on country of use. The instruments are normally pre-set at the factory to 10ppm but authorised personnel may be instructed on the procedure for changing this setting. 51