In Canada Contact CAG Purification Inc.

[Link]

Heatless Desiccant Dryers

Installation, Operating and Maintenance Manual

All models (PD004 - PD365)

EN
The product to which this manual refers must not be supplied, installed,
used, operated or serviced until the contents of the manual has been
fully read and understood by all relevant personnel.

Please complete the following information at the time of installation

found on the rating label on the upper right hand side of dryer

Model Number

Serial Number

Regulated Inlet Pressure

Filtration present with Dryer

Outlet Flow of Dryer

Compressor Outlet Flow

Supply Voltage

When contacting Walker Filtration regarding this product, please have

the above stated information at hand to speed up your query.
Contents

1 Safety 4
Safety Guidelines 4
Symbols 5
2 General Description 6
Function of the Dryer 6
Package Contents 7
3 Mechanical Installation 10
4 Electrical Installation 16
5 Operation 19
Start-Up 19
Shut Down 20
6 Maintenance 23
Servicing 23
Purge Plug 28
Exhaust 30
Replacing Shuttle Valves 36
7 Energy Management 38
8 Troubleshooting 44
9 Technical Data 48
10 Component Parts 51
11 Spares Information 56
12 Warranty 58
13 Declaration of Conformity 59
Section 1: Safety

Safety

The following safety guidelines must be • If carrying out installation work above head height, use
strictly observed. suitable and safe working platforms or other means of
working access.
• Do not make any constructional changes to the product.
• Leave this manual at the place of installation of
Any changes or modifications may only be carried out by
the product.
the manufacturer, Walker Filtration.
• It is essential that only Walker Filtration or it’s appointed
• Any faults or defects that could affect safety must be put
agents carry out maintenance and servicing work.
right fully before using the unit.
Users, maintenance and servicing personnel must be familiar • Used items and materials must be disposed of in the
with: correct manner, complying with local laws and regulations,
• Accident prevention regulations. in particular the desiccant cartridge.
• Safety information (general and specific to the unit).
• Safety devices of the unit.
• Measures to be taken in case of an 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 meet
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.

Pro Dry Instruction Manual | Walker Filtration | [Link] 4

Section 1: Safety

Figure 1.1: Definition of symbols

Manual Handling

As with all areas of the workplace, Health and Safety is of

great importance and must be given due care and attention.
While working with this equipment, manual handling
regulations must be considered and adhered to.
Full advice, support and guidance should be detailed in your
Health and Safety Policy and Manual Handling guide, please
take the time to familiarise yourself with these documents.
The Manual Handling Operations Regulations apply to a wide
Risk of Danger Risk of Electric Shock
range of manual handling activities, including lifting, lowering,
pushing, pulling or carrying.
We ask every person handling this product to take the
responsibility for their own Health and Safety and the Health
and Safety of others around them. If you feel there is a
significant risk, you must take steps to either remove the risk
altogether, or reduce the risk prior to carry out the activity. If
you need further support or guidance with this, please consult
your line manager or the HR Department.
There are safe systems of work and correct procedures in
relation to manual handling, please consult these documents
available within the workplace.
We ask everyone handling this product to:
• Follow appropriate systems of work laid down
Risk of High Pressure Warning for their safety.
• Make proper use of any equipment provided for
their safety.
• Inform the company if they identify hazardous
handling activities.
• Take care to ensure that their activities do not put
others at risk.

If in doubt, please seek further advice and ensure you always

follow the correct procedures and guidance.

For more information please see our Health and Safety

manual attached.
Equipment Protected by Important Note When used in the UK, a 3 amp fuse should be fitted as per the
Double Insulation wiring diagram (figure 4.4).

Pro Dry Instruction Manual | Walker Filtration | [Link] 5

Section 2: General Description

General Description

This manual is valid for the following dryer models

PD004 PD006 PD008

PD010 PD015 PD025
PD035 PD045 PD055
PD065 PD085 PD105
PD135 PD175 PD215
PD275 PD365

Function of the Dryer

Pro Dry is designed to provide a smooth, controlled and

uninterrupted delivery of dry compressed air. Wet air passes
through a pre-filter and travels down to the bottom valve
assembly. The air is then fed through the bottom of the
desiccant bed and moves through the high performance
desiccant until it becomes dry. On exit from the desiccant
cartridge, the air is passed through the outlet valve assembly.
During this process, the dryer control system cycles the process
air between the two desiccant towers. While one chamber is
on stream removing water vapour, the other is being carefully
depressurised in preparation for regeneration. The desiccant
bed is regenerated by expanding a small amount of dry
process air, or purge air, through the saturated desiccant.
Purge air passes to atmosphere through the silencer, which is
fitted to an exhaust valve. The chamber is then repressurised,
with the control system assuring each chamber is at full
operational pressure prior to changeover.
This ensures a reliable and efficient operation. The air stream is
switched and the cycle repeats on a continuous basis.

Pro Dry Instruction Manual | Walker Filtration | [Link] 6

Package Contents

The dryer is delivered in protective packaging. Take care when transporting, loading and unloading the unit.
The package contains the following items (refer to figure 2.1):

1. Dryer unit (6 SCFM shown)

2. Instruction manual (including certificate of conformity)
3. Power connector

Figure 2.1: Package contents

1 4

Pro Dry Instruction Manual | Walker Filtration | [Link] 7

Section 2: General Description

Figure 2.2: Models PD004 – PD035

15

13

16

12

10

1
14
11

18 19

20

17
2

4
8

5
9 7

1. Top valve assembly 8. Pressure housing 15. Banjo fixing bolt

2. Control unit 9. Pressure housing retaining bolt 16. Pressure seal
3. Bottom valve assembly 10. Desiccant cartridge comes with dust filter 17. Exhaust silencer
4. Dryer base 11. Multiport manifold 18. Purge plug
5. Bottom valve fixing bolt 12. Top cover 19. Purge plug fixing screw
6. Front panel 13. Top cover fixing screw 20. Prefilter
7. Front panel fixing screw 14. Rear panel

Pro Dry Instruction Manual | Walker Filtration | [Link] 8

Section 2: General Description

Figure 2.3: Models PD045 – PD365

11

10

16

13

6
1

14

15

3
12

* Models PD215 – PD365 are duplex

1. Inlet valve assembly 7. Desiccant cartridge c/w dust filter 13. Back panel
2. Bottom valve assembly 8. Pressure housing retaining bolt 14. Air transfer down-pipe
3. Exhaust valve assembly 9. Quadra-port manifold retaining bolt 15. Silencer
4. Control/valve unit 10. Quadra-port manifold top cover 16. Prefilter
5. Quadra-port manifold 11. QPM fixing screw
6. Pressure housing 12. Front panel

Pro Dry Instruction Manual | Walker Filtration | [Link] 9

9
Section 3: Mechanical Installation

Mechanical Installation

Connecting the pre-filter to the dryer Figure 3.1: Connecting pre-filter

• PD004-PD035, Utilise O Ring and bolt supplied to

assemble filter as per figure 3.1.
• PD045-PD365, Attach pre filter utilising nipple supplied.
• Fit 4mm (5/32”) black tubing to filter and drain valve inlet.
• Pipe away condensate with 4mm (5/32”) tubing from
drain outlet. Ensure condensate is drained into an oil/
water separator.
• Fit any further filtration or ancillary equipment.
• Drain kits supplied with dryer and comprise of the
following: Swivel elbow adapter and 4mm tubing.

All tubing should be secured up to the point of drain to

prevent whipping during discharge.

It is recommended that a bypass line including filter is

installed, as per figure 3.13
Figure 3.2: Connecting filter drain

1
1

2
2

1. Inlet
2. Outlet

Pro Dry Instruction Manual | Walker Filtration | [Link] 10

Section 3: Mechanical Installation

Orientation Figure 3.3: Horizontal orientation

The Pro Dry range of dryers is designed to operate in both

vertical and horizontal orientation.

Figure 3.4: Vertical orientation

Pro Dry
Pro Dry Instruction
Dry Instruction Manual
Manual ||| Walker
Instruction Manual Walker Filtration || [Link]
Walker Filtration 11
Pro 11
11
Section 3: Mechanical Installation

Reconfiguration of the inlet / outlet ports Figure 3.5: Inlet/outlet ports C

F
E
D A

PD004 – PD035 models only D

Pro Dry has three ports on the inlet (A, B and C) and three E

ports on the outlet (D, E and F). Any of the three can be A
used for inlet (A, B or C) and outlet (D, E or F). Make sure the
remaining two are blanked off with provided pressure plugs. F

Dryer can be reconfigured to interchange position of inlet and

outlet ports (Figure 3.6).
C
B

Directional arrows are etched into the inlet manifold.

