Description

B-MA20.21-en
06/2007 Rev.01

Dual-chamber air dryer units LTZ 011, LTZ011-H LTZ012, LTZ012-H

B-MA20.21-en 06/2007 Rev.01

1 1.1 1.2 1.3 1.4 2 2.1 3 3.1 3.2 3.3 3.3.1 3.3.2 3.3.3 3.3.4 4 4.1 4.2 4.3 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.2 5.2.1 5.2.2 6 6.1 6.1.1 6.1.2 6.1.3 6.2 6.2.1 6.2.2 6.2.3

General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Target group for this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes and warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Basic safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Validity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Authorized use of the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s commitment to due care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assignment of personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Availability of the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Amendments to the document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spares and wearing parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Technical features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leakage testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.3 6.3.1 6.3.2 6.3.3 6.4 6.4.1 7 7.1 7.2

Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auxiliary products and working materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tool for dual-chamber air dryer units LTZ012, LTZ012-H . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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1

General information

DANGER Please read this document carefully from start to finish to ensure safety of operation and to avoid personal injuries and damage to equipment.

1.1

Copyright KNORR-BREMSE Systeme für Schienenfahrzeuge GmbH Moosacher Str. 80, 80809 München, Germany Department: Technical Documentation Phone: Fax: +49 (89) 3547-0 +49 (89) 3547-2767

All data is protected by copyright. All rights are reserved. The CD containing customer documents from KNORR-BREMSE Systeme für Schienenfahrzeuge GmbH − called KB SfS" in the following − may be installed and used on a computer and a connected printer. A copy of the CD may be made provided it is used for backup only. Any such copy must bear copyright notes (and trade marks). A hardcopy of the customer documents may be used in-house if it is marked confidential". No part of the customer documents may be transmitted to others in any form whatever. Any exception to these rules requires the express, written approval of KB SfS.

1.2

Technical changes KB SfS reserves the right to change the unit or this document at any time without giving special notice.

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1.3

Target group for this document This document is intended for use by KB SfS-trained service technicians who S have the skill, experience, safety awareness and professional ability − to remove and install the unit, − to inspect, service and debug the unit, S S have read and understood this document from start to finish and are familiar with the safety codes and accident prevention regulations for these activities.

NOTE This document will be useful to other target groups as well, e.g. project engineers. However, it does not claim to provide complete information for such target groups.

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1.4

Notes and warning messages Warning messages are subdivided into the following hazard levels in this document: DANGER Failure to comply with these instructions will lead to irreversible personal injuries which may have fatal consequences. WARNING Failure to comply with these instructions may lead to irreversible physical injuries which may have fatal consequences. CAUTION Failure to comply with these instructions may lead to personal injuries and/or to damage to the unit or the environment. Safety notes have a specific structure which is explained here for DANGER: DANGER (= word of alert) Source of the danger Consequence of the danger Remedial measures Notes do not contain any messages relevant to safety and are intended merely to complete the reader’s information. NOTE Notes contain useful hints and additional information about the unit.

Warning messages in other parts of this Description draw your attention to the individual risks concerning your use of the product. Warning messages and notes generally precede the descriptions of the relevant applications.

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2

Introduction
This Description contains particulars specific to the unit and discusses operation, installation, removal, function testing and maintenance of the unit on board.

2.1

Related documents The related installation drawing specific to each item number must be consulted.

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3

Basic safety information

3.1

Validity

WARNING Validity note (item number or type designation) ignored! The consequences may be personal injuries and damage to the unit. The validity notes in the document must always be taken into account. The item number or type designation is stated on the name plate and must agree with the validity note stated in this document. This document is valid for units with type designations LTZ011 LTZ011-H NOTE Please contact a KB SfS Service Center if the unit cannot be uniquely identified, e.g. because the name plate is illegible or missing. LTZ012 LTZ012-H

3.2

Authorized use of the product The unit named in Section 3.1 shall be used only in the system that has been designed and engineered by KB SfS for the accompanying vehicle. Other applications and assignments, as well as changes, attachments and modifications may jeopardize the safety, reliability and functionality of the system. They invalidate any warranty on the part of KB SfS and transfer the liability to the operator. KB SfS must always be consulted before any other application or assignment is implemented.

3.3

Operator’s commitment to due care

3.3.1

Assignment of personnel The operator shall ensure that the personnel assigned to the specified activities possesses the qualifications defined for the given target group.

3.3.2

Availability of the document The operator shall ensure that the present document is always available to the relevant personnel in a complete, up-to-date and readable form.

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3.3.3

Amendments to the document The operator shall ensure that, at the place of use, the present document is regularly amended by, or replaced with, instructions based on: S S S statutory accident prevention regulations statutory accident protection regulations trade association regulations

3.3.4

Spares and wearing parts The operator shall ensure that none other than genuine KB SfS parts or KB SfSapproved spares or wearing parts are used. The installation of spares other than approved may impair the safety and reliability of the given unit and overall system and invalidates any warranty on the part of KB SfS.

