NANO D2 - User Manual

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Maintenance Service Manual29 pages

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Summary

About Nano Purification Solutions

General Information and Safety

Manufacturer Details and Support

Contact information and support details for Nano purification solutions worldwide.

Document Introduction

Overview of the user guide, installation, and maintenance procedures for authorized personnel.

Warranty Guidelines

Information on the 2-year manufacturer's warranty and use of genuine service parts.

General Safety Precautions

Critical safety warnings regarding product modifications, authorized personnel, and national regulations.

Intended Use of the Product

Specifies the product's exclusive use for compressed air treatment and installation conditions.

Technical Specifications and Operation

Flow Rates and Correction Factors

Details flow rates for various models and correction factors for pressure and temperature.

Product Dimensions and Weight

Provides physical dimensions (A-E) and weight for each dryer model.

Product Overview and Components

Identifies key components of the heatless desiccant air dryer with numbered labels.

Typical System Layout and Filtration

Illustrates a typical installation layout including recommended inlet filtration.

Site Location Requirements

Specifies environmental and physical conditions for optimal installation site selection.

Operating the Dryer

Instructions for safe and correct operation, including power-up and status indicators.

Remote Start;Stop Control Setup

Guide to connecting and configuring the remote start/stop feature for dryer control.

Remote Stop Control Configuration

Details on how to implement remote stop functionality using electrical connectors.

Shutdown Procedure

Step-by-step instructions for safely isolating and depressurizing the dryer.

Monitoring Dryer Performance, Maintenance, and Service

Adjusting Dewpoint Settings

Procedure for adjusting ES and dewpoint alarm set-points via the control panel.

Power-up Display Information

Details on the program number, total hours, and display shown during power-up.

Normal Operation Display Modes

Explains the display sequences for ONLINE, PURGE, and READY statuses during operation.

Service Re-set Procedure

Instructions for resetting the service hours counter after maintenance.

ES Model Operation Display

Describes how ES models display dew-point readings in Celsius or Fahrenheit.

Energy Saving Mode Display (ES)

Information on the display when the dryer is active in energy saving mode.

Dew-point Sensor Fault Display (ES)

Indicates display messages for dew-point sensor connection or fault issues.

Dew-point Alarm Display (ES)

Shows display messages when the dew-point reading falls below the alarm limit.

Energy Savings Adjustment (ES)

Details the ES SETPOINT, DWPNT ALARM, and ES OVERRIDE settings.

General Maintenance Operations

Guidelines for safe maintenance, including isolation, seal replacement, and part usage.

Cleaning Procedures

Instructions for cleaning the equipment using a damp cloth and mild detergent.

Daily Checks

Routine checks for external damage, service indicators, dust, and leaks.

Service Schedule and Breakdown

Defines service intervals (A, B, C, E) and recommended replacement parts.

Process and Instrumentation Diagram

The document describes the nano heatless desiccant air dryer, specifically the D2 series. This device is designed for the treatment of compressed air, aiming to remove water vapor and achieve a desired dew point. It operates as a heatless desiccant dryer, meaning it uses desiccant material to adsorb moisture from compressed air without requiring external heat for regeneration.

Function Description

The primary function of the nano heatless desiccant air dryer is to purify compressed air by removing water content. It achieves this by passing compressed air through two columns filled with desiccant material. While one column is actively drying the air (online), the other is regenerating (purging) by releasing the adsorbed moisture. This cyclical process ensures a continuous supply of dry air. The dryer is intended for use with compressed air that is already free from bulk water, oil, and solid matter constituents, implying the need for upstream filtration (e.g., 0.01 µm filter, 1 µm filter, and water separator) as recommended in the typical system layout.

The dryer is equipped with a control panel display that shows its operational status, including which column is online or purging, the hours run, and, for ES (Energy Saving) models, the pressure dew-point reading. It can operate in an energy-saving mode where it stops cycling when the dew-point is met, reducing purge air consumption.

Important Technical Specifications

The D2 series heatless desiccant air dryer offers a range of models (NDL-060 to NDL-130) with varying flow rates.

General Specifications:

Maximum Water Content (ISO Class): Class 2 (-40°C / -40°F pdp) as standard. Class 1 (-70°C / -94°F pdp) is available as an option.
Minimum Operating Pressure: 4 barg (58 psig).
Maximum Operating Pressure: 16 barg (232 psig).
Recommended Operating Temperature Range: 1.5°C to 50°C (35°F to 122°F).
Design Operating Temperature Range: 1.5°C to 50°C (35°F to 122°F).
Power Supply Requirements: 100-240V AC @ 50-60 Hz (standard), with 24V DC as an option.
ISO Class 2: Achieved at recommended maximum rated flow at 7 barg and 25°C inlet.

