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IR D5IM-D34IM Desiccant Dryer Maintenance Guide

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D5IM D34IM Desiccant Dryer Maintenance Guide

Safety Information Important: Do not operate this equipment until the safety information and instructions in this user guide have been read and understood by all personnel concerned. Only competent personnel trained, qualified, and approved by Ingersoll Rand should perform installation, commissioning, service and repair procedures. Use of the equipment in a manner not specified within this user guide may result in an unplanned release of pressure, which may cause serious personal injury or damage. When handling, installing or operating this equipment, personnel must employ safe engineering practices and observe all related regulation, health & safety procedures, and legal requirements for safety. Ensure that the equipment is depressurized and electrically isolated, prior to carrying out any of the scheduled maintenance instructions specified within this user guide. 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 recognizing that any machinery is potentially hazardous. Ingersoll Rand 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 can not be all-inclusive. If the user employs an operating procedure, item of equipment or a method of working which is not specifically recommended by Ingersoll Rand the user must ensure that the equipment will not be damaged or become hazardous to persons or property.

BEFORE SERVICING OR DISMANTLING ALL PRESSURE MUST BE RELEASED FROM THE SYSTEM AND ITS ASSOCIATED PIPEWORK AND ANY ELECTRICAL SUPPLY ISOLATED. Hazardous Substances The chambers of the dryer are filled with DRYFIL desiccant material. This is a powerful desiccant and will dry out the atmosphere, eyes, nose, and mouth. If the desiccant comes into contact with the eyes or skin, wash the affected area with copious amounts of water. DRYFIL may contain some dust therefore and or nasal dust respirator should be worn when handling the equipment. Adequate ventilation should be provided when working with desiccant. The desiccant is classified as non-hazardous for transportation. DRYFIL will evolve heat on contact with moisture and may generate pressure in a confined space. DRYFIL should therefore be stored in a dry place in its original packaging. DRYFIL is non-flammable. Any fire should be fought by means appropriate to the material causing the fire. DRYFIL should be disposed of into a licensed land fill site.

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SectionA1 A2 A3 A4 A5 A6 A7

DescriptionLOWER HEAD ASSEMBLY COLUMN ASSEMBLY UPPER HEAD ASSEMBLY PURGE SETTINGS CONTROL BOX ASSEMBLY RECOMMENDED TOOL LIST SCHEMATIC DIAGRAMSCorrection Factors

Page No

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MIDAS CONSTRUCTION

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SECTION

A1

LOWER HEAD ASSEMBLYA1.1 A1.2 A1.3 A1.4 A1.5 Lower Head Removal Silencer Removal Inlet Ball and Retainer Removal Solenoid Valve Removal Lower Head Torque sequence

LOWER HEAD ASSEMBLY

SECTION

A1

A1.1a LOWER HEAD REMOVAL 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove pipework. 3. Remove front trim. 4. Lie dryer down. 5. Remove valve cover. 6. Disconnect solenoid valve plugs. 7. Loosen display 8. Remove control box 9. Remove 6 lower head bolts A1.1b LOWER HEAD REASSEMBLE 1. Re-assemble in reverse order. 6 bolts to be torqued to (20lbf-ft) (27Nm) (see Torque sequence detail A1.5) Ensure all o-rings (3 off) are in place before assembly.

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LOWER HEAD ASSEMBLY

SECTION

A1

A1.2a SILENCER REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove pipework. 3. Lie dryer down. 4. Remove valve cover. 5. Remove silencer. A1.2b SILENCER REASSEMBLE 1. Re-assemble in reverse order

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LOWER HEAD ASSEMBLY

SECTION

A1

A1.3a INLET BALL RETAINER REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove pipework. 3. Remove front trim. 4. Lie dryer down. 5. Loosen and remove display. 6. Remove valve cover. 7. Disconnect solenoid valve plugs. 8. Remove 4 bolts for ball retainer. 9. Remove ball .A1.3b RE-ASSEMBLY Of INLET BALL RETAINER 1. Re-assemble in reverse order as above Torque setting for 4 bolts (2.2lbf-ft) (3 Nm)

