DMN FST Manual DPS1-8A Standard-V10_2013_EN

Operating Manual
Adsorption Dryer
DPS 1-8 A
Version: 10/2013/EN
© FST GmbH 28.10.2013
DMN FST Manual DPS1-8A Standard-V10_2013_EN-20131018-KU
Table of contents
1.
General information ........................................................................................................................................5
1.1
Manufacturer...........................................................................................................................................5
1.2
Dryer data ................................................................................................................................................6
1.3
Contact data ............................................................................................................................................6
1.4
Additional documents .............................................................................................................................6
1.5
Warranty notes ........................................................................................................................................7
1.6
About this operating manual ...................................................................................................................7
2. Description of application ...............................................................................................................................9
2.1
Intended use ............................................................................................................................................9
2.2
Technical data........................................................................................................................................12
3. Safety notes ...................................................................................................................................................13
3.1
Signs and instructions ............................................................................................................................13
3.2
Danger zones at the dryer .....................................................................................................................14
3.3
General safety notes..............................................................................................................................15
4. Technical product description ....................................................................................................................... 17
4.1
Assembly drawing..................................................................................................................................17
4.2
Process flow diagram.............................................................................................................................19
4.3
Nozzle table ...........................................................................................................................................20
4.4
Function description ..............................................................................................................................21
4.5
Options ..................................................................................................................................................25
5. Operating elements .......................................................................................................................................26
5.1
Power connector ...................................................................................................................................26
5.2
Differential pressure gauges on the filters ............................................................................................27
5.3
Pressure gauge ...................................................................................................................................... 27
5.4
Control System ...................................................................................................................................... 28
5.4.1
Function Keys and Display .............................................................................................................28
5.4.2
Direct Indication ............................................................................................................................29
5.4.3
Menu Navigation ...........................................................................................................................30
5.4.4
SERVICE Level.................................................................................................................................35
5.4.5
Compressor Synchronisation Function ..........................................................................................36
5.4.6
Pressure Dew Point Measurement and Energy-saving Function ..................................................37
5.4.7
Differential Pressure Monitoring of Filter .....................................................................................39
5.4.8
Overflow Monitor ..........................................................................................................................39
5.4.9
Service Ticket .................................................................................................................................39
5.5
Allocation Text on Display / Triggering of Valves ..................................................................................40
5.6
Failure Analysis ......................................................................................................................................42
6. Transportation, setting up and storage .........................................................................................................45
6.1
Transportation .......................................................................................................................................45
6.2
Setting up...............................................................................................................................................46
6.3
Storage...................................................................................................................................................47
7. Installation .....................................................................................................................................................48
7.1
Installing the connecting pipelines ........................................................................................................48
7.2
Installing the power supply ...................................................................................................................50
8. Commissioning ..............................................................................................................................................53
8.1
Requirements for initial commissioning................................................................................................53
Table of contents
8.2
Commissioning the dryer...................................................................................................................... 54
8.2.1
Pressurisation of the dryer ........................................................................................................... 55
8.2.2
Opening the outlet valve .............................................................................................................. 55
8.2.3
Starting the dryer.......................................................................................................................... 56
9. Shutting down and restarting the dryer ....................................................................................................... 57
9.1
Shutting down the dryer in case of emergency.................................................................................... 57
9.2
Stopping the dryer ................................................................................................................................ 57
9.3
Shutting down the dryer....................................................................................................................... 57
9.4
Depressurising the dryer ...................................................................................................................... 58
9.5
Restarting the dryer .............................................................................................................................. 58
10. Maintenance and repair ............................................................................................................................... 59
10.1 Regular maintenance intervals ............................................................................................................. 60
10.1.1 Visual check and function monitoring .......................................................................................... 60
10.1.2 Cleaning the dryer and dryer control ........................................................................................... 61
10.1.3 Determining the residual oil content in the compressed air ........................................................ 61
10.1.4 Replacing indicator tube ............................................................................................................... 63
10.1.5 Checking if cable and terminals are securely fixed....................................................................... 63
10.1.6 Calibrating the dew point sensor.................................................................................................. 64
10.1.7 Replacing filter elements .............................................................................................................. 64
10.1.8 Replacing the expansion silencer ................................................................................................. 65
10.1.9 Replacing the sealing set of the valves (V1-4) and the check valves (RV1-2) ............................... 65
10.1.10 Checking and replacing the desiccant .......................................................................................... 65
11. Appendix and technical documents ............................................................................................................. 68
11.1 Manufacturer’s declaration .................................................................................................................. 68
11.2 Declaration of conformity .................................................................................................................... 69
11.3 Tables for oil indicator .......................................................................................................................... 70
11.3.1 ≥ 7 bar (g)...................................................................................................................................... 70
11.3.2 6 bar (g)......................................................................................................................................... 71
11.3.3 5 bar (g)......................................................................................................................................... 72
11.3.4 4 bar (g)......................................................................................................................................... 73
11.4 General arrangement drawing ............................................................................................................. 74
11.5 Process flow diagram............................................................................................................................ 74
11.6 Wiring diagram ..................................................................................................................................... 74
General information
1. General information
1.1 Manufacturer
FST GmbH
Head office: Weiherdamm 17 – 57250 Netphen, Germany
Sales office: Im Teelbruch 106 – 45219 Essen, Germany
℡ +49 (0) 2054 8735-0
+49 (0) 2054 8735-100
info@fstweb.de
! For any questions about the product, please contact the sales office !
In case of questions about the product, please specify the type and the manufacturing number. This
information can be found on the type plate over the control box of the dryer. (→Page 13)
5
General information
1.2 Dryer data
Model:
Order no.:
Manufacturing no.:
Vessel no. (left/right):
Year of manufacture:
Date of commissioning:
1.3 Contact data
Name:
Company:
Address:
Phone / Fax:
E-mail:
The above dryer data differs for each dryer. Please fill in the fields according to the type plate and your contract documents. This data enables the manufacturer to clearly identify the dryer and simplifies service and
provision of the proper spare parts.
Some of the information listed here and other important data can be found on the type plate of the dryer and
on the type plate of the vessels. (→Page 13)
1.4 Additional documents
6
General arrangement drawing
Process flow diagram
Wiring diagram
CE-declaration of conformity
General information
1.5 Warranty notes
For warranty information, please refer to our "General Terms of Sale and Delivery".
(→ www.fstweb.de)
In the following cases the warranty shall be void:
If the safety notes and instructions of this operating manual and of the additional documents are not
observed.
If the dryer is operated or maintained by personnel who do not have the required qualifications.
(→ see “target group“: Page 7)
If the dryer is used for anything other than its intended use. (→ Page 9)
If aggressive substances in the compressed air or ambient air cause damage to the dryer.
If parts other than genuine parts of the manufacturer have been used for maintenance and repair.
If the dryer is operated although defects are evident.
1.6 About this operating manual
This operating manual contains all the technical information required for installation, operation, maintenance
and disposal of the dryer.
Target group
This operating manual is directed to all persons working on and with the dryer. We point out that these persons have to be qualified personnel who, because auf their qualification and experience, are familiar with handling compressed air systems and electrical systems. If you are not experienced in using these systems, please
ask the relevant experts for help. We highly recommend that commissioning and maintenance be carried out
by the manufacturer or one of the authorised service partners.
Using the operating manual
Please read the operating manual and the additional documents carefully prior to installation and follow the
notes and instructions. Safe and proper operation of the dryer can only be guaranteed if the instructions and
notes are observed. The safety notes must be observed in particular.
The operating manual must be kept in the vicinity of the dryer and must be easily accessible.
When selling or hiring out the dryer, also provide this operating manual and all the additional documents to
the new user. (→Page 6)
The manufacturer accepts no liability for damages resulting from disregard of the operating manual.
All the information in this operating manual is valid at the time the manual is published. Due to component or
workflow modifications at any time affecting dryer maintenance, the latest information should be available
prior to maintenance work.
7
General information
Signs and symbols used
Boxes are used for bulleted lists.
1) Enumerated lists point out that the working steps are to be carried out in a specified order.
→ Cross references refer to information on a different page or in a different document.
Note!
This symbol refers to matters that should be given special attention.
Observing the notes helps to ensure safe handling of the product.
Tips and hints!
This symbol refers to matters that should be given special attention.
Observing these advisory notes helps to ensure particular efficient operation of the product.
CAUTION !
This symbol indicates a possible harmful situation.
When not avoiding this situation, there is a danger of injury or damage to the product or to adjacent system components.
WARNING !
This symbol indicates a possible dangerous situation.
When not avoiding this situation, there is a danger of serious injury or death.
DANGER !
This symbol indicates an immediate impending danger.
Not avoiding this danger results in serious injury or death.
8
Description of application
2. Description of application
The dryer is used to remove moisture, oil, smells and gustatory substances from compressed air for industrial
use.
Typically, the dryer is used for drying compressed air from a compressor station.
During pre-treatment of the compressed air by means of separators and fine filters only the liquid water and
oil components can be removed from the compressed air. After this pre-treatment the dryer (first and second
vessel) also removes the vaporous water components. The compressed air is dried until only a very low residual concentration of water vapour remains in the dried compressed air. This residual moisture content is
measured as the pressure dew point in °C.
The dryer works completely automatically and is designed for continuous operation. Thanks to numerous
communication interfaces and an optionally available moisture measuring system the dryer can be operated
very economically.
After this pre-treatment the adsorber (third vessel) also removes the vaporous oil components as well as many
smells and gustatory substances. The compressed air is purified until only a very low residual content of these
substances remains in the compressed air.
The adsorber can remove a wide range of non-polar, long chain hydrocarbons from the compressed air flow.
Compressor oil is adsorbed by the granulate particularly well.
Polar substances or hydrocarbons with low carbon content (e.g. methane, ethane, etc.) are adsorbed to a lesser degree or are hardly adsorbed at all.
