membrane dryer variodry frl superplus sf 0002 … variodry frl sf 0002-us 560 l 0560 3 00 00 0 sf...

O 0560 30100008.2007

VARIODRY FRL SuperplusSF 0002 SP-US - SF 0003 SP-USVARIODRY FRLSF 0002-US - SF 0003-US

US

Operating Instruction

US

Membrane dryer

08.2007

VarioDry FRL

SF 0002-US 560 L 0560 3 00 00 0SF 0003-US 561 L 0561 3 00 00 0

SF 0002 SP-US 560SP L 0560 3 0C 00 0SF 0003 SP-US 561SP L 0561 3 0C 00 0

ultratroc gmbh Telefon +49 (0) 461 949 0Drucklufttechnik Telefax +49 (0) 461 949 369Postfach 2653 . D-24916 Flensburg e-mail: [email protected] 73 . D-24941 Flensburg internet: http://www.donaldson.com

2

Model Type no. Material no.

Type Code

Series

Type Code

08.20073

Table of contents

Type code Page 2Table of contents 3Assembly and parts 4Filter-water-separator 1. Technical Data 5

2. Installation 63. Maintenance 64. Dismantling 75. Reassembly 76. Fitting and removing the bowl guard 77. Disposal 78. Assembly of several components 89. Fitting the mounting bracket 8

Submikcrofilter 1. Technical Data 92. Installation 103. Maintenance 104. Dismantling 115. Reassembly 116. Fitting and removing the bowl guard 117. Disposal 118. Assembly of several components 129. Fitting the mounting bracket 12

Membrane dryer 1. Technical Data 132. Installation 143. Adjustment 144. Maintenance 145. Dismantling 156. Reassembly 167. Disposal 168. Assembly of several components 179. Fitting the mounting bracket 17

Aktivated carbon filter 1. Technical Data 182. Installation 193. Maintenance 194. Dismantling 205. Reassembly 206. Fitting and removing the bowl guard 207. Disposal 208. Assembly of several components 219. Fitting the mounting bracket 21

Pressure regulating valve 1. Technical Data 222. Installation 233. Pressure setting 244. Maintenance 245. Dismantling 246. Reassembly 257. Fitting the lock 258. Disposal 259. Assembly of several components 25

10. Fitting the mounting bracket 26

08.20073 08.20074

Membrane dryerType Art. No. Replacement Membrane module560 L 0560 3 01 00 0 010 0782 000561 L 0561 3 01 00 0 010 0781 000

Mounting brackets(3 sets)011 0987 000

Air inletNPT 1/4“

Filter-water-separator compl.011 0976 000Replacement filter 5µ011 1069 000(Ersatzfilter 30µ011 1068 000)

Submicrofilter compl.011 1016 000Replacement filter026548

Pressure regula-ting valve011 0979 000

Air outletNPT 1/4“

Gauge011 0980 000

Coupling set(4x)011 0986 000

Activated carbonfilter compl.011 0983 000Replacement filter026549

Membrane dryer SuperplusType Art. No.560 SP L 0560 3 0C 00 0561 SP L 0561 3 0C 00 0

includes following parts:

Membrane dryer assembly and parts

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FILTER-WATER-SEPARATOR

Dear Customer,

Thank you for your confidence in our product.In the following pages you will find the technical data required for the trouble-free installation and maintenance of these pneumatic components. Please readthe instructions fully to ensure that the product will give you long, trouble-freeservice.

1. TECHNICAL DATA

Characteristics Pressures quoted as gauge pressure

Port size G1/8 G1/4 G3/8

Pore size of filter element µm 30 (white)5 (yellow)

Max. condensate capacity cm³ 22

Condensate drainage

Installation Vertical

Medium and ambient temperature range

ϑmin ϑmax

°C °C

Weight (mass) kg 0,25Pneumatic CharacteristicsOperating pressure range Inlet

p1min p1max

bar

Recommended flow rate � Qnl/min m³/h

300 18

550 33

850 51

Maximum flow rate � Qmaxl/min m³/h

990 59

1440 86

1520 91

Filtration efficiency at recommended flow rate η % 95 95 90

� at p1=6 bar and 25 m/s� at p1=6,3 bar, ∆p=1 bar

016

(other temperatures on request)

0+50 at 10 bar

Standard: manualOn request: semiautomatic (with

pressure relief)

Warning: Servicing and repair work must only be carried out by a qualifiedtechnician.

5

See flow direction arrows on top ofunit!

p1 p2

2. INSTALLATION INSTRUCTIONS

1. Clean any rust particles or other dirt out of the tubing.2. Fit a mounting bracket, if applicable.

3. Connect the tubing to the filter-water-separator (check flowdirection!).

4. Turn on the compressed airsupply.

3. MAINTENANCE

3.1. Manual Drainage

Push the plastic part up against the bowl to open thevalve and drain the condensate.The condensate level must never be above the„maximum“ mark on the bowl.

