ECOTROC ATK 15 - 110 Operating Manual

ECOTROC® ATK 15 - 110
Operating Manual
Adsorption Dryers
Rev. 0117-05
Operating manual ATK 15-110
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Contents
Contents .................................................................................. 2
1.
General information ................................................................. 4
1.1
1.2
1.3
1.4
1.5
1.6
2.
System data............................................................................................................... 4
Contact data .............................................................................................................. 4
Accompanying documents ....................................................................................... 5
Warranty notes .......................................................................................................... 5
Operating manual ..................................................................................................... 5
Signs and symbols used........................................................................................... 6
Intended purpose / use............................................................ 7
2.1
2.2
3.
Intended use ............................................................................................................. 7
Performance data ...................................................................................................... 8
Safety notes............................................................................ 9
3.1
3.2
4.
Signs and symbols.................................................................................................... 9
Danger zones........................................................................................................... 10
Technical product data .......................................................... 12
4.1
4.2
4.3
5.
6.
Equipment overview, front view............................................................................. 12
Equipment overview, rear view .............................................................................. 12
Function description ............................................................................................... 13
Monitoring the operation ....................................................... 14
Transport, storage and setup...................................................15
6.1
6.2
6.3
7.
Transport.................................................................................................................. 15
Storage..................................................................................................................... 15
Setup........................................................................................................................ 16
Installation ........................................................................... 16
7.1
7.2
7.3
8.
Recommendations for installation ........................................................................ 16
Demands on the installation .................................................................................. 17
Elimination of hazards............................................................................................ 17
Commissioning ..................................................................... 18
8.1
8.2
8.3
8.4
9.
Commissioning prerequirement ............................................................................ 18
Pressurisation ......................................................................................................... 18
Mains operation ...................................................................................................... 19
Disconnecting from the mains ............................................................................... 20
Maintenance ......................................................................... 20
9.1
9.2
9.3
9.4
9.4.1
9.4.2
9.5
9.6
Regular maintenance work..................................................................................... 21
Daily checks............................................................................................................. 21
Checking the pressure dewpoint ........................................................................... 22
Overview of maintenance parts ............................................................................. 22
Annual maintenance ............................................................................................... 22
Two- and four-year maintenance............................................................................ 23
Replacing the filter elements ................................................................................. 24
Replacing the desiccant ......................................................................................... 24
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9.7
9.8
9.9
10.
11.
12.
Replacing the pistons and cylinder liners ............................................................. 26
Replacing the solenoid valves ................................................................................ 27
Replacing the silencers............................................................................................ 28
Replacing the pressure dewpoint sensor ................................. 29
Faults ................................................................................... 30
EU Declaration of conformity ...................................................31
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1.
General information
Please complete the following information according to the type plate, vessel plate and
contract documents. This enables the manufacturer to clearly identify the dryer and
makes it easier to give advice if there are queries. It also simplifies the provision of spare
parts and support. This may correspond to separate pieces of equipment for the
individual devices.
1.1 System data
Model:
___________________________________
Order No.:
___________________________________
Vessel No.:
___________________________________
Serial number:
___________________________________
Year of manufacture:
___________________________________
Date of commissioning: ___________________________________
1.2 Contact data
Company:
___________________________________
Address:
___________________________________
Phone:
___________________________________
E-mail:
___________________________________
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1.3 Accompanying documents
Applicable documents which are not included with this documentation:
-
Container documents
Installation drawing
Documentation for additional equipment parts
Controller documentation
Calibration certificate (if dewpoint controller is installed)
1.4 Warranty notes
For the conditions necessary for compliance with the warranty, please refer to our
"General Terms of Sale and Delivery"
The warranty shall be void if:
-
The adsorption dryer is used for anything other than its intended use.
The instructions in this operating manual are not observed.
External influences (e.g. aggressive substances) cause damage to the adsorption
dryer.
Maintenance intervals are not adhered to.
Damage is caused due to incorrect or defective maintenance.
The adsorption dryer is operated although defects are evident.
An unfavourable or incorrect installation is selected.
The necessary process conditions are not stipulated by the system concept (e.g.
highly undersaturated compressed air at the inlet).
1.5 Operating manual
This operating manual will help clarify any outstanding questions concerning the
setup, installation, operation, maintenance, repair and disposal of the dryer. It
contains useful tips and advice.
It is not only written for the operator who is responsible for monitoring the daily
operation of the device, but also for the service personnel who performs the
installation and service. Maintenance and repair work may only be carried out by
qualified personnel!
