Parker Zander WVM Series User manual

Adsorption dryer
WVM 40-1450
Operating manual
Revision 03—07/2016 /EN
Cod: 398H271785

Declaration of Conformity
Parker Hannifin Manufacturing Germany GmbH& Co. KG
Gas Separation and Filtration Division EMEA
Im Teelbruch 118
D – 45219 Essen Kettwig
hereby declares with sole responsibility, that the products
compressed air adsorption dryer
series
W___ES
W___VM
W___KL
W___KT
size 40 bis 7900
assembly type: assembly acc. to Art. 4 No. 2b,
which this declaration refers to, conform to Directive 2014/68/EU and were
subjected to a conformity assessment according to Annex III Modules B + D (for
assembly assessment).
For the assembly, the EG type approval certificate DTM 1016032/1/AS
by Lloyd’s Register Quality Assurance GmbH, Hamburg, is available.
The quality assurance system is monitored by the service provider stated below
Lloyd’s Register Quality Assurance GmbH (Identification number 0525)
Am Sandtorkai 41, D - 20457 Hamburg.
The assembly consists of pressure appliances according to the classification list
(attached to the technical documentation provided by the manufacturer).
Pressure vessel
Dryer Quantity Allowable
pressure (PS)
Volume
[l]
Category
(PED)
Module
WVM 40
2
10
130
III
H
WVM 50
2
10
130
III
H
WVM 65
2
10
206
III
H
WVM 85
2
10
206
III
H
WVM 120
2
10
305
IV
H 1
WVM 150
2
10
376
IV
H 1
WVM 200
2
10
530
IV
H 1
WVM 235
2
10
627
IV
H 1
WVM 300
2
10
760
IV
H 1
WVM 355
2
10
994
IV
H 1
WVM 410
2
10
1134
IV
H 1
WVM 475
2
10
1324
IV
H 1
WVM 525
2
10
1436
IV
H 1

Pressure vessel
Dryer Quantity Allowable
pressure (PS)
Volume
[l]
Category
(PED)
Module
WVM 620
2
10
2011
IV
H 1
WVM 710
2
10
1963
IV
H 1
WVM 800
2
10
2406
IV
H 1
WVM 920
2
10
2650
IV
H 1
WVM 1080
2
10
3085
IV
H 1
WVM 1230
2
10
3085
IV
H 1
WVM 1450
2
10
3085
IV
H 1
Piping
Dryer Allowable
pressure (PS)
Dimensions
(DN)
Category
(PED)
Module
WVM 40
10
DN40
Art.4.3
Art.4.3
WVM 50
10
DN40
Art.4.3
Art.4.3
WVM 65
10
DN50
Art.4.3
Art.4.3
WVM 85
10
DN50
Art.4.3
Art.4.3
WVM 120
10
DN80
Art.4.3
Art.4.3
WVM 150
10
DN80
Art.4.3
Art.4.3
WVM 200
10
DN80
Art.4.3
Art.4.3
WVM 235
10
DN100
Art.4.3
Art.4.3
WVM 300
10
DN100
Art.4.3
Art.4.3
WVM 355
10
DN100
Art.4.3
Art.4.3
WVM 410
10
DN150
I
A
WVM 475
10
DN150
I
A
WVM 525
10
DN150
I
A
WVM 620
10
DN150
I
A
WVM 710
10
DN150
I
A
WVM 800
10
DN200
I
A
WVM 920
10
DN200
I
A
WVM 1080
10
DN200
I
A
WVM 1230
10
DN250
I
A
WVM 1450
10
DN250
I
A