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4

Technical description
The model LTZ011, LTZ011-H, LTZ012 and LTZ012-H dual-chamber air dryer units dry the compressed air to an insignificant residual level and largely prevent moisture from getting inside compressed air systems and causing pneumatic equipment to malfunction and wear prematurely as a result of corrosion and potential freezing.

4.1

Technical features See Fig. 1 The unit performs the following main function: S Reducing the humidity level of the compressed air to an insignificant residual amount.

Moisture in the compressed air of pneumatic systems may cause the pneumatic equipment to malfunction and wear prematurely as a result of corrosion and potential freezing. Atmospheric air always contains water vapour. As long as the moisture stays in the form of vapour, it is bound inside the air. Only when the saturation limit is exceeded (= 100% relative humidity), is the water precipitated in the form of droplets, fog or snow. Fig. 1 shows how the saturation limit varies with temperature, and how the air is able to absorb more moisture with rising temperature. This explains why water cannot be precipitated as the temperature of the air in the compressor rises during compression. Precipitation only takes place when the air from the compressor is cooled down again in the aftercooler. Let us now illustrate this process in a simple arithmetic example. At an ambient temperature of +30°C and relative humidity of 80%, one cubic metre of aspirated air contains 24.5 g water in the form of water vapour. Hence, one cubic metre of compressed air at 10 bar gauge contains 11 × 24.5 g = 269.5 g water. The temperature of the air rises with increasing compression. After being cooled down to 50°C, however, the air in its saturated state can hold only 83 g/m3 water vapour, which means that 269.5−83 = 186.5 g/m3 water are precipitated. This example demonstrates quite clearly that the air in pneumatic systems is always saturated after being cooled down. Consequently, any further temperature drop due to natural cooling will cause precipitation, leading in turn to commonly known problems such as corrosion and freezing. Let us now continue our example to illustrate the matter still further. As the compressed air cools down from 50°C to 20°C it deposits a further quantity of 66 g/m3 water, while cooling to 10°C will produce as much as 74 g/m3. This arithmetic example shows what a considerable amount of water is still left in the pneumatic system in the form of vapour, even after the air has been well cooled in the compressor and the precipitate removed.
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However, a pneumatic system can only work reliably and efficiently if the air in the system is dried so well that the relative humidity always stays below 35%. Atmospheric corrosion does not take place below this critical moisture" level, even when the air contains so-called corrosion stimulators such as acids. The air dryer units named above work on the heatless regenerative adsorption principle. This method has proved reliable in rail vehicles in particular, and is the most efficient arrangement known for this application. This principle is based on the following physical process. Humid compressed air flows through a desiccant (adsorbent) of crystalline metal aluminosilicates which by virtue of their molecular structure have extraordinarily large, specific inner surfaces and thus withdraw water vapour from the passing air. Compared with other desiccants, they have the decisive advantage that they are largely unaffected by oil. The silicate has very regular pore openings sized just to allow the water molecules to be adsorbed, while the larger oil molecules cannot be coadsorbed. Fig. 1 Absolute water content as a function of air temperature
X Y Z 100% relative humidity Air temperature (°C) Absolute water content (g/m3)

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4.2

Construction See Fig. 4 and 5 NOTE The schematic in Fig. 5 shows a representative construction of a model LTZ012 dual-chamber air dryer unit. The construction of the air dryer units discussed in the present document differs only in minor details from this representation. The part numbers used in the following text relate to the dual-chamber air dryer unit LTZ012 shown in Fig. 4 and 5. The dual-chamber air dryer units LTZ011, LTZ011-H, LTZ012 and LTZ012-H described here consist essentially of the following: S Two desiccant towers (1), each with an integrated oil separator, and consisting of bowl (1.10) full of Raschig rings (1.9); versions LTZ011 and LTZ011-H have two filter cartridges (see Fig. 2) Bracket (21) with regeneration choke (61) and the following valves: − two check valves (26) for the towers, − a precontrol valve (39) for the control air, S S S S Duplex piston valve (14) Silencer (17) to discharge the regeneration air and to drain the unit Valve magnet (27) Electronic circuit board (28) for cycle timing

S

Dual-chamber air dryer units LTZ011 and LTZ012 designated additionally by -H" are equipped with a thermostat-controlled cartridge heater as well. The model LTZ011, LTZ011-H dual-chamber air dryer units have fully exchangeable filter cartridges (1, Fig. 2) instead of the towers (1). The model LTZ012, LTZ012-H dual-chamber air dryer units can be equipped with a slide-in frame (see Fig. 3). All versions come in variants differing according to the diameter of the regeneration choke, the electric connection and the length of the working cycle. The units can therefore be matched very widely to all possible working conditions.

