WALKER FILTRATION PROSFD Series User manual

Instruction & Technical Manual
ULTIMATE FILTRATION TECHNOLOGY
Walker Filtration Ltd, Spire Road, Glover East,
Washington, Tyne & Wear NE37 3ES ENGLAND

2 | Walker Filtration
Table of Contents
Page:
1. Introduction...................................................................................................................................................................... 3
2. Safety....................................................................................................................................................................................... 4
3. Description of the dryer’s main components................................................................................. 6
4. Explanation of the dryer’s main components ............................................................................... 7
5. Connecting the pre-filter to the dryer................................................................................................... 8
5.2 Reconfiguration of the inlet and outlet ports............................................................................ 9
5.3 Installing the dryer in a horizontal orientation..................................................................... 10
6. Installation...................................................................................................................................................................... 11
7. Electrical supply......................................................................................................................................................... 12
8. Energy management and PC interfacing......................................................................................... 14
9. Operation......................................................................................................................................................................... 24
10. Start up........................................................................................................................................................................... 25
11. Service and fault diagnosis......................................................................................................................... 26
12. Dryer troubleshooting..................................................................................................................................... 35
13. Dryer sizing table.................................................................................................................................................. 37
14. Environmental conditions............................................................................................................................ 38
15. EC Declaration of conformity................................................................................................................... 39

Instruction & Technical Manual | 3
1. Introduction
The product to which this manual refers must not be supplied, installed, used, operated
or serviced until the contents of the manual have been fully read and understood by all
relevant personnel.
This manual, and in particular the safety information, should be kept at the place of
installation of the product. All relevant personnel must strictly follow instructions given
in the manual.
When contacting Walker Filtration regarding this product or manual, please have the
following information available:
• Serial number:
• Date of commissioning:
The serial number can be found on the identification plate located at the upper right
hand side of the unit and this information should be copied into this manual for future
use.
The dryer is delivered in protective packaging. Take care when transporting, loading and
unloading the unit.
The dryer is delivered configured for operation at 7 barg. It is important to ensure that
the correct plug is fitted applicable to the operating pressure. See table on page 38 for
further information.
The dryer package includes:
DRYER
PRE FILTER TUBING DIN PLUG CONNECTING KIT
WARRANTY CERTIFICATE OF
CONFORMITY
INSTRUCTION
MANUAL

4 | Walker Filtration
2. Safety
Walker Filtration explicitly excludes all responsibility and liability for damage and/or injury
caused by failure to follow the instructions described in this manual, or by failing to pay
necessary attention when operating handling or servicing this product, even if not
specifically stated in individual cases.
The unit must be used for its intended purpose. The heatless-regenerating adsorption
dryer is designed and manufactured exclusively for drying of compressed air within
conditions as described in section 11 of this manual. Any other use of the unit will be
considered inappropriate and Walker Filtration shall not be liable, where this is permitted
under law, for any damage incurred as a result of misuse.
The following symbols give indication of potential hazard. Appropriate measures must
be taken to reduce risk to any user or operator of the machine wherever such hazard
exists.
Warning:
Risk of Danger
Caution:
Risk of Electric Shock
Caution:
Risk of High Pressure

Instruction & Technical Manual | 5
The following safety guidelines must be strictly observed:
• Leave this manual at the place of installation of the product.
• It is essential that only Walker Filtration or their appointed agents carry out
maintenance and servicing work.
• Users, maintenance and servicing personnel must be familiar with:
• accident prevention regulations
• safety information (general and specific to the unit)
• safety devices of the unit
• measures to be taken in case of emergency
• Allow only suitably trained persons to be involved with installation, start-up,
operation, servicing and maintenance of the product.
• It is the responsibility of the installer to ensure that the pipe work to and from the
dryer is suitable, in accordance with applicable legislation and subject to inspection
and testing prior to being put into service. All piping must be adequately supported.
• Before carrying out any maintenance or servicing work the unit must be taken out of
operation. Users and others will be exposed to risk if work is carried out whilst the
unit is running. This means electrical disconnection plus isolation from the
compressed air supply and full depressurisation.
• Only trained and competent persons familiar with the electrical requirements of the
unit as laid out in this manual and electrical safety rules and regulations
should be allowed to carry out work on the electrical components and power supply
to the unit.
• When carrying out any work on the unit, use only correctly sized appropriate tools in
good condition.
• Only use original spare parts and accessories from the manufacturer. There is no
guarantee that non-original parts have been designed and manufactured to meeting
the safety and operational requirements of the unit. Walker Filtration assume no
liability for any equipment malfunction resulting from the use of non-approved parts.
• If carrying out installation work above head height, use suitable and safe working
platforms or other means of working access.
• Do not make any constructional changes to the product. Any changes or
modifications may only be carried out by the manufacturer, Walker Filtration.
• Any faults or defects that could affect safety must be put right fully before using the
unit.
• Used items and materials must be disposed of in the correct manner, complying with
local laws and regulations, in particular the desiccant cartridge.