Filter
Dryer Filter Quantity Allowable
pressure (PS)
Volume
[l]
Category
(PED)
Module
WVM 40
GL 12
2
16
6
I
B+D
WVM 50
GL 12
2
16
6
I
B+D
WVM 65
GL 13
2
16
6
I
B+D
WVM 85
GL 14
2
16
6
I
B+D
WVM 120
FL 17
2
16
16
II
H
WVM 150
FL 17
2
16
16
II
H
WVM 200
FL 17
2
16
16
II
H
WVM 235
FL20
2
16
57
II
H
WVM 300
FL20
2
16
57
II
H
WVM 355
FL20
2
16
57
II
H
WVM 410
FL30
2
16
57
II
H
WVM 475
FL30
2
16
57
II
H
WVM 525
FL30
2
16
57
II
H
WVM 620
FL30
2
16
57
II
H
WVM 710
FL40
2
16
93
III
H
WVM 800
FL60
2
16
165
III
H
WVM 920
FL60
2
16
165
III
H
WVM 1080
FL60
2
16
165
III
H
WVM 1230
FL100
2
16
280
III
H
WVM 1450
FL100
2
16
280
III
H
The following standards / technical specifications were used:
harmonized standards: DIN EN ISO 12100:2011-03, DIN EN 61000-6-1,
DIN EN 61000-6-3, DIN EN 60204
The following other EG directives were used:
2006/42/EG
2014/30/EG
2014/35/EG
Essen,
19.07.2016
Datum / Date i. V. Dr. Jürgen Timmler
Leiter Technik und Entwicklung /
Manager Engineering and Development

Machine Passport
Machine Type WVM
Order No.
Catalogue No.
Manufacture No.
Vessel 1 No.
Vessel 2 No.
Date of Manufacture 2016
Date of issue this Operating Manual
2016-12 EN
The operator is obliged to
enter missing unit data in the above table,
regularly update the unit data.
The above device specifications are necessary to quickly identify the dryer and its
components and facilitate servicing.
Other important data regarding the dryer such as permitted operation pressure
and electrical power are found on the type plate. (For location of the type plate,
see page 11.)

Table of contents
General information ............................................................................................ 8
Manufacturer's details ............................................................................................................8
Dryer Specifications ...............................................................................................................8
About these operating instructions..........................................................................................9
For your own safety .......................................................................................... 11
Signs and danger zones at the dryer ....................................................................................11
Intended use of the dryer......................................................................................................13
General safety notes ............................................................................................................13
Safety notes on specific operating phases............................................................................14
Technical product description ......................................................................... 17
Summary drawing ................................................................................................................17
Function ...............................................................................................................................19
Options ............................................................................................................... 22
Transportation, installation and storage......................................................... 25
What to do in the case of transport damage occurring?........................................................25
Transporting dryer to its location of installation.....................................................................26
Storage ................................................................................................................................29
Installation.......................................................................................................... 31
Requirements for installation ................................................................................................31
Installation of pipelines .........................................................................................................33
Connection of electrical components ....................................................................................34
Start-up ............................................................................................................... 35
Requirements for initial commissioning ................................................................................35
Overview of the operating and display elements...................................................................36
Commissioning of the dryer ..................................................................................................36
Preparation for commissioning .............................................................................................37
Monitoring dryer operation............................................................................... 41
Notes on specific operating situations ..................................................................................41
Shutdown and restart dryer.............................................................................. 42
Emergency shutdown ...........................................................................................................42
Stopping the dryer ................................................................................................................42
Depressurising and shutting down the dryer.........................................................................43
If work is to be carried out on the electrical system...............................................................44
Restart .................................................................................................................................44

Maintenance and repair of the dryer................................................................ 45
Notes on maintenance ......................................................................................................... 45
Regular maintenance tasks.................................................................................................. 46
Daily maintenance tasks ...................................................................................................... 47
Monthly maintenance........................................................................................................... 48
Six-monthly maintenance work ............................................................................................ 48
Maintenance work to be completed every 12 months........................................................... 49
Maintenance work to be completed every 24 months........................................................... 51
Maintenance work to be completed every 48 months........................................................... 51
Identify and eliminate faults ............................................................................. 55
Notes on error messages and errors.................................................................................... 56
Index ................................................................................................................... 57
Appendix: Technical Documents..................................................................... 60
Technical data – overview of standard dryers ...................................................................... 61
Spare parts list..................................................................................................................... 63

8 WVM_BASIS_EN_03—07/2016
General information
Manufacturer's details
Name and address
Dryer Specifications
Scope of delivery
Adsorption dryer, consisting of
2 vessels filled with desiccant
1 Heater
1 Vacuum pump
1 Switch cabinet including control system
1 Key for switch cabinet
Piping and silencer
Supplementary documents (standard scope)
Operating manual (i.e. this document)
Operating manual of pertaining controller
Operating manual of fitted vacuum pump
Technical documents (see appendix)
—Dimensional drawing
—Process diagram
—Pneumatic diagram of the control air unit
Electrical diagrams

