微热吸干机的操作和维护手册

TPE/PE 系列微热再生/吸附式空气干燥机操作、使用、维护说明 一. 启动步骤1. 正确提供三相电源和气源。2. 将出口截止阀关闭，慢慢将两个干燥塔加压到管网压力。3. 检查有无泄漏，此时进口气动阀全部自动打开，而再生排气阀自动处于关闭状态。4. 合上电控箱内的分断开关后，电源指示灯亮，液晶显示屏自动初始化并自动进入主画面，如右图，在该画面将会显示干燥器型号以及公司联系方式，说明整个干燥机准备就绪。5. 触摸欢迎画面上的任意位置进入流程显示画面，如右图。显示各阀门的开关状态、加热器入口温度和出口温度、出口露点温度等。6. 在完成参数设定后，通过面板的启动按钮使干燥机投入运行。7. 再生排气阀应打开，两个干燥塔中的一个将降压。8. 若上述第7步未动作，请等待10分钟，干燥机可能正处于阶段。9. 当系统相关参数达到设定值时，自动停机并报警。当选择远程控制时面板上的启动停止控制按钮无效。10. 触摸下方的相关按键，选择进入相应的画面，或返回前一画面。11. 按“状态显示”键, 进入状态显示画面，显示A/B塔工作时间以及时序周期等工作状态，如右图。12. 当口令等级为工程师级别以上口令时，按“时序快进”键，可以跳过当前剩下的加热或冷吹时间。二. 调整与设定1. 将净化压力调至推荐值，一般为0.45MPa。2. 按“参数设定”键，进入参数设定画面，如右图。根据需要修改相关的参数设定。3. 口令等级符合修改权限后，触摸参数的设定值，弹出参数修改键盘，正确输入设定值后键盘自动隐藏。4. 当前口令等级不够时，系统自动弹出口令输入窗口，如右图。5. 按键盘打开按钮，弹出键盘，正确输入口令后按回车键；6. 操作员的口令为1111；7. 当口令等级为工程师级别以上口令时（口令等级不足时改键无效），按“恢复出厂设置”键，所有参数的设定值被修改为出厂设定值。加热时间和冷吹时间恢复为出厂设定值（加热时间为147分钟，冷吹时间为86分钟；再生温度设定为150，加热出口温度设定为180。） 8. 加热和冷吹的时间设定值应该在0240分钟之间，若修改的设定值超过240分钟，则无法写入控制器。9. 按“控制方式”键, 进入控制方式选择画面，点击触摸控制方式来选择现场远程控制和常规露点控制方式，如右图。 注 意1 请勿随意修改时间的设定！只有在调试或实际需要时方可修改。2 如果在干燥机运行过程中修改设定值，则修改后的设定值将在下一时序周期或停机后再次开机时方为生效。3 只有在需要远程控制干燥机时才选择远程控制，在选择远程控制后，现场的启动控制无效。4 请在停机时完成远程控制的选择，以免发生非正常停机或意外。10. 若配有露点仪，微微打开露点仪探头仓处的截止阀，让少许空气流经露点仪探头。11. 故障报警在显示任何画面，当有报警信号时，电气箱面故障报警灯亮。如果需要检查报警信息，按“故障记录”键，然后故障报警记录画面，则可以显示具体故障信息和发生时间，如进气压力过低报警等，如图所示。具体可能会出现的报警信号如下：当出现故障时，按 ENT 键报警器将停止报警，但报警信息和状态依然存在，按 复位 键可以使故障报警进行复位注意：进气压力过低报警为选接项，为断开报警信号，当不需要该报警信号时，需要根据图纸将该信号短接，以免影响正常开机。12. 系统口令等级 在修改数据和选择按键之时，如果该数据设定或按键功能受口令保护，按“触屏设置”触摸屏则直接进入触摸屏设置画面，如右图； 可以根据需要更改用户等级和注销用户等级，现场一般操作维护人员的口令等级为操作员，口令为1111；工程师级别的口令为999；更高等级的用户口令需要由厂家来操作或提供。可以根据需要更改触摸屏的屏保时间，当没有操作的时间超过设定值（出厂设定值为10分钟）时，触摸屏自动进入流程画面。 三. 运行中的观察：1 标准工作循环周期是8小时，在其中一塔干燥4小时的同时，另一塔再生4小时，其中，加热再生2小时30分钟，余热再生1小时20分，剩余10分钟用来升压以便换塔，进入下半个循环。（若使用露点控制程序，则干燥塔的工作时间将延长，同时另一塔停止再生。）2干燥塔的压力应于管网压力相同。3再生塔的压力应小于0.022Mpa。（任何较高的回冲压力都说明系统的工作压力状态不良，请参阅“故障诊断指导”。4 燥塔内温度应为2503000F(1211500C)；换塔时的温度应为1500F(660C)；5 请注意控制气路应保持一定的压力值，否则阀门将不进行自动切换，控制气路的最低压力为0.4MPa.6 在整个干燥机系统的压力过低（低于0.35Mpa）的情况下，系统中安装的低压开关将自动切断控制电源并报警。四. 维护及保养：A警示在开始维修之前，断开电源并将设备泄压。1. 在第一个月中，清洗或替换控制气路过滤器的滤芯，并且以后也要定期地更换。清洗排气消声器，如果再生循环中的回冲压力大于或等于0.035MPa,替换消声器。2. 每三个月，短时关闭净化调节阀，检查空气进口气动阀或再生单向阀是否有泄漏，如有空气由排气消声器中排出则说明有泄漏。3 机中不需要任何润滑剂。每天：4 班检查前置过滤器上的自动排水阀。每周：5 检查换塔、再生和升压的动作是否正常。6 检查运转条件、进口压力、进口温度和空气流量。7 检查水份指示器（若选配），蓝色表示干燥，粉红表示潮湿，参阅“故障诊断指导”。8 检查再生消声器是否脏堵，再生塔的回冲压力过大，表示消声器需要替换。9 检查前置过滤器和后置过滤器压力降，如果压力降超过0.05Mpa,更换滤芯。每月：10 检查控制气路过滤器芯，根据需要替换。每三个月：11 检查前置和后置过滤器芯，检查堵塞情况和可能的损坏，根据需要替换。12 用压缩空气吹扫安全阀。13 检查输出的露点状态。每十二个月：14 关闭进/出口阀门或将干燥机旁通，彻底将干燥机系统泄压，打开干燥剂充填口，采样检查干燥剂，如果干燥剂被油污染粉碎，请更换干燥剂。15 拆下并检查出口单向阀。维修或根据情况进行更换。16 拆下并检查进口气动阀和再生排气阀，清洗和替换磨损的阀座和密封圈。17 检查气动阀门气缸是否泄漏或密封件是否磨损。18 检查升压阀，根据需要维修或更换。19 检查并维修控制气路电磁阀。20 校正露点探头。（若配有露点仪）21 检查消声器是否被油或粉尘堵塞，回压超过0.035Mpa应更换。五、突然停电：当突然停电时，两只进气气动阀门会自动打开，两只再生排气阀会自动关闭。重新供电后，首先缓慢升高两个塔的压力至正常工作管道压力，按启动按钮后，两塔中的一塔会降压进入再生状态，调整再生流量调节阀，并将再生压力设定在正常水平（一般为0.45Mpa），若设定不正确将导致：(1)干燥剂的再生不良；(2)干燥剂颗粒相互磨损成细粉状；(3)再生单向阀故障。六 关机：按停止按钮后，干燥机系统自动进入均压阶段，均压后完成停机，而在按下紧急停机按钮后立即停止设备，即立即停止运行。系统具有断电记忆功能，即突然断电或紧急停机后，再次启动时干燥机会从上次停机时段继续运行。七 工作原理：标准的微热再生干燥机按美国全国电器制造商协会（NEMA）规定的8小时循环设计。干燥4小时再生2小时27分钟余热再生1小时25分升压5分钟当压缩空气流进入一塔进行干燥的4小时期间，另一塔内的干燥剂在进行再生。通过再生流量调节阀和再生压力表的调节，大约3%的出口干燥空气引回，先经过再生空气与制冷剂换热器进行热交换，再进入加热塔加热，热的干燥空气进入再生塔后，压力突然降至大气压力，使塔内的干燥剂再生，同时，热的干燥空气流也带走干燥剂颗粒上的水分，再生塔的压力应为0Kg/cm2 注 意露点可达到的程度，取决于干燥剂的再生质量。