6 | Walker Filtration
3. Description of the dryer’s main components
The figure below shows the main elements of a typical dryer unit with the pre-filter
removed for clarity of view.
1 Top valve assembly
2 Control unit
3 Bottom valve assembly
4 Bottom mounting block
5 Bottom valve fixing bolt
6 Front panel
7 Front panel fixing screw
8 Pressure housing
9 Pressure housing retaining bolt
10 Desiccant cartridge c/w dust filter
11 Multiport manifold
12 Top cover
13 Top cover fixing screw
14 Rear panel
15 DIN connector
16 Banjo fixing bolt
17 Pressure seal
18 Exhaust silencer
19 Purge plug
13
12
11
16
17
2
3
6
7
5
4
18
10
8
9
1
14
19
Located on rear
panel of dryer
15

Instruction & Technical Manual | 7
4. Explanation of the dryer’s main components
4.1 Control unit, item ref. 2 on page 6
The top and bottom valve blocks are operated by solenoids within the control unit that
determine the pressure and direction of air flow into the desiccant cartridges.
4.2 Multiport manifold, item ref. 11 on page 6
The dryer is supplied as standard with inlet and outlet ports configured left to right as
viewed from the front of the unit. There are several optional porting arrangements
available by repositioning of port plugs. See also Section 5.2.
4.3 Desiccant cartridge c/w dust filter
The cartridges contain the agent (desiccant) that has been developed for the drying of
compressed air. The desiccant is housed in a clear tube that has a holder permeable to
air at both ends. Located in the top of each cartridge is a 1-micron filter for removal of
residual dust from the desiccant. The length of the cartridge varies with the flow
capacity of the dryer.
4.4 Pressure housing
The cartridges are contained within an extruded aluminium pressure housing and
pressure retaining end plates. Process pressure and flow through each desiccant
cartridge is controlled by means of top and bottom valve blocks located between the
two pressure housings. The regenerating air flow (purge) is controlled by means of a
small orifice plug located externally (front, central) on the top valve block and is
accessible with the front panel removed.

8 | Walker Filtration
5. Connecting the pre-filter to the dryer
1. Fit lubricated ‘o’ ring between the filter and multiport manifold, observing the flow
direction on both.
2. Fasten filter bolts evenly to 4 Nm.
3. Fit 4mm (5/32”) black tubing to filter and
drain valve inlet.
4. Pipe away condensate with 4mm (5/32”)
tubing from drain outlet. Ensure
condensate is drained into an oil/water
separator.
5. Fit any further filtration or ancillary
equipment.
All tubing should be secured up to the point of drain to prevent
whipping during discharge.
5.1 Recommendation
It is recommended that a bypass line including filter is installed.
CD
AB
Figure 5.1

Instruction & Technical Manual | 9
5.2 Reconfiguration of inlet and outlet ports
1. Port configuration as delivered: 3 inlet
options left hand side of dryer as viewed
from front.
5. Dryer with multiport manifold
removed.
4. Remove multiport manifold by means
of 4 fixing bolts.
8. Port configuration following procedure
above.
2. Remove top cover by means of 2
fixing screws
3. Dryer with top cover removed. 7. Replace top cover by means of 2 fixing
screws.
INLETS
OUTLETS
OUTLETS
INLETS
6. Rotate multiport manifold through 180º
and replace by means of 4 fixing bolts. Ensure
2 ‘0’ rings in valve block are properly seated.

10 | Walker Filtration
5.3 Installing the dryer in a horizontal orientation
1. Inlet filter as fitted to dryer in
vertical orientation. Mounting kit
allows filter to couple directly to
multiport manifold.
3. Inlet filter must be fitted vertically
and coupled as closely as possible
to inlet port on multiport manifold.
4. Dryer in horizontal plane.
Consideration must be given to
supporting and to clearance for
removal of inlet filter bowl.
2. For horizontal orientation, dryer
must be suitably supported in flat
plane only as shown. A nippled
adaptor (not supplied) is required
for connection of the pre-filter.