WVM_BASIS_EN_03—07/2016 9
Notes on supplementary documents
Supplementary documents such as operating manuals for options or
pertaining components must always be heeded. They contain additional
information, e.g. regarding maintenance, and are therefore necessary for safe
operation of the plant.
Notes on upstream and downstream filters
Upstream and downstream filters are not contained in the standard scope of
delivery of the dryer. For this reason, the operator must install at least an
upstream filter. Please also heed the notes regarding the intended use on
page 13.
Warranty notes
In the following cases, the warranty shall be void:
If aggressive media in the compressed air and in the environment cause
corrosion damage and functional faults on the dryer.
If the dryer is used without prior approval and confirmation in writing by the
manufacturer for purposes other than those specified in these operating
instructions or contractually agreed.
If preset parameters (e. g. on the control system etc.) are changed without
prior approval and confirmation in writing by the manufacturer.
If the dryer is transported or stored incorrectly.
If the dryer is sited and installed incorrectly.
If the dryer is repaired or maintained incorrectly.
If the dryer is operated by personnel that does not have the requisite
qualifications.
If modifications are carried out on the dryer, the manufacturer did not approve
that.
If notes given in pertaining operating manuals were not heeded.
In the event of non-compliance the manufacturer will not accept any liability for
any consequential damage whatsoever.
About these operating instructions
These operating instructions contain basic information on the safe use of the
dryer.
Characters and symbols used
►Work steps that you have to carry out in the sequence stated are marked by
black triangles.
Lists are marked by a small box.

10 WVM_BASIS_EN_03—07/2016
Note:
These notes provide you with hints and information on the safe and
efficient handling of machines and devices.
Warning!
These safety notes warn against damage to property and help you to
avoid such damage.
Danger!
These danger notes with a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid serious or
life-threatening situations for yourself and/or third parties.
Target group of these operating instructions
These operating instructions are intended for all persons working on and using
the dryer. We assume that all such persons are specialist personnel, e.g. fitters
or electricians.
Operating instructions: handling
These operating instructions must be continuously available at the site where the
dryer is used. We recommend to prepare a copy and to keep the same in a safe
and freely accessible place next to the dryer. Keep the original document in a
safe place.

WVM_BASIS_EN_03—07/2016 11
For your own safety
The dryer has been built in accordance with the state of the art and the
recognized technical safety regulations. Nevertheless, there is a risk of personal
injury and damage to property when the dryer is used, if
it is operated by non-qualified personnel,
not used within its intended design specifications,
is repaired or maintained incorrectly.
Note:
For your own safety and to prevent machine damage, please note the
information and safety notes in these operating instructions when
working with the dryer.
Signs and danger zones at the dryer
Signs and instructions
1
Type plate
2
Vessel plate
Please note the above plates and instructions attached to the dryer. Make sure
they are always complete and readable.

12 WVM_BASIS_EN_03—07/2016
Danger zones at the dryer
1, 6
Risk of injury from hot vessel and piping surfaces 4 Risk of injury by suddenly escaping gas
2
Risk of injury by high voltage 5 Risks of injury by hot regeneration gas flow
3
Risk of injury from crushing by shaft during switching
7
Risk of injury by blocked silencer
Danger zone
Symbol in this
manual
Excess pressure warning
The entire dryer is under pressure. Air that is suddenly released through expansion and relief
valves can lead to serious injury.
Hot surfaces
During operation, certain surfaces of the dryer reach temperatures above 120 °C. At insulated
dryers, screw connections might protrude from the insulation.
Voltage
Various parts of the dryer are live. These components may only be connected, opened and
serviced by authorised technical personnel.
Risk of slipping
During the emptying and filling of the vessels, there is a risk of injury from slipping on spilt
desiccant.
Risk of crushing
At the universal shaft and the drives, there is a risk of injury from crushing during the switching
from absorption to regeneration.