This operating manual must be read before any installation and maintenance work is
started. All safety instructions must be observed!
The operating manual must be kept in the vicinity of the dryer.
As already mentioned in the warranty notes, the manufacturer accepts no liability for
damages resulting from disregard of the operating manual.
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1.6 Signs and symbols used
The following symbols are listed in this manual and /or are affixed to the adsorption
dryer:
Tip
This symbol indicates tips for the efficient use of the adsorption
dryer!
Note
This symbol indicates instructions for the safe handling of the
adsorption dryer.
Caution / Warning
This symbol indicates general hazards or dangerous situations.
Danger! Compressed air
This symbol warns of dangers due to compressed air.
Danger! High voltage
This symbol warns of dangers due to electric voltage.
Slip hazard
This symbol warns of the risk of slipping.
Wear ear protectors
Wear respiratory protection
Wear goggles
These three symbols point out the necessity to wear personal protective equipment.
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2.
Intended purpose / use
The adsorption dryer is designed for removing compressed air by adsorption in industrial
compressed air systems. It requires the supply of saturated compressed air from a
supply source.
The main task is to reduce vaporous water components in the compressed air. Upstream
filters and dryers ensure that only particles and drop shapes are separated.
The desiccant which is specifically designed for this purpose is used to store the water
vapour molecules from the compressed air in the open pores of the adsorbent, thereby
reducing the moisture content of the compressed air.
2.1 Intended use
The adsorption dryer is exclusively designed for drying compressed air! If the
adsorption dryer is to be used with other gases, this must be agreed with the
manufacturer. Other safety guidelines may apply here!
The adsorption dryer must be set up at a site indoors:
-
which is suitable for the weight,
weatherproof (exposure to sun should be avoided),
dry,
frost-free,
vibration-free,
not in potentially explosive atmospheres,
which can be accessed for maintenance and servicing,
which at best has little dust exposure,
which is free from dangers due to the expansion factor or airflow sounds,
which is free from aggressive or corrosion-promoting substances.
The adsorption dryer must only be operated within the allowable operating
conditions. These are defined on the type plate and vessel plate. Any other use is
considered improper and the manufacturer accepts no liability.
The adsorption dryer must not be converted in any way and its components must
not be modified. The use of components other than the original ones from the
manufacturer is not permitted, unless this has been agreed with the
manufacturer.
The values shown on the vessel plate are the maximum permissible values as per
the pressure equipment directive. These values are not directed at the operating
conditions. The maximum operating conditions can be found on the type plate of
the adsorption dryer.
For the nominal performance data of the adsorption dryer, please refer to the
Section "Performance data".
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Exceeding or even significantly undercutting the design data can lead to bad
pressure dewpoints!
The compressed air supplied to the device must be of the following quality:
-
Free from aggressive and corrosive substances
Free from particles and solids
Moisture-saturated
Must be within the temperature conditions for the design.
In principle, the adsorption dryer can also be operated without any pre-treatment,
but this may be detrimental to the service life of the adsorbent. Droplets of oil and
particles are stored in the open pores and reduce the adsorption capacity of the
adsorbent.
Where temperatures are above 55°C, previously collected moisture can be released
again or can no longer be absorbed!
2.2 Performance data
Type
Nominal
volumetric flow
rate m³/h
Connection
Height mm
Width mm
Depth mm
Weight kg
The performance data of the individual types of devices is shown in the table
below. The data is based on the operating conditions of the compressed air
temperature
+ 35°C and 7 bar operating pressure, and a moisture content of the compressed
air of 100 %.
ATK 15
ATK 18
ATK 22
ATK 34
ATK 45
ATK 55
ATK 75
ATK 90
ATK 110
150
180
210
340
480
600
820
1000
1200
1180
1340
1460
1453
1603
2013
1726
1906
2106
1036
1036
1036
943
943
943
1220
1220
1220
546
546
546
773
773
773
954
954
954
156
174
187
294
378
416
638
888
936
1“
1”
1”
1 ½”
1 ½”
1 ½”
2”
2”
2”
Based on 1 bar(a) and 20°C
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Classification acc. to DGRL
2014/68/EU
Classification acc. to DGRL
2014/68/EU
Classification acc. to DGRL
2014/68/EU
Fluid group
Supply voltage
Safety class
Min. / max. allowable pressure
Sound pressure level (free-field
measurement in distance of 1.5m)
Min. / max. temperature
ATK 15-22 Category II
ATK 34 Category III
ATK 45-110 Category IV
2
230 V, 50-60 Hz
IP 54
4 / 16 bar
up to 80 dB (A)
+2 to 50 °C
Routine inspections must be carried out on the pressure vessels. The operator is
solely responsible for the registration. Regional or national regulations may apply
in addition. Please also refer to the additional vessel documentation!