八 微热再生式干燥机8小时循环工作梯形图：1. GENERALA.Install dryer on a level base, indoors or under a shed.B.During shipment, flange and connecting bolts can come loose. All bolts should be checked and tightened as needed.C.Make sure when the piping is in place that no undue stress is placed on dryer connections. Union joints or flexible connections are recommended to relieve stress. Also, properly support the pipes as needed with hangers or brackets. Air piping must be installed by an experienced pipe fitter.D.Equip dryer with inlet and outlet isolation valves and a bypass valve for ease of servicing and start up.E.Connect electric power to the dryer through a properly sized fused disconnect switch.F.Reactivation exhaust may be piped away from the dryer, making sure proper pipe size is used. The pipe size should be increased by one size at the valve, and one additional pipe diameter size for every tenfoot run to reduce back pressure.G.Electrical Connections: Follow the recognized local and municipal electrical codes. All components must be load rated as approved by NEC, NEMA, CSA, and UL.H.During shipment, wire connection may become loose. Per U.L. specification, torque screws inside enclosure to 20 in. lbs.I.GROUNDING: It is mandatory that the dryer be grounded.Use an adequate ground with the conductor size to NEC.J.STORAGE: In case of extended storage period before the installation, follow these simple procedures.a.Seal or cover all the partsb. Wrap the electrical enclosure c. Wrap the mufflerse.If the desiccant is shipped loose, store it inside to avoidany rain or water damage.f.Prior to start up, check the heater element resistance. The element (phase) to ground should exceed the resistance value by 20 MEG. OHMS. If this value is not indicated, energize the heater at low voltage to drive the moisture from the element insulation. Remove the cover to vent the moisture from the heater terminal enclosure.K.STEAM CONNECTIONS: For units with optional steam heat exchanger, the steam connections are supplied as flanges for both inlet and condensate return.L.WATER CONNECTIONS: For units with optional watercooledaftercooler, connect the water supply and drain lines.M.LOW PRESSURE SHUT DOWN FEATURE: The electrical control on the air dryer system is set up with low pressure shut down switch. The controls, including the heater and blower shall stay cleenergized as long as the dryer system is not pressurized above 50 PSIG. This feature safeguards the system against the loss of air flow.N.LEAK TEST All the dryers are tested at the factory for any leaks before shipment. An air leak could develop during transportation or installation. Pressurize the system and check for any leaks.2. START UP PROCEDURE1.Leave the power switch in the OFF position.2.Keeping the dryer outlet isolation valve closed, slowly pressurize both the adsorbent chambers to the line pressure.3.Check for any leaks in the system.4.When the towers are at line pressure, turn the power switch to the ON position.5.One inlet valve will close, and the chamber purge valve will open and depressurize. This may take as long as 10 minutes.6.Adjust the purge pressure to the recommended setting, and lock the valve locking mechanism in