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Fig. 2

Dual-chamber air dryer unit LTZ011-H (example)

1 2 17 20 26 57

Filter cartridge Bracket Duplex piston valve Silencer Valve magnet Housing

A1 A2

Air inlet Air outlet (optionally usable)

E1 K3

Opening for electric connection Regeneration air outlet

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Fig. 3

Dual-chamber air dryer unit LTZ012-H with a frame (example)

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Fig. 3 (continued) Dual-chamber air dryer unit LTZ012-H with a frame (example)

1 2 3 4 5 6 7 8 9 10 11

Air dryer unit Frame Deep-groove ball bearing Retaining ring Swivel fitting Pipe Machine screw Lock washer Extension O-ring Thrust screw

12 13 14 15 16 17 18 19 20 21 22

Thrust ring Sealing ring Pipe Screw plug Sealing ring Thrust screw Sealing ring Thrust ring Extension O-ring Rubber-jacketed cable

23 24 25 30 31 32 34 A1 A2 E1 K3

Connecting case Connector Socket case Rivet Name plate Female connector Sleeve insert Air inlet Air outlet Electric connection Regeneration air outlet

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Fig. 4

Dual-chamber air dryer unit LTZ012-H (example)

1 1.5 1.10 14 17

Tower Bolt Bowl Duplex piston valve Silencer

21 27 28 57

Bracket Valve magnet Circuit board Housing

A1 A2 E1 K3

Air inlet Air outlet Opening for electric connection Regeneration air outlet

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Fig. 5

Dual-chamber air dryer unit LTZ012 (schematic)

1.. 1.5 1.6 1.9 1.10 14 14.4 14.5

Tower Bolt Desiccant Raschig rings Bowl Duplex piston valve Piston KNORR K-ring

14.8 14.10 17 21 26.. 27

KNORR K-ring Piston Silencer Bracket Valve head, check valve Valve magnet

38 39 A1 A2 O.. K3 V..

KNORR K-ring Piston, precontrol valve Air inlet Air outlet Exhaust port Regeneration air outlet Valve seat

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Fig. 6

Pneumatic diagram LTZ012

1 14 17 21

Tower Duplex piston valve Silencer Bracket

26 27 39 61

Check valve Valve magnet Precontrol valve Choke

A1 A2 K3

Air inlet Air outlet Regeneration air outlet

4.3

Working principle See Fig. 4 to 7 Functional characteristics A heatless regenerative adsorption dryer of the dual-chamber type operates simultaneously in two phases, i.e. drying and regeneration run in parallel. While the main airstream is being dried in one of the towers, the desiccant is being regenerated in the other. Functional description Fig. 5 shows the air dryer unit in the operating state in which the tower (1a) is drying and the tower (1b) is regenerating. The valve magnet (27) is energized by the electric input signal coming from the cycle timer; the valve seat V3 is open. The compressed air drawn off the air pipe to the port A2 flows through the open valve seats V2 and V3 to the duplex piston valve (14).

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NOTE The precontrol valve (39) is designed to prevent the duplex piston valve (14) from assuming an intermediate position. It opens only after the necessary shuttling pressure has been reached. The shuttling pressure pushes the pistons (14.4) and (14.10) to the top and bottom positions against the acting spring forces, and thereby opens the valve seats V5 and V8. Having been cooled down and predrained, the compressed air delivered by the compressor flows through the port A1 and the open valve seat V5 to the tower (1a), passes through this tower from bottom to top and is subsequently redirected down through the central tube and the check valve (26a) to the port A2. Before the air can enter the desiccant (1.6), it is first carried through the Raschig ring filling (1.9) in the oil separator (bowl 1.10). Being repeatedly deflected, swirled and impacted, the minute droplets of oil and water that are still suspended in the compressed air are precipitated on the relatively large surfaces of the Raschig rings. They gather to form larger drops which then fall under gravity into the collecting chamber. As the air passes subsequently through the desiccant it gives off so much of its water content that the relative humidity of the compressed air leaving the tower (1a) is less than 35%. Some of the air thus dried is drawn off, expanded through the regeneration choke (61) and conveyed through the desiccant in the tower (1b) in the opposite direction. This expanded air, which is also known as regeneration air, extracts the moisture from the desiccant that is to be regenerated, and escapes to atmosphere through the open valve seat V8 and the silencer (17). Shortly before the desiccant reaches its saturation limit, the unit is shuttled by the electric cycle timer at T/2 (see Fig. 7), i.e. the valve magnet (27) is deenergized. The valve seat V3 is closed and the valve seat V4 opened. The control line to the duplex piston valve (14) is vented. As a result, the spring forces push the pistons to the top and bottom positions, respectively. This action closes the valve seats V5 and V8 and opens the valve seats V6 and V7. In this condition, the main airstream (A1 −> A2) is dried in the tower (1b) and the desiccant is regenerated in the tower (1a). Fig. 7 shows the cycle timing and the various working phases. To work correctly, the unit requires a certain shuttling pressure at which the precontrol valve (39) opens and the duplex piston valve (14) can shuttle. The two check valves (26) prevent the main reservoir and the onboard pipes from being vented while the compressor is idle.