Any / all of the three outlet ports can be used on occasion.
Please ensure combined flow at outlet should not exceed
specification. Please adhere to regional regulations.
It is strongly advised to connect a non-return valve to each
outlet used.
Only use one inlet port at any one time Figure 3.6: Reconfiguration of inlet/outlet ports
Ensure original seals are in place.
Check dryer is leak-free prior to operation.

D
Tools required E

• 4mm hex key

• 6mm hex key

Pro Dry Instruction Manual | Walker Filtration | [Link] 12

Section 3: Mechanical Installation

Figure 3.7: Level ground

Figure 3.8: Drainage (all tubing should be secured up to the point of drain to prevent whipping during discharge)

Pro Dry Instruction Manual | Walker Filtration | [Link] 13

Section 3: Mechanical Installation

Figure 3.9: Location

Figure 3.10: Hard piped installation

Figure 3.11: Exposure to heat

MaxMax
50OC50OC >Max>Max
50OC50OC
Max
(122
Max 5050
(122
O
CF)O
O O
F)OC50 >Max
(122
>Max F)50
(122
O
50
OO
CO
O F)
C50
Max C >Max C
(122
O F) O
O

(122(122
F) F) (122
O F) O
O

(122(122
F) F)

Pro Dry Instruction Manual | Walker Filtration | [Link] 14

Section 3: Mechanical Installation

Figure 3.12: Direction of flow

Figure 3.13: Typical installation

To prevent back flow into the dryer a non-return valve should be placed
in-line, downstream of the dryer. This is essential when more than one dryer
is used in a single application.

Pro Dry Instruction Manual | Walker Filtration | [Link] 15

Section 4: Electrical Installation

Electrical Installation

Connection
Power Supply

The dryer is designed to operate on either AC or DC supply

voltage. Supply Amp

Electrical wiring must comply with local regulations. Voltage 12 VDC 0.80
requirements must be confirmed to be within the specification
24 VDC 0.40
on the dryers rating plate.
100 VAC 0.16
Ensure only one power source is connected at any one time
and is connected to the correct socket as shown in figure 4.3 115 VAC 0.14
and 4.4. 230 VAC 0.07
The dryer controller is double insulated therefore no earth 240 VAC 0.07
is required on the power connector. External fuse to be
connected to plug.
The cable selection must suit local installation regulations and
be appropriate to power consumption as shown in the Power
Supply table.

How to wire a power connector Figure 4.1: Din connector

Figure 4.1 illustrates how to wire power connector. Please

EARTH
refer to wiring diagram, figure 4.2, page 17, for further
information.
GASKET
1 (+)
LIVE

2 (-)
NEUTRAL

Pro Dry Instruction Manual | Walker Filtration | [Link] 16

Section 4: Electrical Installation

Different voltage setting

Figure 4.2: Wiring diagram

-
+

RIGHT

+ (Pin 1)

- (Pin 2)

Figure 4.3: 100 to 240 VAC Figure 4.4: 12 to 24 VDC

Pro Dry Instruction Manual | Walker Filtration | [Link] 17

Section 4: Electrical Installation

Controller Description

Controller Specification

Ambient temperature 1.5°C to 50°C (35°F to 122°F)

Max. relative humidity 80% up to 31°C, decreasing linearly to 50% RH at 50°C
Input voltage range 100–240VAC, 50–60Hz, 12–24VDC
Mains supply voltage not to exceed ±10% of nominal
Protection class IP65
Transient over voltage IEC 60664 Class II
Pollution degree 2, IEC 60664

For energy and alarm installation management please see

section 8

A circuit breaker or switch must be installed near the dryer.

This should be easy to reach and shall be certified according
to EN60947-1 and EN60947-3. The switch or circuit breaker
shall be marked as the disconnecting device for the dryer
and needs to be marked with on and off positions.
Output connections do not provide isolation from the mains
connectors and interconnecting wiring must meet EN61010-
1:2001 requirements for reinforced insulation.

Pro Dry Instruction Manual | Walker Filtration | [Link] 18

Section 5: Operation

Operation

Background / Function of the dryer green.

b. After 120 seconds, tower LED X switches off and drain
LED Z illuminates green.
The dryer operation is designed to give smooth, uninterrupted
delivery of compressed air to the designated specification. c. After a further 50 seconds drain LED Z switches off and
tower LED Y illuminates green.
During the cycle of operation, the first pressure housing is
d. After a further 120 seconds, tower LED Y switches off.
fully pressurised and airflow is directed upwards through the
desiccant cartridge, removing moisture from the air during its e. After a further 50 seconds, tower LED X illuminates green
passage, to the minimum specified dewpoint. - this is point ‘a’ in the cycle described above.
The above cycle (a – e) repeats.
During the drying cycle, a small bleed of process air is directed
to the opposite pressure housing. This process air flows down On initial commissioning only run the dryer for a minimum
through the desiccant cartridge and into the atmosphere by of 6 hours to ensure dewpoint is adequate. Thereafter,
means of an exhaust silencer, thereby affecting regeneration continue directly to next point.
of the desiccant. Open valve B slowly.
After 120 seconds of operation, the cartridge under
regeneration is sealed by closing of the exhaust valve and the Start-up procedure PD045 - PD365
pressure housing is brought up to full system pressure by the
purge air.
• See figure 5.1 and 5.2.
After an extended time (See start-up procedure for individual • Close valves A, B, C and D.
sizes) the pressure in the first housing is released into the
• Switch on compressor.
atmosphere by means of the corresponding exhaust valve and
the desiccant cartridge then operates in regeneration mode. • Open valve A slowly.
The main air flow and drying function is then transferred • Check there are no leaks from the dryer.
to the desiccant cartridge that was previously under • Switch on electric power. All four display panel LED’s will
regeneration. flash simultaneously green four times then simultaneously
The cycle of operation continues in this pattern with red four times to acknowledge application of power
the cartridges switching alternately between drying and and readiness to function. Observe display panel for one
regenerating. complete cycle. Note: cycle described is factory setting.
a. Power LED illuminates green and tower LED X illuminates
green.
Start-up procedure PD004 - PD035 b. After 120 seconds, tower LED X switches off and drain
LED Z illuminates green.
• See figure 5.1 and 5.2. c. After a further 20 seconds drain LED Z switches off and
• Close valves A, B, C and D. tower LED Y illuminates green.
• Switch on compressor. d. After a further 120 seconds, tower LED Y switches off.
• Open valve A slowly. e. After a further 20 seconds, tower LED X illuminates green
- this is point ‘a’ in the cycle described above.
• Check there are no leaks from the dryer.
The above cycle (a – e) repeats.
• Switch on electric power. All four display panel LED’s will
flash simultaneously green four times then simultaneously On initial commissioning only run the dryer for a minimum of
red four times to acknowledge application of power 6 hours to ensure dewpoint is adequate. Thereafter, continue
and readiness to function. Observe display panel for one directly to next point.
complete cycle. Note: cycle described is factory setting. Open valve B slowly.
a. Power LED illuminates green and tower LED X illuminates

Pro Dry Instruction Manual | Walker Filtration | [Link] 19

Section 5: Operation

Shut-down Procedure

• Close valve B.
• Close valve A.
• Leave dryer running for 15 minutes to fully de-pressurise.
• Switch off all electrical power to the dryer.

Under no circumstances must compressed air be allowed

to flow through the dryer following switch off of electrical
power. This will result in terminal failure of the desiccant
cartridges and regeneration will not be possible.

Figure 5.1: Typical installation

C D

A B

Figure 5.2: Controller description

X Y X Left tower regenerating (Right tower drying)

Y Right tower regenerating (Left tower drying)
Z Drain solenoid
Power Power connected to controller
Z POWER

Pro Dry Instruction Manual | Walker Filtration | [Link] 20

Section 5: Operation

Figure 5.3: Process & Instrumentation diagram (PD004 – PD035)

1. Air inlet
2. Connecting tube
3. Inlet shuttle valve
4. LH desiccant bed
5. LH built in dust filter
6. Outlet shuttle valve
7. Air outlet
8. RH exhaust valve 2/2 NC
solenoid valve
9. Exhaust silencer
10. Purge valve
11. RH desiccant bed
12. RH built in dust filter
13. LH exhaust valve 2/2 NC
solenoid valve
14. Left diaphragm control valve
15. Right diaphragm control valve

Note: Diagram shown in one of

six possible positions, Left Tower
Drying, Right Tower Purge.
Certain feature are intentionally
shown out of position for reasons
of clarity.