place.7.Slowly open the dryer outlet isolation valve to pressurize the downstream system.8.Use the manual advance button to cycle the dryer through the valve sequences.3. SHUT DOWN PROCEDUREExternally Heated dryers are typically installed in 24 Hr.operations. The dryers operate on a standard time cycle of 8 hours, 4 hours drying and 4 hours regenerating. This cycle should not be interrupted (except for servicing). If the dryer needs to be shut down for a certain shift or weekend; the dryer should be turned off at the end of the 4 hour regenerating cycle, and with both towers at line pressure.1. If servicing is required advance the time sequence so the purge valves close, and pressurize both towers.2. If the compressed air system has been piped with a bypass around the dryer then the following should be completed:Open the bypass valve to allow process flow to continue downstream, then close the dryer outlet isolation valve. Turn the dryer ON/OFF switch to the OFF position. Close the dryer inlet isolation valve on the dryer bypass piping. At this time the dryer is isolated and can be depressurized for servicing.3.If the compressed air system has not been piped with a bypass then the following should be completed: Turn the power switch to the OFF position. The tower switching valves are normally open valves; therefore, with the power off the inlet valves to the towers will be open, and the purge valves will close. This will give you extended drying time until desiccant chambers are saturated.4. ADJUSTMENTS & SET71NGSA. Adjust the purge pressure to the recommended level PSIG.B.get heater thermostat TH1. 390F. (Located in the bottom ofthe heater shell)C.Set over temperature thermostat TH2. 200F. (Located in thetop of the heater shell)D.Set desiccant bed thermostat TH3/TH4. 250FE.Set heater failure thermostat TH5. 300F (Located in thebottom of the heater shell) OptionalF.Set heater failure time delay relay 3 HRS. OptionalG.Set failure to shift time delay relay TDR 5 HRS. OptionalH.Check and set the dew point monitor Setpoint Settings.OptionalI.Open the bleed valve on the optional dew point sensorprobe.J.Dew Point Demand Setpoint (SP1):High Humidity Alarm Setpoint (SP2):WARNINGDisconnect power and depressurize unit completely before starting maintenance procedures.5. MAINTENANCEA.During the first month, clean or replace the pilot air filter element and repeat periodically. Also clean the exhaust mufflers. Replace mufflers if the tower pressure gauge reads any back pressure during the regeneration cycle,B,Every three (3) months, close the purge adjusting valve momentarily to check for any leaks in the inlet and/or check valves indicated by air coming through the exhaust mufflers.C.No lubrication is required for any system.DAILYD.Check auto drain on prefilter every shift.WEEKLYE.Check the dryers sequence of operation, and valveoperation.F.Check the purge control setting.G.Check the operating conditions; inlet pressure, inlettemperature and the flow rate.H.Check the moisture indicator, BLUE color indicates DRY conditions. If the color is PINK, refer to the moisture indicator chart on alarm conditions for probable cause. (Optional equipment).I.Check the purge mufflers