Instruction & Technical Manual | 11
Correct Wrong
< 35°C > 35°C
< 16 barg < 4 barg
> 12 V < 12 V
Correct Wrong
6. Installation requirements

12 | Walker Filtration
7. Electrical supply
7.1 Connection
1. The dryer is designed to operate on either an AC or DC supply voltage.
Ensure only one power source is connected at any one time, and it is connected to
the correct socket. Cover supplied must be fitted to the power connection not in use.
2. The power supply is to the DIN plug.
3. The dryer is double insulated
therefore no earth is required.
4. Suitable external fuse connection
must be provided.
5. The cable selection must suit
local installation regulations and
be appropriate to power consumption.
Supply Amp
12 VDC 0.8
24 VDC 0.4
100 VAC 0.16
115 VAC 0.14
230 VAC 0.07
240 VAC 0.067
No connection must be made
to earth terminal
Figure 6.1

Instruction & Technical Manual | 13
7.2 DIN plug drawings
Voltages: 100 to 240 VAC
Voltages: 12 to 24 VDC
cover
cover

8. Energy management and PC interfacing
8.1 Interfacing the controller with a PC
8.1.1 Introduction to the software
The dryer controller has the ability to interface
with a PC. This gives the user or the service
engineer the opportunity to interrogate the
dryer to check the following:
• Operating stage times
• Service warnings
• Operating history
• Alarm settings
• Fault history
• Fault and service history
• Real Time displays
• Setting Energy Management Parameters –
contact Walker Filtration for details
8.1.2 PC requirements
Controller Application software: Windows 95, Windows 98,Windows 2000, Windows
ME & Windows XP.
8.1.3 Installing the application software
Simply load the CD into the PC and the software will automatically load-up and
complete installation.
The Walker Filtration icon will be visible on the desktop.
8.1.4 Connecting the PC to the controller
Ensure that power to controller is isolated
Access to the controller is by removing the screw on the front panel, and removing the
panel.
Using the lead supplied connect the serial port connector to the PC.
The RS232 connector is located on the underside of the controller.
Remove the blanking plug taking care not to lose it and connect the RS232 connector
with the latch to the front of the dryer.
14 | Walker Filtration
Connecting the PC to the controller

Instruction & Technical Manual | 15
Controller shown in the inverted
position for reasons of clarity
1. Condensate solenoid valve
2. Tower 1 solenoid pilot valve
3. Tower 2 solenoid pilot valve
4. AC&DC supply DIN connections
5. Energy management DIN
connection
6. Controller clear LED cover
7. RS232 Software connection
8. Alarm DIN connection

16 | Walker Filtration
8.1.5 Starting the program
If not already connected, connect the RS232 serial link cable between the controller and
the host PC.
Switch the power to the controller on. Launch the dryer application software by either
double clicking the Walker Filtration icon found on the PC desktop or by clicking:
Start > Programs > Walker Filtration > Dryer Application Software
The first time the software is used the
following window will appear.
Choose your preferred language by
clicking the appropriate flag.
With the power to the dryer switched
on the lead connecting the controller to
the PC, double click the Walker
Filtration CD icon on the screen.
This will display the screen below, if the language is not as you require it then click the
appropriate national flag and the next time the application software starts the language
will be in the requested language.
1. Establish communication
Click the “Establish Communication”
switch on the screen this will look for
the link between the PC and the dryer
controller.
The serial number on the software
must match the serial number on the
controller to allow communications to
be established.
If communication cannot be made, a
warning will appear at the bottom of
the screen.
This may be due to the following:
• Poor connections to the controller
• Controller switched off
• Application software/controller serial number mismatch
Once communication has been established, click the “Read dryer” button on the screen
this will then display the default setting from the works or the last setting the Service
Engineer made.
It is possible to change some of the controller settings from the factory default settings
on the screen. This should only be done by a qualified service engineer.
1
2
3
4
5
6
7
8
9
10
11
12
13

Instruction & Technical Manual | 17
8.1.6 Programming dryer
Once it has been decided to change the default settings, and communications have
been established and the dryer existing valves read the procedure for change is:
• Click into the box you wish to change.
• Over write with the items you require (note stage times are in 10 second intervals).
• Click “Program dryer” ( a warning will appear asking to confirm the change).
• Click to confirm and this will change operating parameter.
• Click in real time to check set up.
2. Read dryer
Reads the current settings of the controller
3. Program dryer
Programs the controller with the new settings
4. Real Time view
This screen can be opened by clicking the real time screen. In addition to the main
display panel shown previously there is also a real time view, which illustrates the
operation of the dryer valves as it happens. It also counts down the remaining time to
run on the valve operation. This is useful in confirming faults, which are displayed with
the LED’s on the front display panel.
To view the status of the controller in real time, click the ‘real time’ view switch. A new
window will appear animating the dryer controller status in real time.
The following information is shown:
• The stage the controller is in through its cycle, including remaining time on the
particular stage.
• Valve conditions
• Power condition
• Cartridge and valve service conditions
• Energy management condition
• Alarm condition
5. Load settings
Allow previously stored settings to be loaded into the controller
6. Stage times
• Tower 1 & Tower 2 – Indicates the time that a tower is depressurised.
• Re-pressurization – Indicates the re-pressurization time set on the controller.
• Link – Enables or disables the tower 1 & tower 2 settings to be linked.

