Parker Balston SMART Dryer - Davis Controls Ltd. · PDF fileParker Balston® SMART Dryer...

Bulletin TI-5100G Installation, Operation and Manintenance Manual Balston® SMART Dryer™ Models

www.balstonfilters.com11-800-343-4048

Parker Balston® SMART Dryer™

Installation, Operation, and Maintenance Manual

Models SMRT5100, SMRT5200, SMRT5300, SMRT5400, SMRT5500, and SMRT5600





Figure 1 - Overall Dimensions

Model SMRT5400

These instructions must be thoroughly read and understood before installing and operating this product. Any modification of the product will result in void-ing the warranty. Failure to operate this product in accordance with the instruc-tions set forth in this manual could jeopardize the safety of the operator. If you have any questions or concerns, please call the Technical Services Department at 800-343-4048, 8AM to 5PM Eastern Time (North America only) or email at: [email protected]. For other locations, please contact your local representative or email at [email protected].

Model SMRT5300

Bulletin TI-5100G

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Model SMRT5100 Model SMRT5200

Model SMRT5500 Model SMRT5600

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Installation, Operation, and Maintenance ManualBalston SMART Dryer™ Models SMRT5100, SMRT5200, SMRT5300, SMRT5400, SMRT5500, and SMRT5600



Location

All installation, operation, and maintenance procedures for the Balston SMRT Series Air Dryers should be performed by suitable personnel using reasonable care.

Warning: Use PTFE tape on all threaded components. Use of pipe sealants other than PTFE tape will damage the membrane and void the warranty. Please note that pipe dope of any kind is not to be used in the installation of Balston Air Dryers; use only PTFE tape.

Warning: Warranty will be void if black iron pipe or other material that will rust or corrode is used between the prefilters and SMART Air Dryer. Do not weld any connec-tions between prefilters and dryer. Use only stainless steel or brass for all piping and fittings between prefilters and SMART Air Dryer.

The Balston SMART Series Air Dryers should be mounted on the floor. The vibration free dry-ers should be installed indoors, in an area where the ambient temperature is less than 110°F (43°C) and above 37°F (3°C). Do not install the dryer outdoors.

A typical compressed air system with a membrane dryer is shown in Figure 2. The ambient air surrounding the compressor should be free of contaminants (e.g. ammonia compounds, chemical solvents, etc.) which can be drawn into the compressed air and damage the dryer.

Compressed Air - The compressed air supply pressure should be between 60 psig and 150 psig (4.1 barg and 10.3 barg) for proper operation of the dryer. The compressed air temperature should be within 10°F (6°C) of the ambient temperature and should not exceed 120°F (49°C) for optimal operation of the membrane dryer. The ambient air temperature should not exceed 110°F (43°C). If the ambient temperature or compressed air temperature exceeds recommendations, a properly sized aftercooler should be installed upstream from the dryer. Do not exceed inlet air or ambient air recommended temperatures or the perfor-mance and life of the dryer may be adversely affected and the warranty will be void.

Installation

Utilities

General DescriptionThe Balston SMART Dryers (see Figure 1) provide clean, dry compressed air from an existing compressed air supply through the use of state-of-the-art membrane technology. The dryer delivers dry air with a dewpoint of 35°F (2°C). The compressed air supply should be between 60 - 150 psig (4.1 - 10.3 barg). The dryer monitors system conditions and adjusts the sweep (regeneration flow) as system conditions warrant. The variable sweep system results in sig-nificant energy savings. Each membrane dryer is equipped with two high efficiency coalesc-ing prefilters to remove oil, water, and particulate contamination to 0.01 micron.

Flow Capacity(1)Model SCFM lpmSMRT5100 100 2830SMRT5200 200 5660

SMRT5300 300 8490

SMRT5400 400 11320

SMRT5500 500 14150

SMRT5600 600 16980Notes: 1 For 35°F (2°C) dewpoint.

Table 1: Compressed Air Han-dling Capacity and Operating Pressure Range

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Prefilter Installation

Shutoff valves should be installed directly upstream and downstream from the Balston Mem-brane Dryer to facilitate routine maintenance. Use only a gate valve or other slow-opening valve upstream from the dryer. Use of a valve which is not slow-opening will pressurize the dryer too quickly and may cause membrane rupture. Membrane failures resulting from improper valve installation will not be covered under warranty (see figure 2 or 3 for recom-mended dryer installation).

