Professional Documents
Culture Documents
50
Table of Contents
Introduction
Purpose of This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Why a Vehicle Needs an Air Dryer What a Desiccant-Type Air Dryer Does
Components
Air System Components Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Types of Air Compressor Air Governor Air Governor Signal Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Compressor Discharge Line Air Dryer to Supply Tank Line Air System Reservoir Tanks
PCCV Placement
Pressure-Controlled Check Valve (PCCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Determine the Correct Pressure-Controlled Check Valve (PCCV) Placement for the System Saver 1000 and 1200 Series Air Dryer Air Dryer Operating Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
How to Order
Order publications from Meritor Literature Distribution Center, c/o Vispac, Inc., 35000 Industrial Road, Livonia, MI 48150. Phone orders are also accepted at 800-535-5560.
Introduction
Purpose of This Guide
Introduction
This Application Guide for Meritor WABCOs System Saver Series and System Saver TWIN air dryers r addresses air dryer selection and installation criteria for Meritor WABCOs System Saver 1000 and 1200 Series and System Saver TWIN air dryers, r discusses the air supply system, r illustrates and describes system components and r highlights features and benets of the System Saver 1000 and 1200 Series and TWIN air dryers.
DRYER INLET
SYSTEM RESERVOIR
TO BRAKE SYSTEM
SYSTEM RESERVOIR
PURGE VALVE
Typical Vocations
r Single or tandem axle on-highway tractors that pull trailers with a tractor/trailer combination of up to a total of six axles. r Trucks with single or tandem axles that are used for construction, P&D and local hauling.
Typical Vocations
r City buses that stop frequently. r Garbage trucks in residential areas. r On-highway tractors with a tractor/trailer combination of over six axles.
Typical Vocations
r Bulk unloaders that typically use air from large compressors to unload a bulk (usually liquid cargo) tank. r Vehicles with Central Tire Ination (CTI) systems. r Specialized trucks or tractors, when accessories demand a high air consumption (for example, trucks for sewers, septic tanks, etc.). r Vehicles with air start systems.
Requirements
40F to 175F ( 40C, 80C) 12V or 24V available 45F, 86F (7C, 30C) 1/2-inch ID minimum Determined by the temperature of the air at the inlet port of the dryer. After the vehicle has reached normal operating temperatures, the length of the line must be sufcient to keep temperature below 175F (80C).
Requirements
140 psi 115 psi 15 to 25 psi (cut-out cut-in) 25 cfm maximum 2 minutes maximum 7 minutes 20 seconds 30% To minimize the likelihood of a discharge line blockage during cold climate operation, it is recommended that for discharge lines exceeding 9 feet in length, a minimum of 3 feet of 1/2-inch thick closed-cell polyethylene pipe insulation be used at the connection to the air dryer.
Requirements
TWIN with 0.8 mm orice TWIN with 1.0 mm orice TWIN with 1.3 mm orice (Industrial Applications Only) 140 psi 85 psi 50 cfm maximum unlimited 100%
21 cfm and under To minimize the likelihood of a discharge line blockage during cold climate operation, it is recommended that for discharge lines exceeding 9 feet in length, a minimum of 3 feet of 1/2-inch thick closed-cell polyethylene pipe insulation be used at the connection to the air dryer. over 21 cfm 10 feet/20 feet use copper pipe or stainless steel braided teon tubing for minimum of rst 10 feet.
CAUTION
Neither the air dryer, nor the heater in the air dryer, can prevent moisture in compressed air from condensing and freezing in the compressor discharge line between the air compressor and the air dryer inlet. Blockages can occur that can result in damage to components.
r Minimize the length of the compressor discharge line to the extent that air dryer inlet temperature does not exceed the 175 fF (80 fC) maximum. r To help prevent water traps and blockages, follow the vehicle manufacturers guidelines on discharge line material and how to route the line. r For technical assistance, call Meritor WABCO engineering at 248-435-1500.
Application
Non-towing trucks minimum volume of reservoirs contributing to regeneration Towing trucks and tractors where tractor and trailer combination has up to 6 axles total minimum volume of reservoirs contributing to regeneration Any air system with more than 12,000 in3 total for all components, including trailers towed, auxiliary air systems, air start tanks, etc.
Regeneration Volume
1800 in3 or 28% of total air system volume, whichever is greater 2450 in3
System Saver 1000 and 1200 Series not recommended; use System Saver TWIN
Port Identification: 21 Inlet Port 24 Governor/Control Port 21 Delivery Port 22 Delivery Port (Not Used) 31 Relief Valve Port
1/2-14 NPTF
1/2-14 NPTF
56 REF 88 REF
136 REF
70 REF
105
283 REF
CONNECTOR 280 METRI-PACK NR. 1202 0599 133 REF 80 REF 75 REF 28 REF
1/2-13 UNC-2B
72
(179) MAX
NOTE: When the compressor receives inlet air from the engine turbocharger, you must install an external cut-off valve at the inlet port of the System Saver TWIN air dryer to avoid engine power loss or degraded fuel economy.
(75)
(70)
(317) MAX
1/2"-14 NPTF
(320)
Components
Air System Components Discussion
Components
Air Governor
The air governor senses pressure uctuations in the systems rst tank (typically the supply tank, also known as the wet tank) and activates/loads or deactivates/unloads the compressor to control system air pressure. In some air systems, the governor actuates other components, such as automatic drain valves, greasing systems, etc. However, to ensure proper air dryer operation, the governor should only control the compressor, air dryer and auxiliary devices directly related to the compressor and the air dryer.
Mounting Congurations
1. Bolted to the air compressor head. 2. Remote-mounted, connected by an air line to the compressor head. 3. Integral to air dryer.