Stage Time (Seconds) SV Valve Status Dryer Operation

1. 0 Left valve closed, right valve opens Left tower at pressure (drying), right tower depressurises and
Then purges (this stage is shown on pd1 pneumatic schematic)
2. 120 Both valves closed Right tower repressurising

3. 170 Left valve opens, right valve closed Left tower depressurises and then purges, right tower at pressure
(drying)
4. 290 Both valves closed Left tower repressurising
340 Back to stage 1 -

Pro Dry Instruction Manual | Walker Filtration | [Link] 21

Section 5: Operation

Figure 5.4: Process & Instrumentation diagram (PD045 – PD365)

1. Air inlet
2. Down pipe
3. Inlet shuttle valve
4. LH desiccant bed
5. LH dust filter
6. Outlet shuttle valve
7. Air outlet
8. RH exhaust valve 3/2 NO
solenoid valve
9. Exhaust silencer
10. Purge valve
11. RH desiccant bed
12. RH dust filter
13. LH exhaust valve 3/2 NO
solenoid valve

Note: Diagram shown in one of

six possible positions, Left Tower
Drying, Right Tower Purge.
Certain feature are intentionally
shown out of position for reasons
of clarity.

Stage Time (Seconds) SV Valve Status Dryer Operation

1. 0 Left valve closed, right valve opens Left tower at pressure (drying), right tower depressurizes and
Then purges (this stage is shown on pd2 pneumatic schematic)
2. 120 Both valves closed Right tower repressurizing

3. 140 Left valve opens, right valve closed Left tower depressurizes and then purges, right tower at
Pressure (drying)
4. 260 Both valves closed Left tower repressurizing
280 Back to stage 1 -

Pro Dry Instruction Manual | Walker Filtration | [Link] 22

Section 6: Maintenance

Maintenance

Servicing Figure 6.1: Models PD004 – PD035

1 2 3 4 5 6
DRG. NUMBER DO NOT SCALE DRG. IF IN DOUBT GENERAL TOLERANCE SYSTEM - UNLESS OTHERWISE STATED 1ST ANGLE UNLESS STATED GEOMETRICAL
A4- $ident 0 NOM = ± 1.00 mm 0.00 = ± 0.10 mm
ASK! ALL DIMENSIONS IN mm. TOLERANCE TO BE 50% OF LINEAR
REV DRG SIZE SHEET 0 = ± 0.50 mm ANGULAR :-
$version$format $sheet REMOVE ALL SHARP EDGES 0.0 = ± 0.25 mm 0.0° = ± 0.50 ° TOLERANCE. REFER TO B.S. 8888:2000
A

THIS DRAWING& ANY INFO OR DESCRIPTIVE MATTER SET OUT HERON ARE THE CONFIDENTIAL & COPYRIGHT PROPERTY OF WALKER FILTRATION, & MUST NOT BE DISCLOSED, LOANED, COPIED OR USED FOR MANUFACTURING, TENDERING OR FOR ANY OTHER PURPOSE WITHOUT THEIR WRITTEN PERMISSION. C 2000.
Important information.
B

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer. C

Walker Filtration will not accept responsibility for physical

injury, damage or delays caused by failure to observe the D

instructions in this manual and manuals provided with your

equipment. 1 2 E 3 4 5
DRG. NUMBER DO NOT SCALE DRG. IF IN DOUBT GENERAL TOLERANCE SYSTEM - UNLESS OTHERWISE STATED 1ST ANGLE UNLES
A4- $ident 0 NOM = ± 1.00 mm 0.00 = ± 0.10 mm
ASK! ALL DIMENSIONS IN mm. TOLER
REV DRG SIZE SHEET 0 = ± 0.50 mm ANGULAR :-
$version$format $sheet
Please refer to Section 11-Spares Information. REMOVE ALL SHARP EDGES 0.0 = ± 0.25 mm 0.0° = ± 0.50 ° TOLER
F

A
G

WASHINGTON,TYNE & WEAR

$aei5 $aet5 $aed5 $aeu5 PROJECT REFERENCE DRG SIZE

Service Intervals
$field3 NE37 3ES, ENGLAND $format
H $aei4 $aet4 $aed4 $aeu4 DESIGN REF. TEL: (+44191) 0191 4177816
FAX: (+44191) 0191 4153748 SCALE

$aei3 $aet3 $aed3 $aeu3 $field2 Web: [Link] $scale1

CREATED BY DATE DRG. TITLE CHECK
$aei2 $aet2 $aed2 $aeu2 $created_by $created_at$ben1 $norm_by
$aei1 $aet1 $aed1 $aeu1 REVISED BY DATE DRG. NUMBER MATERIAL REV
REV CHANGE ORDER DATE BY $changed_by $changed_at A4-$ident $mat $version

Pre Filter Element Annually (6000 hrs)

Cartridges Every Two BYears (12000 Hrs)
Valves Every Four Years (24000 Hrs)

Front Panel Removal Figure 6.2: Models PD004 – PD035 with front panel removed

Models PD004 – PD035 only

• See figure 6.1.
• Using a hex key remove screw from the front panel.
• Open from bottom, allowing top to drop out releasing the
panel entirely.
D

Tools required E

• 4mm hex key

23

Pro Dry Instruction Manual | Walker Filtration | [Link] 23

Section 6: Maintenance

Front Panel Removal Figure 6.3: Models PD045 – PD365

Models PD045 – PD365 only

• See figure 6.3.
• Using a hex key remove screw from the front panel.
• Open from bottom, allowing top to drop out releasing the
panel entirely.

1 2 3
R DO NOT SCALE DRG. IF IN DOUBT GENERAL TOLERANCE SYSTEM - U
$ident
1 2 IN mm. 0 NOM = ±31.00 mm
Tools required ASK! ALL DIMENSIONS
R DRG SIZE SHEET DO NOT SCALE DRG. IF IN DOUBT = TOLERANCE
0 GENERAL ± 0.50 mm SYSTEM
$ident
$version $format $sheet REMOVE ALL SHARP EDGES 0.0
0 NOM == ±±0.25
1.00mm
mm
ASK! ALL DIMENSIONS IN mm.
DRG SIZE SHEET 0 = ± 0.50 mm
• 5mm hex key. $version$format $sheet REMOVE ALL SHARP EDGES 0.0 = ± 0.25 mm
Figure 6.4: Models PD045 – PD365 with front panel removed

Important information.
Ensure shutdown and start-up procedures are followed prior
to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with
your equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 24

Section 6: Maintenance

Desiccant Changeout Figure 6.5: Models PD004 – PD035 with pre-filter removed

Models PD004 – PD035 only

1. See figure 6.5.
2. Remove prefiltration.
3. Unscrew four bolts ¾ turn on the opposite tower to aid
desiccant changeout process.
4. Unscrew the four pressure housing retaining bolts and
slide out the pressure housing.
5. Remove banjo fixing bolt using hex key.
6. Extract end cap and banjo assembly from pressure
housing.
7. Using banjo fixing bolt, retract the cartridge from pressure
housing.
8. Replace with new cartridge supplied as part of the
cartridge service kit.
9. Ensure O-ring seals are in place when installing cartridge
and assembly in pressure housing.
10. Follow above steps in reverse to finish installing new
cartridge into the dryer.
11. Repeat steps 1 – 10 for the second pressure housing.
12. Ensure the dryer is leak-free before operating pressure is
applied to the dryer.
Figure 6.6: Models PD004 – PD035 with tower assembly removed
13. Follow start up procedure as stated on page 19 of this
manual.
14. Continue to page 27 to reset the controller.

Tools required

• 5mm hex key.

• 6mm hex key.

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 25

Section 6: Maintenance

Desiccant Changeout Figure 6.7: Models PD045 – PD365 - QPM removal stage 1

Models PD045 – PD365 only

See figure 6.7.
1. Unscrew QPM cover fixing screw, remove QPM cover.