3.2. Cleaning the Filter Element

As soon as serious pressure drop is observed, clean the filter elementand bowl.Clean the filter element with petrol, paraffin or similar and blow it out frominside to outside. The element must must be completely dry beforereassembly.The bowl and the other plastic parts should only be cleaned with warmwater and normal washing-up liquid.

Warning: The unit must only be used in industrial applications forcompressed air.To avoid danger of injuries, the compressed air systemmust be fully depressurized while pneumatic componentsare being installed.

Note: The bowl must not come into contact with the followingmaterials (whether in liquid or gaseous form):acetone, benzene, brake fluid, chloroform, acetic acid,glycerine, methanol, carbon bisulphide, tri-, tetra- and per-compounds, toluene, xylene (cellulose thinners) and highflash-point synthetic oils (e.g. phosphoric ester base, etc.). Ifin doubt, please consult your sales contact.

6

4. DISMANTLING

1. Screw off bowl �.2. Unlock deflector disc � by turning it to the left and

pull it off the spigot.3. Pull conical filter element � from its seat.4. Remove O-ring (35 × 2 � from housing.

5. REASSEMBLY

Reassembly of the unit is carried out in reverse order.

1. Place O-ring (35 × 2 � in housing.2. Push filter element � (5µm…yellow, 30µm… white)

into its seat.3. Push deflector disc � with slot on to spigot, press

gently and turn to right to lock it.4. Screw bowl � back into housing hand-tight.

6. FITTING AND REMOVING THE BOWL GUARD

Fitting:Locate the lugs of the guard � in the recess of thehousing � and lock it by turning it to the right.

Removal:Press the release catch (see arrow) and turn the guardto the left.

7. DISPOSAL

The method of disposal of packaging and discarded parts must complywith local regulations.

Warning: To avoid danger of injuries, the unitmust only be dismantled with thepneumatic system completelydepressurized!

Note: If new seals are fitted, grease themthoroughly before fitting.

1

2

3

4

5

6

7

8. ASSEMBLY OF SEVERAL COMPONENTS

Only components of the same size can beassembled into combined units.

1. Remove the black cover plates from theinlets and outlets of the compo-nents you wish to assemble.The coloured cover platesremain in place.

2. Turn the component so thatthe flange surface which is to bejoined to the other component is on top.

3. Lay the O-ring À from the coupling kit onthe flange surface.

4. Place the hexagon nuts Á in therecesses on the component.

5. Place the other component on the flange surface.6. Place the clamping cones Ã with the screws Â in the recesses on the

components.7. Tighten the clamping screws.8. Push the small cover plates Ä from the coupling kit on to the

clamping cones.

9. FITTING THE MOUNTING BRACKET

1. Remove the coloured cover plate from thecomponent.

2. Screw the mounting bracket to thecomponent with the screws provided usinga Phillips screwdriver.

Note: The mounting bracket can befitted with the mounting strapeither upwards or downwards.

1

2

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5

8

SUBMICROFILTER

Dear Customer,


1. TECHNICAL DATA



Condensate drainage

Installation Vertical, bowl downwards


ϑmin

ϑmax

°C °C


p1min

p1maxbar

Maximum flow rate � Qnl/min m³/h

200 12

200 12

200 12

Pressure drop at maximum flow rate

∆p barCa. 0,07 with new filter element toCa. 0,3 during operation (saturated

element)

Filtration efficiency at maximum flow rate η %

� at 6 bar

016


+1,5+50 at 10 bar

Standard: manualOn request: semi-automatic with

pressure relief

Over 99,999%,Solids >0,01µm(DOP or BS 3928, 2577)


9


1. Clean any rust particles or other dirt out of the tubing.2. Fit a mounting bracket, if applicable.3. Connect the tubing to the

submicrofilter (check flowdirection!).

4. Turn on the compressedair supply.

3. MAINTENANCE

3.1. Manual Drainage

Push the plastic part up against the bowl to open thevalve and drain the condensate.The condensate level must never be above the„maximum“ mark on the bowl.

3.2. Cleaning

As soon as serious pressure drop is observed, replace the filter element.The filter element cannot be washed out and must always be replaced.The bowl and the other plastic parts should only be cleaned with warmwater and normal washing-up liquid.


Note: A filter-water-separator with pore size 5 µm (yellow) mustalways be installed before the submicrofilter (as close aspossible).The bowl must not come into contact with the followingmaterials (whether in liquid or gaseous form):acetone, benzene, brake fluid, chloroform, acetic acid,glycerine, methanol, carbon bisulphide, tri-, tetra- and per-compounds, toluene, xylene (cellulose thinners) and highflash-point synthetic oils (e.g. phosphoric ester base, etc.). Ifin doubt, please consult your sales contact.