The Balston Membrane Air Dryers utilize a variable "sweep" flow to carry water vapor laden air away from the membrane. The variable sweep system works by monitoring system condi-tions through the dryer and adjusting the sweep flow proportionately to the airflow through the dryer. The sweep flow rate is approximately 13.2% of the actual airflow through the dryer. This sweep flow results in a hiss of air from the top of the membrane modules. The total com-pressed air consumption of the dryer is the sum of the downstream demand plus the "sweep" flow. See Table 2 for the sweep flow as a function of dryer flow rate. The compressor and associated piping components must be adequately sized to supply the sweep flow and compressed air demand. (See Principal Specifications for Maximum Compressed Air Requirement for each Model.)

The high efficiency condensate filters and coalescing prefilters are shipped separately from the dryer (see figure 2 or 3 for recommended prefilter installation). The drain on the prefilters will pass water and compressor oil which should be piped away to a suitable containment device or drain.

If the compressed air supply contains an excessive amount of condensate, a properly sized drip leg or receiver tank should be installed directly upstream from the dryer. Install an auto-matic drain on any drip leg or receiver tank used in the compressed air supply system (see figure 2 or 3 for recommended dryer installation).

Model Number Max. Downstream Sweep Flow Maximum Compressed Demand Demand* Air Consumption

SMRT5100 100 13.2 113.2

SMRT5200 200 26.4 226.4

SMRT5300 300 39.6 339.6

SMRT5400 400 52.8 452.8

SMRT5500 500 66.0 566.0

SMRT5600 600 79.2 679.2

Table 2: Sweep Flow as a Function of Dryer Flow Rate

* Sweep Flow Demand is measured at 100 PSIG and 100°F PDP per CAGI ADF 100-2001 (Refrigerated Compressed Air Dryers - Methods for Testing and Rating.) Consult factory for maximum compressed air consumption at different operating conditions.



To maximize membrane dryer performance, Parker recommends the following installation for a single membrane air dryer:

Compressor - Piston, rotary screw, rotary vane, or liquid ring compressor.

Aftercooler - Sized to bring compressed air temperature below 100°F. Air to air aftercooler should be on the same electri-cal circuit as compressor to insure operation.

Air Receiver - Air line to enter the tank in the lower 1/5th of the vessel, exit at the top 1/5th. For horizontal tanks, enter the side of the tank and exit from the top.

Condensate Separator - Install condensate separator in line after the receiver tank. Separator must be equipped with automatic drain.

Timed Solenoid Drain - Install at bottom of air receiver to remove condensate.

Coalescing Filter Housings - (Included with Smart Dryer System) Install immediately upstream of dryer. Use only brass, copper, or stainless steel piping between the filters and the air dryer. Maximum distance between the filters and the air dryer should be 10 linear feet of pipe.

Air Dryer - 60 to 150 psig operating pressure.

Bypass Valves - (Recommended) Bypass valves should be installed after coalescing filters and before dryer.

Figure 2 - Recommended SMART Membrane Dryer Installation

Notes: 1 Aftercooler and condensate separator should be installed after air receiver if compressor and air receiver are built as one unit.2 Each drain line should be vented to atmosphere. Do not tie together. 3 Assure that the room ambient temperature does not exceed 110°F. 4 If copper piping is used, dielectric fittings must be installed on the inlet port of the air dryer.5 Compressed Air Feed Temperature to dryer must not exceed 120°F.

Failure to follow these guidelines will void the warranty.



For multiple SMART membrane air dryers, Parker recommends the following installation:

Compressor - Piston, rotary screw, rotary vane, or liquid ring compressor.

Aftercooler - Sized to bring compressed air temperature below 100°F. Air to air aftercooler should be on the same electri-cal circuit as compressor to insure operation.

Air Receiver - Air line to enter the tank in the lower 1/5th of the vessel, exit at the top 1/5th. For horizontal tanks, enter the side of the tank and exit from the top.

Timed Solenoid Drain - Install at bottom of air receiver to remove condensate with minimum line size of one inch.

Drip Leg - Install drip leg from bottom of air supply header with automatic drain.

Condensate Separators - Install condensate separators in line in front of coalescing filters. Separators remove excess condensate from the air line. Separators must be equipped with automatic drains.

Coalescing Prefilters - (Included with SMART Dryer) Install prefilter immediately upstream of dryer. Use copper, brass, or stainless pipe between filter and dryer.

Membrane Air Dryer - Install non-iron piping between prefilters and membrane module cabinet.

Bypass Valves - Bypass valves install after coalescing filter and before dryer.