2. Unscrew QPM retaining bolts.

3. Unscrew pressure housing retaining bolts.

4. Remove QPM.

5. Pull out desiccant cartridge using the handle.

For dryer models PD105 - PD365 each tower assembly

includes 2 desiccant cartridges.
6. Replace installed desiccant cartridges with new cartridges
supplied as part of the cartridge service kit.

7. Ensure o-ring seals are in place when installing desiccant

cartridges.

8. Follow steps 1 to 4 in reverse order to finish installing in

tower assembly.

9. Repeat steps 1-8 for remaining tower assemblies.

Figure 6.8: Models PD045 – PD365 - QPM removal stage 2
10. Ensure dryer is leak free at lower pressure prior to applying
operating pressure to dryer.

11. Follow start-up procedure as stated on page 19 of this

manual.

12. Continue to page 27 to reset the controller.

Tools required

• 5mm hex key

• 6mm hex key
• 8mm hex key
• 16mm hex key
• Adjustable spanner
• Flathead screwdriver

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 26

Section 6: Maintenance

Resetting the Controller Figure 6.9: Controller reset

• After following the start-up procedure it is necessary to

reset the controller. This is done by using the re-set disc
(supplied with cartridge service kit) then:
• Hold the disc against the blue pad on the front display of
the dryer panel for 5 seconds.
• During the five second period the power indicator will
flash green. When the reset has been successful indicator
X will flash green once to confirm that it has been
completed successfully.

Sweep the reset disc on the blue pad if the LEDs do not flash
as stated.
Please note: If Energy Management is activated, their will be
a 6 hour delay after reset before Energy Management will be
operational again.

Figure 6.10: Controller description

POWER

Pro Dry Instruction Manual | Walker Filtration | [Link] 27

Section 6: Maintenance

Purge Plug Removal Figure 6.11: PD004 - PD035 - Purge plug changeout stage 1

Models PD004 – PD035 only

• Remove dryer front panel.
• Remove purge plug securing screw from the upper
valve block.
• Remove purge plug.
• Replace with appropriate purge plug according to inlet
pressure. Refer to Spares section, page 56
• Grease purge plug O-ring to ensure ease of fit
Appropriate purge plug selection is very important for
function of the dryer. Failure to comply with this may affect
your warranty.

Tools required

• Pozidrive screwdriver

Important information Figure 6.12: PD004 - PD035 - Purge plug changeout stage 2

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your 1
equipment.
21

1. Securing screw
2. Purge plug

Pro Dry Instruction Manual | Walker Filtration | [Link] 28

Section 6: Maintenance

Purge Plug Removal Figure 6.13: PD045 - PD365 Purge plug changeout stage 1

Models PD045 – PD365 only

• Remove dryer front panel.
• Remove fixing screws from one of the bonnets holding
the purge orifice.
• Remove purge plug from remaining bonnet.

Tools required

Figure 6.14: PD045 - PD365 Purge plug change out stage 2

• 6mm hex key

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 29

Section 6: Maintenance

Exhaust Silencer Changeout Figure 6.15: PD004 - PD35 Silencer changout stage 1

Models PD004 – PD035 only

• Remove dryer front panel.
• Unscrew silencer from bottom valve block and remove.
• Replace with new silencer.

Tools required

• Not required

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 30

 1 2 3
R DO NOT SCALE DRG. IF IN DOUBT GENERAL TOLERANCE SYSTEM - U
Section 6: Maintenance $ident 0 NOM = ± 1.00 mm
ASK! ALL DIMENSIONS IN mm.
DRG SIZE SHEET 0 = ± 0.50 mm
$version$format $sheet REMOVE ALL SHARP EDGES 0.0 = ± 0.25 mm

Exhaust Silencer Changeout Figure 6.16: PD045 - PD085 Silencer changout stage 1

Models PD045 – PD085 only

• Remove dryer front panel.
• Unscrew silencer from bottom valve block and remove.
• Replace with new silencer.

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 31

Section 6: Maintenance

Exhaust Silencer Changeout Figure 6.17: PD105 - PD175 Silencer changout

Models PD105 – PD175

• Remove dryer front panel.
• Unscrew silencer from bottom valve block and remove.
• Replace with new silencer.

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 32

Section 6: Maintenance

Exhaust Silencer Changeout Figure 6.18:PD215 - PD365 Silencer changout stage 1

Models PD215 – PD365

• Remove dryer front panel.
• Unscrew silencer from bottom valve block and remove.
• Replace with new silencer.

Tools required

• Spanner Figure 6.19:PD215 - PD365 Silencer changout stage 2

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
The manufacturer will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Pro Dry Instruction Manual | Walker Filtration | [Link] 33

Section 6: Maintenance

Diaphragm Replacement Figure 6.20: PD004 - PD035 Diaphragm changeout stage 1

Models PD004 – PD035 only

• Remove front panel.
• Remove bonnets by means of four fixing screws.
• Separate bonnet from valve block.
• Disconnect tubing from fitting on bonnet.
• Remove diaphragm assembly.
• Insert new Diaphragms and springs, ensuring Diaphragm
holes are clear.

Tools required

• 4mm hex key

Figure 6.21: PD004 - PD035 Diaphragm changeout stage 2

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
1.4 mm Hole
Walker Filtration will not accept responsibility for physical 1.4 mm Hole
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

0.8 mm Hole

0.8 mm Hole

A Instruction Manual is included in the changeout kit to

assist Diaphragm Replacement
1. Diaphragm
2. Spring

35
Pro Dry Instruction Manual | Walker Filtration | [Link] 34
Section 6: Maintenance

Replacing Shuttle Valves Figure 6.22: PD004-PD035 Filter and tower removal

Models PD004-PD035
• Remove tower
• Pull out shuttle seat
• Remove shuttle
• Replace shuttle
• Reinsert shuttle seat
• Re-secure tower

Tools required

• 5mm hex key

Figure 6.23: PD004-PD035 Shuttle seat and shuttle removal

Pro Dry Instruction Manual | Walker Filtration | [Link] 35

Section 6: Maintenance

Replacing Shuttle Valves Figure 6.24: PD045-PD365 Shuttle seat and shuttle removal (Top block)

Models PD045-PD365
• Remove tower
• Pull out shuttle seat
• Remove shuttle
• Replace shuttle
• Reinsert shuttle seat
• Re-secure tower

Tools required

• 8mm hex key

Important information

Ensure shutdown and start-up procedures are followed prior

to carrying out any maintenance work on the dryer.
Walker Filtration will not accept responsibility for physical
injury, damage or delays caused by failure to observe the
instructions in this manual and manuals provided with your
equipment.

Figure 6.27: PD045-PD365 Tower removal Figure 6.25: PD045-PD365 Shuttle seat and shuttle removal (Bottom block)

Pro Dry Instruction Manual | Walker Filtration | [Link] 36

Section 7: Energy Management

Energy Management

Overview The following schematic ( Fig 7.1) offers an overview of the

devices mentioned as they might be connected for use in
controlling a dryer’s purge function. Please note that specific
Regenerative dryers must expel a portion of the process air details differ between device manufacturers, so in all cases the
in order to free themselves of accumulated moisture. During manufacturer’s specifications should be adhered to.
periods of low air demand, however, this air loss is not
necessary and is therefore undesirable. In many cases, the
compressor runs almost continuously in order to keep up with Fig 7. 1 Manual switch purge control
the dryer’s purge loss.

All Walker Filtration dryers are equipped with an Energy

Management feature that allows the purge to be shut off
during periods of low or no demand. The dryer controller
is fitted with a set of field accessible contacts, that can be DRYER
employed to shut off the solenoid valves which control the CONTROLLER
purge function of the dryer, therefore eliminating any air loss
from the dryer.