In case of doubt, please contact the manufacturer to evaluate your application and to find a suitable solution.
2.1 Intended use
The dryer is exclusively designed for drying compressed air!
Using the dryer for drying other gases (e.g. pure nitrogen) must be agreed on with the manufacturer. It may be
necessary to observe special safety directives.
The dryer is designed to be set up at a site that complies with the following requirements:
Indoors
Protected against weather impact
Frost-free
Dry
Zero to low dust-laden ambient air
No vibration via floor or connected piping
Ambient air must be free from aggressive and corrosive substances
Ambient air must be free from substances that damage the desiccant or influence its effectiveness
(e.g. ammonia or other alkaline-reacting substances, oil mist, water spray or drizzle)
9
Description of application
Free from dangers due to explosive atmospheres inside and outside the dryer. (The standard dryer
version does not comply with ATEX.)
The dryer must only be operated with compressed air within the maximum allowable operating conditions.
The voltage supply must correspond to the specified values.
The maximum allowable operating conditions and the required voltage supply are specified on the type plate
(→Page 13).
Modifications to the dryer or use of third-party parts may cause unpredictable danger and damage. These
measures must only be carried out after previous check and approval of the manufacturer. Only use genuine
spare parts of the manufacturer.
Any other use is considered improper and therefore not permissible. The manufacturer accepts no liability
caused by improper use.
The values specified on the type plate are mechanical design limits.
Please note that dryer performance is not defined to these mechanical design limits. Dryer performance is
guaranteed for use under the "nominal operating conditions" as well as for a certain combination of the individual operating parameters, that has been established for this dryer in the planning phase (compressed air
flow rate, pressure, temperature, desired pressure dew point).
For the nominal operating conditions please refer to the following table. (→Page 12)
For a dryer designed to your individual operating conditions, please refer to your contract documents or contact the manufacturer.
Dryer performance cannot be guaranteed if the dryer is not operated within these operating conditions.
The supplied compressed air must be of the following quality:
Free from aggressive and corrosive substances
Filtered acc. to ISO 8573-1:2010 (1:*:3)
Free from substances damaging the desiccant
*= The compressed air should be saturated with moisture or only be slightly subsaturated. When using predried compressed air (e.g. downstream of a fridge dryer) the dryer performance may be reduced.
During initial commissioning and after desiccant replacement in particular, pre-dried compressed air may negatively affect dryer performance.
10
Description of application
In the event of pre-dried compressed air
For some days, operate the dryer using moisture-saturated compressed air in order to activate the
desiccant. For this activation process the dryer control system should be set as follows:
1) Select the "variable" cycle mode. (→ Page 30 )
2) Select a dew point limit value that can still be tolerated, however, it must not be worse than
-10°C. (→ Page 30 )
The dew point should become better within the next days.
3) Monitor the development of the dew point measured value for some days.
4) Select a dew point limit value that is approximately 10°C worse than the dew point that is
usually reached, however, it must not be worse than -10°C.
Usually, dryer performance will be adequate after this procedure even when using pre-dried compressed air. If the dew point becomes worse again at a later point in time, the procedure must be
repeated.
Example:
The dryer is to be reaching a dew point of -40°C. However, in most cases it only reaches -30°C.
Select the "variable" cycle mode and then a dew point limit value of -20°C.
The adsorption phases of the dryer are now very long and thus the dryer is increasingly laden with moisture.
After some days the dew point becomes better and reaches values around -55°C.
Now, select a dew point limit value of -40°C. The dryer should now permanently be reaching good dew points.
High compressed air temperatures reduce the purification performance of the adsorber.
The ability of the granulate to take up oil and other substances strongly depends on the temperature. The colder the compressed air, the better the purification performance and the longer the
lifetime of the granulate. Furthermore a low temperature reduces the oil vapour content in the
compressed air. Consequently the oil load on the adsorber is reduced the lifetime is considerable
increased.
Temperatures below 35°C are ideal for operating the adsorber.
Note: even short temperature spikes above 60°C can lead to previously adsorbed oil being released from the granulate back into the compressed air flow.
Make sure that the compressed air temperature stays low and avoid heavy temperature changes.
11
Description of application
*
Height
Width
Depth
Compressed air
connection
V [m³/h]*
8
G 3/8"
Weight
DPS 1A
Nominal
volume flow rate
Dryer
2.2 Technical data
[kg]
[mm]
[mm]
[mm]
14
450
412
185
DPS 2A
15
G 3/8"
20
625
412
185
DPS 3A
25
G 3/8"
28
875
412
185
DPS 4A
35
G 3/8"
35
1125
412
185
DPS 6A
57
G 1/2"
65
1180
614
220
DPS 7A
72
G 1/2"
78
1405
614
220
DPS 8A
82
G 1/2"
90
1605
614
220
= Standardised to 1 bar(a) and 20°C as well as to the following operating conditions: 7 bar operating
overpressure, 35°C inlet temperature and -40°C pressure dew point
Classification acc. to PED 97/23/EG
Fluid group
Supply voltage
Class of protection
Min. / max. allowable pressure (PS)
Min. / max. allowable temperature (TS)
Noise pressure level (free-field measurement in distance
of 1 m)
DPS1...2A: Art.3 Par.3 / DPS3...8A: I
2
230V 50-60Hz (optional 115V 50-60Hz and 24V-DC)
IP65
4 to 16 bar
+1 to +50°C
up to 85 dB(A)
Individual operating conditions
Please contact the manufacturer when your operating conditions are not within the limits stated
above.
Options adapting the dryer to your operating conditions can be provided for numerous special
cases.
12
Safety notes
3. Safety notes
The dryer has been built according to state-of-the-art technology and recognised safety rules. However, there
is a risk of danger that every person working with the dryer must be aware of. In particular, improper handling
of compressed air and electricity may result in serious injury or death. If you are not experienced in using these
systems, please ask the relevant experts for help..
Note!
In order to prevent personal injury or damage, the safety notes must be observed when using
this dryer.
Observe the specific safety notes in the relevant chapters.
Observe the legal guidelines and the accident prevention regulations.
Observe the safety notes of the local site regulations.
3.1 Signs and instructions
Type plate of the dryer
The type plates show important information. Make sure that the type plates are always clearly readable.
The plate is placed at the left side of the dryer.
13
Safety notes
3.2 Danger zones at the dryer
1;4
2;5
3
6
7
Risk of injury from pressure-bearing parts
Risk of injury from electric voltage
Risk of injury from suddenly escaping compressed air
Risk of slipping due to split desiccant
Risk of injury from loose indicator tube
DANGER ! – Overpressure (1,4)
The dryer is under pressure.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical or electrical work on the dryer as long as the dryer is under pressure.
DANGER ! – Electric voltage (2;5)
The dryer is operated electric voltages up to 230 V.
Touching live parts may result in serious injury or death.
Work on electrical components must only be carried out by qualified and authorised personnel.
Use a voltage detector to make sure the dryer has been disconnected from the power supply and
that there are no live parts before starting maintenance work.
In the event of fire, do not extinguish the fire using water.
14
Safety notes
WARNING ! – Suddenly escaping compressed air (3)
The dryer is depressurised approximately every 6 hours using a silencer. A loud and strong airstream may carry small particles and cause injury.
Do not place any equipment in the vicinity of the silencer. The silencer must not be manipulated or
removed. Always wear hearing protectors when working in the vicinity of the dryer.
WARNING ! – Risk of slipping (6)
After desiccant replacement some amounts of desiccant may still remain on the floor.
The desiccant is very slippery and may result in serious fall injury.
Immediately remove residual desiccant properly from the floor.
3.3 General safety notes
DANGER ! – Overload
The dryer must only be operated with compressed air within the maximum allowable operating
conditions. The operating conditions are defined on the type plate (→ page 13).
Exceeding the maximum allowable operating conditions may result in serious injury or death.
It is the duty of the operator to ensure that the connected pressure source is safe-guarded such
that the maximum allowable operating pressure (PS) and the maximum allowable temperature
(TS) are not exceeded.
Please also refer to section "Intended use" (→ page 9).
DANGER ! – Unauthorised modifications
Modifications to the dryer or the dryer control system may result in dangerous operating states.
Violations may cause serious injury or death.
Never modify the dryer function by means of conversions.
Never carry out welding work on pressure-bearing parts.
Never change the control program of the dryer.
Any modifications of the dryer must be agreed on with the manufacturer and confirmed in writing.
DANGER ! – Suspected misuse
Using the dryer for unintended purposes may result in dangerous situations. Violations may cause
serious injury or death.
Never use the dryer as a climbing aid.
Never use the dryer as a support for external weight loads.
Never use dryer components for unintended application purposes.
Please also refer to section "Intended use" (→ page 9).
WARNING ! – Risk of falls
The dryer must never be used as a climbing aid. The dryer components will not provide adequate
support and parts of the dryer may break off. Disregard may lead to dryer damages and falls with
serious injuries.
When working at height only use approved climb assist systems.
15
Safety notes
CAUTION ! – Desiccant dust
Using the desiccant may lead to mineral dust formation.
Desiccant dust may cause eye and respiratory tract irritations.
Wear eye protection and a dust mask when handling the desiccant.
Desiccant
The desiccant used is not subject to labelling requirements according to the Hazardous Substances
Ordinance. Nevertheless, the common safety measures with regard to using chemicals apply.
The manufacturer will provide safety data sheets on request.
The desiccant may accumulate contaminants from the compressed air. Depending on the type of
contamination there may be a risk of injury or damage when using the desiccant. As the type of
contamination is not known to the manufacturer, the resulting risks cannot be evaluated in this
operating manual.
Additional safety notes
For additional safety notes, please refer to the relevant chapters.