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Fig. 7

Diagram of one working cycle
1) 2) 1.. T Regeneration phase Drying phase Desiccant tower Working cycle

Cycle timing The cycle timer is switched on together with the compressor. It controls the ON and OFF times of the valve magnet (27) according to a fixed program. When the compressor is off or idling, the cycle timer remembers the actual state and continues the count when the compressor is switched on again. This arrangement ensures that the desiccant to be regenerated is dried entirely and will not get oversaturated in case the working cycle is displaced. The air dryer unit is controlled in such a way that compressed air can always continue flowing through one of the desiccant towers, even if the shuttling facility works irregularly. Rating See Fig. 8 The desiccant towers and the regeneration air choke orifice must be sized to ensure that − above a certain ambient temperature limit − the relative humidity of the dried air is always below 35%. The performance of an air dryer unit depends on the amount of desiccant used and on the regeneration air consumption. It is described by the following parameters: S S S S S Compressor’s volumetric intake Working pressure Air inlet temperature Ambient temperature limit Working cycle

The ratio of desiccant quantity to regeneration air consumption is optimized for the conditions under which the air dryer units are required to operate in rail vehicles.

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Please observe the following notes on the ambient temperature limit. It is not advisable to rate an air dryer unit for ambient temperatures below −30°C if such values occur just rarely within the vehicle’s range of operation. KB SfS dual-chamber air dryer units are engineered to yield a pressure dew point reduction of at least 10°C relative to ambient temperature (see Fig. 8). At ambient temperatures below -30°C there is very little risk of corrosion due to elevated humidity; this means the air dryer units can be operated at levels as low as -40°C without any thought of danger. The duplex piston valve in the model LTZ 011-H and LTZ012-H air dryer units is heated by a thermostat-controlled cartridge heater to prevent it from freezing. The condensate can therefore be discharged reliably to the drainage outlet under all conditions. To keep the air dryer units performing at their most efficient level, you should ensure that their air inlet temperature is not much above ambient temperature and never exceeds 60°C. Fig. 8 Relationship between pressure dew point, ambient temperature and relative humidity
X Y ϕ Ambient temperature (°C) Pressure dew point (°C) Relative humidity (%)

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5

Removal and installation

DANGER Beware of a moving vehicle! A vehicle allowed to move inadvertently will cause personal injury. It is vital to observe the working rules for arresting a vehicle.

5.1

Installation

CAUTION Beware of contaminating the pneumatic system! Device and/or system functions will fail. Keep out dirt during installation. If necessary, blow out the pipes of the pneumatic system. CAUTION Beware of disregarding the installation instructions! Safety will be diminished and functions restricted. Installation instructions and installation drawings must be taken into account. CAUTION Beware of installing untested units! Safety will be diminished and functions restricted. Make sure that units are always tested before they are installed. The system must have been tested and found to be in order before the vehicle is cleared for service. NOTE It is vital to observe the maker’s safety instructions and directions for the use of cleaning substances, sealants, adhesives, auxiliary products, working substances, etc.

5.1.1

Requirements See Fig. 9 The unit can be installed with standard tools. The unit is designed for installation anywhere in the sprung part of a vehicle, provided it is protected from wet and dirt. The place of installation must be defined accordingly when the vehicle is being engineered.

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To keep the air dryer units performing at their most efficient level, you should ensure that their air inlet temperature (A1) is not much above ambient temperature. On no account may the air dryer unit be installed in the immediate vicinity of sources of heat that might additionally elevate the desiccant temperature. A good aftercooler (N) downstream of the compressor (K) lowers the air inlet temperature and, hence, the temperature of the desiccant as well. However, the desiccant should not fall below a temperature of +10°C. Fig. 9 shows how an effective aftercooler influences the temperature and water content of the air prior to entering the air dryer unit. At +50°C inlet temperature, the air still contains 83 g/m3 water, but only 23 g/m3 at +25°C. Fig. 9 Construction of an air supply system (schematic)

a b T W

Poor aftercooler Good aftercooler Temperature (°C) Water content (g/m3)