Developing a Purge Control Strategy PIN 2 PIN 1 (puts out +5 VDC signal)

MANUAL SWITCH
In order to utilise this function, the operator must provide a (Field Installed)
switching system that provides acceptable logic to indicate to
the dryer that there is little or no air demand. On the following N.C.*
SIGNAL OUT
pages, some examples of commonly used switching systems
are provided in ascending order of complexity. SIGNAL BACK

* Normally Closed, open to turn purge off

Using a Manual Switch for Purge Control

The simplest of arrangements, a manual switch may be

employed to shut the purge off when the air downstream of
the dryer is not being used. Commonly used on point of use
systems. For example, if the dryer is only used to supply air of
an appropriate dryness to a specific machine or application, DRYER
the dryer will only be required when the machine is in use and CONTROLLER
may be shut off either manually or possibly via extra contacts
provided in the machine’s on/off switch.
It is extremely important to understand that the purge may
only be shut off during periods of low or no demand. This
feature, if used otherwise, can result in permanent damage PIN 2 PIN 1 (puts out +5 VDC signal)
to the desiccant beds resulting in loss of drying capacity
and possibly mechanical failure. The cartridges must not be MANUAL SWITCH
allowed to become fully saturated at any time. (Field Installed)

N.O.

SIGNAL OUT

N.C.*
Pro Dry Instruction Manual | Walker Filtration | [Link] SIGNAL BACK 37
* Normally Closed, open to turn purge off
Section 7: Energy Management

Using a Standard Pressure Switch for Purge Control Figure 7.2: Using a standard pressure switch for Purge Control.

Many compressors come equipped with pressure switches

with extra contacts that can be utilised to switch off the
dryer’s purge when the compressor is in an unloaded state.
Unfortunately, many of these switches have significantly large DRYER
dead bands (difference between the load (on) and unload (off) CONTROLLER
settings that in most cases cannot be altered). The amount of
air that can pass downstream, through the dryer, while the
compressor is unloaded must be taken into consideration as it
can be significant, especially if there is a large dead band and/
or large wet receiver. PIN 2 PIN 1
(Puts out+5 VDC Signal)
Often, a stand-alone pressure switch is a better option
as it allows the user to adjust it independently from the PRESSURE SWITCH
compressor’s pressure switch. When selecting a stand-alone (Field Installed)
pressure switch, the smaller the dead band the better.
N.O.
When using a stand-alone pressure switch, the dryer is wired
into the normally closed contacts on the pressure switch. N.C.*
When the switch is actuated (at 100 psig in the example), the Signal Out

purge shuts off until the pressure switch deactuates (at 95 Signal Back
psig in example). The point at which the switch deactuates, * Normally Closed, open to turn purge off
may be adjusted to suit the system.
If it is determined that the dew point drops to an
unacceptable level, the deactuation point must be increased.
Please note that with most standard pressure switches, the
dead band is fixed such that the activation and deactuation
points move together.
It is extremely important to understand that the purge may
only be shut off during periods of low or no demand. This
feature, if used otherwise, can result in permanent damage
to the desiccant beds resulting in loss of drying capacity
and possibly mechanical failure. The cartridges must not be
allowed to become fully saturated at any time.
The following schematic offers an overview of the devices
mentioned as they might be connected for use in controlling
a dryer’s purge function. Please note that specific details
differ between device manufacturers, so in all cases the
manufacturer’s specifications should be adhered to.

Pro Dry Instruction Manual | Walker Filtration | [Link] 38

 PIN 2 PIN 1 (puts out +5 VDC signal)

MANUAL SWITCH
(Field Installed)
Section 7: Energy Management
N.C.*
SIGNAL OUT

SIGNAL BACK

Fig 7.3 Pressure switch setting * Normally Closed, open to turn purge off

ADJUST TO SUIT SYSTEM

(pressure switch deactivation point)

PURGE OFF (switch activated) PURGE OFF (switch activated)

OFF
ON
DRYER
PURGE ON (switch deactivated) CONTROLLER PURGE ON
105

100

95
SYSTEM PRESSURE (psig)

90 PIN 2 PIN 1 (puts out +5 VDC signal)

85
MANUAL SWITCH
85 (Field Installed)

80 N.O.

SIGNAL OUT

SIGNAL BACK N.C.*

* Normally Closed, open to turn purge off

Using an Electronic Pressure Switch for Purge Control Figure 7.4 Using an Electronic Pressure Switch for Purge Control

The best choice if using a pressure switch is to select an

electronic programmable type pressure switch which is
effectively a pressure transmitter and process controller
DC POWER ELECTRONIC
built into one device. While significantly more costly than SUPPLY PRESSURE SWITCH
a standard pressure switch, an electronic programmable
pressure switch can be setup to provide a much more DRYER
CONTROLLER
customized operation. Typically, the dead band can be reduced
or eliminated so that an immediate reaction to changes, in
system pressure indicating air flow, can be obtained.
SIGNAL OUT
-VDC (COM)

+VDC

+VDC

It is extremely important to understand that the purge may

COM

only be shut off during periods of low or no demand. This PIN 2 PIN 1 (puts out
feature, if used otherwise, can result in permanent damage +5 VDC signal)
to the desiccant beds resulting in loss of drying capacity
and possibly mechanical failure. The cartridges must not be RELAY
allowed to become fully saturated at any time.
SIGNAL OUT N.O.
The following schematic offers an overview of the devices N.C.*

mentioned as they might be connected for use in controlling SIGNAL BACK

a dryer’s purge function. Please note that specific details
* Normally Closed, open to turn purge off
differ between device manufacturers, so in all cases the
manufacturer’s specifications should be adhered to.

This setup is for example only. This configuration can be

amended, depending on application.

DC POWER PROCESS
SUPPLY CONTROLLER

Pro Dry Instruction Manual | Walker Filtration | [Link] DRYER 39

CONTROLLER
 RELAY

SIGNAL OUT N.O.

N.C.*
SIGNAL BACK
Section 7: Energy Management
* Normally Closed, open to turn purge off

Using a Dew Point Transmitter and Process Controller Figure 7.5: Using process controller
for Purge Control

The best option for purge control if the delivered dryness DC POWER PROCESS
(pressure dew point) of the air from the dryer is critical. If the SUPPLY CONTROLLER
air is deemed dry enough, than the purge can be shut off until
the air’s moisture starts to climb. If the purge is turned off, DRYER
care must be taken to ensure that the desiccant beds are not CONTROLLER
allowed to wet out too far before the purge is turned back on.

SIGNAL OUT
Also, after turning the purge back on, the air’s pressure dew

-VDC (COM)

SIGNAL IN
point may increase a bit before starting to drop again. This

+VDC

+VDC

COM
should be taken into consideration to ensure that the air flow PIN 2 PIN 1 (puts out
remains sufficiently dry. +5 VDC signal)

It is extremely important to understand that the purge may DEW POINT

TRANSMITTER
only be shut off during periods of low or no demand. This RELAY
feature, if used otherwise, can result in permanent damage COM
+VDC N.O.
to the desiccant beds resulting in loss of drying capacity
SIGNAL N.C.*
and possibly mechanical failure. The cartridges must not be SIGNAL OUT
allowed to become fully saturated at any time.
SIGNAL BACK
The following schematic offers an overview of the devices
* Normally Closed, open to turn purge off
mentioned as they might be connected for use in controlling
a dryer’s purge function. Please note that specific details
differ between device manufacturers, so in all cases the
manufacturer’s specifications should be adhered to.
This setup is for example only. This configuration can be
ammended, depending on application.

Making Connections between a Switching Device &

Dryer EM Contact

Cable / Wire Selection Criteria:

Selected wire should have...
• at least 2 conductors. More conductors can be useful
in the case of a conductor break. Conductors can be
swapped without having to run new cable.
• a conductor gauge of no greater than 18 awg is
recommended to fit comfortably into the DIN connector
insert.
• an outside diameter of no greater than 6mm (1/4”). Larger
diameters do not fit well into the cable gland of the EM
DIN connectors.
• an insulation type compatible with the environment that
it will be run in.