for blockage. Possible indication is back pressure on tower under regeneration. Replace if necessary.J.Check the pressure drop across prefilter and afterfilter. Replace the elements when the differential reaches 510 PSID.MONTHLYJ.Check the pilot air filter element. Replace if necessary.THREE MONTHSK.Check the prefilter and afterfilter elements for excessiveclogging or possible damage. Replace as necessary.L.Blow down relief valves.M.Check outlet dew point conditions.TWELVE MONTHSN.Close the inlet and outlet valves on the dryer or bypass the dryer completely depressurize the dryer system. Open the desiccant fill port and check visually. If desiccant is contaminated with oil or broken, replace the desiccant.O.Remove the outlet check valves. Repair or replace asnecessary.R.Remove the inlet switching valves and purge exhaust valves.Clean and replace worn out seats and seals.Q.Check the heater thermostats and heater operation. Repair or replace as necessary.R.Inspect the pilot air cylinders for leaks or worn out seals. Repair or replace as necessary.S.Check repressurizing valve. Repair or replace as necessary.T.Check pilot air solenoid valves for possible defects.U.Replace diaphragms in valves on economy EESeries dryers.See parts list for sizing.6. DEW POINT SENSOR (OPTIONAL)A.It is recommended to recalibrate the sensor probe annually to maintain accuracy. Contact your local distributor or factory for exchange policy.7. MUFFLERSA.Purge mufflers are installed to reduce the noise level. The mufflers tend to plug up and increase back pressure over time due to oil 6arry over and contaminants from compressor, or due to desiccant dust at the initial start up. To eliminate back pressure, replace muffler after three months, or when the back pressure increases in the regenerating tower.8. SEQUENCE OF OPERATIONThe sequence of operation of the External Heat Reactivated Dryer can be readily followed by referring to the following flow schematic and timing sequence.During initial startup with the power switch in the OFF position, and the towers pressurized with air, both inlet valves stay in the OPEN position (standard with models PE300 and larger) and the purge valves stay in the CLOSED position. This type of fail safe valve operation allows the air to dry through both the towers, without any purge in the event of loss of power to dryer. This will give you extended drying time until desiccant chambers are saturated.The desiccant is designed to handle air saturated with water vapor only. Any liquids or slugs of water tend to decrease the efficiency of the desiccant and retard the regeneration process to provide the designed dew point.With the power switch in the ON position at time equal to 0.0 hr, the left tower air inlet valve is open to allow the air to pass through the left tower. The right tower inlet valve is closed. The saturated compressed air/gas passes through the desiccant in the left tower where the desiccant adsorbs the moisture, and the dry air at a pressure dew point of 40F or less exits through the left outlet check valve and goes out into the plant air system through the afterfilter.At time equal to 5 minutes, the right lower purge valve depressurizes the