See flow direction arrows on topof unit!

p1 p2

10

1

2

3

4

5

6

4. DISMANTLING

1. Screw off bowl �.2. Screw filter insert � out of housing �.3. Remove O-ring (15 × 2 � from filter insert �.4. Take O-ring (35 × 2 � out of housing �.

5. REASSEMBLY

Reassembly of the unit is carried out in reverse order.

1. Place O-ring (35 × 2 � in housing �.2. Fit O-ring (15 × 2 � onto filter insert �.3. Screw filter insert � into housing �.4. Screw bowl � into housing � hand-tight.

6. FITTING AND REMOVING THE BOWLGUARD �

Fitting:Locate lugs of bowl guard � in recess of housing � andlock it by turning it to the right.

Removal:Press release catch (see arrow) and turn bowl guard.

7. DISPOSAL

The method of disposal of packaging and discardedparts must comply with local regulations.

Warning: To avoid danger of injuries, the unitmust only be dismantled with thepneumatic system completelydepressurized!

Note: If new seals are fitted, grease them lightlybefore fitting.

11



1. Remove the black cover plates from theinlets and outlets of the compo-nents you wish to assemble.The coloured cover platesremain in place.






clamping cones.



2. Screw the mounting bracket to thecomponent with the screws provided usinga Phillips screwdriver.

Note: The mounting bracket can befitted with the mounting strapeither upwards or downwards.

1

2

43

5

12

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17

ACTIVATED CARBON FILTER

Dear Customer,


1. TECHNICAL DATA


Port size G1/8 G1/4 G3/8Installation Vertical (Bowl downwards)Medium and ambient temperature range

ϑmin ϑmax

°C °C


p1min

p1maxbar

Maximum flow rate � Qnl/min m³/h

200 12

200 12

200 12

Pressure drop at maximum flow rate ∆p bar

Oil vapour filtration efficiency

η %

� at 6 bar

ca. 0,07

016


+1,5+50 at 10 bar

99,999%,Residual oil content 0,003 ppm


18


1. Clean out the tubing carefully.2. Fit a mounting bracket, if applicable.3. Connect the tubing to the

activated carbon filter (checkflow direction ⇒ thewrong flow directionwill damage the filter elementirreparably!).

4. Turn on compressed air supply.

3. MAINTENANCE

3.1. Cleaning the Filter Element

As soon as serious pressure drop is observed, replace the filter element.The filter element cannot be washed out, it must be replaced.The bowl and the other plastic parts should only be cleaned with warmwater and normal washing-up liquid.

Warning: This unit must only be used in industrial applications forcompressed air, but can also be used in medicalapplications.NOTE! The housing and activated carbon filter are notsterilized (not suitable for steam sterilization)!To avoid danger of injuries, the compressed air systemmust be fully depressurized while pneumatic componentsare being installed.

Note: A submicrofilter must always be installed before theactivated carbon filter (as close as possible).The bowl must not come into contact with the followingmaterials (whether in liquid or gaseous form):acetone, benzene, brake fluid, chloroform, acetic acid,glycerine, methanol, carbon bisulphide, tri-, tetra- and per-compounds, toluene, xylene (cellulose thinners) and highflash-point synthetic oils (e.g. phosphoric ester base, etc.). Ifin doubt, please consult your sales contact.

See flow direction arrows on topof unit!

p1 p2

19

4. DISMANTLING

1. Screw off the bowl �.2. Screw the filter insert � out of the housing �.3. Remove the O-ring (15 × 2 � from the filter insert �.4. Remove the O-ring (35 × 2 � from the housing �.

5. REASSEMBLY

Reassembly of the unit is carried out in reverse order:

1. Place the O-ring (35 × 2 � in the housing �.2. Fit the O-ring (15 × 2 � on to the filter insert �.3. Screw the filter insert � into the housing �.4. Screw the bowl � into the housing � hand-tight.

6. FITTING AND REMOVING THE BOWL GUARD

Fitting:Locate the lugs of the guard in the recess in thehousing and lock it by turning it to the right.

Removal:Press the release catch (see arrow) and turn the guard tothe left.

7. DISPOSAL

The method of disposal of packaging and discardedparts must comply with local regulations.We will undertake the disposal of used filter elements ifthey are returned to us.

Warning: To avoid danger of injuries, the unitmust only be dismantled with thepneumatic system completelydepressurized.

1

2

3

4

5

6

20



1. Remove the black cover plates from theinlets and outlets of the componentsyou wish to assemble. Thecoloured cover plates remainin place.