Pro Dry Instruction Manual | Walker Filtration | [Link] 40

Section 7: Energy Management

Installation Figure 7.6: connecting to EM port

• Make the connection at the switch end first. This way you can
check continuity at the dryer end before connecting to the
dryer. Make sure that the contacts on the switch are normally
closed. Pin 1 of the dryer EM connection puts out a 5 VDC
signal. Take care to ensure that the contacts on the switching
device are ‘dry’ and free of any voltage which could harm the
dryer controller.
• Locate the DIN connector on the base of the controller.
• Remove the screw completely from the centre of the
connector.
• Remove the blanking plug from the connector and discard
• Insert a small flat screwdriver into the small recess at the edge
of the insert, pry the insert out of the DIN connectors outer
shell (Figure 8.7).
• Remove the jumper wire which is between plug 1 and 2 and
discard.
• Slip cable end through DIN connector’s cable gland and out
through the front of the DIN connector.
• Strip the outer insulation of the cable back approx 20mm
(3/4”).
• Strip the conductor insulation back approx 3mm (1/8”).
• If possible using a meter, check the continuity between the
two wires to ensure that the switch is in a closed position. If
it is possible to verify the switch function as well this may be Figure 7.7: DIN connector
helpful.
• Insert conductors into pins 1 & 2 of insert. Tighten retaining
screws securely.
• Determine which direction the cable gland should point.
• Carefully pull the cable back through the shell until the insert
snaps back into place. Take care to work the wires around the
retaining screw hole as they can become fairly easily pinched.
• Plug the DIN connector back onto the dryer’s EM connection
taking care to make sure that sealing gasket is in place.

Note: The male ground pin is slightly wider than pins 1 & 2.
Take care to ensure that the female connector is oriented
correctly.

Pro Dry Instruction Manual | Walker Filtration | [Link] 41

Section 7: Energy Management

Alarm Figure 7.8: Remote alarm wiring diagram

External
Power Source

Remote fault alarm: -

A remote alarm relay is built into the controller. This facilitates

the activation of a remote audible or visual indicator. The
alarm can be set to activate at the service interval and/or after
a pre-defined number of electrical faults.

Alarm connection details

To enable the alarm facility it is recommended that a suitable

cable is brought into the controller via the rear panel with a
grommet. An external power source is required.
1. Connect the switching pole of an externally powered alarm
device to terminals 1 and 2 of alarm DIN connector.
2. With the power removed from the dryer and the alarm External
Power Source
lead wired as described in 1 above, remove the cover from the
DIN connection marked ‘Alarm’ and connect the wired DIN
connector ensuring the seal and screw are fitted.

Alarm relay rating Alarm connection type

Hirschmann GDS 207
3 Amp Max 28 VDC industrial standard DIN
connector or equivalent

Pro Dry Instruction Manual | Walker Filtration | [Link] 42

Section 8: Troubleshooting

Troubleshooting

General troubleshooting

Before specific identification of any fault is looked for, the following general points must be verified:
• Has the unit been damaged externally or are any parts missing?
• Is power being supplied to the unit?
• Was start-up carried out in accordance with the instructions in this manual?
• Are all external valves correctly set for operation?
• Do the operational conditions meet those specified at time of ordering and used for product selection?

Troubleshooting: General

Problem Possible Cause Action

Poor dewpoint Liquid water at dryer inlet Check pre-filtration and drains
Excessive flow Check actual flow against maximum
specified
Low inlet pressure Check against specification
High inlet temperature Check against specification
Silencer blocked or damaged Replace silencer
Air leaks Tighten joints or fit new seals
Desiccant life exceeded Replace desiccant cartridges
Desiccant contaminated Check inlet filter and drains,
replace cartridges
EM is active when air is flowing Check EM wiring, logic and/or control
through dryer method used
Power to dryer off while air is flowing Ensure that power is on whenever air is
through dryer flowing through dryer
Incorrect dryer operation Jammed shuttle valves or faulted electrical See electrical operation troubleshooting
components section
Excessive or loud purge, or purge on Jammed Main Shuttle Valve Clean or replace shuttles
only one tower
Jammed Purge Exhaust Shuttle (PD2) Clean or replace exhaust shuttles
Faulty Solenoid Valve Clean or replace solenoid valve
Not utilizing Energy Management feature Refer to Energy Management instructions
(Section 8)

Pro Dry Instruction Manual | Walker Filtration | [Link] 43

Section 8: Troubleshooting

Troubleshooting: Electrical

Problem Possible Cause Display Priority Location Action

No dryer function No power supply None - - Check supply

Incorrect dryer Left solenoid open or short Flashing red P1 X LED Replace solenoid valve
operation circuit
Right solenoid open or short Flashing red P1 Y LED Replace solenoid valve
circuit
Controller fault Flashing red P2 POWER LED Replace controller
Low power fault Continuous red P1 POWER LED Check supply
Drain not operating Energy Management active None - - Check installation
Drain solenoid open or short Flashing red P1 Z LED Replace solenoid valve
circuit
Controller fault Flashing red P2 POWER LED Replace controller
Tube connections from filter None - - Reverse tubes
into dryer and from filter to
drain reversed

Troubleshooting: Energy Management

Problem Possible Cause Action

Dryer does not enter Energy Shorted or incorrect device wiring Remove external wiring from the dryers EM
Management when switching device is contacts and place jumper between pins 1
activated and/or Dryer does not enter & 2. To test with Energy Mangement not
Energy Management when EM contacts connected.
are opened.
Faulty switching device Consult device manufacturer
Recent cartridge change, where the control Allow dryer to be energised for 6 hours
does not have a minimum of 6 hours on
the ‘Service hours from new’ found on the
dryer’s main software window

Pro Dry Instruction Manual | Walker Filtration | [Link] 44

Section 8: Troubleshooting

LED Controller Display

Status LED Signal Description

Power off

Left-hand tower purge cycle

Repressurisation cycle

Right-hand tower purge cycle

Repressurisation including second drain

Service warning every 11,500 hours

Pro Dry Instruction Manual | Walker Filtration | [Link] 45

Section 8: Troubleshooting

LED Controller Display

Status LED Signal Description

Service due every 12,000 hours

Right-hand solenoid fault

Left-hand solenoid fault

Drain valve fault

Controller fault

Low power fault

Pro Dry Instruction Manual | Walker Filtration | [Link] 46

Section 9: Technical Data

Technical Data

Environmental Conditions

All dryers are designed to be safe under the following conditions:

• Indoor use
• Altitude up to 2,000m
• Ambient temperature 5°C to 40°C
• Maximum RH 80% for temperatures up to 31°C, decreasing linearly to 50% RH at 40°C
• Mains supply voltage fluctuations not to exceed +/- 10% of nominal
• Transient over voltage IEC 60664 Class II
• Pollution degree 2, IEC 60664

For operation extended from the above conditions, please contact Walker Filtration.

Excessive vibrations from external sources may cause failure of this product.

Reference Conditions

Measurement Performance

Effective inlet pressure 7 barg 101.5 psig

Effective inlet temperature 35°C 95°F
Relative humidity of air at inlet 95%
Pressure dewpoint, standard version -50°C -50°F

Specified Limitation for Operation

Measurement Performance

Maximum inlet air pressure 16 barg 232 psig

Minimum inlet air pressure 4 barg 58 psig
Maximum ambient air temperature 50°C 122°F
Minimum ambient air temperature 5°C 41°F
Standard pressure dewpoint -40°C -40°F
Optional pressure dewpoint with application -70°C -100°F
of flow correction factor
Electrical supply voltage 12 VDC to 24 VDC 100 VAC to 240 VAC

Pro Dry Instruction Manual | Walker Filtration | [Link] 47

Section 9: Technical Data

Dryer Sizing Table

Dryer Inlet Flow Rate Dryer Dimension (mm) Weight Dimension (inches) Pre
Unit Dryer
Model Config. FIlter
Nm³/h SCFM A B C Kg lb A B C
PD004 /
38 7 4 simplex 490 351 92 13 28.7 19 13.8 3.6 PD004 A038
PD006 /
38 10 6 simplex 549 351 92 14 30.9 22 13.8 3.6 PD006 A038
PD008 /
38 14 8 simplex 609 351 92 15 33.1 24 13.8 3.6 PD008 A038
PD010 /
38 17 10 simplex 679 351 92 17 36.4 27 13.8 3.6 PD010 A038
PD015 /
38 25 15 simplex 859 351 92 20 43.0 34 13.8 3.6 PD015 A038
PD025 /
38 42 25 simplex 1109 351 92 24 52.9 44 13.8 3.6 PD025 A038
PD035 /
38 59 35 simplex 1504 531 92 31 68.4 59 13.8 3.6 PD035 A038
PD045 ¾ 76 45 simplex 768 530 272 53 116.9 30 20.9 10.7 PD045 A038
PD055 ¾ 93 55 simplex 868 530 272 59 130.1 34 20.9 10.7 PD055 A078
PD065 ¾ 110 65 simplex 968 530 272 64 141.1 38 20.9 10.7 PD065 A078
PD085 1 144 85 simplex 1170 530 272 75 165.4 46 20.9 10.7 PD085 A108
PD105 1 178 105 simplex 1480 530 272 91 200.7 58 20.9 10.7 PD105 A108
PD135 1¼ 229 135 simplex 1680 530 272 102 224.9 66 20.9 10.7 PD135 A128
PD175 1¼ 297 175 simplex 2080 530 272 123 271.2 82 20.9 10.7 PD175 A128
PD215 1½ 365 215 duplex 1488 530 459 172 379.3 59 20.9 18.1 PD215 A158
PD275 1½ 467 275 duplex 1688 530 459 192 423.4 66 20.9 18.1 PD275 A158
PD365 1½ 620 365 duplex 2098 530 483 232 511.6 83 20.9 19.0 PD365 A159