WVM_BASIS_EN_03—07/2016 13
Intended use of the dryer
The dryer is exclusively intended for drying compressed air. Depending on
defined input conditions, it dries compressed air for industrial use.
The dryer is designed for compressed air, which is free from aggressive water,
oil, and solid matter constituents.
Note:
Never operate the dryer without upstream filter. For this reason, the
operator must install an appropriate upstream filter (degree of
filtration < 0.01 µm, residual oil contents < 0.001 mg/m³).
We recommend that you install an additional downstream filter to
protect the downstream compressed air network against desiccant
residues.
Suitable filter solutions can be obtained from the manufacturer.
As standard, the dryer is intended to be sited within a building and protected
against the weather. When it is sited in the open air (option), the instructions on
page22 must be complied with.
The dryer may be operated only in accordance with the data on the type plate
and in accordance with the contractual conditions.
Suspected misuse
The dryer must not be misused as a climbing aid! Pipes, valves, and similar
fittings have not been designed for such loads. They could fracture, tear off, or
become damaged in another way.
General safety notes
For your own safety, when carrying out any work on the dryer comply with
all applicable national safety regulations!
Personnel qualification
Only authorized and qualified specialist personnel may be tasked with the work
on the dryer described in these operating instructions. The electropneumatic
switch cabinet in particular must be opened and serviced by an instructed trained
electrician only.
Conversions and modifications
Without prior approval by the manufacturer, no conversions and modifications
must be made to the dryer! Any non-approved modifications may restrict the
operational safety of the dryer and cause damage to property or personal injury.

14 WVM_BASIS_EN_03—07/2016
Notes on desiccant handling
The used desiccant is perfectly safe when new. Increased dust formation can
nevertheless occur when desiccant is filled into or removed from a vessel .
Therefore, heed the following hints:
Wear a dust mask and eye protection when filling desiccant into the vessels!
Collect spilt desiccant immediately! There is a risk of injury from slipping on
spilt desiccant!
Note:
For information on how to dispose of used desiccant refer to page 16.
Safety notes on specific operating phases
Transportation and siting
Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
Carefully secure the dryer during transportation.
Commissioning of the dryer
Risk of injury from suddenly escaping gas!
While the unit is under pressure, never remove any components or
otherwise interfere with the dryer! Suddenly escaping gases can lead to
serious injury!
Prior to any work, release all pressure from the unit.
Execute the stipulated tests and checks.
On no account should the factory settings of the control programme be
altered without consulting the manufacturer.
Prior to commissioning make sure there are no tools or foreign objects in, on
or near the dryer that could turn into a hazard for commissioning the dryer.
Emergency shutdown
In any emergency, proceed as described in the section on page 42.
Monitoring of the operation
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
A loud cracking noise occurs which can injure your hearing.
Particles carried in the air can injure your eyes or skin.
Always wear eye and ear protection, therefore, when you are in the
vicinity of the dryer!

WVM_BASIS_EN_03—07/2016 15
Operate the dryer only within the permitted limits (see type plate). If the unit is
operated under conditions where the defined limit values are exceeded, it is
exposed to stresses for which it is not designed. This can result in
malfunction or failure of the dryer.
The higher the capacity of the dryer, the more noise it produces during
operation. The operator must therefore provide suitable protective equipment
(earmuffs).
The dryer must be regularly inspected for visible damage. Any observed
changes, including changes in the operation behaviour, must be immediately
reported to the responsible person.
In the event of an emergency and if safety-relevant malfunctions are
observed (e.g. escaping compressed air, higher noise level, defective
components), the dryer must be immediately switched off (see page 42). The
unit may only be restarted after all defects have been eliminated.
Servicing and troubleshooting the dryer
Risk of injury from escaping compressed air!
Never remove any parts of the dryer, or manipulate the same in any way,
as long as the unit is pressurised! Suddenly escaping compressed air
might cause serious injuries.
Prior to any work, release all pressure from the unit.
Carry out all maintenance work only when the plant has been shut down and
depressurised!
Do not modify the factory settings of the control system in any way without
prior consultation with the manufacturer.
Bolt connections must be undone with care! Note ram pressure values!
Otherwise emerging media may cause personal injury.
Never carry out welding work on a vessel or modify the same in any way!
Never use pipes and fittings as steps or holding points! The components
might fracture, or the distortions which occur may cause internal damage on
the dryer. There is a risk of injury by slipping off the components, components
breaking off, and expanding compressed air!
Never leave tools, loose parts or cloths in, at or on the dryer.
Following maintenance work, always check all flange and bolt connections for
leakage and secure seating.
Only use replacement parts that are suitable for the relevant function and
meet the technical requirements stipulated by the manufacturer. This is
always the case, if you use original replacement parts only.