16
Technical product description
4. Technical product description
4.1 Assembly drawing
Front View
7
5
6
4
8
9
3
10
14
11
2
12
13
1
1
2
3
4
5
6
Solenoid valves (solenoids: Y1, Y2, Y3, Y4)
Lower valve block (V1, V2, V3, V4)
Power Connector (power supply)
Control with display and operator keys
Upper check valve block (RV1, RV2)
with orifices (O1, O2)
Compressed air inlet (GJ)
7
8,12
9,11
10
13
Compressed air outlet (GO)
14
Oil indicator (OI), pressure reducer (PC) and
shut off valve (HV1)
Flat gasket
Demister-Pads (SD1), internal
Twin vessel (A1, A2); single vessel (A3)
Dryer support legs
17
Technical product description
Rear view
16
15
17*
18
21
19
22
23*
20
15
16
17
18
19
18
Differential pressure gauge (DPI01, DPI02)
Note: only for DPS6-8
Pressure gauge (PI01, PI02)
Connection for regeneration back-feed-line
(RV3) (*optional)
Pre-filter (F1) with filter element
Condensate drain (D1) and
Condensate outlet (CO)
20
21
22
23
Expansion silencer (X1) with regeneration
gas outlet (RO)
After- filter (F2) with filter element
Manual drain
Dew point sensor (MT01) (*optional)
Technical product description
4.2 Process flow diagram
Symbolic diagram of the dryer components, their locations and interconnections.
A
F
V
HV
RV
SD
X
D
Dryer vessel
Filter
Valve
Manual valve
Check valve
Sieve mesh / demister
Expansion silencer
Condensate drain
O
PI
DPI
MT
GJ
GO
RO
CO
orifice
Pressure gauge
Differential pressure gauge
Dew point transmitter
Gas inlet
Gas outlet
Regeneration gas outlet
Condensate outlet
19
Technical product description
4.3 Nozzle table
The valve block comprises several connections, which can be used alternatively to the standard connections.
DPS 1-4 A DPS 6-8 A
20
Function
GJ
3/8“
1/2"
inlet
GO
3/8“
1/2"
outlet
CO
1/8“
1/8"
Condensate outlet
N1
3/8“
1/2"
Dryer inlet
N2
3/8“
1/2"
N3
3/8“
1/2"
N4
3/8“
1/2"
Dryer outlet
Inlet for regeneration back-feed-line
Dryer inlet, alternative connection 1
outlet for regeneration back-feed-line
Dryer outlet, alternative connection 1
Dew point sensor MT01, alternative connection 1
N5
3/8“
1/2"
Dryer outlet, alternative connection 2
N6
1/8“
1/8“
Pressure gauge vessel A1
N7
1/8“
1/8“
Pressure gauge vessel A2
N8
3/8“
1/2"
Dryer inlet, alternative connection 2
N9
3/8“
1/2"
N10
3/8“
1/2"
Dryer inlet, alternative connection 3
Expansion
Regeneration gas outlet
N11
3/8“
1/2"
Expansion - Regeneration gas outlet, alternative
connection 1
Technical product description
4.4 Function description
The operation principle of the dryer is adsorption. The principle of moisture adsorption is water molecules
being attracted to a hygroscopic solid material (desiccant). This process is reversible and, after a regeneration
phase, the desiccant can be reused for drying.
For compressed air drying the compressed air flow is led through a vessel containing the desiccant and
brought into intensive contact with the desiccant. The desiccant removes moisture from the compressed air
and stores it in its internal structure. With continuous moisture loading of the desiccant the dryer performance
is reduced until the desiccant is saturated with moisture. The saturated desiccant then requires regeneration,
i.e. the moisture stored in the inner desiccant structure is removed again. The desiccant can then be reused for
drying.
Continuous operation of an adsorption dryer requires two vessels that are operated alternately. One vessel is
used for drying the compressed air (adsorption). In the other vessel the regeneration phases are carried out.
The change interval between adsorption and regeneration is approx. 5 Minutes*.
Adsorption phase
Duration approx. 3 Minutes to max. 2 hours*
The moist compressed air is supplied from a compressed air source (e.g. compressor) to the compressed air
inlet (GJ) of the dryer. The pre-filter (F1) removes dust and liquids from the compressed air flow. The lower
valve block (V1-4) forwards the compressed air to the vessel which is in "adsorption" mode (here A2). In the
lower part of the vessel the compressed air is decelerated and distributed over the vessel cross-section. The
compressed air passes the demister pad (SD1) and slowly
flows through the desiccant bed. The compressed air exits
the vessel via a second demister pad (SD1) and is forwarded
from the upper checkvalve block (RV1, RV2) to the compressed air outlet (GO).
The optional dew point sensor (MT01) checks the dryer
performance at the compressed air outlet.
During this time the second vessel is in standby mode and
waits for operation.
The adsorption phase is completed and the vessels are
switched over if...
1 stand-by – adsorption
... the cycle mode “CYCLE MODE – FIX“ has been pre-selected and a time of 5 minutes has expired.
... cycle mode “CYCLE MODE – VAR“ has been pre-selected and optional dew point measurement
has reached the selected limit value. The maximum allowable duration of the adsorption time is
gradually increased as long as the dew point stays good. Switch-over of the vessels is carried out
compulsorily after 2 hours at the latest.
21
Technical product description
For vessel switch-over the main valves (V1) is opened and shortly later the main valve (V2) is closed. The compressed air flows from one vessel to the other. A free flow path through the dryer is available at any time during switch-over. As a result, the task of drying is passed on to the other vessel without interruption.
Now vessel (A2) has gone “offline” and vessel (A1) has gone “online”.
Regeneration
Duration approx. 5 min*
After the "wet" vessel (A2) has completed the adsorption
phase and passed on the task to the second vessel (A1), the
first vessel (offline vessel) runs the regeneration phases.
Regeneration is divided into the following phases:
Expansion
Purging (regeneration)
Pressurisation
Standby
Expansion phase
Duration a few seconds*
After vessel switch-over the expansion valve (V4) is opened
and the "wet" vessel is depressurised. Via the silencer (X1)
the compressed air flows to the outside.
The next phase begins a after the vessel pressure has almost
reached atmospheric pressure.
1 adsorption - expansion
22
Technical product description
Purging (regeneration)
Duration approx. 4 min*
When the vessel pressure drops, dry air (regeneration gas) from vessel (A1) flows through the orifice (O2) into
vessel (A2).
The dry and pressureless regeneration gas is distributed
throughout the vessel cross-section and led through the
desiccant. The dry regeneration air vaporises the water
stored in the desiccant. In the form of steam the water,
together with the regeneration air flow, is then led via
valve (V4) to the regeneration outlet (RO).
The wet regeneration gas is led via the expansion silencer
(X1) to the outside
After a preset time of app. 4 minutes* has expired the
purge phase is ended and the next phase begins.
4 adsorption – purging (regeneration)
Pressurisation phase
Duration approx. 1 min
The pressurisation phase ensures that the two vessels have the same vessel pressure prior to vessel switchover.
The regeneration air valve (V4) is closed and dry compressed air continues to flow through orifice (O2) into
vessel (A2) gradually equalising the pressure in both vessels.
The next phase begins when the vessel pressure is almost the
same in both vessels.
After a preset time of app. 1 minute* has expired the pressurisation phase is ended and the next phase begins.
5 adsorption – pressurisation
23
Technical product description
Standby
Duration approx. 0 minutes to max. 2 hours
Vessel regeneration is now complete and the vessel is immediately ready to operate. During this phase the both
vessels stay connected via the orifice (O1) and (O2). Thus
the pressure in both vessels stays equal throughout the
complete stand-by phase.
When the current adsorption phase has been completed,
the vessels are switched over and the process is restarted.
6 adsorption - stand-by
* : Note
The above time values are variables which can be pre-set individually for each dryer. Therefore, deviations
from the above mentioned values are possible
24
Technical product description
4.5 Options
Various options are available for improved operation and special installation site conditions. For detailed information on the options or dryer modification to meet your operating and installation site requirements,
please contact the manufacturer or the responsible sales partner
Dew point sensor
Control of the adsorption phases changes from purely time-dependent vessel switch-over to load-dependent
operation when using the dew point sensor. The dew point sensor allows for considerable energy savings and
increased dryer performance.
Use of a dew point sensor is highly recommended.
Automatic start-up device (pressure maintaining valve)
The dryer must always be operated with an adequately high pressure in order to avoid excessive flow velocities in the dryer. There is a danger of damage to the dryer. (→ Page 55)
If the dryer is started against a pressureless compressed air network, the compressed air network must be
filled through the dryer. To ensure adequate operating pressure in the dryer the manual valve behind the dryer must be throttled and only be opened very slowly.
In the event the dryer is frequently started against pressureless compressed air networks (e.g. after the weekend) or if there is no personnel available for the start-up procedure, an automatic start-up device is useful. It
ensures that there is an adequately high pressure in the dryer at any time during operation.
Regeneration gas back-feed-line
The valve arrangement in the upper check valve block obstructs any reverse flow of compressed air through
the dryer. I.e. flow wise the dryer acts like a non-return valve.
The dryer and the piping upstream of the dryer might be depressurised when the pressure is decreased
through air loss (e.g. through purge loss during the current regeneration).
This can be avoided by using a regeneration gas back-feed-line.
A regeneration gas back-feed-line Is recommended for the following scenarios:
When the piping upstream of the dryer shall not be depressurised.
When the operation mode “CYCLE STOP – FINISH CYCLE” has been pre-selected and sufficient
quantities of regeneration gas shall be available. (→Page 30 )
When the compressor is operated via a pressure switch, that is installed upstream of the dryer and
... the volume between compressor and dryer is too small.
... the compressor is operated in a very narrow pressure band (i.e. the distance between start- and
stop-pressure is to small).
