Related Manuals for Sullair SAR 180
Summary of Contents for Sullair SAR 180
- Page 1 MODELS :- SAR 180 to SAR 900 DESICCANT DRYERS MAINTENANCE MANUAL DATE : 23mar2000 REVISION :...
- Page 2 Page 2 of 34 FOREWORD The compressed air dryer systems have been designed and manufactured to ensure that maximum safety and performance is achieved. It is expected that users of these systems will employ safe working practices and ensure that when installing, commissioning, operating or maintaining the equipment, any legal requirements are fulfilled.
- Page 3 Page 3 of 34 RECOMMENDED ROUTINE MAINTENANCE Daily 1. Open kaddis drains on lower manifold and valve housings to discharge any entrained condensate. 2. Ensure ’power on’ light is illuminated (SHR versions only). Monthly As above and include: 1. Ensure cam timer motor rotates to specification. 2.
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Page 4: Table Of Contents
Page 4 of 34 MAINTENANCE CONTENTS Section Description Page Inlet Valve Assembly Manifolds Exhaust Valve Assembly Column Assemblies Outlet Valve Assembly Control & Instrumentation Piping & Wiring Diagrams Fault Finding Guide... -
Page 5: Inlet Valve Assembly
Page 5 of 34 SECTION INLET VALVE ASSEMBLY A1.1 Inlet Head Removal A1.2 Inlet Valve Disc Removal A1.3 Cylinder Piston Seal Renewal... - Page 6 SECTION INLET VALVE ASSEMBLY A1.1 Inlet Head Removal Remove inlet flange nuts and nylon pipes. Remove Allen screws from cylinders and pull back cylinders. The bolts from the head assembly can now be removed.Take care when removing the valve strike plate. A1.2 Inlet Valve Disc Removal Secure valve stem and unscrew retaining nut.
- Page 7 Page 7 of 34 SECTION UPPER & LOWER MANIFOLDS A2.1 Upper Manifold Removal (SAR) A2.2 Quick Re-Pressurisation Valve Removal (SAR)) Purge Plate Removal A2.3 A2.4 Purge Adjustment A2.5 Controller Box Removal A2.6 Lower Manifold Removal (SAR) A2.7 Changeover Valve Maintenance A2.8 Bolt Torque Sequence (SAR) A2.9...
- Page 8 UPPER & LOWER MANIFOLDS SECTION A2.1 Upper Manifold Removal (SAR) Remove nylon pipes from end plate,remove bolts from end plate connected to side plates, remove shroud as detailed in section A6, remove outlet housing as detailed in section A5. Slacken and remove bolts in the reverse order of torque sequences shown.
- Page 9 35˚C inlet temperatures the table below gives recommended flow settings for both -40˚C and -70 ˚C PDP. Purge flow rates are factory set to 6barg (88 CFM). This may need to be re-set by a Sullair trained installation engineer at other operatiing pressures during commissioning.
- Page 10 Page 10 of 34 LOWER MANIFOLD REMOVAL A 2.7 A2.7 Lower Manifold Removal (SAR) Remove inlet and outlet pipes as detailed in section A1 and A5 respectively, remove exhaust silencers as shown in section A3. Remove shroud as detailed in A6. Remove the two eye bolts on the top manifold and invert the dryer completely.
- Page 11 Page 11 of 34 MANIFOLDS - Bolt Torque Sequence Note: Tighten the bolts in the numerical order shown, always starting with the middle column working outwards. TORQUE to 25lbs.ft A2.9 - SAR...
- Page 12 Page 12 of 34 INLET, OUTLET & EXHAUST VALVE A 2.11 Bolt Torque Sequence When removing or assembling the INLET VALVE, OUTLET VALVE or EXHAUST VALVE housings always loosen and tighten in the sequence shown above TORQUE TO 25lbs.ft...
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Page 13: Exhaust Valve Assembly
Page 13 of 34 SECTION EXHAUST VALVE ASSEMBLY A3.1 Exhaust Valve Removal. A3.2 Exhaust Valve Disc Removal. A3.3 Cylinder Piston Seal Renewal. - Page 14 SECTION EXHAUST VALVE ASSEMBLY A3.1 Exhaust Valve Assembly Removal. Unscrew exhaust elements. Remove assembly bolts and nylon pipes. Take care when removing the valve strike plate. A3.2 Exhaust Valve Disc Removal. Secure valve stem and unscrew retaining nut. Inspect strike plate before re-fitting. A3.3 Cylinder Piston Seal Renewal.
- Page 15 Page 15 of 34 SECTION COLUMN ASSEMBLY A4.1 Column/Desiccant Removal A4.2 Desiccant Replacement...
- Page 16 SECTION COLUMN ASSEMBLY A4.1 Column/Desiccant Removal Remove upper manifold as described in manifold section and remove gaskets. The desiccant can now be extracted from the column using a vacuum cleaner. Bottom column bolts can then be removed and the column lifted clear A4.2 Desiccant Replacement Ensure columns are free from dust and that the lower manifold gasket is in good condition.