3.
Safety notes
The ATK adsorption dryers have been built according to state-of-the-art technology and
the latest safety regulations. However, there is still a risk of danger during operation,
maintenance, installation and servicing, and during transport and setup. In particular,
the disregard of safety regulations when handling compressed air may result in serious
injury or death. Expertly trained personnel and those trained in safety should therefore
only use the system.
-
Observe the safety notes in this manual and on the adsorption dryer.
Observe all safety notes, even those in the individual chapters.
Observe all legal guidelines and safety regulations (the latter may vary from
region to region!)
Observe all local site regulations which are stipulated for the field of application.
3.1 Signs and symbols
The following signs are affixed to the adsorption dryer:
-
-
Vessel plate (on the front underneath the pressure gauge)
it includes details of the year of manufacture, vessel number, max. permissible
temperature, maximum permissible pressure, volume, min. temperature, test
pressure and test date.
Type plate (on the right side of the vessel)
it shows details of the type, year of manufacture, serial number of the device,
performance data, weight and filters installed.
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On every vessel:
Vessel plate:
Only once on the adsorption dryer:
Type plate:
The type plates on the device show important information. Please make sure that they
are always legible and that they can be accessed.
3.2 Danger zones
Risk from pressure-bearing
parts
Risk of slipping due to spilt desiccant on
the floor
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-
Never operate the device outside of the load limits shown on the vessel plate.
Never carry out work as long as the device is under pressure.
Do not modify the structure of the device or change its function.
Only use the adsorption dryer for its intended purpose.
Do not climb onto the device.
Do not carry out welding work on pressure-bearing parts.
Wear respiratory protection and eye protection when changing the desiccant.
Risk of slipping due to spilt desiccant.
Always check that the silencers are secure and wear eye protection.
Never operate the device if there is apparent damage.
Avoid sparks and naked flames in the vicinity of the desiccant.
Never lift the device by the equipment parts, only use the lifting lugs.
Only carry out work on the device if it has been disconnected from the power
supply.
Adsorbents
The desiccants used do not fall into the hazardous substances group and are therefore
not subject to labelling requirements. Nevertheless, please observe all common safety
measures with regard to using chemicals. Please also wear your personal protective
equipment (goggles and respiratory protection). Please also note that the material
accumulates contaminants, including oil vapour parts. This can cause additional
dangers.
Should you require further information, contact the manufacturer to obtain a copy of the
safety datasheet for the desiccant.
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4.
Technical product data
4.1 Equipment overview, front view
1 - Changeover valve outlet
2- Filling nozzle
3 - Pressure gauge
4 - Controller
5- Prefilter
6- After-filter
7- Changeover valve inlet
8- Vessel plate
9- Manual drain after-filter
10- Condensate drain prefilter
11- Draining nozzle
12- Lifting lugs
4.2 Equipment overview, rear view
1.
2.
3.
4.
5.
6.
7.
8.
Changeover valve
Removable screw connection, bottom
Lifting lugs
Silencer
Solenoid valve
Purge pipe
Purge air jet
Compressed air outlet
9. Compressed air inlet
10. Removable screw connection, top
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4.3 Function description
From the filled adsorbent material, (desiccant in this case), moisture is stored in the
large, open pores of the adsorbent material, thus reducing the moisture content in
the compressed air.
Through the joining pipe and possible pre-treatment, the compressed air is fed via
the inlet into the diffuser (flow distributor and sieve). The compressed air is hereby
distributed over the whole vessel cross-section for optimum efficiency. Based on the
laws of physics and a calculated and required contact time, the abovementioned
moisture content is stored in the open pores of the desiccant. The cleaned
compressed air then exits the vessel again through a sieve on the outlet.
As the temperatures rise, the performance of the desiccant is reduced since the socalled adsorption heat builds up in the desiccant as the amount of moisture
increases and as temperatures exceed 55 °C, the stored moisture is then released
again from the agent, i.e. no more moisture is stored.
The moisture stored in the desiccant gradually saturates the material. During the
course of the defined adsorption phase, the desiccant bed is optimally used. After a
predetermined time, the desiccant is then desiccated again following the counterflow principle using the dried compressed air, which is removed from the dry output
flow through a nozzle. This process constantly switches between the two vessels.