Further options include:
Special voltages: 115V – 50-60Hz , 24V-DC
Wall-mounting supports
Heated frost protection housing
Differential pressure gauges with electric alarm contact (only for DPS6-8)
Multistage pre- or after-filtration
Oil adsorber as third vessel flanged to the dryer. (can be added to an existing dryer)
25
Operating elements
5. Operating elements
The following sections describe the dryer components used for dryer monitoring and dryer operation.
5.1 Power connector
1 2
3
The power supply is connected via a female power connector (1) (part of the
dryer scope)
Loosen the mounting screw of the power connector and pull the power connector off the male power connector (2).
Now the control (3) is disconnected for the power supply.
The main valves open when the power supply is interrupted
Please note that both main valves will open instantly when the power supply is interrupted. I.e. a
pressureless vessel in regeneration mode will be pressurised via the main valve with a sudden
pressure blow.
We recommend to wait until both vessels have reached equal pressure before you remove the
female connector (e.g. when the cycle is close to the end of the “pressurisation phase” or during
“stand-by”
Switch off the dryer from remote
The dryer consumes only little power. Therefore the dryer can be switched off by externally interrupting the power supply.
A standard line switch installed in the power supply line is sufficient to switch off the dryer.
The dryer control is fitted with a digital input port (“compressor contact”). The dryer program can
be stopped and restarted via this “compressor contact” without interrupting the power supply. (→
Seite 36)
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Operating elements
5.2 Differential pressure gauges on the filters
The pre- and after-filter of some dryers are fitted with differential pressure
gauges. The differential pressure gauge gives evidence of the condition and the
degree of contamination of filter element.
For further information and instructions please refer to the manual of the filter
and the differential pressure gauge.
5.3 Pressure gauge
The vessel pressure of each vessel is shown on their respective pressure gauge
PI01 / PI02.
The pressure gauges allow to monitor the proper function of the dryer. When
the display shows “REG” the corresponding pressure gauge should indicate a
pressureless vessel.
27
Operating elements
5.4 Control System
The dryer is operated by means of a display and three function keys on the control system.
5.4.1
Function Keys and Display
1 Status LED indicating operating
states
2 Menu window
two-line LCD display showing program steps, remaining time, and
pressure dew point
3 Control keys
for selection and change of values /
parameters
The C1 control system is provided with supply voltage through the device plug. After having applied voltage,
the display shows the software version number for about 5 seconds.
Then the C1 control system switches to the operating mode. The C1 control system starts from the program
step in which it was shut down. All operating conditions and settings are saved persistently, i.e. after a power
failure the control system continues the program automatically.
Operation and entry of parameters is effected by means of the three function keys ( Item "Menu structure").
Arrow key "UP" for browsing the menu or incrementing figures (+).
Enter key for confirming changes.
Arrow key "DOWN" for browsing the menu or decrementing figures (-).
The menu window shows all relevant operating conditions, the corresponding remaining runtimes, and the
pressure dew point (optional). After pressing a key, the background of the display is lit for 2 minutes.
28
Operating elements
The following table shows the most important operating messages of the display and their meaning.
Display
ADS
REG
REP
CHG
ECO
STB
Meaning
Adsorption
Regeneration
Pressure build-up
Changeover
Economy mode
Standby mode
Moreover, the status LED informs about energy saving mode and alarm conditions.
LED
Green
Orange
Red (flashing)
Red (solid light)
5.4.2
Meaning
Normal operation
Economy mode
Alarm
Service required
ECO is shown for a vessel
Direct Indication
Press arrow key "UP“ or "DOWN" saving, and service timer status.
to obtain additional information on operating mode, energy
CYCLE MODE → Shows the operating modes VAR (variable cycle)
or FIX (fixed cycle).
The displayed remaining runtime corresponds to the variable
adsorption time extension which is limited to 2 hours. This time
depends upon the dew point course of the previous cycles (only
in mode VAR).
NEXT SERVICE → Indicates the time already elapsed (as a percentage value) until the service warning will be shown. This value depends on the actual utilisation of the dryer. For this value,
the operating hours are counted during which the dryer regenerates. Depending on the degree of utilisation, the period until
the display shows 100 % and the service warning is displayed
may be of different lengths.
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Operating elements
5.4.3 Menu Navigation
Access to the menu and thus to the parameters is protected by a password to prevent unauthorised intervention.
The password is:
Press the function keys as shown in a smooth and steady way!
Please consider that the password must be entered several times under certain circumstances!
The display shows:
The menu is divided into SERVICE and PARAMETER.
5.4.3.1
PARAMETER Level
Press the arrow key "UP" to access the PARAMETER level!
Various sensors for measuring and monitoring of pressure dew point, pressure, differential pressure, etc. as
well as potential-free switch contacts of the compressor control system (load/no-load detection) and an external pressure dew point measuring device can be connected to the control system.
Operating mode, dew point analysis, function check, and alarms of the dryer can be set individually.
These settings affect performance and energy consumption of the dryer.
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Operating elements
Operating modes
Setting of operating modes FIX and VAR
FIX → The dryer uses fixed cycle times assuming permanent full
load operation irrespective of the input conditions. Adsorption
and regeneration phase are of equal length in each cycle.
VAR → Changeover is effected when the measured pressure dew
point exceeds the set limit value or after lapse of the ECO time.
The adsorption time is being extended. Losses due to regeneration during operation of the dryer under partial load are thereby
reduced.
Setting of operating modes DIREKT STOP and FINISH STOP (also
refer to Section 5.5.)
DIREKT STOP → When opening the compressor contact (load /
no-load detection), the program of the control system is stopped
immediately irrespective of the program step. Expansion valves
V3 and V4 are no longer triggered. An unpressurised vessel is
pressurised if necessary. When closing the contact (input IN1)
again, the control system continues its program at this step.
FINISH CYCLE → Other than in operating mode DIREKT STOP the
program of the control system is stopped only after lapse of the
regeneration time. When closing the contact (input IN1) again,
the control system continues its program at step "Changeover".
Dew point evaluation
Setting of limit value of pressure dew point (see Section 5.9)
Changeover is effected when the measured pressure dew point
exceeds the set limit value.
Setting range: -100 °C to PDP ALARM SET -1K
[only effective with pressure dew point sensor being connected to
terminal X9 and CYCLE MODE VAR]
Setting of pressure dew point alarm (see Section 5.9)
If the measured pressure dew point exceeds the set limit value,
the pressure dew point is shown on the display and transmitted
via terminal X6.
The alarm parameter must be higher than the limit value for the
pressure dew point.
Setting range: PDP SET +1K to +20 °C
[only effective with pressure dew point sensor being connected to
terminal X9; CYCLE MODE VAR or FIX]
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Operating elements
Setting of measurement / evaluation of pressure dew point
In operating mode VAR, the dryer can be operated irrespective of
the pressure dew point of the compressed air at the dryer outlet.
For this purpose, either a pressure dew point sensor with output
signal 4…20 mA (terminal X9) or a potential-free switch contact of
an external pressure dew point measuring device (terminal X12)
can be connected to the control system.
ANALOG → Connection of a pressure dew point transmitter to
terminal X9 in the control system
DIGITAL → Connection of the potential-free switch contact of an
external pressure dew point measuring device to terminal X12 in
the control system
OFF → No pressure dew point sensor / switch contact connected
to terminal X9 and terminal X12.
Setting of pressure dew point display
ON → The currently measured pressure dew point is shown in
the display
[only with pressure dew point sensor being connected]
OFF → The currently measured pressure dew point is not shown
in the display. You can continue to operate the dryer in CYCLE
MODE VAR. The analogue output X10 on the printed circuit board
remains active. If the measured pressure dew point exceeds the
set limit value, the alarm is shown on the display and transmitted
via alarm contact X6.
Setting of alarm output via display and / or terminal X6
ON → If the measured pressure dew point exceeds the set value
for the "pressure dew point", the display shows ALARM DEWPOINT and at the same time the alarm is transmitted in a potential-free way via terminal X6 from the control system.
OFF → If the measured pressure dew point exceeds the set
alarm dew point, ALARM DEWPOINT is shown on the display and
no output is given via terminal X6 in the control system.
Setting of time interval for suppression of alarm output
The alarm can be inhibited for a certain period of time. Processrelated variation of the dew point and possible short-term exceeding of the limit value connected therewith are not displayed.
The alarm is transmitted only after lapse of the set time via display and terminal X6.
Setting range: 00:00:00h to 00:20:00 hours
You can go to the next step by means of the Enter key.
Setting of the pressure dew point unit
The pressure dew point can be displayed in °C or °F.
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Operating elements
Evaluation of pressure / differential pressure
Setting of differential pressure alarm of pre-filter or failure condensate drain / pre-filter if wired correspondingly (ALARM FILTER1)
The differential pressure of the pre-filter element can be monitored by connecting a differential pressure gauge with potentialfree switch contact to terminal X13 in the control system.
ON → The alarm will be transmitted via display and alarm relay.
OFF → No output of alarm on display and alarm relay.
Setting of differential pressure alarm filter 2 (ALARM FILTER2)
The differential pressure of the after-filter element can be monitored by connecting a differential pressure gauge with potentialfree switch contact to terminal X14 in the control system.
ON → The alarm will be transmitted via display and alarm relay.
OFF → No output of alarm on display and alarm relay.
Setting of time interval for suppression of differential pressure
alarms of pre-filter and after-filter
The alarm can be inhibited for a certain period of time. Processrelated changes of differential pressure by varying volume flow
and possible short-term exceeding of the limit value are thus not
displayed. The alarm will be transmitted only after lapse of the
set period via display and alarm relay.
Setting range: 00:00:00h to 00:20:00h
You can go to the next step by means of the Enter key.
Setting of overload alarm
If the control system detects a differential pressure alarm at the
same time on pre-filter and after-filter, this condition will be
evaluated as exceeding of the operating parameter "volume
flow".
