Sullair SAR 180 User manual

MODELS :- SAR 180 to SAR 900
DESICCANT DRYERS
MAINTENANCE MANUAL
DATE : 23mar2000 REVISION : 1

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. For example, in the UK, users should refer to the
Health and Safety Act, 1974.
All ancillary equipment such as pipework, valves, fittings etc., must be suitable for the pressures and
capacities involved.
Replacement parts are available from your distributor or the manufacturers ( see back page for
information). The adoption of a regular servicing policy is strongly recommended and will result in
ensuring that a high performance is achieved. Serial numbers and customer order numbers should
be referred to in any communication. (Serial numbers can be found on the identification plate on the
left hand side of the instrumentation shroud). The figure number and the appropriate diagram in this
manual and the item number (shown in circle,) will also assist in part identification.
Any warranty will be invalidated if the dryer is not commissioned in accordance with the
manufacturers recomendations or non-approved parts substituted. Substitute parts could reduce the
performance or service life in addition to creating potential hazards.
The manufacturers reserve the right to modify the contents of this manual without notice. The data
given is a guideline to users and in no way binding on the manufacturers.
BEFORE SERVICING OR DISMANTLING ALL PRESSURE MUST BE RELEASED
FROM THE SYSTEM AND ITS ASSOCIATED PIPEWORK AND ANY ELECTRICAL
SUPPLY ISOLATED.

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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. Ensure all manifold, valve housing and end plate gaskets do not leak.
3. Check all control valves, pipe and fittings (within instrumentation shroud) for air leaks.
4. Check interface operation - green pneumatic indicator will show during operation.

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CONTENTS
Section
A1
A2
A3
A4
A5
A6
A7
A8
Description
Inlet Valve Assembly
Manifolds
Exhaust Valve Assembly
Column Assemblies
Outlet Valve Assembly
Control & Instrumentation
Piping & Wiring Diagrams
Fault Finding Guide
Page
5
8
14
16
19
21
26
32
MAINTENANCE

Page 5 of 34
SECTION A1
INLET VALVE ASSEMBLY
A1.1
A1.2
A1.3
Inlet Head Removal
Inlet Valve Disc Removal
Cylinder Piston Seal Renewal

INLET VALVE ASSEMBLY SECTION A1
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. Inspect strike plate before re-fitting.
A1.3 Cylinder Piston Seal Renewal.
Remove 4 allen screws from cylinder body, secure piston across flats and unscrew valve stem.
Remove circlip from cylinder body and pull out piston. New seals should be fitted using silicon free
grease, press out retaining cover nose seal and renew.
For re-assembly, follow reverse procedure always fitting new moulded gaskets, and ’O’ ring on center
head bolt.. Ensure that the strike plate is located with it’s recessed side towards the valve disks.
TORQUE HEAD BOLTS TO 25lbs.ft
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Page 7 of 34
SECTION A2
UPPER & LOWER MANIFOLDS
A2.1
A2.2
A2.3
A2.4
A2.5
A2.6
A2.7
A2.8
A2.9
Upper Manifold Removal (SAR)
Quick Re-Pressurisation Valve Removal (SAR))
Purge Plate Removal
Purge Adjustment
Controller Box Removal
Lower Manifold Removal (SAR)
Changeover Valve Maintenance
Bolt Torque Sequence (SAR)
Bolt Torque Sequences - Inlet, Outlet & Exhaust Valve
Assemblies