With the appropriate compressed air quality at the inlet, it is possible for the service
life of the desiccant to exceed well over 10,000 hours.
Compressed air outlet
Operating principle:
Changeover valve
Purge air jet
Regeneration
(Container B)
Adsorption
(Container A)
Changeover valve
Blow-off valve
Silencer
Compressed air inlet
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5. Monitoring the operation
The following components are provided for regular monitoring:
The pressure gauges show the operating pressure.
They provide information about the regular switch-over
of the adsorption dryer.
The Ecomatic control display (shown on the right here),
uses LEDs to inform you of the
status or phase which the adsorption dryer
is currently in.
If a dewpoint controller is used, then the
operating status is also shown. To do so, press the
arrow keys to display all information about the
current status. The screens shown on
the right are then displayed.
When daily checks are carried out, be mindful of any noises which are caused by the
regeneration process. The pressure gauges should also be taken into consideration
here. The expansion and noises of the purging air should always be regular. Brief
interruptions in the flow noises for example indicate a defective solenoid valve or
control fault.
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6. Transport, storage and setup
6.1 Transport
Although great care is taken, please check immediately whether the adsorption dryer
has been damaged in any way. Any kind of transportation damage must be pointed
out immediately to the deliverer and manufacturer.
-
Suitable hoisting equipment must be provided for the transportation, loading and
unloading process.
The device must only be lifted at the designated points: lifting lugs or transport
pallet.
Take the weight of the adsorption dryer into account and provide suitable
assistive equipment.
Secure the adsorption dryer against tilting using suitable means.
Do not remove the packaging material until the device is moved to its place of
installation.
Only appropriately qualified personnel may carry out the abovementioned tasks.
Observe all regulations on accident prevention.
Lifting lugs
6.2 Storage
If the device needs to be stored before being commissioned, ensure that the storage
site fulfills the following requirements:
-
Indoors only
Dry
Frost-free
Protected against weather impact.
If the device is stored after having been commissioned, please proceed as follows:
-
Depressurise the adsorption dryer.
Disconnect the adsorption dryer from the compressed air system.
Close the compressed air inlet and outlet.
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6.3 Setup
Please refer to the setup conditions described in Section 2.1. The basic data required
for the setup can be found in the Performance data in Section 2.2.
When setting up, make sure
-
that the ground is level and capable of carrying the weight. Please also take into
account that the vessel will be filled with water during the routine inspection.
Make sure there is enough space around the adsorption dryer to carry out the
servicing and maintenance work. We recommend at least 0.8m.
Make sure that the adsorption dryer can be reached and accessed by the lifting
gear.
The adsorption dryer must not be accessible to non-experts, or warning signs
should be affixed for inexperienced persons.
The adsorption dryer cannot be rammed by haulage vehicles.
The signage is clearly visible at all times.
There are mounting holes in the base section of the adsorption dryer. These should
be used to anchor the device into the ground, as long as the ground allows it.
7. Installation
7.1 Recommendations for installation
Proper installation is the basic prerequisite for the safe and problem-free operation
of the ATK series.
We recommend the installation of shut-off devices both upstream and downstream of
the adsorption dryer. The adsorption dryer can thereby be disconnected from the
compressed air system during maintenance.
If operation cannot be interrupted during maintenance then a by-pass line must be
provided. It should at least include a filter combination MFO and SMA to prevent a
contamination of moisture in liquid form downstream of the adsorption dryer.
We recommend installation after a corresponding pre-treatment. Filters and
separators should already be installed prior to this to prevent the rapid saturation of
the prefilter which is part of the delivery. The adsorption dryer is usually installed
behind an air cauldron.
A filter with a separation degree of 0.01 μ must be installed immediately in front of
the adsorption dryer (included in the delivery) to collect any possible additional
liquid drops and solids which would otherwise close up the open pores of the
adsorbent material for the drying process.
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Installing the device behind an air cauldron also has the advantage in that pulsating
compressed air is buffered and the temperature at the inlet of the adsorption dryer is
lower because it cools down in the air cauldron.
Choose a place of installation with the lowest possible compressed air temperature
and with the highest level of saturated compressed air. This then increases the
service life of the desiccant and the adsorption dryer works most efficiently.