Flow Rates (at standard conditions):

NDL-060: 58 Nm3/hr (34.1 scfm)
NDL-070: 70 Nm3/hr (41.2 scfm)
NDL-080: 90 Nm3/hr (52.9 scfm)
NDL-090: 112 Nm3/hr (65.9 scfm)
NDL-100: 150 Nm3/hr (88.2 scfm)
NDL-110: 180 Nm3/hr (105.9 scfm)
NDL-120: 224 Nm3/hr (131.8 scfm)
NDL-130: 301 Nm3/hr (177.1 scfm)

Inlet Pressure Correction Factors: These factors adjust the flow rate based on inlet pressure, ranging from 0.63 at 4 barg (58 psig) to 2.13 at 16 barg (232 psig).

Inlet Temperature Correction Factors: These factors adjust the flow rate based on inlet temperature, ranging from 0.72 at 50°C (122°F) to 1.0 at 20-25°C (68-77°F).

Dimensions and Weight: The dryers vary in height (Dimension A) from 743 mm (29.25 inches) for NDL-060/070 to 1848 mm (72.75 inches) for NDL-130. Width (Dimension B) is consistent at 426 mm (16.77 inches), and depth (Dimension C) is 283 mm (11.14 inches). Weights range from 47.0 kg (104 lbs) for smaller models to 117.5 kg (259 lbs) for the largest.

Usage Features

Installation: The dryer should be installed indoors on a flat, level surface, protected from extreme weather. Ambient temperature must be between 1.5°C (34.7°F) and 50°C (122°F). Sufficient space around the unit is required for operation and maintenance. A pressure limiting/relief device must be installed between the compressor and the dryer.
Operation: The unit must be switched on and cycling before air is allowed to flow to prevent desiccant contamination. Inlet air pressure and temperature must be within specified limits. The unit should be allowed to cycle at least twice before slowly opening the outlet flow.
Control Panel Display: Provides real-time status updates, including "COLUMN A/B ONLINE," "PURGE," "HOURS RUN," and "SERVICE REQUIRED." For ES models, it also displays the dew-point reading.
Remote Start/Stop Control: Allows external control of the dryer's operation by connecting a remote switch or relay to specific wires in the flying lead. A 24V DC output must be connected to enable operation.
Remote Stop Control: Enables remote shutdown of the dryer by linking specific pins on an electrical connector, ensuring a proper shutdown sequence.
Energy Saving (ES) Option: When fitted, the dryer monitors the dew-point and enters an energy-saving mode (zero purge) when the dew-point is met (-40°C / -40°F PDP or better). It restarts cycling if the dew-point degrades. The ES set-point and dew-point alarm levels are adjustable via the control panel.
Dew-point Alarm: Activates if the dew-point degrades above -30°C (-22°F), indicated on the display and via a remote alarm output.
Shutdown Procedure: Involves closing inlet and outlet valves, ensuring the dryer is isolated and fully depressurized (cycling at least twice until no air exhausts), then isolating from the electrical supply.

Maintenance Features

Safety First: All maintenance operations must be performed by authorized and trained personnel after the system is shut down and fully depressurized.
Genuine Parts: Only certified and approved replacement parts should be used.
Seals: All seals removed during maintenance must be replaced with new ones.
Connections: All connections and sealing faces must be clean and securely seated.
Cleaning: The equipment should be cleaned with a damp cloth only, avoiding excessive moisture around electrical connections. Mild detergent can be used; abrasives/solvents are prohibited.
Daily Checks: Include checking for external damage, active service indicators, loose dust/dirt, proper operation within specification, and leaks.
Service Schedule:
- Service A (Every 1 year / 12 months): Replace external exhaust silencer/muffler element.
- Service B (Every 2 years / 24 months): Replace desiccant cartridges and top manifold gasket seals.
- Service C (Every 4 years / 48 months): Replace exhaust valves, inlet valves, outlet valves, and solenoid coils.
- Service E (Every 1 year / 12 months, ES models only): Calibrate the dew-point sensor.
Service Reset: After servicing, the "SERVICE REQUIRED" message on the display can be reset by holding a magnet to a specified area on the dryer shroud for 10 seconds.
Troubleshooting Guide: Provides solutions for common problems such as insufficient inlet pressure, electrical faults, moist desiccant, excessive inlet air temperature, insufficient purge air, blocked exhaust silencer, controller malfunction, failure to de-pressurize, outlet flow stops, failure to initialize, and erratic air flow from exhaust.