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LOWER HEAD ASSEMBLY

SECTION

A1

A1.4a SOLENOID VALVE REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove pipework. 3. Remove front trim. 4. Lie dryer down. 5. Loosen display 6. Remove valve cover. 7. Disconnect solenoid valve plugs. 8. Remove solenoid block retainer (clip or nut) 9. Remove valve stem and plunger .A1.4b RE-ASSEMBLY OF SOLENOID VALVE 1. Re-assemble in reverse order as above Torque setting on valve stems (3.6lbf-ft) (5 Nm)

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LOWER HEAD ASSEMBLYA1.5 Torque Torque all bolts to 27N/M

SECTION

A1

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SECTION

A2

COLUMN ASSEMBLYA2.1 A2.2 A2.3 Desiccant Cartridge Replacement Column Replacement Torque sequence & Settings

COLUMN ASSEMBLYA2.1a CARTRIDGE REPLACEMENT 1. 2. 3. 4. Ensure dryer is fully depressurised. Remove top cover. Remove cartridge twist inserts.(Anti-clockwise) Remove cartridge from inserts

SECTION

A2

A2.1b CARTRIDGE REASSEMBLY 1. Reassemble in reverse order 1. Ensure o-ring on cartridge is in place.

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COLUMN ASSEMBLY

SECTION

A2

A2.2a COLUMN REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove pipework. 3. Remove front trim. 4. Lie dryer down. 5. Remove valve cover. 6. Disconnect solenoid valve plugs. 7. Loosen display 8. Remove control box 9. Remove 6 lower head bolts 10. Remove lower head. 11. Remove top cover. 12. Remove filter and cartridge inserts 13. Remove 6 bolts from top head. A2.2b COLUMN REASSEMBLE 1. Re-assemble in reverse order. 6 bolts to be torqued to (20lbf-ft) (27Nm) (see Torque sequence detail A1.5) Ensure all o-rings (3 off top head and 3 off bottom head) are in place before assembly.

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COLUMN ASSEMBLYA2.3 Torque Settings Torque all bolts to 27 N/M

SECTION

A2

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SECTION

A3

UPPER HEAD ASSEMBLYA3.1 A3.2 A3.3 A3.4 A3.5 A3.6 Upper Head Replacement Cartridge Twist Insert Replacement Filter Replacement Drain Bowl and Auto Drain Replacement Filter Replacement. Torque Sequence Detail

UPPER HEAD REPLACEMENT

SECTION

A3

A3.1a UPPER HEAD REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove the top cover. 3. Remove pipework. 4. Remove front trim. 5. Remove filter and cartridge twist inserts, be careful of oulet ball falling from cartridge twists insert. 6. Remove drain bowl by pushing bowl up and rotating approx 90 deg.from right to left (as viewied from front) then pull down. 7. Remove 6 bolts and lift off top head. A3.1b UPPER HEAD REASSEMBLE 1. Reassemble in reverse order. 6 bolts to be torqued to (20lbf-ft) (27Nm) (see Torque sequence detail A3)

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UPPER HEAD REPLACEMENT

SECTION

A3

A3.2a CARTRIDGE TWIST INSERT REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove the top cover. 3. Remove cartridge twist insert (Anti-clockwise) 4. Remove cartridge from insert. 5. Remove puge plug. A3.2b CARTRIDGE TWIST INSERT REASSEMBLE 1. Reassemble in reverse order. 2. Set purge flow.

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UPPER HEAD REPLACEMENT

SECTION

A3

A3.3a FILTER TWIST INSERT REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove the top cover. 3. Remove filter twist insert.(Anti-clockwise) 4. Unscrew filter. A3.3b FILTER TWIST INSERT REASSEMBLE 1. Reassemble in reverse order.