K N

Compressor Aftercooler

LTZ HL

Air dryer unit Pipe to main reservoir

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The supply line from the compressor to the air dryer unit must be rustproof steel. Before attaching any piping to an air dryer unit, take care to remove all traces of dirt, scale and chippings from inside this piping. The installation drawing of the unit contains mandatory notes on the mounting position and necessary clearances. The vehicle builder’s documents on installation − especially the data on fastening screws and tightening torques − must also be observed. 5.1.2 Procedure See Fig. 4 WARNING Beware of electric shock! Danger of physical injuries that may have fatal consequences. Before starting work, switch off the power supply to the electric connection and prevent it from being restored without due authorization. S S S S Prior to installing the dual-chamber air dryer unit, thoroughly clean the sealing surfaces and threads. Carefully blow off and blow out the pipes with compressed air to remove and expel any trace of dirt. Locate the air dryer unit on the onboard rack and attach by its fastening screws. Connect the pipes for compressed air inlet and compressed air outlet to the air dryer unit.

NOTE Connect the electric circuits correctly. Refer to the applicable vehicle documents, the circuit diagram of the unit, and the circuit diagrams valid for each of the component assemblies. S S S S Connect the ground circuit between the air dryer unit (see ground tag) and vehicle rack. Detach housing (57), run the onboard connecting cable through the bracket and connect as shown in the circuit diagram. Re-attach housing (57). Version with a connector: Plug in the connector.

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5.1.3

Leakage testing WARNING Beware of electric shock! Danger of physical injuries that may have fatal consequences. The work of testing a unit equipped with electric components must always be left to specially trained and authorized personnel. Never allow a leakage testing substance to get into contact with electrically live components. Carry out the leakage test by applying a leakage testing substance. The test may be performed alternatively with a soap solution if no such special products are available. S S Test the pipe connections for leakage at the maximum acceptable working pressure. Air bubbling is unacceptable. Leakage testing substances and all traces of soap must be removed immediately after the test.

5.1.4

Function testing The unit is an integral part of a system and must be tested for correct interaction with this system in the manner instructed by the railway administration / vehicle builder.

5.2

Removal

WARNING Pneumatic system is under high pressure! Particles flung outwards will, for instance, cause severe eye injuries. Observe the safety regulations for pneumatic systems. Prior to removal, unload the pressure from the (sub-)system. CAUTION Beware of contaminating the pneumatic system! Device and/or system functions will fail. Keep out dirt after removal, such as by masking the ports.

5.2.1

Requirements The unit can be removed with standard tools.

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5.2.2

Procedure See Fig. 4 WARNING Beware of electric shock! Danger of physical injuries that may have fatal consequences. Before starting work, switch off the power supply to the electric connection and prevent it from being restored without due authorization. S S S S Turn off the supply of compressed air and entirely vent all the air pipes connected to the unit. Switch off the power supply and prevent it from being restored. Do not allow electric power to reach the air dryer unit any longer. Unplug the connector from the mating socket. If your version does not have a connector, detach housing (57) from the air dryer unit, disconnect the onboard connecting cable and then re-attach housing (57). Disconnect the pipes for compressed air inlet and compressed air outlet from the air dryer unit. Disconnect the ground circuit between the air dryer unit and vehicle frame. Remove the fastening screws and lift the air dryer unit off the onboard rack. Cover up the ports of the air dryer unit. Cover up the onboard air pipes unless a replacement air dryer unit is going to be fitted immediately after removal.

S S S S S

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6

Maintenance
Maintenance at KB SfS is basically subdivided into: S Inspection S Servicing S Repair S Overhaul The maintenance intervals required for the activities described below must be timed according to the statutory operating requirements, the service conditions under which the unit is used, and the environmental influences in the area where the vehicles are run. An interval stated generally for all projects will therefore be of only limited validity. KB SfS has the capacity to test the state of its products regularly during their lifetime. The aim of this service is to find jointly with the customer the best maintenance interval for each individual project. The interval applicable to a specific project can be derived from the targets named in the table. The first target is always more significant than the successively lesser targets. The following tables contain an overview of the necessary maintenance activities.

6.1

Inspection The unit must be checked for good external condition and correct operation at regular intervals as specified by the vehicle operator.

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6.1.1

Interval Activity Function testing (the cycle timer must be inspected and the main reservoir checked for water) Making sure that the silencer’s regeneration air outlet K3 is clear Interval 1. According to vehicle operator’s project-specific experience 2. In accordance with project-specific maintenance schedule, if any (*) For all item 3. According to vehicle operator’s project-spe- numbers covcific experience ered by the validity 4. In accordance with project-specific maintenance schedule, if any (*) Valid for

Function test5. Once a year before winter starts ing with a pressure dew point meter**
* If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the customer and KB SfS. ** Activity is recommended (see Fig. 10)

6.1.2

Special tools Item number II 51382 Name Pressure dew point meter

6.1.3

Procedure See vehicle operator’s instructions

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Fig. 10

Measuring the pressure dew point

B DM

Main reservoir Pressure dew point meter

F K

Micromesh oil filter Compressor plus aftercooler

L S

Air dryer unit Safety valve

The air dryer unit can be monitored accurately for correct operation using a pressure dew point meter (see Fig. 10). The dew point reading must be below the boundary curve of 35% relative humidity at the prevailing ambient temperature.