2. Turn the component so thatthe flange surface which is tobe joined to the othercomponent is on top.





clamping cones.



2. Screw the mounting bracket to thecomponent with the screws provided usinga Phillips screwdriver.Note: The mounting bracket can be

fitted with the mounting strapeither upwards or downwards.

1

2

43

5

21

PRESSURE REGULATING VALVE

Dear Customer,


1. TECHNICAL DATA




ϑmin ϑmax

°C °C

0 +60


p1min

p1maxbar 0

16Operating pressure range Outet

p2min p2max

bar

Minimum pressure range p1-p2 bar 0,2Hysteresis p1=10/p2=0 Hysteresis p1=10/p2=8 bar 0,5

0,4

Recommended flow rate � Qnl/min m³/h

300 18

550 33

850 51

Maximum flow rate � Qmaxl/min m³/h

790 47

1050 63

3300 198

� at p2=6 bar and 25 m/s� at p1=10 bar on p2=6,3 bar, ∆p=1 bar

0,5 on request 0,5 0,58 4 15



22


1. Clean any rust or dirt out of the tubing.2. Fit a mounting bracket, if applicable.3. Fit a pressure gauge, if applicable.4. Connect the tubing to the regulator

(check flow direction!).

5. Pull the handwheelupwards and turn itanticlockwise (seearrow onhandwheel) to set p2 to 0bar.

6. Turn on the compressed air supplyand turn the handwheel until thedesired pressure isobtained. Push the handwheeldown again to lock it.


Note: Dirt must be kept out of the regulator as it can cause seriousmalfunction or damage!If required, a filter should be installed in the line before theregulator.

See flow direction arrows on top ofunit!

p1 p2

Option „-T“ (p1 goes through):The connection for the regulated pressure line is on theside of the unit.

p1p1

p2 (G¼)

(G1/8)

23

3. PRESSURE SETTING

1. To set the desired pressure, pull the handwheelupwards and turn it anticlockwise until thepressure is below the new desired pressure.

2. Turn the handwheel clockwise to obtain thedesired pressure, then push it down again to lock it.

4. MAINTENANCE

The regulator itself is maintenance-free. Thecompressed air system as a whole must be correctlymaintained (air filtered and dewatered).

5. DISMANTLING

5.1. Dismantling the Upper Part

1. Pull the handwheel � upwards, turn it anticlockwiseto the stop and push it down again to lock it.

2. Screw off the upper part �.3. Remove the regulating spring �.4. Remove the white spacer disc � and the

diaphragm assembly � from the housing �.

5.2. Dismantling the Lower Part

1. Preferably remove the regulator from the air line.2. Screw off the bottom cover � with a pin

spanner.

3. Pull the valve piston � out of the housing �.4. Take the O-ring (2,5 × 1,5 � out of the housing.5. Take the O-ring (35 × 2 � out of the housing.

Warning: To avoid danger of injuries, the unit mustonly be dismantled with the pneumaticsystem completely depressurized!

Caution: The compression spring � falls out ofthe housing with the bottom cover.

+-

1

2

3

4

5

6

7

8

9

11

10

24

6. REASSEMBLY

Reassembly of the unit is carried out in reverse order to dismantling:Lower part first, upper part last.

Note on Reassembly of the Upper Part:1. Screw the upper part �� 1 to 2 turns into the housing.2. Unlock the handwheel �, hold the upper part with one hand and turn

the handwheel 3 - 4 turns to the right: ⇒ this centres the diaphragm� to the valve piston �.

3. Turn the handwheel � back to the left and lock it.4. Screw the upper part in tight up to its stop.

7. FITTING THE LOCK

1. Position the key obliquely to the hole and placethe lock on the peg.

2. Turn the key clockwise and remove it.

8. DISPOSAL

The method of disposal of packaging anddiscarded parts must comply with localregulations.



1. Remove the black cover plates from theinlets and outlets of thecomponents you wish toassemble. The coloured coverplates remain in place.


Note: If new seals are fitted, grease them thoroughlybefore fitting.

Note: The lock can only be used on regulatorsfitted with the projecting locking bolt.

1

2

43

5

25

3. Lay the O-ring À from the coupling kit on the flange surface.4. Place the hexagon nuts Á in the recesses on the component.5. Place the other component on the flange surface.6. Place the clamping cones Ã with the screws Â in the recesses on the


clamping cones.



2. Screw the mounting bracket to thecomponent with the screws provided usinga Phillips screwdriver.Note: The mounting bracket can be

fitted with the mounting strapeither upwards or downwards.

26

membrane dryer variodry frl superplus sf 0002 … variodry frl sf 0002-us 560 l 0560 3 00 00 0 sf...

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