When installing an air cauldron, make sure that:
-
There is no reverse flow (e.g. install a non-return valve)
The compressed air inlet temperature does not exceed the maximum permissible
value
Pressure shocks or pulsating compressed air are buffered by the corresponding
filters
The condensate separation of the prefiltration works properly
7.2 Demands on the installation
Prior to installation, check the following points:
-
The compressed air system and the adsorption dryer must be free from pressure.
For compressed air systems which need to remain under pressure, shut-off
devices have to be protected against unintentional opening.
The operating pressure in the system cannot be higher than the maximum
permissible operating overpressure of the adsorption dryer.
There must be no pressure surges in the system in the desiccant (e.g. from valves
which open abruptly).
The pipelines are designed for the operating pressure, nominal width and volume.
No possible vibration transmission or vibration.
No residue left in the pipeline from mechanical processing.
7.3 Elimination of hazards
Please be aware of the risks associated with the installation of the device:
Do not work on parts which are under pressure.
The pipelines must held in place with brackets, the adsorption
dryer is not designed to act as a support for the pipes.
The adsorption dryer must only be used in the predetermined
operating conditions (see vessel plate), it is the operator's duty to
observe these values.
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8. Commissioning
All work on ATK adsorption dryers and on the feeder and drainage systems must only
be carried out by expertly trained persons and by those with experience in the field of
compressed air!
8.1 Commissioning prerequirement
The following points must be checked immediately prior to commissioning:
-
The maximum operating values must not be exceeded.
Upstream and downstream shut-off devices are closed.
All connections and screw connections are secure. Check this and tighten if
necessary using a suitable tool.
Visually check again for any signs of damage. Do not use the adsorption dryer if it
is damaged in any way.
8.2 Pressurisation
Only once you've successfully completed all of the checks listed in Section 8.1 can
you perform the following steps in the specified order.
Wear ear protection for this as the flow noise can get very loud.
1. Make sure that the compressed air system is under pressure upstream of the
adsorber.
2. Slowly open the cut-off valve upstream of the adsorption dryer until you hear the
flow noise.
3. Keep an eye on the pressure gauge on the vessel. Pressurisation must rise slowly.
4. At 4 bar, close the shut-off device again at the inlet. Check all connections for
leaks. If leaks are found, the adsorption dryer must be rendered pressureless
again and the leaks must be repaired.
5. If no further flow noises can be heard and if the pressure gauge does not indicate
any further increase in pressure, you can open the cut-off valve completely.
6. Only then switch on the adsorption dryer controller.
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8.3 Mains operation
Pressurisation has been successful. Check whether the compressed air system
downstream of the adsorption dryer can be opened safely. Then proceed as follows:
1. Slowly open the cut-off valves at the outlet of the adsorption dryer until you hear
the flow noise.
2. Keep an eye on the pressure gauge. Should the pressure suddenly drop, check
whether any tapping points are still open.
3. If the pressure remains stable and you no longer hear any flow noise, the cut-off
valve downstream of the adsorption dryer can be opened completely.
4. Start the controller. Once switched on, it can take 1 minute until the first valve is
opened.
5. Keep an eye on the pressure gauges. The operating pressure must be virtually "0"
on the expanding side. The expansion noise is loud, only quiet flow noises should
be perceived after this.
6. Once regeneration has been completed, pressurisation starts. During this time,
the previously opened valve must be closed and pressurisation must start again.
7. Once the pressurisation time has passed, the pressure on both vessels must be
virtually the same.
8. Now also take into account the expansion (regeneration) on the other side. If this
also works as described above, the adsortpion dryer is ready for operation.
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8.4 Disconnecting from the mains
Should you have to disconnect the adsorption dryer from the mains, e.g. for a
maintenance operation, make sure that this work is only carried out when the device
is free from pressure.
Wear your personal protective equipment. Proceed as follows:
1. Close the cut-off valves at the inlet and outlet of the adsorption dryer.
2. Open the manual drain on the after-filter housing.
Man. drain cock
3. Keep an eye on the pressure gauge and wait until it displays "0" bar before
starting work.
4. Then close the manual cock again.
Instead of using the manual drain cock, you can also depressurise the adsorber
vessels by allowing the controller to continue to run upstream and downstream of the
dryer if the shut-off devices are closed, until both sides are depressurised.
The adsorption dryer is now disconnected from the mains.
9. Maintenance
Maintenance work may only be carried out by suitably qualified personnel! Make sure
that the device is free from pressure before starting work and observe the applicable
accident prevention regulations for the place of installation!