6.2

Servicing Servicing the air dryer units named in the present Description is confined to changing the filter cartridges (1, Fig. 2) in units LTZ011 and LTZ011-H.

6.2.1

Interval Activity Changing the filter cartridges Interval 1 year 1. In accordance with project-specific maintenance schedule, if any (*) LTZ011, LTZ011-H Valid for

*

If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the customer and KB SfS.

6.2.2

Special tools Strap wrench to release filter cartridges (1, Fig. 2)

6.2.3

Procedure Change the filter cartridges in accordance with Section 6.3.

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6.3

Repair Please contact a KB SfS Service Center if the unit develops a malfunction that cannot be corrected by the measures described in Section 7.2. Notes on repair, exchanging the desiccant The desiccant will not need exchanging if it gets oversaturated as a result of a malfunction in the air dryer unit, e.g. a cycle timing failure. The desiccant is regenerated automatically as soon as the unit starts to work normally again. Depending on the degree of oversaturation, the unit may take several hours of compressor air delivery until it has fully recovered. The main reservoir will have to be well drained if large amounts of water have collected there after an air dryer failure. The life of the desiccant is virtually unlimited under good service conditions. As a rule, it will be sufficient to exchange the desiccant of units LTZ012 and LTZ012-H at the time of the main vehicle inspection. However, the desiccant may have to be exchanged prematurely if it is severely contaminated by dirt and oil.

6.3.1

Auxiliary products and working materials The following auxiliary products and working materials are needed; they can be purchased from KB SfS by their order numbers (where stated): S S S S Chemical cleaning spirit for aluminium alloys, eroding less than 420 mg/(m2 h) Grease (order number: ID No. 502647) for LTZ012, LTZ012-H: Desiccant (order number: ID No. 503328 or ID No. 503329), see related parts list for LTZ011, LTZ011-H: Filter cartridge (item number II17793)

6.3.2

Special tool for dual-chamber air dryer units LTZ012, LTZ012-H S Special tool according to Fig. 11

Special tools can be purchased from KB SfS by their order numbers (where stated). Special tools without an order number must be made to the specifications in the figures. The dimensions specified in the figures are mandatory values. Unspecified dimensions are left to the toolmaker’s discretion.

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Fig. 11

Thrust member (D)

C11220/3

6.3.3

Procedure The towers (1) or filter cartridges (1) must be removed before the desiccant can be exchanged. If lack of space makes this impossible while the air dryer unit is still on board, the air dryer unit will have to be removed in accordance with Section 5.2. DANGER Beware of a moving vehicle! A vehicle allowed to move inadvertently will cause personal injury. It is vital to observe the working rules for arresting a vehicle. WARNING Pneumatic system is under high pressure! Particles flung outwards will, for instance, cause severe eye injuries. Prior to removal, unload the pressure from the (sub-)system and observe the safety regulations for pneumatic systems. CAUTION Beware of contaminating the pneumatic system! Device and/or system functions will fail. Keep out dirt after removal, such as by masking the ports.

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WARNING Pretensioned spring (spring force up to about 400 N)! Pretensioned springs may jump abruptly out of the housing and cause, say, severe eye injuries. Perform all the working steps in the specified sequence and use no tools other than named. CAUTION Undue disposal of substances harmful to the environment! This would mean unnecessary and legally punishable harm to the environment. Observe the officially applicable waste disposal regulations. CAUTION Beware of incorrect handling! Malfunctions and/or leakage due to damaged sealing surfaces. Take care not to damage the sealing surfaces in the course of dismantling, assembling and cleaning the unit. Exchanging filter cartridge (1) (LTZ011, LTZ011-H) S S S Turn off the supply of compressed air and entirely vent all the air pipes connected to the unit. Switch off the power supply and prevent it from being restored. Do not allow electric power to reach the air dryer unit any longer. Exchange the filter cartridges. Use a strap wrench to release the filter cartridge.

Dismantling the towers (LTZ012, LTZ012-H) See Fig. 4, 11, 12, 13 and 14 S S S S S S S S S Turn off the supply of compressed air and entirely vent all the air pipes connected to the unit. Switch off the power supply and prevent it from being restored. Do not allow electric power to reach the air dryer unit any longer. Release bolt (1.5), and remove tower (1) from the bracket. Turn over the tower (1) and put down on the press bed. Apply thrust member (D) to spring retainer (1.12). Lower the press punch onto thrust member (D), and adjust the press force to 480 N. Unscrew the unloaded nut (1.13). Slowly draw back the press punch and remove the unloaded compression spring (1.11). Dismantle the tower (1) (see Fig. 14).
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Fig. 12

Removing and installing the compression spring

1.1 Tower 1.11 Compression spring

1.12 Spring retainer 1.13 Nut

D

Thrust member

CAUTION Undue disposal of substances harmful to the environment! This would mean unnecessary and legally punishable harm to the environment. Observe the officially applicable waste disposal regulations. S Tip out and discard the desiccant (1.6).