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UPPER HEAD REPLACEMENT

SECTION

A3

A3.4a DRAIN BOWL and AUTO DRAIN REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove front trim. 3 Loosen display pozi screws 4. Unlock and remove drain bowl ,by first pushing up then rotating from left to right as viewed from the front. Pull drain down and remove. 5. Remove auto drain - (Note nut of auto drain turns into housing to remove auto drain) A3.4b DRAIN BOWL and AUTO DRAIN REASSEMBLE 1. Reassemble in reverse order. Auto drain to be torqued to (2.5Nm) (1.8lbf.ft)

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UPPER HEAD REPLACEMENT

SECTION

A3

A3.5a FILTER REPLACEMENT 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove the top cover. 3. Remove filter twist insert.(Anti-clockwise) 4. Unscrew filter. A3.5b FILTER REASSEMBLY 1. Reassemble in reverse order.

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UPPER HEAD REPLACEMENTA3.6a TORQUE SEQUENCE DETAIL

SECTION

A3

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SECTION

A4

PURGE SETTINGSA4.1 A4.2 Purge Screw Replacement Purge Adjustment

SECTIONA4.1a Purge Screw Replacement. 1. Ensure dryer is fully depressurised and electrically isolated 2. Remove top cover. 3. Unscrew purge plugs. A4.1b Purge Screw Reassembly 1. Reassemble ensuring purge is set correctly. See A4.2

A4

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SECTIONA4.2 PURGE FLOWDRYER MODELD5IM DAS 1

A4

MUST BE SET AT MINIMUM SYSTEM PRESSURE SCFM L/MIN

0.6 1.0 1.6 2.0 2.6 3.0 4.0 PURGE SETTING

17.0 28.32 45.31 56.64 73.63 84.95 113.30

DAS 2D14IM DAS 3

DAS 4 DAS 5D25IM DAS 6

D34IM DAS 7

1. Gain access to the lower head by removing the front valve cover. 2. Replace silencer 1/4"bsp fitting with a suitable fitting to connect a flow meter 3. Allow dryer to cycle at its minimum pressure. (Note dryer to be in upright position) 4. Do not connect the flow meter until straight after a blow down has occured. 5. After a blow down connect flow meter and adjust one of the purge screws. Once set to required flow remove meter and allow blow down of other chamber. 6. Set flow to this chamber. 7. remove fitting and reconnect silencer. 8. Reassemble valve covers.

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SECTION

A5

CONTROL BOX ASSEMBLYA5.1 A5.2 A5.3 A5.4 A5.5 A5.6 A5.7 A5.8 A5.9 A5.10 A5.11 Exploded View of Control Box Control Box Removal Timer Replacement Display Replacement Transformer Replacement Fuse Replacement Solenoid Cable Replacement Control Box Replacement Relay Replacement Timer Configuration Sevice Reset Sequence

SECTIONA5.1 EXPLODED VIEW OF CONTROL BOX

A5

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SECTIONA5.2 CONTROL BOX REMOVAL

A5

A5.2a CONTROLBOX REMOVAL 1. Ensure dryer is fully depressurised and electrically isolated. 2. Remove pipework. 3. Remove front trim. 4. Lie dryer down. 5. Remove valve cover. 6. Disconnect solenoid valve plugs. 7. Loosen display 8. Remove control box A5.2b CONTROL BOX REASSEMBLE 1. Reassemble as above in reverse order

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SECTIONA5.3aTIMER REPLACEMENT1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Ensure dryer is fully depressurised and electrically isolated. Remove pipework. Remove front trim. Lie dryer down. Remove valve cover. Disconnect solenoid valve plugs. Loosen display Remove control box Remove 9 screws from timer base plate and open control box. Remove all leads from timer board. Remove 4 nuts from timer board. Remove timer board.

A5

A5.3b TIMER REASSEMBLE 1. Reassemble as above in reverse order. 4 nuts to be torqued to (0.5Nm) (0.4lbf.ft) Pozi retaining screws to be torqued to (0.5Nm) (0.4lbf.ft) See wiring schematic for cable positions.