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9.1 Regular maintenance work
Silencer
Prefilter and afterfilter element
Desiccant
Sieves / diffuser
O-rings of filter
housing
Piston changeover
valves
Solenoid valves
Pressure dewpoint
sensor (if installed)
X
Page
Every 48
months
Visual check, functional
check
Check that the cables
and terminals are
securely fixed
Clean
Replace
Replace the filter
element
Replace
Clean, replace if
necessary
Replace
Every 24
months
Pressure gauge and
controller
Control box
Every 12
months
Activity
Every day
Maintenance of
Every month
The following table gives an overview of the intervals and scope of the maintenance
work:
12
X
-
X
26
26
X
X
23
X
23
X
23
X
Replace
X
Replace
Recalibrate
X
X
23
25
27
28
9.2 Daily checks
The following points should be checked every day:
-
The difference in the operating pressure upstream and downstream of the
adsorption dryer is not more than 0.5 bar.
Open the manual drain cock slightly on the after-filter. It must not drip.
Check if you can hear any unusual or loud noises.
Check for leaks.
If prefilters are installed, check that the condensate drains work properly.
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9.3 Checking the pressure dewpoint
If a pressure dewpoint controller is installed, the pressure dewpoint is displayed. You
can then set the pressure dewpoint according to your requirements.
With the standard package, the ECOMATIC (time control only) is already installed.
Since this controller can't measure the pressure dewpoint, you should measure it
externally from time to time.
Determine a measuring point behind the dryer and connect an external measuring
device. Make sure that this measurement is used in accordance with the
manufacturer specifications and that it is suitable for the pressure dewpoint range of
the adsorption dryer which is to be measured. Record these values in order to be able
to track the course of the pressure dewpoint.
9.4 Overview of maintenance parts
9.4.1 Annual maintenance
The following maintenance parts should be replaced every 12 months:
Type
ATK 15
Component Designation
GTE-ATK 15 Filterelements
ATK 18
GTE-ATK 18
ATK 22
GTE-ATK 22 Filterelements
ATK 34
GTE-ATK 34 Filterelements
ATK 45
GTE-ATK 45 Filterelements
ATK 55
GTE-ATK 55
Filterelements
ATK 75
GTE-ATK 75
Filterelements
ATK 90
GTE-ATK 90 Filterelements
ATK 110
GTE-ATK 110 Filterelements
Operating manual ATK 15-110
Filterelements
Quantity Interval
1
Every 12
months
1
Every 12
months
1
Every 12
months
1
Every 12
months
1
Every 12
months
1
Every 12
months
1
Every 12
months
1
Every 12
months
1
Every 12
months
Measure
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
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9.4.2 Two- and four-year maintenance
The following maintenance parts should be replaced every 24 months:
Type
ATK 15
ATK 18
Component Designation
FT-ATK 15
Functional
components set
F-ATK 15
Desiccant filling
FT-ATK 18
F-ATK 18
ATK 22
FT-ATK 22
F-ATK 22
ATK 34
FT-ATK 34
F-ATK 34
ATK 45
FT-ATK 45
F-ATK 45
ATK 55
FT-ATK 55
F-ATK 55
ATK 75
FT-ATK 75
F-ATK 75
ATK 90 FT-ATK 90
F-ATK 90
ATK 110 FT-ATK 110
F-ATK 110
Functional
components set
Desiccant filling
Quantity Interval
1
Every 24 months
1
1
1
Functional
components set
Desiccant filling
1
Functional
components set
Desiccant filling
1
Functional
components set
Desiccant filling
1
Functional
components set
Desiccant filling
1
1
1
1
1
Functional
components set
Desiccant filling
1
Functional
components set
Desiccant filling
1
Functional
components set
Desiccant filling
Operating manual ATK 15-110
1
1
1
1
Measure
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Every 24 months
Replace
Every 48 months/
when required
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
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9.5 Replacing the filter elements
The prefilter of the adsorption dryer retains particles and liquid forms of oil and
water, thereby protecting the desiccant against contamination.
The job of the after-filter is to stop any abrasion dust that has built up from the
desiccant. Proceed as follows to replace these filter elements:
1. Close the cut-off valves upstream and downstream of the adsorption dryer.
2. Open the manual drain cock on the filter and wait until the pressure gauge on the
adsorption dryer shows "0" bar.
3. Turn the bottom part of the filter in a clockwise direction to open it. Unscrew it
completely and carefully put it down.
4. Now you can remove the filter element out of the filter.
5. Use a damp cloth to clean inside the filter housing.
6. Check whether the O-ring in the filter head is OK. Replace if necessary.
7. Please fit the new filter element into the three pockets, on the inside of the filter
bowl.