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Cleaning the component parts WARNING Beware of using auxiliary products and working materials incorrectly! The skin or respiratory tracts may be harmed or inflamed. It is vital to observe the maker’s safety codes and directions for use. NOTE Prior to putting components in a bath for cleaning, check them for compatibility with the chemical cleaning spirit. Any component suspected of attack by the chemical cleaning spirit must be handled and cleaned like a non-metallic part. S Clean all metal parts with chemical cleaning spirit in a bath at 70°C to 80°C and then blow dry with compressed air. Read the notes and details on cleaning substances in Section 6.3.1. Clean all non-metallic parts with a cold cleaning substance and wipe dry with a cloth.

S

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Fig. 13

Removing and installing the tower (1)

1 (1) 2

Tower Filter cartridge O-ring

3 4

O-ring Ring

5 21

O-ring Bracket

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Fig. 14

Tower (1)

1.1 1.2 1.3 1.4 1.5

Tower Washer O-ring Strainer Bolt

1.6 1.7 1.8 1.9 1.10

Desiccant Retaining ring Strainer Raschig rings Bowl

1.11 1.12 1.13 1.14

Compression spring Spring retainer Nut Sign

Filling up with desiccant S S Put strainer (1.4) in tower (1.1). Close the pipe opening (see Fig. 15) and fill up with desiccant.

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S

Compact the desiccant by tapping the tower wall gently with a rubber-headed hammer while simultaneously turning the tower to and fro.

CAUTION Beware of assembling the unit incorrectly! The unit might malfunction or its performance be impaired. To operate the air dryer unit correctly, fill the towers with enough desiccant to locate the bottom of bowl (1.10) 37mm below the tower rim (see Fig. 15).

Fig. 15

Filling up with desiccant

C11220/2

*

Close the tube opening

Assembling the tower (1) See Fig. 4, 11, 12, 13 and 14 S S S Assemble the tower (1) in the reverse sequence to disassembly. Lubricate O-rings (2) and (3) and O-ring (5) with a thin film of grease. Insert a new greased O-ring (1.3) and washer (1.2), and attach tower (1) to bracket (21) by bolt (1.5); tightening torque 200 Nm.

NOTE Drain and dry the main reservoir after the desiccant has been exchanged, yet before the air dryer unit is returned to service. S Carry out the leakage test in accordance with Section 5.1.3.

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6.4

Overhaul KB SfS gives top priority to safety and quality. To guarantee this claim, KB SfS offers to overhaul its own products. KB SfS performs overhauls in its capacity as the original equipment manufacturer, while accounting for the safety aspects of the production processes. The KB SfS Service Centers have the experience and technical equipment needed for performing professional overhauls.

6.4.1

Interval To judge when overhauls are required under the actual service conditions, you are urged to inspect a few randomly selected units for functionality and condition after a sufficient period of operation, and dismantle them to check for wear. Activity Interval 1. According to vehicle operator’s project-specific experience Overhaul 2. In accordance with project-specific maintenance schedule, if any (*)

*

If a project-specific maintenance schedule is drawn up, it must be worked out jointly by the customer and KB SfS.

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7

Troubleshooting
If the unit starts to malfunction, trace possible problems on board. Causes of trouble can be corrected with the help of the directions proposed for debugging.

7.1

Special tools Not required

7.2

Procedure

Problem Air dryer unit inoperative

Cause

Remedy

Unit not being acti- Test the unit for correct pneumatic vated pneumatically control. Unit not being activated electrically Test the unit for correct electric control. Tighten the air pipe connections and test for leakage in accordance with Section 5.1.3. Exchange the desiccant as described in Section 6.3. Thaw out the duplex piston valve. Remove the unit as described in Section 5.2 and ship to a KB SfS Service Center for repair.

Air discharging constantly from the air pipe connections White coating forming at regeneration air outlet K3 Only for LTZ011-H, LTZ012-H: MR pressure not rising, although compressor is running

Air pipe connections leaking Desiccant is no longer good Air dryer frozen because heater has failed

Regeneration air not Unit defective discharging from the silencer’s regeneration air outlet K3 while the compressor is delivering air

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Problem

Cause

Remedy Remove the unit as described in Section 5.2 and ship to a KB SfS Service Center for repair.