16 WVM_BASIS_EN_03—07/2016
Removal and disposal
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the dryer is still pressurised! A sudden escape of pressure
may cause serious injuries.
Depressurise the plant before carrying out any work on the dryer.
Notes on the disposal of used desiccant
As the used desiccant is contaminated with various substances, its properties
differ from those of new desiccant. For this reason, the manufacturer or supplier
of desiccant cannot give any information on the used product.
Deliver used desiccant to a controlled dumping while heeding local official
regulations.
Waste codes
New product: 060899 (European waste code).
Used product: These codes are governed by the industrial use and must
therefore be determined by the waste originator.


WVM_BASIS_EN_03—07/2016 17
Technical product description
Summary drawing
Front view
1 Main outlet valve l 7
Pressure transducer
2 Control air filter and pressure reducer 8
Vessel
3 Filler sleeve for desiccant 9
Dew point measuring chamber
4 Switch cabinet with operating panel 10
Pressure build-up valve
5 Vessel pressure gauge 11
Discharge sleeve for desiccant
6 Stop valve for vessel pressure gauge 12
Main inlet valve

18 WVM_BASIS_EN_03—07/2016
Rear view
0 Lifting eye 5
Connector box of the heater with release
button for the safety thermostat
1 Resistance thermometer for regeneration gas
final temperature 6
Suction opening for regeneration gas
2 Vacuum pump 7
Heater
3 Lashing eye 8
Expansion valve with silencer
4 Regeneration gas outlet of the vacuum pump 9
Resistance thermometer for the control
temperature of the regeneration gas

WVM_BASIS_EN_03—07/2016 19
Function
The dryer dries the compressed air provided by the compressor and makes it
available for industrial use.
Upstream filters clean the compressed air and remove dust, dirt, oil, and water
droplets, before the compressed air reaches the dryer. Thus, an upstream filter is
also used for extending the service life of the drying agent.
Downstream filters clean the compressed air from drying agent abrasions, before
it is fed into the compressed air system.
The two vessels contain an extremely porous drying agent by means of which
humidity is removed from the compressed air and stored just as in a sponge. The
stored humidity is then removed again from the drying agent and re-introduced
into the ambient environment.
To this end, the two vessels alternate between different operating modes. Whilst
in one vessel, compressed air is de-humidified (adsorption), in the other vessel
the humid drying agent is prepared for another charge (regeneration).
These two states, which run in parallel during compressed air preparation, are
described below.
Adsorption
The humid air is supplied through a compressor
and the inlet valve of the dryer. The compressed
air is then transferred upwards through the
pressurised vessel, where the water contained in
the air is absorbed by the desiccant. The dried
compressed air is subsequently fed into the pipe
system at the top of the dryer.
Adsorption (here: absorption in left
vessel)
Regeneration (completed in parallel with adsorption)
The regeneration is subdivided into four phases:
expansion, heating, cooling and pressure build-
up.
With the dewpoint-sensing control option, the
regeneration phase is followed by a standby
phase.
The following figures show the
regeneration phases (here:
regeneration in right vessel)

20 WVM_BASIS_EN_03—07/2016
Expansion phase (duration: some minutes)
The pressure in the right vessel is released
through the expansion valve until the ambient
pressure is reached. The escaping of the
compressed air is thereby audible at the silencer
as a low hum.
Expansion phase
Heating phase (duration: several hours)
A vacuum pump sucks ambient air through the
heater* to the vessel to be regenerated. The air
is thereby heated by the heater. The warm air
subsequently flows through the humid desiccant,
removing the water contained in the agent, which
is fed out in the form of steam together with the
air through the piping.
* This can be either a steam or an electrical heater, but also a
combination of both heater types
Heating phase
Cooling phase
(duration: approx. one hour)
The hot, dried desiccant must now be cooled and
is then ready for absorption. The heater is
switched off so that the vacuum pump feeds cold
ambient air through the vessel.
If the “loop regeneration” option has been
installed, the regeneration air flows in a closed
circuit. Heat dissipation occurs via a water cooled
heat exchanger.
Advantage: No desiccant preloading with
ambient moisture.
Cooling phase