ON → When simultaneously exceeding the differential pressure
of pre-filter and after-filter, the alarm is transmitted via display
and alarm relay.
OFF → No output of alarm on display and alarm relay.
Setting of time interval for suppression of overload alarm output
The alarm can be inhibited for a certain period of time. Processrelated variation of differential pressure on pre-filter and afterfilter and possible short-term exceeding of the limit value connected therewith are thus not displayed. The alarm is transmitted
only after lapse of the set time via display and terminal X6.
Setting range: 00:00:00h to 00:20:00 hours
You can go to the next step by means of the Enter key.
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Operating elements
Setting of function check (as from version 2.10)
By means of separate pressure switches on vessel A1 and A2, the
control system compares the operating pressure in the vessel to
the current triggering of valves V1 to V4. Each program step is
identified by corresponding vessel pressures and valve positions.
(→ Chapter 5.10)
ON → Function check is activated.
OFF → Function check is deactivated
Setting of time interval for suppression of alarm output "function check" (as from version 2.10)
Setting range: 00:00:00h to length of cycle step
You can go to the next step by means of the Enter key.
The alarm is transmitted only after lapse of the set time via display and terminal X6.
Setting of alarm output
This parameter applies to all alarms!
ON → An alarm will be transmitted continuously via display,
status LED, and terminal X6. The alarm output can only be
stopped by pressing the Enter key.
OFF → The alarm message via terminal X6 of the control system
is reset automatically as soon as the alarm cause is no longer
present. The alarm message via display and status LED remains
active.
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Operating elements
5.4.4
SERVICE Level
The SERVICE level can be accessed by actuating the arrow key "UP".
By pressing the arrow key "UP", the relevant menu item is selected. By pressing the Enter key, the parameter
level opens up. Here, the parameters can be changed by pressing the arrow keys "UP" and "DOWN". Afterwards, confirm the parameter by pressing the Enter key. The display returns to the menu item.
The numeric codes on the service level can also be set by arrow keys "UP" and "DOWN". By pressing the Enter
key, the cursor moves to the next digit until the entire code is entered.
Entry of four-digit numeric codes to confirm the service warning (see Section 5.12.)
Each digit of the ticket number is entered using the arrow keys.
You can go to the next step by means of the Enter key.
The four-digit numeric code ("service ticket") is enclosed when
purchasing original maintenance kits and can be used only once.
Display of previous load changes
For pressure vessels (here: drying agent vessels) which are subject to registration and for which the admissible number of pressure load changes (depressurise to atmosphere; pressurise up to
maximum admissible operating pressure) is defined, an inspection of the vessel is to be effected by relevant organisations (authorised person or authorised supervisory organisation, e.g.
German TÜV) after one half of the admissible number of pressure load changes.
The number of pressure load changes already effected is shown
here.
Display of current control of internal switching outputs Y1 to Y5
as well as A1 of control system
In the scope of maintenance and repair works, triggering of outputs Y1 to Y5 as well as alarm output A1 can be checked. Triggering cannot be influenced.
ON → The corresponding switching output is triggered
-- → The corresponding switching output is not triggered
ATTENTION: Terminal X6 is used as alarm output and shows -- in
case of alarm / error.
Display of condition of digital switching inputs IN 1 to IN 4
In the scope of maintenance and repair works, the function and
effectiveness of external switching elements (e.g. compressor
contact for compressor synchronisation) can be checked, here.
ON → The connected switching contact is closed.
OFF → The connected switching contact is open.
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Operating elements
5.4.5
Compressor Synchronisation Function
The control system allows to switch the dryer ON and OFF by means of terminal X11 via an external potential-free signal.
ATTENTION: The function "Compressor synchronisation" must only be used if the compressed air dryer is installed between compressor and compressed air storage!
A compressor contact or a remote ON / OFF switch can be connected to terminal X11.
In menu item PARAMETER CYCLE STOP you can select the response of the control system to the signal
at terminal X11. The manufacturer delivers terminal X11 with a jumper. If this jumper and / or the connected contact is opened, the control program is stopped according to the respective setting.
Two options are available:
In mode DIRECT-STOP the control system
stops immediately and outputs Y3 and Y4 are
no longer controlled. Any unpressurised vessel is pressurised if necessary. All time values
elapsed until then are "frozen" (stored).
36
In mode FINISH-CYCLE the control system is
stopped only after the regeneration phase;
valves Y3 and Y4 are no longer triggered.
Operating elements
Irrespective of how the cycle has been completed, the display shows STB for both vessels.
E.g. terminal X11 can be connected to the auxiliary contact of a compressor's contactor. Thereby, dryer
and compressor are synchronised. The dryer regenerates only when compressed air is generated. This
effect through the compressor contact does not have any influence on the triggering of inlet valves V1
and V2. Compressed air can flow through the dryer.
At this time, pending alarms in the control system are "frozen".
A dew point alarm is suppressed and displayed only after start of the dryer and lapse of the delay time.
The compressor contact can also be used as a remote switch and be connected to subordinate time or
emergency control systems.
If the compressor contact is connected to terminal X11 again, the control system continues at that point
where it was stopped.
5.4.6
Pressure Dew Point Measurement and Energy-saving Function
If the dryer is operating below its performance limit (i.e. not with maximum volume flow), it can generate a better (lower) pressure dew point value than prescribed by the set limit value. After regeneration,
the dryer switches to the ECO mode and delays the next vessel changeover and / or regeneration phase
until the measured pressure dew point exceeds the limit value or until the maximum admissible ECO
time elapses. Information on the maximum ECO time can be seen on the direct display (→ See Section
5.4.)
This setting can be made in menu item:
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Operating elements
The pressure dew point transmitter with output signal
4…20 mA is connected directly to terminal X9 on the
printed circuit board.
The potential-free switching output of an external pressure dew point measuring device is connected directly
to terminal X12. No 4-20 mA signal is transmitted at
terminal X10.
Contact connected to terminal X12: After lapse of the
regeneration phase, the control system switches to the
ECO mode.
Contact open at terminal X12: The control system is in
FIX mode (time-dependant).
The control system does not evaluate the dew point.
Changeover of the vessels is effected on a timedependant basis. No 4-20 mA signal is transmitted at
terminal X10.
The following items are possible only with setting:
The operating point of the dryer is prescribed by the changeover dew point. The latter can be set in
menu PDP SET by means of the two arrow keys "UP" and "DOWN". The factory setting is -40 °C.
The pressure dew point alarm is set to 10° to 20° above the changeover dew point. This is how an excessive sensitivity to alarms is avoided. Sudden variations of the measured dew point value caused by pressure or load changes within the equipment are dependant upon the process and thus normal.
Release of a dew point alarm in case of so-called dew point peaks can be avoided by increasing the delay
time.
38
Operating elements
5.4.7
Differential Pressure Monitoring of Filter
As an option, pre-filters and after-filters of an adsorption dryer can be fitted with differential pressure
gauges with integrated switch contacts. Using the C1 control system, the signals of these contacts can
be evaluated separately for pre-filter and after-filter and be displayed. Connection is provided via the
switching inputs of terminal X13 and terminal X14.
It is possible to switch the alarms ON and OFF individually and to delay their transmission.
5.4.8
Overflow Monitor
If pre-filter and after-filter housings are provided with a differential pressure gauge with integrated
switch contacts, an overflow evaluation can be effected by common query of both contacts. It is to be
assumed that the dryer is subject to excessive load (volume flow too high) if the differential pressure
switches at pre-filter and after-filter are activated at the same time.
In the factory configuration, the overflow indicator ALARM OVERFLOW is switched OFF (parameter
OFF).
The delay time set in item PARAMETER OVERF. ALARM DLY must always be lower than that of the separate differential pressure monitoring of the filters under PARAMETER FILTERALARM DLY.
The control system's function is not affected thereby.
5.4.9
Service Ticket
The C1 control systems counts the switching cycles of the dryer's valves. The load changes of the vessels
can thereby be displayed. Moreover, these values – in relation to the operating time of the dryer – allow
to determine the actual utilisation of the dryer and thus also the consumption of drying agent as well as
wear of pre-filter and after-filter. After having reached a limit value (approx. 1 year under normal conditions of use), a service warning is displayed.
In order to confirm the service warning, a four-digit numeric code – the so-called "service ticket" – is to
be entered. When purchasing FST maintenance parts and filter elements, the customer obtains a new
"service ticket" with the numeric code. Once entered the code cannot be used again. When the next
service warning is displayed, the control system expects a new code.
Each number of the service ticket is to be entered individually by means of the arrow keys. Press the Enter key to select the next digit.
If the service ticket was entered correctly, the message TIMER RESET DONE is displayed. If the service
ticket was not entered correctly, the message TIMER RESET FAIL is displayed.
If the service ticket was entered incorrectly, a new attempt can be made after about 2 minutes. Thereafter, the waiting time for the next attempt doubles each time the code is entered incorrectly until the
correct code is entered.
39
Operating elements
5.5 Allocation Text on Display / Triggering of Valves
The following overview shows the pointer positions of the pressure gauges and valve positions in relation to
the text on the display in the most important program steps.
Adsorption left / regeneration right
right vessel is unpressurised
left vessel is pressurised
valve V2 and valve V4 are triggered
valve V1 and valve V3 are not triggered
Bottom view of valve plate
Adsorption left / pressure build-up right
pressure build-up of right vessel
left vessel is pressurised
valve V2 is triggered
Valves V1, V3, and V4 are not triggered
Bottom view of valve plate
40
Operating elements
Regeneration left / adsorption right
right vessel is pressurised
left vessel is unpressurised
valve V1 and valve V3 are triggered
valve V2 and valve V4 are not triggered
Bottom view of valve plate
Pressure build-up left / adsorption right
right vessel is pressurised
pressure build-up of left vessel
valve V1 and valve V3 are triggered
valve V2 and valve V4 are not triggered
Bottom view of valve plate
41
Operating elements
5.6 Failure Analysis
The following table provides a list of possible failures and alarms, their root causes and actions to be taken.