Notes: 1 Each condensate drain must be functioning and vented to atmosphere. Maximum two feet incline for condensate drain lines.2 Piping must be from top of main line header to each SMART membrane air dryer.3 All SMART membrane air dryers must be piped in parallel with all feed and product air piping an equal distance from main air line headers.4 Compressed air feed temperature to dryer must not exceed 120°F.5 Assure that ambient room temperature does not exceed 110°F.

Failure to follow these guidelines will void the warranty.

Figure 3 - Dual Dryer Installation



All maintenance procedures for the SMART Dryer should be performed by suitable per-sonnel using reasonable care.

Depressurize the dryer prior to performing any service.

If necessary, the SMART Dryer may be wiped clean with a dry cloth on an as-needed basis. DO NOT use water, aerosols, or other cleaning agents to clean the unit.

The only maintenance required by the Balston SMART Series Air Dryer is the replacement of the prefilter cartridges (see Figure 4) every 12 months. The part numbers for the replacement filters are listed in the Ordering Information table at the end of this section.

The coalescing prefilter housings are included with the SMART Dryer and are installed by the customer per Figure 2 or 3. The filter cartridges are replaced by removing the filter bowl and then unscrewing the element retainer to remove the filter cartridge. Insert a new filter cartridge and reassemble the housing in reverse order. The time required to change the prefilter cartridge on the Balston SMART Series Air Dryer is less than 5 minutes.

In the unlikely event of a membrane module failure, the membrane module can be replaced by removing 8 socket screws on the top and bottom of the module. Slowly lift the module away from the dryer and disconnect the tubing from the fitting on the bottom of the membrane module. (The tubing is disconnected by pushing on the ring then pulling on the tubing).

To install a new module, install the o-ring in the grooves on the membrane module end caps and install the module in reverse order. First connect the tubing on the bottom then secure all 8 socket cap screws. The time required to change the membrane module on the Balston SMART Series Air Dryer is less than 5 minutes.

Operation

Gauges

To operate the Balston Membrane Air Dryer, simply open the shutoff valves (customer installed) on the inlet and outlet air lines. Do not exceed rated flow or pressure of dryer (see Table 1).

There are three gauges on the SMART Dryer. Two differential pressure (DPI) gauges are mounted on the top of the coalescing prefilter housings. A system pressure gauge is mounted on the front panel of the SMART Dryer.

Maintenance

Operation

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Figure 4 - Maintenance Item Locations



Membrane Air Dryers

Model Number SMRT5100NA SMRT5200NA SMRT5300NA SMRT5400NA SMRT5500NA SMRT5600NAMax Flow Rate @35°F dewpoint 100 SCFM 200 SCFM 300 SCFM 400 SCFM 500 SCFM 600 SCFM Dewpoint (1) 35°F (2°C)Min/Max Inlet Air Temp. 40°F/120°F (4°C/49°C)Ambient Temp. Range 40°F/110°F (4°/43°C)Min/Max Inlet Pressure 60 psig/150 psig (4.1 barg/10 barg)Max Feed Dewpoint 120°F PDP (Pressure Dewpoint)Altitude 2000MMax Compressed Air 113 SCFM 226 SCFM 339 SCFM 452 SCFM 565 SCFM 678 SCFM Requirement (1) Max Pressure Drop 10 psi (0.7 bar)Inlet/Outlet Port Size 1-1/2"NPT(female) 2"NPT(female) 2"NPT(female) 2"NPT(female) 2-1/2"NPT(female) 3"NPT(female)Physical Dimensions (See Figure 1)Shipping Weight 175 lbs(79 kg) 225 lbs(79 kg) 300 lbs(136 kg) 375 lbs(170 kg) 475 lbs(216 kg) 550 lbs(250 kg)

1 Dewpoint and maximum com-pressed air required are specified for 100 psig @ 100°F PDP per CAGI ADF 100-2001 (Refrigerated com-pressed air dryers - methods for test-

Principal Specifications

Notes:

Ordering Information

Model Number SMRT5100NA SMRT5200NA SMRT5300NA SMRT5400NA SMRT5500NA SMRT5600NA

Condensate Separator 1st stage F602-12EJQ/M4 F602-16EJQ/M4 F602-16EJQ/M4 F602-16EJQ/M4 F602-20EJQ/M4 F602-20EJQ/M4Replacement Element for Separator EK602B EK602G EK602G EK602G EK602G EK602GDrain Kit for Separator SA603D SA603D SA603D SA603D SA603D SA603DCoalescing Prefilter 2312N-1B1-DX A15/80-DX CO2-2356 CO2-2358 CO2-2360 CO2-2362Assembly - Stage 2, 3 2312N-1B1-BX A15/80-BX CO2-2357 CO2-2359 CO2-2361 CO2-2363Replacement Prefilter 200-35-DX 200-80-DX 210-800-DX 210-955-DX 300-960-DX 300-960-DXCartridges (every 6 mos.) 200-35-BX 200-80-BX 210-800-BX 210-955-BX 300-960-BX 300-960-BX Membrane Module D01-0086(2ea.) D01-0086(4ea.) D01-0086(6ea.) D01-0086(8ea.) D01-0086(10ea.) D01-0086(12ea.)Automatic Drain Kit 21552 21552 21552 21552 21552 21552Drip Leg Drain 20-613 20-613 20-623 20-623 20-211 20-211