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SECTIONA5.4a DISPLAY REPLACEMENT1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Ensure dryer is fully depressurised and electrically isolated. Remove pipework. Remove front trim. Lie dryer down. Remove valve cover. Disconnect solenoid valve plugs. Loosen display Remove control box Remove 9 screws from timer base plate, and open control box. Disconnect display leads from timer board. Loosen cable gland nut and remove display.

A5

A5.4b DISPLAY REASSEMBLE 1. Reassemble as above in reverse order.See wiring schematic for cable positions. Pozi retaining screws to be torqued to (0.5Nm) (0.4lbf.ft)

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SECTIONA5.5a TRANSFORMER REPLACEMENT1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

A5

Ensure dryer is fully depressurised and electrically isolated. Remove pipework. Remove front trim. Lie dryer down. Remove valve cover. Disconnect solenoid valve plugs. Loosen display Remove control box Remove 9 screws from timer base plate, and 4 from the fuse access area. Remove transformer leads from the fuse block and timer board. Remove the transformer holding down nuts and remove transformer.

A5.5b TRANSFORMER REASSEMBLE 1. Reassemble as above in reverse order.See wiring schematic for cable positions. Pozi retaining screws into control box to be torqued to (0.5Nm) (0.4lbf.ft) Torque setting for 2 off transformer nuts (2Nm) (1lbf.ft)

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SECTIONA5.6a FUSE REPLACEMENT1. 2. 3. 4. 5. Ensure dryer is fully depressurised and electrically isolated. Remove pipework. Lie dryer down. Remove 4 screws on small plate. Remove fuse from fuse holder.

A5

A5.6b FUSE REASSEMBLE 1. Reassemble as above in reverse order. Pozi retaining screws into to be torqued to (0.5Nm) (0.4lbf.ft)

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SECTIONA5.7a SOLENOID CABLE REPLACEMENT1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Ensure dryer is fully depressurised and electrically isolated. Remove pipework. Remove front trim. Lie dryer down. Remove valve cover. Disconnect solenoid valve plugs. Loosen display Remove control box Remove 9 screws from timer base plate, and open control box. Disconnect soleniod cables from timer board. Loosen cable gland nuts and remove solenoid cables

A5

A5.7b SOLENOID CABLE REASSEMBLE 1. Reassemble as above in reverse order.See wiring schematic for cable positions. Pozi retaining screws to be torqued to (0.5Nm) (0.4lbf.ft)

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SECTIONA5.8a CONTROL BOX REPLACEMENT1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Ensure dryer is fully depressurised and electrically isolated. Remove pipework. Remove front trim. Lie dryer down. Remove valve cover. Disconnect solenoid valve plugs. Loosen display Remove control box Remove 9 screws from timer base plate and 4 from fuse access area. Disconnect soleniod cables and display at the timer board, loosen cable gland nuts 11. Disconnect lead from fuse holder to transformer and mains lead 12 .Remove control box.

A5

A5.8b CONTROL BOX REASSEMBLE 1. Reassemble as above in reverse order.See wiring schematic for cable positions. Pozi retaining screws into control box to be torqued to (0.5Nm) (0.4lbf.ft)

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SECTIONA5.9a RELAY REPLACEMENT (OPTIONAL)1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Ensure dryer is fully depressurised and electrically isolated. Remove pipework. Remove front trim. Lie dryer down. Remove valve cover. Disconnect solenoid valve plugs. Loosen display Remove control box Remove 9 screws from timer base plate. Remove cables from relay. Loosen relay holding down nuts and remove relay.

A5

A5.9b RELAY REASSEMBLE 1. Reassemble as above in reverse order.See wiring schematic for cable positions. Torque setting on relay nuts (2Nm) (1.5lbf.ft) Pozi retaining screws to be torqued to (0.5Nm) (0.4lbf.ft)

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SECTIONA5.10a TIMER CONFIGURATION

A5

Dryer running with a pressure in excess of 7 bar (Timer Configuration) The Dryer is factory set to 6 bar min operating condition. If the minimum pressure is in excess of 7 bar the jumper in side the control box requires altering 1. Remove control box 2. Remove 9 screws from timer base plate to give access to timer board. 3. Move jumper to position 2. A5.10b TIMER CONFIGURATION REASSEMBLY 1. Reassemble as above in reverse order.