Typical Ratings
Ratings (cubic feet/minute)
12-13
Applications
r Standard rating on most on-highway tractors, based on sizing criteria in FMVSS 121. r Vehicles that require additional air demands, such as multiple trailers, air accessories, etc. r Vehicles with especially high air requirements, such as bulk unloading, providing air for a central tire ination system, etc.
15-16
30-34
Components
Air Governor Signal Line
The air governor signal line activates the purge and regeneration cycles of the air dryer, as well as the compressor unload cycle. NOTES: r Do not use the air governor line to activate other devices, such as automatic drain valves, after-cooler-type dryers, etc. r Install the line directly from the air governor to the air dryer.
Installation
1. The compressor discharge line must be installed in a continuous downhill run from the compressor to the air dryer. 2. A valve or other component installed in the compressor discharge line can restrict airow to the dryer and form areas where water can pool and freeze. 3. Avoid sharp bends and 90 ttings, especially at the dryer inlet. 4. Ensure that no loops, bends or sags exist in the line.
When the air dryer is at the same level or lower than the compressor and a downhill line is not possible:
r Route the compressor discharge line up immediately out of the compressor as high as necessary to allow the remainder to continue down to the dryer. 9
PCCV Placement
Pressure-Controlled Check Valve (PCCV)
PCCV Placement
The PCCV is typically installed on one of the system tanks in place of the inlet check valve. The valve maintains a minimum air pressure in the reservoir tanks and also allows the air dryer to use 10 psi of air volume from the supply (wet) tank and select system tank(s) during the regeneration cycle. r The PCCV allows air to ow freely into the system reservoir tank and back into the supply (wet) tank above 95 psi. r The valve ensures that air pressure in the system reservoir tank is not below approximately 90 psi. r If a problem occurs upstream of an air tank with a PCCV installation, the valve allows air pressure to drop to 90 psi and closes (normal check valve function) to protect the remaining air in the tank. When properly installed, the PCCV complies with FMVSS 121 and corresponding Federal Motor Carrier Safety Regulations. (The valve returns to normal check valve function when air pressure in the system tank drops below 95 psi.)
Determine the Correct Pressure-Controlled Check Valve (PCCV) Placement for the System Saver 1000 and 1200 Series Air Dryer
The regeneration volume is determined by how much compressed air is pumped through the air dryer during each compressor cycle. The following gure shows the proper sizing of the system and the volume of the reservoirs contributing to the regeneration volume required for a given installation. The reservoirs contributing to regeneration will determine the placement of the PCCV in the system. Since the air dryer will take approximately 10 psi from the contributing reservoirs, the volume for regeneration will be a function of the reservoir sizes. The Total System Size is the sum of all the air tanks to be lled on all vehicles that the compressor will be lling. For instance, if the tractor has a total air system of 6000 in3 (supply 900 in3, primary 3200 in3, secondary 1900 in3) and it pulls a lead single trailer with 1400 in3, a single axle dolly with 1400 in3, and a second single axle trailer with 1400 in3, the total system size is 10,200 in3. Looking at the chart and nding 10,200 in3 at the bottom, reading up and over shows the system needs 2856 in3 of reservoir volume contributing to regeneration. From this volume, 10 psi would be taken for regeneration. In this case, installing the PCCV on the primary tank gives adequate regeneration volume (supply 900 in3 + primary 3200 in3 = 4100 in3).
10
PCCV Placement
Formula for Total System Size
Use the formula below to compute total system size. r Total System Size = Sum of all reservoir tanks an air compressor must service in the vehicles air system. Example: (IN3) r Supply (Wet) Tank Primary Reservoir Tank Secondary Reservoir Tank Tractors Total Air System r Lead Single Axle Trailer Single Axle Dolly Second Single Axle Trailer Total Load Pulled: r Total Combination Vehicle System Size (IN3) The Air Compressor Must Service 6000 + 4200 = Figure 3 900 3200 1900 6000 (IN3) 1400 1400 1400 4200
10,200
5000
4000
3000
2000
1000
0 0 5000
Total reservoir volume in3
10,000
11
PCCV Placement
Air Dryer Operating Parameters
The air dryer cools, lters and dries compressed air to prevent problems with moisture in an air system.
12
Todays single-chamber air dryers regenerate the desiccant by using either the On-Board Volume (also known as the Integral Purge Volume) method, the Purge Tank method or the System Air Regeneration method.
1. On-Board Purge Volume Method (also known as Integral Purge Volume Method)
r The air dryer stores regeneration air within the air dryer instead of in a separate air reservoir. r Dryer-mounted operating components constitute a heavy, bulky unit. r This method can only accommodate an air system up to a specic size. r Single-purpose; uses on-board air only to regenerate desiccant.
CFM 13 20 30 40
Drying Capacity
Cubic feet per minute (cfm)
An air dryers design and the amount of desiccant it contains determines drying capacity. r A System Saver 1000 and 1200 Series single-cartridge air dryer has drying capacity to handle a 25 cfm compressor, pumping at maximum output for two minutes, without regenerating the desiccant. r In special applications, the System Saver 1000 and 1200 Series can handle a compressor larger than 25 cfm. r A tractor trailers average compressor on-time is 15-25 seconds.
13
Governor Range
The governor range is the difference between cut-in pressure and cut-out pressure. The amount of air that a compressor pumps through a dryer is proportional to the governor range. r The wider the governor range, the more air a compressor pumps through a dryer during any given cycle. r The amount of purge air volume a system requires is proportionate to the governor range.
14
Meritor WABCO Vehicle Control Systems 2135 West Maple Road Troy, MI 48084 U.S.A. 800-535-5560 www.meritorauto.com
Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise the information presented or discontinue the production of parts described at any time. Copyright 1998 Meritor WABCO All Rights Reserved TP-9672 Revised 11-98 16579/24240
ii