8. Screw the bottom part of the filter back in again and close the manual drain cock.
9. Slowly open the shut-off device at the outlet and check for leaks.
10. Once the pressure is back to normal again, slowly open the shut-off device at the
outlet.
9.6 Replacing the desiccant
Draining nozzle at the bottom
Filling nozzle at the top
Operating manual ATK 15-110
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When replacing the desiccant, make sure to wear your personal protective
equipment, namely the respiratory protection and goggles.
Risk of slipping if material is spilt!
The service life of the desiccant is hugely dependent on the quality of the
compressed air at the inlet of the adsorption dryer. Strain from oil vapour
significantly reduces the service of the desiccant. In favourable conditions, the
service life can exceed well over 10,000 hours. Proceed as follows to replace the
desiccant:
1.
2.
3.
4.
5.
6.
7.
8.
9.
Depressurise the adsorption dryer.
First, open the sealing plug on the top.
Place a collecting vessel underneath the bottom sealing plug and remove it.
Collect the desiccant as it runs out.
Empty the vessel completely. (you can also empty the vessel using a vacuum
cleaner).
Blow through the sieves inside the vessel.
Close up the bottom sealing plug again and pour the new adsorption material
through the top opening. Depending on its use, the desiccant can consist of
several layers. Make sure that you add the materials in the correct order. WS and
alumina materials generally form the water protective layer and must be added
first.
Once you've reached the filler plug, condense the material through slight
vibration of the sheath of the adsorption dryer and then top up again until the
desiccant no longer condenses, even with vibration.
Screw the top sealing plug back in again.
We recommend that you only change the filter element after the desiccant has been
changed. Likewise, only change, or at least clean the solenoid valves after the trial
run. To do so, allow the adsorption dryer to run for half an hour. The dust particles
that accumulate are hereby captured in the after-filter element which is to be
replaced. Only then replace the filter element.
As a rule, the adsorption dryer needs several cycles before it reaches the desired
pressure dewpoint. Take into account that the piping system behind the adsorption
dryer may become contaminated with moisture during this phase. You may need to
provide a blow-off line during the installation operation.
Contaminated desiccant must be disposed of in accordance with the local
regulations! As a rule, the disposal code is:
"Used, non-contaminated desiccant" with the disposal code number: 06 08 99
If other toxic or hazardous substances have been stored, then this must be
determined by the operator and the desiccant must be disposed of taking the type of
contamination into consideration!
Operating manual ATK 15-110
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9.7 Replacing the pistons and cylinder liners
The change-over valves consist of a guide sleeve and a piston. These pistons are
subject to a mechanical load and must be replaced after two years. Proceed as
follows to replace them:
1. Depressurise the adsorption dryer.
2. Make sure that the pressure gauges show "0" and that the adsorption
dryer is fully depressurised.
3. Switch off the controller.
4. Remove the removable screw connections. Be mindful of the seals which
are inside the screw connections. The pipeline connection and both vessel
connections must be disconnected here.
5. Place the top pipe bridge onto a table and then loosen the purge pipe on
one side.
6. You can now remove the change-over valve by unscrewing it, as shown in
the diagram below.
7. Replace the piston, cylinder liner and seal.
8. Build the changeover valve back together again in the reverse order.
Torque moment for screws 6 Nm.
9. Mount the purge pipe again and then fit the pipe bridge back onto the
vessels.
10. Make sure that the seal is positioned correctly and then tighten all
removable screw connections again.
11. Repeat the same operations on the bottom side.
Pipe bridge
Changeover valve
Torque moment for screws
6 Nm after assembly
Operating manual ATK 15-110
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9. 8 Replacing the solenoid valves
The solenoid valves are supplied fully assembled and should also be installed as
such. These valves are also subject to a mechanical load and must be replaced after
two years. Proceed as follows to replace them:
1. Depressurise the adsorption dryer.
2. Make sure that the pressure gauges show "0" and that the adsorption
dryer is fully depressurised.
3. Switch off the controller by disconnecting the mains power plug.
4. Loosen the solenoid valve plug.
5. Loosen the removable screw connections.
6. Remove the exhaust bridge.
7. Dismantle and replace the solenoid valves.
8. Mount the exhaust bridges again and make sure that the seal fits correctly.
Tighten all screw connections again.