UPPER & LOWER MANIFOLDS SECTION A2
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. Screw in M12 location studs. Lift manifold off
using eye bolts provided.
A2.2 Quick Re-pressurisation Valve Removal (SAR)
The Q.R.V can be removed without removing the end plate, by removing the four retaining bolts. To
service the valve, remove the end cap and withdraw the piston, clean piston and refit. (Lubrication is
not recomended).
A2.3 Purge Plate Removal (Where Applicable)
Remove outlet housing as shown in Section A5. This will give access to 2 Hex. head screws securing
the purge plate, slacken and remove. The purge plug ‘O‘ ring can be changed by pressing the brass
purge plug clear from the purge plate.
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Page 9 of 34
A 2.4 PURGE ADJUSTMENT SAR
A2.4 Purge Adjustment
Before attempting to check or reset the purge on
dryer, ensure that the dryer is operating in the purge
mode of the cycle ie. one column at working
pressure, one column at atmospheric pressure.
Before removing the exhaust silencers it is essential
that the cam timer be stopped. The cam timer is
stopped as follows:-
1. Pneumatic product, disconnected the 4mm pipe
to the air motor and seal the end of the pipe.
2. Electrically controlled SAR product, disconnect
the 4mm pipe to the electric interface located on the
top of the cam timer box.
Once the cam timer is stopped, unscrew the two
exhaust silencers located in the control shroud at
the front. Using a 1" BSP plug, blank off one of the
exhaust ports so that all the purge air escapes
through one port. Ensure that the flow meter to be
used has a full scale deflection larger than the
required purge flow.
Using 1" BSP flexible hose, connect from the
exhaust port to the inlet of the flow meter NB. never
allow the float of the flow meter to go off the top of the scale, and never pressurise the flow meter.
Using the brass purge plug, adjust the purge flow to the correct flow rate for the dryer, this must be carried
out with the dryer at its MINIMUM operating pressure. On certain dryers there will be two purge plugs, on
these dryers it is recommended that the plug nearest the inlet and outlet be fully open and the plug inside the
control shroud be used for fine adjustment.
Once the purge flow is set, remove the flow meter and the 1" BSP plug and replace the silencers. Re-start
the cam timer according to its type. Ensure that the dryer cycles correctly.
Purge Settings
Specific purge setting may vary from site to site according to operational/enviromental conditions. In general
for up to 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.
SAR
Code
SAR 180
SAR 270
SAR 360
SAR 450
SAR 540
SAR 630
SAR 720
SAR 900
Purge flow rate
CFM (73-147 PSIG)
714
1070
1427
1784
2141
2498
2855
3568

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A 2.7 LOWER MANIFOLD REMOVAL
SAR
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. Remove the nylon pipes from the changeover valve and slacken bolts in the
reverse order of torque sequence shown and lift manifold clear.
A2.8 Changeover Valve Maintenance
Remove nylon pipes, 2 allen screws and detatch from dryer foot. To service unit, remove end cap and
withdraw spindle, lubricate and re-fit ensuring seals and ’O’ rings are in good condition.
For re-assembly follow reverse procedure always fitting new graphite gaskets, seals and "O" rings on
retaining bolts.

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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

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A 2.11 INLET, OUTLET & EXHAUST VALVE
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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SECTION A3
EXHAUST VALVE ASSEMBLY
A3.1
A3.2
A3.3
Exhaust Valve Removal.
Exhaust Valve Disc Removal.
Cylinder Piston Seal Renewal.

EXHAUST VALVE ASSEMBLY SECTION A3
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.
Remove 4 cap screws from cylinder body, secure piston across flats and unscrew valve stem. Remove
circlip from cylinder body and pull out piston. New seals should be fitted using silicon grease, press out
retaining cover nose seal and renew.
A3.4 Exhaust Element Replacement
Unscrew element and replace, ELEMENTS ARE NOT REUSABLE. Ensure o-ring is firmly seated in
groove and greased with silicone
For re-assembly, follow reverse procedure always fitting new graphite gaskets and ’O’ rings on
retaining bolts.
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Page 15 of 34
SECTION A4
COLUMN ASSEMBLY
A4.1
A4.2
Column/Desiccant Removal
Desiccant Replacement

COLUMN ASSEMBLY SECTION A4
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. Refilling
can now take place. In order to maintain dryer performance, the columns must be refilled using a snow
storm filling device which will achieve maximum packing density. The best results are obtained by
using a smooth and continuous operation.
SAR
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Page 17 of 34
Desiccant Replacement
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).
The upper manifold can be replaced as described in section A2.

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SECTION A5
OUTLET VALVE ASSEMBLY
A5.1
A5.2
Outlet Housing Removal
Outlet Valve Disc Removal

OUTLET VALVE ASSEMBLY SECTION A5
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.
For re-assembly follow reverse procedure. Always fitting new graphite gaskets, seals and o-ring on
centre retaining bolt.
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SECTION A6
CONTROL & INSTRUMENTATION
A6.1
A6.2
A6.3
A6.4
A6.5
A6.6
A6.7
A6.8
Control Shroud Removal
Pressure Gauge removal
Moisture Indicator removal
Cam Timer Removal (SAR)
Pilot Valve Removal
Cam Motor/Gearbox Removal
Contactor Removal
Interface Removal