18 | Walker Filtration
7. Drain valve
• Operate drain operation toggle - Allows the drain to operation to be toggled to
function after both towers or only one tower.
• Operate operation time- Sets the drain operation time.
8. Alarm settings
Allows the service Engineer to toggle and adjust the remote alarm activation values from
the default values.
9. Energy management
Allows the user to set application parameters to save energy during periods of low
demand.
10. Service information
Indicates the default settings at which the cartridge and valve service indicators will
illuminate. The service history of the machine is logged, giving total hours run and hours
run since the last service. Service re-sets provides an alternative method of resetting
service hours than using the re-set disc after a service has been carried out.
11. Address
Indicates the network address for networked dryers.
12. Faults
The first column indicates the number of faults up to 50 every 30 minutes. The second
column indicates the type of fault and the hour it occurred from new.
13. Serial number
Indicates software & dryer serial number to ensure they correspond.
8.1.7 Remote fault alarm
A remote alarm relay is built into the controller to facilitate an alarm connection remote
from the dryer. This can activate at the service due period or with a pre-defined number
of electrical faults or both.
This can be enabled or disabled using the software interface. The alarm requires a power
source to be brought to the controller and on activation the controller will switch on in
an alarm condition. This in turn can be used to activate a remote audible or visual
indicator.

Instruction & Technical Manual | 19
8.2 Energy management feature (EM)
8.2.1 Description
The purpose of the energy management feature is to save energy by reducing
compressed air consumption during periods of low demand by interrupting the normal
purge cycle. This can be activated with a link from the receiver upper and lower pressure
switches normally fitted to receivers.
In the case where the compressor is a continually running type or the dryer is remote
from the receiver then a dew point dependent switch can be used to activate the energy
management feature.
As standard, the energy management feature is supplied activated on all controllers.
When connected to an external switching system, the energy management process will
become operational. For systems where energy management will not be required, a
jumper link is fitted to the supplied DIN plug.
8.2.2 Energy management connection
1. Remove DIN plug from EM
connection on controller.
2. Remove blanking plug from cable
entry nut on DIN plug.
3. Remove fixing screw and gasket from
DIN plug body.
4. Separate DIN plug body internal from
cover.
5. Remove jumper wire from pins 1 & 2
on DIN plug body internal.
6. Connect external switching device
cable to pins 1 & 2 on DIN plug body
internal, ensuring that cable entry
nut, washer and seal are in place.
7. Assemble DIN plug body internal into cover and reconnect DIN plug to EM
connection on controller, ensuring that screw and gasket are fitted.
8. The controller gives a +5VDC from pin 1 on the EM DIN. Operation of the EM
feature is by opening and closing the circuit.
9. Opening the circuit with an appropriate external relay or switch will activate the EM
feature.
The user must ensure that the EM DIN plug as supplied with jumper wire, or an external
switching arrangement is in place before the dryer becomes operational.
Ensure the energy management switching arrangement is in place before activating the
EM facility and flowing air through the dryer.

20 | Walker Filtration
8.2.3 Energy management application selection
For correct energy management operation it is important to select the correct mode of
operation for the application.
For applications where the compressor, receiver and the dryer are in the same location
linking the controller energy management into the compressor pressure limit switch, an
effective method of energy saving is offered.
For applications where the compressor is a continual operating type or the dryer is point
of use or is remote from the receiver, then a dew point dependant method of switching
should be employed.
This links the operation of the energy management to the outlet dew point from the
dryer.
The flow diagram below illustrates the correct selection:
Energy management
required
Point of use dryer
application (remote from
compressor)
Dewpoint dependant energy
management switching
Dewpoint monitoring
Continuous running
compressor
Dewpoint dependant energy
management
switching
Dryer directly connected to
local compressor
and receiver
Compressor load energy
management
switching
Dry receiver application
15 second default EM delay
Wet receiver application
Input compressor/receiver
operating parameters
Calculated EM delay
Compressor
Dry air receiver
Wet air receiver
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DRY AIR RECEIVER
COMPRESSOR
WET AIR RECEIVERCOMPRESSOR
1
4
5
6
7 8
9 10
11
12
13
14
15
16
2
3