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ing and rating.) Contact factory for dewpoint and maximum compressed air requirement at different operating conditions.

2 If compressed air is extremely contaminated, additional coalescing filters should be installed before the dryer.



All troubleshooting activities should be performed by suitable personnel using reasonable care.

Symptom Course of Action

Check drain for leaks. Replace automatic drain kit (P/N 21552 or 20-211) if necessary.

Check flow demand. Match process flow requirements to dryer capacity.

Check inlet filter for particulate clogging; replace if necessary.

Check for leaks in dryer and downstream piping and process.

Check supply line source (compressor).

Check to make sure all customer installed valves are open.

Check fittings and drain for leaks.

Check inlet air temperature of compressor air to dryer. Inlet air should not exceed 10 degrees above ambient air temperature.

Make sure inlet air is conditioned properly before the dryer. Follow guidelines on page 4 and 5. Compressor outlet should have an aftercooler with separator, air receiver with autodrain, dripleg with autodrain.

Directly before the dryer check that coalescing filters are properly installed and that autodrains function properly.

Check coalescing filters for excess water.

Check flow rate, do not exceed dryer's maximum flow capabilities.

Auto float drains are stuck in the open position. Replace autodrains, P/N 21552.

Check autodrain on coalescing filters for leaks.

Check inlet filters for particulate clogging; replace if necessary.

Check for leaks in dryer.

Make sure dryer purge is not excessive. All membranes should purge the same amount of air from top purge ports.

Check flow demand. Do not exceed maximum flow capabilities of dryer.

Membrane could be ruptured. See course of action for "water in outlet line" above.

Replace suspect membrane.

High Pressure Drop Through Dryer (low flow)

No Flow Through Dryer

Note: To arrange for system service, contact the Technical Services Department at 1-800-343-4048, 8AM-5PM Eastern Time or email at: [email protected]. For locations outside North America, please call your local representative or email at [email protected].

Troubleshooting

Water in air outlet line

Coalescing filters air constantly

Large pressure drop across dryer

Purge very loud from 1 or more membranes



Explanation of Warning Symbols

Symbol Description

Caution, refer to accompanying documents for explanation.

Caution, risk of electric shock.

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1 Complete and mail your registration card.

2 Keep your product certification in a safe place.

3 Call the Technical Services Department at 800-343-4048, 8AM to 5PM Eastern Time with any questions or email at: [email protected]. For locations outside North America, please contact your local representative or email at [email protected].

The serial number label is attached to the side of the unit, near the inlet and outlet ports. For your own records, and in case service is required, please record the following:

DATE IN SERVICE SERIAL NO.

Please have the serial number available when calling for assistance.

Don’t Forget To:

Serial Numbers

WARRANTY (NORTH AMERICA ONLY)(FOR INFORMATION CONTACT YOUR LOCAL REPRESENTATIVE)

Parker Hannifin guarantees to the original purchaser of this product, that if the product fails or is defective within 12 months from the date of purchase, when this product is operated and maintained according to the instructions provided with the product, then Parker guarantees, at Parker’s option, to replace the product, repair the product, or refund the original price for the product. This warranty applies only to defects in material or workmanship and does not cover: ring and valve wear on compressors, routine maintenance recommended by the instructions provided with this product, or filter cartridges. Any modification of the product without written approval from Parker will result in voiding this warranty. Complete details of the war-ranty are available on request. This warranty applies to units purchased and operated in North America.

Parker Hannifin CorporationFiltration and Separation Division242 Neck Road, P.O. Box 8223Haverhill, MA 01835-0723Tel: 978-858-0505 Fax: 978-556-7501www.balstonfilters.com

Parker Filtration & SeparationFiltration Group EuropeHermitage Court, Hermitage LaneMaidstone, Kent ME16 9NT, EnglandTel: +44 (01622) 723300 Fax: +44 (01622) 728703www.parker.com/pag

Copyright© Parker Hannifin Corporation 2004, 2009Printed in U.S.A. Bulletin TI-5100G

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