Strong stream of air Unit defective from the silencer’s regeneration air outlet K3 (provided the air dryer unit is working correctly, regeneration air must be discharged as usual while the compressor is delivering air) Air discharging constantly from exhaust port O2 (provided the air dryer unit is working correctly, a short blast of air must be discharged at intervals of 4 minutes every second time the valve magnet toggles while the compressor is delivering air) Valve magnet (43) not toggling while the compressor is delivering air (the working cycle must be 2 minutes) and air not discharging from exhaust port O2 Air discharging constantly from exhaust port (O1) Pressure dew point above the boundary curve of 35%
*

Desiccant dirty

Exchange the desiccant as described in Section 6.3.

Observe the following note on disposal.

CAUTION Undue disposal of substances harmful to the environment! This would mean unnecessary and legally punishable harm to the environment. Observe the officially applicable waste disposal regulations.

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Notes:

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D

Knorr-Bremse Systeme für Schienenfahrzeuge GmbH Moosacher Str. 80 80809 Munich Germany Phone: +49 89 3547-0 Fax: +49 89 3547-2767 Knorr-Bremse GmbH Beethovengasse 43-45 2340 Mödling Austria Phone: +43 2236 409-0 Fax: +43 2236 409-412 Oerlikon-Knorr Eisenbahntechnik AG Mandachstrasse 50 8155 Niederhasli Switzerland Phone: +41 44 852-31 11 Fax: +41 44 852-31 31 Knorr-Bremse Rail Systems (UK) Ltd. Westinghouse Way, Hampton Park East Melksham, Wiltshire SN12 6TL United Kingdom Phone: +44 1225 898 700 Fax: +44 1225 898 705 Knorr-Bremse Vasúti Jármû Rendszerek Hungária Kft. Helsinki út 86. 1201 Budapest Hungary Phone: +36 1 421 1100 Fax: +36 1 421 1192 Sociedad Española de Frenos Calefacciõn y Señales, S.A. Nicolás Fúster, 2 28320 Pinto (Madrid) Spain Phone: +34 91 69 10-054 Fax: +34 91 69 10-100 Freinrail Systèmes Ferroviaires S.A. 47-49 rue Gosset BP 185 51057 Reims Cedex France Phone: +33 3 2679-7200 Fax: +33 3 2679-7201 Frensistemi S.r.l. Via della Cupola, 112 50145 FLorence Italy Phone: +39 055 3020-1 Fax: +39 055 3020-333 Knorr-Bremse Nordic Rail Services AB Traktorvägen 8 226 60 Lund Sweden Phone: +46 46 3293-50 Fax: +46 46 1489-71

USA

New York Air Brake Corporation 748 Starbuck Avenue Watertown, NY 13601 USA Phone: +1 315 786-52 00 Fax: +1 315 786-56 76 Knorr Brake Ltd. 675 Development Drive Kingston, Ontario K7M 4W6 Canada Phone: +1 613 389-46 60 Fax: +1 613 389-87 03 Knorr-Bremse Sistemas para Veículos Ferroviários Ltda. Av. Engenheiro Eusébio Stevaux, 1071 Jurubatuba, 04696-902 São Paulo Brazil Phone: +55 11 5681-1129 Fax: +55 11 5686-8344 Knorr-Bremse (SA) (Pty) Ltd. 3 Derrick Road (Corner Chestnut Road) 1619 Spartan South Africa Phone: +27 11 961-7800 Fax: +27 11 975-8249 Knorr-Bremse India Private Ltd. 14/6 Mathura Road Faridabad-121003 Haryana India Phone: +91 129 227-64 09 Fax: +91 129 227-59 35 Knorr-Bremse Rail Systems Japan Ltd. Nishiikebukuro TS Bldg., 8F 3-1-15 Nishiikebukuro Toshima-ku Tokyo, 171-0021 Japan Phone: +81 3 53 91-10 13 Fax: +81 3 53 91-10 22 Knorr-Bremse Asia Pacific (Holding) Ltd. Suite 2901, 29/Fl Central Plaza 18 Harbour Road Wanchai Hong Kong China Phone: +852 2861-2669 Fax: +852 2520-6000 Knorr-Bremse Rail Systems Korea Ltd. 6th Floor, Bongwoo Bldg. 31-7, 1 Ka, Changchung-Dong, Choong-Ku Seoul 100-391 Korea Phone: +82 2 22 80-55 55 Fax: +82 2 22 80-55 99 Knorr-Bremse Australia Pty. Ltd. 1/2D Factory Street Granville NSW 2142 Australia Phone: +61 2 8863-6500 Fax: +61 2 9897-9980
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Systeme für Schienenfahrzeuge GmbH
Moosacher Str. 80 · 80809 München · Germany · Phone +49 89 3547-0 Fax +49 89 3547-2767 · Homepage http://www.knorr-bremse.com Printed in Germany.

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