1. Removable screw connection
2. Solenoid valve
3. Silencer
Operating manual ATK 15-110
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9.9 Replacing the silencers
The silencers lessen the noise generation of the regeneration process. In these
silencers, proportionate desiccant abrasion in the form of dust is retained. Combined
with the outgoing moist air, the silencers become clogged with dust over time and
must be replaced. Proceed as follows to replace them:
1.
2.
3.
4.
5.
This work must only be carried out after the device has been depressurised.
To do so, close the inlet and outlet shut-off devices.
Switch off the controller by disconnecting the mains power plug.
Unscrew the silencers in an anticlockwise direction from the thread.
Wrap a few layers of Teflon around the thread of the new silencer to make it easier
to dismantle it later on. Then screw the new silencer back in again in a clockwise
direction until hand-tight.
6. If the desiccant also has to be replaced, replace this first, then the silencers, then
perform a trial run.
Disassembly
Assembly
Operating manual ATK 15-110
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10.
Replacing the pressure dewpoint sensor
If you've chosen the "ECOTROConomy" option, you must replace the sensor element
every two years. Desiccant abrasion and oil vapours can cause the accuracy of the
sensors to drift. This sensor element must therefore be replaced as follows:
1. This work must only be carried out after the device has been depressurised.
2. To do so, close the inlet and outlet shut-off devices.
3. Switch off the controller by disconnecting the mains power plug.
4. Loosen the cubic plug of the sensor element.
5. Unscrew the sensor element in an anticlockwise direction.
6. Fit the new sensor element by screwing it in a clockwise direction.
7. Screw the cubic plug back onto the sensor.
8. Slowly open the inlet shut-off device until both vessels are pressurised again.
9. Check for leaks on the screw connection. If there is a leak, seal it.
10. Then start up the controller and open the shut-off device on the outlet.
Sensor in output pipe
Sensor element with cubic plug
Operating manual ATK 15-110
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11.
Faults
The following faults may occur:
Error
Possible cause
Corrective action
Device does not switch
on
Dryer does not
regenerate
No power supply
Microfuse defective
Controller does not work
No power supply
Compressor
synchronisation circuit is
active
Solenoid valve does not
open
Check supply voltage
Replace fuse
Call Maintenance
Check supply voltage
Set DIL switch No. 8 to "1"
(for ECOMATIC)
Dryer does not reach the Desiccant not sufficiently
pressure dewpoint
regenerated yet
Water breakdown / oil
breakthrough
Defective condensate
drain
Inlet conditions incorrect
(pressure, temperature)
Compressed air extremely
undersaturated
Check input parameters,
possible by-pass buildup
in the desiccant due to
flow rate being too low
Silencer blocked
No pressure according to Inlet to dryer closed
pressure gauge on dryer
Differential pressure
Filter element is clogged
indicator is in red zone
Dryer keeps returning to Reverse flow through byalarm status
pass, reverse flow via oil
vapour adsorber
Compressors start up
Leaks
too frequently
No pressurisation
Piston in undefined
position
Operating manual ATK 15-110
Check cable connection /
terminals
Replace magnetic coil if
necessary
Allow it to keep running (after
48 hours at the latest, the
pressure dewpoint should be
reached)
Call Maintenance, replace
desiccant if necessary
Check prefilter for buildup of
condensate
Call Maintenance
Apply moisture
Call Maintenance
Replace
Open the supply line
Call Maintenance
Change by-pass, install nonreturn valve, call Maintenance
Call Maintenance
Switch off controller, allow
pressurisation to take place,
then switch controller back on
again
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12.
EU Declaration of conformity
EU Declaration of conformity
We, the manufacturer,
KSI Filtertechnik GmbH
Siemensring 54-56
D-47877 Willich
hereby declare that for the assemblies listed below:
Adsorption dryer ECOTROC ATK Type 15 to 110
the harmonised standards:
DIN EN ISO 12100-1-2: DIN EN ISO 14121-1; DIN EN 55011; DIN EN 61000-6-2, 61000-3-2,
61000-3-3 have been adhered to.
The conformity assessment procedure was completed in accordance with Module A.
The pressure vessels which are part of these assemblies have been manufactured in
construction and design conforming to the European Guideline 2014/68/EU Appendix I
for pressure equipment as per the technical rules of the AD2000 instruction sheets.
Separate declarations of conformity have been issued by the manufacturer for the
vessels which are supplied with this documentation.
Any modifications made to the equipment which has not been approved by the
manufacturer will annul this declaration.
Signed:
Holger Krebs,
Managing Director
Operating manual ATK 15-110
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