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SECTIONA5.11 SERVICE RESET SEQUENCE

A5

Once the dryer has been serviced and all pipework connected, the timer board requires resetting. To reset the timer do not switch on the air. Remove the reset button on the control box, Insert a small terminal driver in to the hole and depress and hold the reset button. Switch the mains power on holding the reset button for 5 seconds. Remove ternminal driver and switch off mains. Wait 5 seconds before commencing start up sequence of dryer and replace reset button.

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SECTION

A6

RECOMMENDED TOOL LIST

SECTIONRecommended Tool List

A6

SOCKETS. 5.5mm 7.0mm and 16.0mm ALLEN KEY SOCKETS. 6mm and 8mm FLAT BLADE SCEWDRIVER POZI SCREWDRIVER FLAT BLADE TERMINAL DRIVE WIRE STRIPPERS PLIERS TORQE DRIVER (0.6NM) TORQUE WRENCH (5-40Nm) TOGGLE BAR 5dia x 300mm long ALLEN KEY 4mm ALLEN KEY 3/16" SPANNER 17mm SPANNER 14mm 6" ADJUSTABLE SPANNER GREASE PTFE TAPE DRAIN BOWL SPANNER TUBE CUTTERS

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SECTION

A7

SCHEMATIC DIAGRAMS.A7.1 A7.2 A7.3 Wiring Schematic (230V) Wiring Schematic (115V) Piping and Instrumentation Schematic

Correction Factors D5IM to D34IM

Model Selection Chart Model Nominal Capacity3

m /hr cfm D5IM 5.1 3 D14IM 13.6 8 D25IM 25.5 15 D34IM 34 20 Capacity at 100 psig (7 barg) and 95 (35C) inlet F Correction Factors

Sizing Factors for Ingersoll Rand Modular Desiccant Air DryersInlet Pressure barg 4 5 6 7 8 9 10 11 12 psig 58 73 87 100 116 135 145 160 175 35 (95) 0.63 0.75 0.88 1 0.97 1.08 1.18 1.29 1.4 Inlet Temperature 40 (104) 0.61 0.73 0.85 0.97 0.94 1.05 1.14 1.25 1.36 C (F) 50 (122) 0.46 0.55 0.64 0.73 0.71 0.79 0.86 0.94 1.02

45 (113) 0.55 0.66 0.77 0.88 0.85 0.95 1.04 1.14 1.23

Dew Point Correction Factors Outlet Dew Point C F -40 -70 -40 -94 Correction Factor 1 0.7

Inlet temperature, inlet pressure, required air flow and pressure dew point must be established before an adsorption air dryer can be specified for your application. Once these operating conditions are known, you can select the most economical adsorption dryer using the dryer sizing chart on the previous page and the model selection chart. Example Select a dryer for a compressor producing, at full load 8 cfm (13.60 m /hr) at 87 psig (6 barg) with 95 F (35 air inlet temperature with a pressure dew point of -40 (40 C) F C). Temperature and Pressure Step 1Page 1 of 23

Correction Factors D5IM to D34IM

On the sizing chart locate the inlet temperature 95 (35 F C). Step 2 At 95 (35 read down the chart to 87 psi g (6 bar g) operating pressure, the correction factor is 0.88. F C), The correction factor for the pressure dew point is 1.0. At the operating temperature and pressure, the capacity of the adsorption dryer will be 0.88 of the capacity at ISO 7183 rating conditions. No correction for the pressure dew point. Step 3 To adjust the required flow for ISO 7183 rating conditions, divide the required flow by 0.88 Example: Sizing Capacity = Actual Capacity Sizing Factor x DPF Sizing Capacity = 8 cfm 0.88 x 1 = 9.1 cfm (15.5 m3/hr) Step 4 Using the model selection chart, select a dryer which has a rated capacity of 9.1 cfm (15.5 m /hr) or larger. Selected model is a D25IM.3

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D5IM – D34IM Desiccant Dryer Maintenance Guide
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