- Page 17 SAR COLUMN ARRANGEMENT A4.2.1 GENERAL Each extrusion consists of 2 E-shaped chambers containing a total of 15kg of desiccant material. Sullair suggests a performance life of 10,000 - 30,000 hours, however, many factors can influence this nominal figure which should only be used as a guide. Accurate dewpoint monitoring with a hygrometer is the only true indication of the desiccant condition ( consult Sullair).
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Page 18: Outlet Valve Assembly
Page 18 of 34 SECTION OUTLET VALVE ASSEMBLY A5.1 Outlet Housing Removal A5.2 Outlet Valve Disc Removal... - Page 19 SECTION OUTLET VALVE ASSEMBLY A5.1 Outlet Housing Removal. Remove outlet flange nuts, head bolts and nylon pipes. Take care when removing the valve strike plate A5.2 Outlet valve disc removal Remove valve and spring from guide, secure valve stem and unscrew retaining nut. Inspect strike plate before re-fitting.
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Page 20: Control & Instrumentation
Page 20 of 34 SECTION CONTROL & INSTRUMENTATION A6.1 Control Shroud Removal A6.2 Pressure Gauge removal A6.3 Moisture Indicator removal A6.4 Cam Timer Removal (SAR) A6.5 Pilot Valve Removal A6.6 Cam Motor/Gearbox Removal A6.7 Contactor Removal A6.8 Interface Removal... - Page 21 Page 21 of 34 CONTROL & INSTRUMENTATION A6.1 Control Shroud Removal Disconnect electrical supply (SAR only). Disconnect nylon pipes from control box, cam timer and pressure gauges. Remove the two upper and two lower bolts from the end plates (ensure the shroud is supported during this operation).
- Page 22 Page 22 of 34 CONTROL & INSTRUMENTATION A6.8 Interface Removal Disconnect the nylon pipe and wiring. Remove the interface fron the DIN rail by gently pulling forward from the top (Fig B) Fig A Fig B...
- Page 23 Page 23 of 34 SECTION Piping & Wiring Schematics A7.1 SAR Electric Piping Schematic A7.2 SAR Pneumatic Piping Schematic A7.3 SAR Electric Wiring Diagram...
- Page 24 7.2 - SAR ELECTRIC PIPING SCHEMATIC Page 24 of 34...
- Page 25 7.3 - SAR PNEUMATIC PIPING SCHEMATIC Page 25 of 34...
- Page 26 7.4 - SAR ELECTRIC WIRING DIAGRAM Page 26 of 34...
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Page 27: Fault Finding Guide
Page 27 of 34 SECTION FAULT FINDING GUIDE A8.1 POOR DEWPOINT A8.2 FAILURE TO DEPRESSURISE A8.3 FAILURE TO REPRESSURISE A8.4 GENERAL... - Page 28 8.1 - POOR DEWPOINT Page 28 of 34 VISUAL POSSIBLE CAUSE CHECK REMEDY INDICATION Low reading on Faulty sensor Check by using other Change sensor hygrometer sensor No flow rate across Flow at exhaust from Adjust flow restrictor to sensor sensor block within spec.
- Page 29 8.1 - POOR DEWPOINT (cont) Page 29 of 34 VISUAL POSSIBLE CAUSE CHECK REMEDY INDICATION Exessive dust Desiccant fails to Contaminated Ascertain reason for carryover regenerate desiccant, contamination. Faulty cycle. Change desiccant. Check dryer operation. Adjust where necessary Moisture indicator Moisture at indicator Air flow over Check air flow at moisture...
- Page 30 8.2 - FAILURE TO DEPRESSURISE Page 30 of 34 VISUAL POSSIBLE CAUSE CHECK REMEDY INDICATION All pressure gauges Loss of power Power on lamp and Replace fuse check showing line pressure incoming supply wiring for longer than 5 minutes Cam timer failure Check free movement Replace motor gearbox.
- Page 31 8.2 - FAILURE TO DEPRESSURISE (cont) Page 31 of 34 VISUAL POSSIBLE CAUSE CHECK REMEDY INDICATION Neon indicator Incoming supply Check power supply light off failure. Failure to change All gauges showing Sticking valve stems due to Clean and renew where line pressure.
- Page 32 8.3 - FAILURE TO REPRESSURISE Page 32 of 34 VISUAL POSSIBLE CHECK REMEDY INDICATION CAUSE Column not Slow Q.R. valve not opening Check control signal from achieving line repressurisation (SAR only) logic element (black control pressure before pipe) changeover. If OK change valve. If no signal change logic No air from exhaust Purge valve closed or...
- Page 33 8.4 - GENERAL Page 33 of 34 VISUAL POSSIBLE CHECK REMEDY INDICATION CAUSE Replace elements Pressure gauge Exhaust elements Element media blocked up Check dust filter for signs of on purge side starting to block up. with water or desiccant. desiccant attrition.
- Page 34 FAX: 33-78907168 FAX: 755-6694313 SULLAIR CORPORATION Subsidiary of Sundstrand Corporation 3700 East Michigan Boulevard Michigan City, Indiana 46360 U.S.A. Telephone: 1-800-SULLAIR (USA Only) or 1-219-879-5451 FAX:(219) 874-1273 FAX:(219) 874-1835 (Parts) FAX:(219) 874-1805 (Service) Specifications Subject To Change Without Prior Notice...