Only one alarm is shown on the display of the control system. If the control system detects several alarms, the
last accumulated alarm is displayed.
Please observe the described safety notes when working on the dryer:
DANGER! – Overpressure (1;4)
The dryer is pressurised.
Suddenly escaping compressed air may result in serious injuries.
Never perform any mechanical or electrical works on the dryer as long as it is pressurised.
DANGER! – Electrical voltage (2;5)
The dryer is operated with electrical voltage of up to 230 v.
Touching of live components may cause serious injuries and death.
Works on electrical components must only be effected by qualified and authorised personnel.
Before starting any maintenance operations, make sure that the dryer was disconnected from the
power supply and that no components are live using a voltage tester.
In case of fire, do not extinguish using water.
WARNING! – Suddenly escaping pressure (3)
Pressure is released through a sound absorber about every 5 minutes. A loud and strong air blast
may sweep away small parts and cause injuries.
Do not place any small parts next to the sound absorber. The sound absorber must neither be manipulated nor removed. Wear ear protection when working close to the dryer.
42
Operating elements
Failure
Control system not in
working order (no
display) / status LED
not lighted
Display "ALARM
24VDC"
Solenoid valve(s)
is/are not triggered
No dew point value
shown on display
Cause
Faulty power supply to
control system C1
Device plug mounted incorrectly
Fine-wire fuse on printed
circuit board defective
Internal voltage monitoring
of control system released
Cable connection between
printed circuit board and
valve solenoid interrupted
Valve solenoid defective
No voltage applied to valve
output on printed circuit
board
Pressure dew point sensor
is not registered in the
control system
Sensor cable connected
incorrectly
Action
Check power supply
See Chapter "Installation Power Supply"
Replace fine-wire fuse, 500 mA slow-blow fuse;
length 20 mm
Remove voltage from control system, put into operation again after 30 seconds
Check cable connection and replace it if necessary
Replace defective component
Control system C1 defective; replace
Display "ALARM SENSOR" alternating with
dew point display
"+++°C"
Sensor defective
Register pressure dew point sensor in control system
(proceeding see
Section 5.4.3.1.)
Check connection of cable at plug to pressure dew
point sensor and at terminal X9 on printed circuit
board of the control system
Replace defective sensor
Replace sensor cable; pay attention to correct connection at sensor and control system (polarity)
Replace defective sensor
Short circuit sensor cable
Replace defective sensor cable
Sensor cable connected
incorrectly
Pressure dew point
indicated by control
system deviates from
separate measurement
Display
"ALARM DEWPOINT"
Scaling of connected pressure dew point sensor deviates from scaling stored
in the control system
Check connection of cable at plug to pressure dew
point sensor and at terminal X9 on printed circuit
board of the control system
Check sensor scaling
(factory setting of control system: 4 mA = -100 °C; 20
mA = +20 °C
Display "ALARM SENSOR" alternating with
dew point display "--°C"
Display
"ALARM OVERFLOW"
Sensor defective
Cable break
Dryer overloaded due to
deviating operating conditions
Both differential pressure
switches on pre-filter and
after-filter switched
Check operating conditions of compressed air dryer
(see Section 2.2.)
Check operating conditions of compressed air dryer
(see Section 2.2.)
Check filter elements of pre-filter and after-filter.
Excessive differential pressure by soiling
43
Operating elements
Failure
No or insufficient
pressure release of
right or left vessel
44
Cause
Pressure-release valves V3
/ V4 not open
Action
Check supply line to valves V3 / V4
Check valve solenoids of valves V3 / V4
Upper check valves leaky
Remove, clean check valves
High differential pressure
at sound absorber by
abraded drying agent
Replace sound absorber (proceeding see
Section 10.1.6.)
Transportation, setting up and storage
6. Transportation, setting up and storage
6.1 Transportation
DANGER ! – Damage
Damages of the dryer may lead to unpredictable hazardous situations.
Operating a damaged dryer may result in serious injury or death.
Never start to operate a damaged dryer.
DANGER ! – Risk of tilting
The centre of gravity is in the upper part of the dryer.
Tilting of the dryer may result in serious injury or death.
During transport and during loading and unloading secure the dryer against tilting using the lifting
lugs.
Although great care is taken damages caused by transportation cannot be ruled out. Therefore, always check
the dryer for possible damages after transportation and packaging removal.
The haulage contractor and the manufacturer or the sales partner must immediately be informed about any
damage.
Make sure to provide adequate lifting equipment when transporting and loading or unloading the
dryer.
Persons responsible for transportation must be appropriately qualified.
The dryer must only be lifted at the appropriate points using lifting equipment. (Transport pallet;
base frame; support feet) (→ see Figure).
Take the dryer weight and the maximum allowable load of the lifting and transport equipment used
into account.
Do not remove the packaging material until the dryer is moved to its final place of installation.
The national regulations for accident prevention must be adhered to.
45
Transportation, setting up and storage
6.2 Setting up
Please refer to section "Description of application" (→ page 9). Here, you will find a list of requirements on the
installation site.
Important data of the dryer can be found in section "Technical data" (→ page 12).
Additional requirements on the installation site:
The ground for dryer installation must be level and capable to carry heavy loads. Ground irregularities must be levelled in order for tensional forces not to occur in the piping of the dryer.
Because of noise emissions the installation site should not be in the vicinity of stationary workplaces.
Keep a service distance to walls and other systems around the dryer of 0,1 m, minimum.
During maintenance of the dryer components lifting equipment with adequate load capacity should
be available and access of this equipment to the dryer must be ensured.
The place of installation should not be in the vicinity of hallways in order to avoid risks to inexperienced persons.
Set up the dryer such that the pressure gauge and the control are clearly visible and can be operated properly.
We recommend anchoring the dryer into the ground using the holes in the vessel supports.
46
Transportation, setting up and storage
6.3 Storage
To maintain the dryer quality the dryer must be stored at a suitable location and properly prepared for storage.
The place of storage has to fulfil the following requirements:
Indoors
Protected against weather impact
Frost-free
Dry
If the dryer is to be stored immediately after delivery, it must only be protected against dust using an additional cover.
If the dryer has already been used for drying compressed air, please proceed as follows:
1) Disconnect the compressed air flow from the dryer by closing the valves up- and downstream of
the dryer.
2) Change the setting of the control to „CYCLE MODE – FIX“(→ Page 30 )
3) Operate the dryer for at least 4 more hours without compressed air flowing through the dryer. This
ensures the dryer to be stored with dry vessels. The more regeneration cycles are performed, the
dryer the desiccant.
4) Decommission the dryer. (→ Page 57)
5) Depressurise the dryer. (→ Page 58)
6) Disconnect the dryer from the electrical supply. (→ Page 26)
7) Disconnect the dryer from the compressed air system.
8) Close the inlets and outlets of the dryer using flange covers.
9) Place a desiccant bag in the control box.
10) Protect the dryer against dust using a cover.
To recommission the dryer after storage, please proceed as described for initial commissioning. (→ Page 54)
CAUTION ! – Moisture in electrical components
Long-term storage may lead to penetration of moisture into electrical components. This may result
in short circuits or damages to these components.
Check the electrical dryer components for internal moisture.
The necessary actions (insulation resistance test) must only be performed by a qualified electrician.
47
Installation
7. Installation
7.1 Installing the connecting pipelines
DANGER ! – Overpressure
The dryer is under pressure.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical or electrical work on the dryer as long as the dryer is under pressure.
DANGER ! – Overload
The dryer must only be operated with compressed air within the maximum allowable operating
conditions. The operating conditions are defined on the type plate (→ page 13).
Exceeding the maximum allowable operating conditions may result in serious injury or death.
It is the duty of the operator to ensure that the connected pressure source is safe-guarded such
that the maximum allowable operating pressure (PS) and the maximum allowable temperature
(TS) are not exceeded.
Please also refer to section “Intended use” (→ page 9).
DANGER ! – Bursting components due to external forces
The dryer components are not designed for externally applied forces and may burst due to additional load impact.
Bursting, pressure-bearing components may result in serious injury or death.
The support required for the connected pipelines has to be provided by the customer. Transmission of loads or stress into the connection flanges of the dryer is not permissible.
Proper installation is required for safe and error-free operation of the dryer.
Please observe the following steps when installing the compressed air pipeline (4) + (6):
Make sure that the dryer and the compressed air system are free from pressure. If the compressed
air system has to remain under pressure during installation, the shut-off valves have to be protected against unintentional opening. (2) + (8)
The compressed air source (e.g. compressor) must be safe-guarded against exceeding of the maximum allowable operating pressure using safety equipment.
The compressed air pipelines must be provided with shut-off valves used for disconnecting the dryer from the piping system (2) + (8). We recommend using shut-off valves with continuous opening
behaviour (e.g. shut-off valves with stem or gear handwheel). This valve behaviour avoids sudden
pressure equalisation between the piping sections.
We recommend using a bypass line (11) around the dryer.
The pipelines must be suitable for use with the maximum possible operating pressure.
The transfer points (threaded connectors) have to be compatible to the dryer inlet and outlet with
regard to nominal width, nominal pressure and type. (→ See general arrangement drawing in the
appendix)
Any vibrations or pulsation must not be transmitted to the dryer via the piping. This may damage
the desiccant, the dryer control system or other components. If required, install compensators or
pulsation absorbers in the pipelines to be connected.
48
Installation
Wet pipelines upstream of the dryer (4) should be installed at a slope in order for condensate (water and oil) in the line to be discharged in flow direction. If installation of an upright pipeline is inevitable, a condensate drain must be provided at the lowest point of the pipeline. This avoids condensate from being accumulated in the pipeline and suddenly being swept away by the compressed air
flow. These kinds of water shocks may damage the filter and dryer and must be avoided.