right tower so that the desiccant is not disturbed. (on high pressure dryers depressurization is accomplished by a designated valve) At the same time the heater is energized to commence the heating cycle.NOTE: As soon as the purge valve has opened, adjust the purge adjustment valve to the recommended purge control setting. This adjustment should only be required once, and then the locking mechanism should be locked in place.The temperature of the purge air is controlled by the heater control thermostats to maintain the preset temperature. The hot and dry purge air passes through the right purge flow check valve and enters the desiccant bed at the top of the tower and removes the previously adsorbed water vapor from the desiccant and purges out through the right purge valve, and is exhausted into the atmosphere through the exhaust muffler.NOTE: During the regeneration air flow through the desiccant bed, the tower pressure gauge should read 0 PSIG. Any higher pressure is an indication of a plugged muffler, which will retard the regeneration of desiccant. During the heating cycle, the bed temperature should rise to 250F (121C) in approximately two hours. The heater control thermostats will cycle the heater to maintain this 250F bed temperature.At time equal to 2 hr. 30 minutes, The heater is deenergized, and the cooling cycle begins to reduce the temperature in the desiccant bed and prepare it for the drying cycle.At time equal to 3 hr. 50 minutes, the right tower purge valve will close. With this valve closed, the flow of purge air repressurizes the right tower and prepares it for switch overAt time equal to 4 hr., the right tower inlet valve opens, and left tower inlet valve closes, so the flow of wet air/gas is switched from left chamber to the right chamber.At time equal to 4 hr. 5 minutes, the left tower purge valve opens and depressurizes the left tower. The above sequence is then repeated on the opposite towers.选配件详介一 声音报警：声音报警由蜂鸣器及复位按钮构成。用于当再生机工作不正常时提供一个声音警报，如“换塔失败”或“高露点警报”。二 换塔失败报警：换塔失败报警由报警指示灯，在预定时间内干燥塔、再生塔不互相切换的动作失误，并配有中间继电器便于远距离控制。三 高露点报警：当露点仪探头探测到干燥机出口气流的露点高于某设定值时（一般设为-250C）,露点仪给出一个报警信号至高露点指示灯。同时配有中间继电器便于远距离控制。注 意露点仪及其探头应每季度校验四 水份指示器：水份指示器由一个小的透明度良好的过滤器壳体内装入变色硅胶而构成。少许来自干燥机出口的气流流经变色硅胶，当露点低于-23.50C时，硅胶呈粉红甚至无色表示潮湿。五 液晶控制器液晶控制器，也是本公司干燥机的一种标准配置，特别是当用户需进行露点控制时，必须选此项。六 露点控制功能：露点控制是为了节能，当露点仪探头探测到的出口气流露点低于（即满足）用户的设定值时，（一般设为-400C）,PLC可编程控制器自动延长干燥塔工作时间，同时停止再生塔的再生。而当露点仪探头探测到的露点高于设定值时，PLC自动控制干燥塔、再生塔立刻进行切换，进入下一个正常循环周期。全部功能包含以下项目：数字式露点仪露点设定按钮常规循环指示高露点报警指示/中间继电器OPTIONS LISTING WEXPLANATIONAUDIBLE ALARM (All types of regenerative dryers)The Audible Alarm consists of a buzzer with reset push button and ON/OFF selector switch.The audible alarm provides an audible warning to alert an operator that the dryer is not functioning properly, This option is used with options such as Failure to Shift Alarm or High Humidity Alarm.FAILURE TO SHIFT ALARM (All types of regenerative dryers)The Failure to Shift Alarm consists of an alarm light that illuminates if the desiccant towers fail to shift at a prescribed time. Dry contacts are provided for remote annunciation.HEATER FAILURE ALARM (PE & EE series dryers)The Heater Failure Alarm consists of an alarm light that illuminat