Pressure Correction Factor (PCF)

Operating Pressure

barg 4 5 6 7 8 9 10 11 12 13 14 15 16
psig 58 73 87 102 116 131 145 160 174 189 203 218 232
PCF* 0.62 0.75 0.87 1.00 1.12 1.25 1.37 1.50 1.62 1.75 1.87 2.00 2.12
*Always use the pressure correction factor (PCF) closest to actual inlet pressure condition

Temperature Correction Factor (TCF) Dewpoint Correction Factor (DCF)

Temperature Temperature

°C 20 25 30 35 40 45 50 °C -40 -70
°F 68 77 86 95 104 113 122 °F -40 -94
TCF 1.07 1.06 1.04 1.00 0.88 0.67 0.55 DCF 1.0 0.7

Pro Dry Instruction Manual | Walker Filtration | [Link] 48

Section 9: Technical Data

Figure 9.1: Models PD004 – PD035

FILTER MOUNTING HOLES M6

INLET PORT OUTLET PORT
SIZE Rp3/8” SIZE Rp3/8”
44

A
B

INLET PORT SIZE

Figure 9.2: Models PD045 – PD175 OUTLET PORT SIZE Rp¾" TO Rp1¼"
Rp¾" TO Rp1¼"

A
INLET PORT SIZE
INLET PORT SIZE
OUTLET PORT SIZE Rp¾" TO Rp1¼"
Rp¾" TOOUTLET
Rp1¼"PORT SIZE
Rp¾" TO CRp1¼"
Rp¾" TO Rp1¼"

A
A
INLET PORT SIZE
B OUTLET PORT SIZE Rp¾" TO CRp1¼"C
Rp¾" TO Rp1¼"

A
INLET PORT SIZE
Rp1½"
B C
B

Figure 9.3: Models PD215 – PD365 OUTLET PORT SIZE

Rp¾" TO Rp1¼" INLET PORT SIZE
Rp1½" INLET PORT SIZE
A B Rp1½"

OUTLET PORT SIZE C

Rp¾" TO Rp1¼"PORT SIZE
OUTLET
Rp¾" TO Rp1¼" INLET PORT SIZE
A Rp1½"
A
C
B OUTLET PORT SIZE C
Rp¾" TO Rp1¼"

B C
B

55

Pro Dry Instruction Manual | Walker Filtration | [Link] 49

55
Section 10: Component Parts

Component Parts

PD004 -- PD035

Fig 10.1 PD004 – PD035

10

6
7

4
3

11
8

1. Cover plate 7. Bottom block assembly

2. Cruciform 8. Base/skid
3. Tower assembly 9. Back panel
4. Front panel 10. Downpipe
5. Top block assembly 11. XA pre-filter
6. Controller

Pro Dry Instruction Manual | Walker Filtration | [Link] 50

Section 10: Component Parts

PD004 -- PD035

Fig 10.2 Top block assembly

1. Top Block
2. Shuttle seat
3. Shuttle
4. Purge Plug
5. Diaphragm with disc
3
6. Compression spring
7. Top bonnet

Fig 10.3 Bottom block assembly

1. Bottom block
2. Shuttle seat
3. Shuttle
4 4. Silencer
5. Diaphragm with disc
6. Compression spring
7. Bottom bonnet
8 8. 1/8 pressure plug
9 9. 4mm straight adaptor

3
2

1
5
7
6

Pro Dry Instruction Manual | Walker Filtration | [Link] 51

Section 10: Component Parts

PD004 -- PD035

Fig 10.4 Tower assembly Fig 10.5 Top tower plug assembly

2
8

3
9

4 Fig 10.6 Bottom tower plug assembly

10

11

5
6

1. Top tower plug assembly

2. Cartridge
3. Extrusion bolt
4. Extrusion
5. Extrusion corner bracket
6. Bottom tower plug assembly
7. Wire handle
8. Tower plug
9. Banjo adaptor
10. Banjo adaptor
11. Tower plug

Pro Dry Instruction Manual | Walker Filtration | [Link] 52

Section 10: Component Parts

PD045 - PD365

Fig 10.7 PD045 – PD365

11

10

* Models PD215 – PD365 are duplex

1. XA pre-filter 7. Bottom valve block assembly

2. Back panel 8. Base/skid
3. Tower assembly 9. Controller
4. Downpipe 10. Front panel
5. Top valve block assembly 11. Silencer
6. Exhaust manifold assembly

Pro Dry Instruction Manual | Walker Filtration | [Link] 53

Section 10: Component Parts

PD045 - PD365

Fig 10.8 Tower assembly Fig 10.9 Top valve block assembly

10
1
9

4 11

12

Fig 10.10 Exhaust manifold assembly

16

15

14

7
6 13

Fig 10.11 Bottom valve block assembly

1. QPM cover 12. Purge plug

2. QPM 13. Exhaust bonnet
3. Extrusion gasket 14. Exhaust shuttle
20
4. Cartridge 15. Exhaust manifold
5. Extrusion 16. ¼ Rp blanking plug
18 19
6. Extrusion bolt 17. Bottom valve
7. QPM bush manifold
17
8. Top valve manifold 18. 6mm swivel tee
9. Shuttle 19. Shuttle
10. Valve seat 20. Valve seat
11. Purge bonnet

Pro Dry Instruction Manual | Walker Filtration | [Link] 54

Section 11: Spares Information

Spares

Purge Plug Identification

Each dryer is set with the appropriate purge plug for the operating pressure specified at point of order. The purge plug fitted on
the unit will be identified on the purge plug label, located underneath the rating plate on the right. If the inlet pressure to the dryer
is adjusted to operate at an alternative working pressure other than initially specified, please contact Walker Filtration and order
an appropriate purge plug (identified in the table below). Before operating at the new working pressure this purge plug must be
installed into the dryer. Failure to comply with these instructions could result in component failure and affect any warranty claims.

Purge Plug Identification

Model Operating Pressure (barg)

4 5 6 7 8 9 10 11 12 13 14 15 16
PD004 PPK008 PPK008 PPK007 PPK007 PPK006.5 PPK006.5 PPK006 PPK006 PPK006 PPK006 PPK005 PPK005 PPK005
PD006 PPK011 PPK010 PPK009 PPK008 PPK007.5 PPK007.5 PPK007.5 PPK007 PPK007 PPK007 PPK006.5 PPK006.5 PPK006.5
PD008 PPK012 PPK011 PPK010 PPK010 PPK009 PPK008 PPK008 PPK007.5 PPK007.5 PPK007.5 PPK007 PPK007 PPK007
PD010 PPK013 PPK012 PPK011 PPK011 PPK010 PPK009 PPK009 PPK009 PPK008.5 PPK008.5 PPK008.5 PPK008 PPK008
PD015 PPK015 PPK014 PPK013 PPK013 PPK012 PPK011 PPK011 PPK010 PPK010 PPK010 PPK009 PPK009 PPK009
PD025 PPK020 PPK018 PPK016 PPK015 PPK014 PPK014 PPK013 PPK013 PPK013 PPK012 PPK012 PPK012 PPK012
PD035 PPK028 PPK023 PPK021 PPK020 PPK018 PPK018 PPK016 PPK015 PPK015 PPK014 PPK014 PPK014 PPK014
PD045 PPK28 PPK25 PPK23 PPK22 PPK20 PPK19 PPK18 PPK17 PPK17 PPK16 PPK16 PPK15 PPK15
PD055 PPK31 PPK28 PPK26 PPK24 PPK23 PPK21 PPK20 PPK19 PPK19 PPK18 PPK17 PPK17 PPK16
PD065 PPK33 PPK30 PPK28 PPK26 PPK25 PPK23 PPK22 PPK21 PPK20 PPK20 PPK19 PPK18 PPK18
PD085 PPK38 PPK35 PPK32 PPK30 PPK28 PPK27 PPK26 PPK24 PPK23 PPK23 PPK22 PPK21 PPK20
PD105 PPK43 PPK39 PPK36 PPK34 PPK32 PPK30 PPK29 PPK27 PPK26 PPK25 PPK24 PPK23 PPK23
PD135 PPK49 PPK44 PPK41 PPK38 PPK36 PPK34 PPK32 PPK31 PPK30 PPK29 PPK28 PPK27 PPK26
PD175 PPK55 PPK51 PPK47 PPK44 PPK41 PPK39 PPK37 PPK36 PPK34 PPK33 PPK32 PPK31 PPK30
PD215* PPK43 PPK39 PPK36 PPK34 PPK32 PPK30 PPK29 PPK27 PPK26 PPK25 PPK24 PPK23 PPK23
PD275* PPK49 PPK44 PPK41 PPK38 PPK36 PPK34 PPK32 PPK31 PPK30 PPK29 PPK28 PPK27 PPK26
PD365* PPK55 PPK51 PPK47 PPK44 PPK41 PPK39 PPK37 PPK36 PPK34 PPK33 PPK32 PPK31 PPK30
* 2 purge plugs are required