Prior to closing the connected pipelines, please check that there are no objects or contaminations
left in the pipelines.
Remove the end caps from the dryer inlet and outlet.
When checking the installation for leaks the maximum allowable operating pressure of the dryer
must not be exceeded. (→ See specification on the type plate, page 13)
Never fill the dryer with water when performing a pressure test. Liquids will destroy the desiccant!
Installation example
1
2
3
4
5
6
7
8
Compressed air inlet
Valve at compressed air inlet
Compressed air pipeline at inlet
Pre-filter with condensate drain
Dryer
After-filter with manual drain
Compressed air pipeline at outlet
Valve at compressed air outlet
9
10
11
12
13
14
15
16
17
Compressed air outlet
Bypass valve at inlet
Bypass line
Bypass filter with condensate drain
Bypass valve at outlet
Expansion silencer
Condensate line
Pressure maintaining valve
Regeneration back-feed-line
Please note that the standard scope of supply only comprises the dryer (5) in the grey outline.
49
Installation
7.2 Installing the power supply
DANGER ! – Electric voltage
The dryer is operated at electric voltages up to 230 V.
Touching live parts may result in serious injury or death.
Work on electrical components must only be carried out by qualified and authorised personnel.
Use a voltage detector to make sure the dryer has been disconnected from the power supply and
that there are no live parts before starting maintenance work.
In the event of fire, do not extinguish the fire using water.
CAUTION ! – Qualification and experience required
Persons working on and with the dryer have to be qualified personnel who, because of their qualification and experience, are familiar with handling compressed air systems and electrical systems.
If you are not experienced in using these systems, please ask the relevant experts for help. We
highly recommend that commissioning and maintenance be carried out by the manufacturer or
one of the authorised service partners.
DANGER ! – Moisture and contamination in electrical components
Moisture and contamination in electrical components may lead to damages resulting in unpredictable dangers for the operating personnel. As a consequence, short circuits and faulty circuits may
occur.
Always keep the control box and the terminal box dry and free from contamination and foreign
bodies.
Make sure the control box and the terminal box are securely closed during operation.
Qualified electrician required
Electrical connection of the dryer must only be carried out by a qualified electrician who is familiar
with reading electro-technical documentation.
For the data required for connecting and securing the voltage supply, please refer to the wiring diagram (→
see appendix: wiring diagram)
The power supply is connected via a female power connector on the dryer control box (part of the dryer
scope):
1) Use a cable that is sufficiently sized for the voltage and power consumption of the dryer when connecting the dryer to the power supply. (→ see appendix: wiring diagram)
2) Make sure the power supply is switched OFF and secure it against unintentional reclosing.
3) Pull the female power connector off the male power connector on the control box. (→Page 26)
50
Installation
4) Remove the mounting screw (1) from the connector
housing (2) first.
(The mounting screw serves as locking device for the
connector insert (3). The connector insert cannot be removed from the housing of the power connector before
the mounting screw has been removed.)
5) Carefully lift the connector insert (3) out of the connector housing using a small screw driver.
6) Lead the cable (8) through the various components of
the cable gland:
(5) gland plug
(6) washer
(7) rubber seal
Now lead the cable through the gland opening in the
connector housing (2).
7) Connect the leads of the cable according to the information in the wiring diagram.
8) Put the connector insert (3) back into the connector
housing (2). Put the connector seal (4) back onto the female power connector and tighten the cable gland (5).
1
5
6
7
8
2
3
4
1
2
Communication interfaces
The dryer is provided with different signal inputs and outputs for dryer control and dryer monitoring. These communication interfaces are used to implement improved monitoring and economical
operation of the dryer. For the interfaces, please refer to the wiring diagram ( → see appendix).
The connection of the signal cables is done via the cable glands on the bottom side of the control box:
1) Pull the female power connector off the male power connector on the control box in order to disconnect the dryer control from the power supply. (→Page 26)
2) Open the housing of the control box.
3) Individual ports for each IN and OUT signal are available on the circuit board. The allocation of these
ports is shown in the wiring diagram.
4) Choose the cable type according to the details stated in the wiring diagram.
5) Loosen a cable gland with free cable ports and remove the blind plug from the cable feedtrough.
51
Installation
6) Connect the leads of the signal cable according to the information in the wiring diagram.
The standard scope of the dryer includes the most frequently used connector plugs and cable feedtroughs.
Additional connector plugs and cable glands are required when all signal ports are used. Details of the connector plugs and cable glands can be found in the parts list of the wiring diagram.
52
Commissioning
8. Commissioning
CAUTION ! – Qualification and experience required
Persons working on and with the dryer have to be qualified personnel who, because of their qualification and experience, are familiar with handling compressed air systems and electrical systems.
If you are not experienced in using these systems, please ask the relevant experts for help. We
highly recommend that commissioning and maintenance be carried out by the manufacturer or
one of the authorised service partners.
8.1 Requirements for initial commissioning
All the requirements for unhindered commissioning must be fulfilled, especially when commissioning is carried
out by external qualified personal.
Make sure the following requirements for initial commissioning have been fulfilled:
External qualified personnel have been informed about the commissioning date in good time (2
weeks in advance, minimum).
External qualified personnel have been informed about the following in good time: special local
conditions; site-specific safety guidelines; required safety instructions, if necessary; specially required qualifications, if necessary; special personal protective equipment.
The place of installation can be freely accessed and entered without any risks.
Neighbouring construction sites do not affect commissioning.
The dryer is connected to the compressed air system using pipelines. (→ Page 48)
The dryer is connected electrically and voltage supply is ensured.
(→ Page 50)
The compressor is ready to operate and personnel for starting and operating the compressor are
present.
Compressed air can be delivered to the downstream system. A volume flow rate of at least 40% of
the nominal dryer performance can be led through the dryer.
The dryer is classified pressure equipment (see declaration of conformity in the appendix). Prior to
commissioning the dryer has to be approved by the local authorities according to the applicable national regulations. In the EU, the Pressure Equipment Directive 97/23/EC has to be observed.
Please check the following directly before commissioning:
The operating limits must not be exceeded. (→ Page 9)
The female power connector is pulled off and the control box is disconnected from the voltage
supply. (→ Page 26)
The shut-off valves provided by the customer and located upstream and downstream of the dryer
are closed.
The connections may have become loose due to dryer transportation. Make sure the piping connections, screwed joints and pneumatic lines are tightly secured. Tighten loose connections using
the appropriate tools.
53
Commissioning
Make sure the cable clamps in the control box are tightly secured. Tighten all the screw connections
using the appropriate tools.
Check all the components for visible damages. If there are defective components, commissioning of
the dryer is not permitted!
DANGER ! – Moisture and contamination in electrical components
Moisture and contamination in electrical components may lead to damages resulting in unpredictable dangers for the operating personnel. As a consequence, short circuits and faulty circuits may
occur.
Always keep the control box and the terminal box dry and free from contamination and foreign
bodies.
Make sure the control box and the terminal box are securely closed during operation.
8.2 Commissioning the dryer
DANGER ! – Overpressure
The dryer is under pressure.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical or electrical work on the dryer as long as the dryer is under pressure.
DANGER ! – Electric voltage
The dryer is operated at electric voltages up to 690 V.
Touching live parts may result in serious injury or death.
Work on electrical components must only be carried out by qualified and authorised personnel.
Use a voltage detector to make sure the dryer has been disconnected from the power supply and
that there are no live parts before starting maintenance work.
In the event of fire, do not extinguish the fire using water.
WARNING ! – Suddenly escaping compressed air (3)
The dryer is depressurised approximately every 6 hours using a silencer. A loud and strong airstream may carry small particles and cause injury.
Do not place any equipment in the vicinity of the silencer. The silencer must not be manipulated or
removed. Always wear hearing protectors when working in the vicinity of the dryer.
If all conditions required for commissioning are fulfilled, the commissioning procedure can be started. Perform
the following steps in the listed order.
54
Commissioning
8.2.1 Pressurisation of the dryer
CAUTION ! – Pressure blows and overload
Rapid opening of the valves may cause pressure blows and increased flow rates in the dryer. Pressure blows and increased flow rates may lead to damages of the dryer.
Open the valves very slowly and make sure that the flow noise does not become too loud. Pay
special attention when opening valves that can be opened rapidly by means of a pivoting movement.
The dryer valves are controlled by compressed air which is supplied from inside the dryer. For this reason the
first requirement for commissioning is reaching a minimum pressure of 4 bar in the dryer. Pressurise the dryer
as follows:
1) Make sure the compressed air system upstream of the dryer inlet is under pressure. If necessary,
the compressor must be started.
2) Open the valve upstream of the dryer inlet very slowly until hearing the first clear flow noise. Stop
the procedure when the flow noise becomes loud.
3) Observe the vessel pressure gauges. Pressurisation can be monitored on one of the two pressure
gauges. Make sure the pressure is only rising slowly. Pressurisation speed may not exceed 2
bar/min.
4) Check the system for leaks during pressurisation. In the event of leaks, pressurisation must be
stopped and the leaks must be repaired. To repair the leaks the dryer has to be depressurised
again. (→ Page 58)
5) If flow noise and a pressure increase is no longer present when further opening the valve, it can be
opened completely.
8.2.2 Opening the outlet valve
Special attention must be paid if the compressed air system downstream of the dryer is free from pressure.
1) Open the valve downstream of the dryer outlet very slowly until hearing the first clear flow noise.
2) Observe the vessel pressure gauges. Make sure there is no sudden pressure drop in the vessel. The
vessel pressure may not drop for more than 1 bar.
3) If flow noise is no longer present when further opening the valve, it can be opened completely.
4) Air can now freely flow through the dryer. If a volume flow is to be transferred via the dryer, commissioning should be performed quickly or the valve downstream of the dryer outlet should be
closed again, in order for the dryer not to be overladen with moisture during standstill.