Appropriate purge plug selection is very important for function of the

dryer. Failure to comply with this may affect your warranty.

Pro Dry Instruction Manual | Walker Filtration | [Link] 55

Section 11: Spares Information

dryer
description kit number
model
PD004 PDC004-12000
PD006 PDC006-12000
PD008 PDC008-12000
PD010 PDC010-12000
PD015 PDC015-12000
PD025 service kit (2 cartridges) PDC025-12000
PD035 PDC035DF-12000
PD045 PDC045DF-12000 12,000 hour service kit includes:
desiccant cartridges, pack of sealing O-rings
PD055 PDC055DF-12000
and sealing washers, instruction manual,
controller re-set disc.
PD085 PDC085DF-12000
PD44SFD PDC044DF-12000
PD66SFD PDC066DF-12000
PD105 service kit (4 cartridges) PDC105DF-12000
PD135 PDC135DF-12000
PD175 PDC175DF-12000
PD215 PDC215DF-12000
PD275 service kit (8 cartridges) PDC275DF-12000
PD365 PDC365DF-12000
PD004-PD035 VSKS 01 24,000 hour valve service kit includes:
PD44SFD/PD66SFD VSKD 01 shuttle seats, shuttles, O-rings, diaphragms and
valve service kit
PD045-PD175 PDVSKS 01 springs, solenoid valves, controller re-set disc,
PD215-PD365 PDVSKD 01 spare pressure plugs
PD004-PD035 foot mounting bracket WKN01805
PD004-PD035 PD1SKS01
PD044SFD/PD066SFD PD1SKD01 Shuttle kit includes:
shuttle kit shuttle seats, shuttles, exhaust block shuttles,
PD045-PD175 PD2SKS01 O-rings and seals
PD215-PD365 PD2SKD01
PD004-PD035 PD1TDKS01
top diaphragm kit
PD044SFD/PD066SFD PD1TDKD01 Diaphragm kit includes:
valve diaphragms
PD004-PD035 PD1BDKS01 and diaphragm springs
bottom diaphragm kit
PD044SFD/PD066SFD PD1BDKD01
PD004 PD1SK01
PD006-PD035 PD1SK02
PD044SFD/PD066SFD PD1SK03
silencer kit 6,000 hour silencer service kit
PD045-PD085 PD2SK01
PD105-PD175 PD2SK02
PD215-PD365 PD2SK03
PD004-PD035 PDCK01
controller assembly kit
PD044SFD/PD066SFD PDCK01 Controller assembly kit includes:
(with valves)
PD045-PD365 PDCK02 electronic controller complete
PD004-PD035 PD1 controller (without valves) PDC01 with solenoid valves
PD045-PD365 PD2 controller (without valves) PDC02
Purge plug kit includes:
All models purge plug kit PPK004-PPK365
sized purge plugs and assembled O-rings

DIN plug kit includes:

All models DIN plug kit PDDIN01
DIN plug, gasket and screw

Pro Dry Instruction Manual | Walker Filtration | [Link] 56

Section 12: Warranty

Warranties and liabilities

Claims for warranty and liability concerning personal injury or

material damage are excluded if they resulted due to one or
more of the following factors:
• Inappropriate use
• Inappropriate application of the dryer.
• Technically incorrect installation, start-up operation or
maintenance of the dryer.
• Operation of a known damaged dryer.
• Failure to observe the information given in this manual
concerning all life phases of the dryer.
• Undertaking constructional or operational modifications to
the dryer without prior agreement with Walker Filtration.
• Inadequate monitoring and replacement of components
of the dryer that are subject to wear.
• Improper completion of repairs.
• Use of non-original or non-approved parts for service or
maintenance.

Important Note
Industrial Compressed Air Desiccant Dryers

The Walker Filtration Ltd desiccant dryer range is designed for, Such additional undertakings are the responsibility of
warrantied and intended for use in fixed industrial compressed the package or system builder, installer or end user.
air applications only.
Use on non-fixed installations such as :

• marine (e.g. offshore, shipboard)

• transportable (e.g. portable air treatment units)
• non-fixed (e.g. rolling stock, railway etc)

are not strictly prohibited, however use in such applications is

not recommended nor endorsed as additional design features,
function testing, certification (both mechanical and electrical)
and validation may be required to satisfy relevant end user
application specific specifications and/or mandatory and
non-mandatory local, national or international standards
and legislation.

Pro Dry Instruction Manual | Walker Filtration | [Link] 57

Section 13: Declaration of Conformity

Declaration of Conformity

2006/42/EC, 2006/95/EC, 2004/108/EC, 97/23/EC

Name of Manufacturer Walker Filtration Ltd.

Address of Manufacturer Birtley Road, Washington, Tyne & Wear, NE38 9DA, England.

Description of Product Pro Dry Compressed Air Dryer

Designation of Product PD004, PD006, PD008, PD010, PD015, PD025, PD035, PD045, PD055, PD065, PD085,
PD105, PD135, PD175, PD215, PD275, PD365

Standards Used Machines: 2006/42/EC ISO 12100-2:2003+A1:2009*

Harmonised Standards* applied where LVD: 2006/95/EC EN 60204-1:2006+A1:2009*

available — with alternatives specified where
harmonised standards do not exist. EMC: 2004/108/EC EN 61000-6-1:2007*
EN 61000-6-2:2005*
EN 61000-6-3:2007+A1:2011*
EN 61000-6-4:2007+A1:2011*

PED: 97/23/EC Generally in accordance with

ASME VIII Division1 Rules for
construction of pressure vessels

Notified Body (97/23/EC only) Lloyd’s Register EMEA

(Not applicable to SEP or Cat I Products) Notified Body No. 0038, 71 Fenchurch Street, London, EC3M 4BS, England.

Conformity Assessment Module PD004 - PD025: Cat I – Module A

(97/23/EC only) PD035 - PD135: Cat II – Module D1: COV0310124/1
PD175 - PD365: Cat III – Module B+D: COV0712098/1 + COV1112690/1
Assessment based on Group 2 Gas service

Quality Assurance System: Lloyd’s Register Quality Assurance Ltd (LRQA)

ISO 9001:2008-LRQ0930553 Hiramford, Middlemarch Office Village, Siskin Drive, Coventry, CV3 4FJ, England.

Year of Manufacture Refer to product marking

Name of Authorised Representative Simon Wise

Position of Authorised Representative Technical Manager

I declare, on behalf of Walker Filtration Ltd and as the authorised representative, that the
above stated products fulfil the requirements of the applicable New Approach Directives.

December 2013

Pro Dry Instruction Manual | Walker Filtration | [Link] 58

Notes

Pro Dry Instruction Manual | Walker Filtration | [Link] 59

Notes

Pro Dry Instruction Manual | Walker Filtration | [Link] 60

 In Canada Contact:
CAG Purification Inc.
3770B Laird Road, Unit 2 Mississauga, ON.
toll 1-800-951-0777, fax 1-905-829-8331

04 1078 001 01 Rb