Automatic start-up device
In the event the dryer is frequently started against a pressureless compressed air system, we recommend using an automatic start-up device. (→ Page 25)
The automatic start-up device prevents pressure blows and increased flow speeds from occurring
even when the compressor is started automatically.
55
Commissioning
8.2.3 Starting the dryer
1) Make sure the dryer is under pressure and that all the valves upstream and downstream of the dryer are opened in order for the compressed air to be able to flow through the dryer.
2) Put the female power connector onto the male power connector on the control box. (→Page 26)
Now the display is illuminated and the software version of the control appears on the display for a
few seconds. The dryer programs starts up. The start of the program is accompanied by a notable
clicking of the valves (V1-4)
3) Acknowledge any alarm messages, if required.
4) If any alarm messages are present that cannot be acknowledged, please proceed as described in
section "Error messages and measures". (→ Page 42 )
5) If there are no additional alarm messages, the dryer has been commissioned properly.
Monitor dryer operation. The dryer now performs the phases described in section "Function description". (→
Page 21)
56
Shutting down and restarting the dryer
9. Shutting down and restarting the dryer
9.1 Shutting down the dryer in case of emergency
1) Disconnect the power supply to the dryer. (e.g. by pulling the power connector off the control box.
(→ Page 26)
2) Close the valves upstream and downstream of the dryer.
3) The dryer has now been shut down.
9.2 Stopping the dryer
The dryer can be stopped by ...
1) Disconnecting the power supply.
2) Pulling the power connector off the control box.
3) Opening the “compressor contact”. . (→Page 36 )
Compressed air must no longer flow through the dryer. Otherwise, it is overladen with moisture.
Please note that the dew point becomes worse after a certain standstill period. Worsening of the dew point is
not a dryer error but is caused by external moisture slowly penetrating the static volume in the piping. As soon
as the compressed air flows again, the dew point will also become better again
9.3 Shutting down the dryer
1)
2)
3)
4)
5)
Stop the dryer as described in the above section.
Pull the power connector off the control box.
Close the valves upstream and downstream of the dryer.
The dryer has now been shut down.
Prior to working on the dryer it has to be depressurised.
57
Shutting down and restarting the dryer
9.4 Depressurising the dryer
WARNING ! – Exhausting pressure
Compressed air exhausting to the outside is very loud and may carry small particles.
This may cause hearing damage as well as injuries of the eyes and of the skin.
Close the openings used for releasing the pressure by means of a silencer suitable for the pressure.
Open the valves for releasing the pressure only very slowly.
Always wear eye and hearing protectors when working in the vicinity of the dryer.
1)
2)
3)
4)
Close the valves upstream and downstream of the dryer.
Open the valve on the after-filter or the condensate drain at the pre-filter, respectively.
Monitor the pressure on the pressure gauges of the dryer.
Wait until the pressure has dropped to 0 bar on both pressure gauges.
9.5 Restarting the dryer
Please proceed as described in chapter "Commissioning". (→ Page 54)
If the relevant requirements have already been fulfilled, the corresponding steps of the chapter can be
skipped.
58
Appendix and technical documents
10.
Maintenance and repair
DANGER ! – Overpressure
The dryer is under pressure.
Suddenly escaping compressed air may result in serious injury.
Do not carry out mechanical or electrical work on the dryer as long as the dryer is under pressure.
DANGER ! – Electric voltage
The dryer is operated at electric voltages up to 230 V.
Touching live parts may result in serious injury or death.
Work on electrical components must only be carried out by qualified and authorised personnel.
Use a voltage detector to make sure the dryer has been disconnected from the power supply and
that there are no live parts before starting maintenance work.
In the event of fire, do not extinguish the fire using water.
CAUTION ! – Qualification and experience required
Persons working on and with the dryer have to be qualified personnel who, because of their qualification and experience, are familiar with handling compressed air systems and electrical systems.
If you are not experienced in using these systems, please ask the relevant experts for help. We
highly recommend that commissioning and maintenance be carried out by the manufacturer or
one of the authorised service partners.
Please observe the following requirements for maintenance:
Observe the notes in section "Intended use". (→ Page 9)
Observe the "Safety notes" and the "General safety notes" in particular. (→ Pages 13, 15)
Provide the required spare parts. Only use genuine spare parts of the manufacturer.
The manufacture provides prepared spare part packets. (→ Page 5)
Maintenance must only be carried out if the dryer is depressurised and disconnected from the
power supply.
Please observe the following when completing maintenance work:
Make sure that all the flange connections and screwed joints are tight and sealed.
Carry out a leak test.
Make sure not to forget any tools, detergents or other objects in and around the dryer.
Commission the dryer as described on → page 54.
Maintenance contract
It is possible to conclude a maintenance contract with the manufacturer or one of their service
partners. A maintenance contract guarantees that the dryer has been maintained regularly by
qualified personnel and that only genuine spare parts are being used.
For contact data, please refer to → page 5.
For communication purposes, please specify the type and the manufacturing number. This information can be found on the type plate on the control box of the dryer. (→ Page 13)
59
Appendix and technical documents
10.1 Regular maintenance intervals
See page
Every 4
years
Every 2
years
Every
year
Maintenance activity
Every
month
Component
Every day
The following table gives an overview of routine maintenance tasks. The required activities are described on
the following pages.
Dryer and
dryer control
Visual check and function
monitoring
Dryer
Clean
Control box
Check if cable and terminals are securely fixed
63
Dew point sensor
(MT01)
Calibration required
64
Pre- and after-filter
Replace filter element
64
Expansion silencer (X1)
Replace
valves
(V1-V4 + RV1-2)
Replace sealing set
Demister (SD1)
Replace
*
64
desiccant
Check/replace
*
65
Activated charcoal
Check/replace
60
61
*
65
65
64
* = These activities should be carried out at the same time.
10.1.1 Visual check and function monitoring
1) Check the dryer for external damages.
2) Check the operating parameters of the incoming compressed air (pressure and temperature in particular). (→ Page 12)
3) Check the individual components for unusual noise development and leaks.
4) Check the error messages on the touch panel and, if required, proceed as described in section
"Alarm messages". (→ Page 42 )
5) Check if the condensate drains on the compressor and on the upstream filters are working properly.
6) Check the dew point.
60
Appendix and technical documents
10.1.2 Cleaning the dryer and dryer control
Make sure the surroundings are clean and tidy.
1) Clean the dryer surface using a slightly moist cloth. Do not use detergents containing acids or solvents.
2) Make sure the operating elements and the type plates can always be clearly read.
3) Keep water and metallic dust away from the electrical components.
10.1.3 Determining the residual oil content in the compressed air
The adsorber is equipped with an oil indicator. The oil indicator (QI) is used to periodically measure the residual oil content on the outlet side of the adsorber. The measurement can be performed by the operator in regular intervals.
1
Indicator tube (QI) with scale division (0 bis 2,0)
2
Threaded joint to fix the indicator tube with 3x O-ring
3
Needle valve (HV1)
4
Pressure reducer (PC) reduces the operation pressure to 7 bar measuring pressure
5
Vessel connection
The measuring principle is as follows: For the duration of the measurement, the needle valve (3) is opened so
that a pressure-reduced partial flow of purified compressed air is fed through the indicator tube (1). The indicator tube is secured by means of a union nut (2).
Any residual oil contained in the air leads to a change of colour of the scale segments of the tube, whereby a
higher concentration leads to more segments being coloured.
The change of colour is irreversible; after completion of the measurement, the indicator tube must thus be
replaced
To measure the residual oil concentration, proceed as described below. A template of the measuring log used
for this procedure is included in the appendix.
WARNING ! – Risk of loose indicator tube
Risk of damage to eyes! If not properly secured, the indicator tube might be propelled out of its
holder.
Prior to opening the needle valve, check that the union nut at the indicator tube is properly tightened.
When working at the oil indicator, always wear protective goggles.
61
Appendix and technical documents
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
Prepare measuring log and hold it ready.
Check union nut holding the indicator tube and retighten, if necessary.
At the indicator tube, mark the highest segment with a colour change, using a suitable pen.
Open needle valve by turning its handle anticlockwise. Write down start date and time of the
measurement..
Leave needle valve open for the desired duration of measurement (e.g. 5 hours)..
Subsequently, close the needle valve. Write down end time of measurement.
At the indicator tube, mark the highest segment with a colour change, using a suitable pen. Write
down the number of scale segments that have changed colour since the start of the measurement.
Determine the concentration in the above table, based on the duration of the measurement and
the number of scale segments with colour
Write down the residual oil concentration in ppm, parts per million] in the measuring log.
To determine the residual oil content in [mg/m3], multiply the above value by a factor 1.2. Write
down this value in the measuring log.
Example: Duration of measurement
No. of scale segment with colour change
Operating pressure during measurement
It follows ...
admissible residual oil concentration
for 0,2 scale change
for 0,4 scale change
for 0,3 scale change
residual oil content in g/m³
=
=
=
25 h
0,3 ( = approx 7mm)
8,5 bar (ü)
table 1. is to use !
0,09 ppm
0,18 ppm
(0,09 +0,18)/2 =
0,135 x 1,2
=
0,135 ppm
0,162 mg/m³
1) Choose a measuring interval (e.g. 4 weeks) and a duration of measurement (e.g. 4 hours)
2) To establish the remaining capacity of the purifying agent, you must carry out measurements of the
same duration at fixed intervals
3) Record the development of residual oil content over the time.
4) If the residual oil begins to rise more rapidly, the granulate is exhausted and must be replaced.
62
Appendix and technical documents
10.1.4 Replacing indicator tube
If all scale segments in the indicator tube show a colour change, the indicator tube is spent and must be replaced.
WARNING ! – Risk of loose indicator tube
Risk of damage to eyes! If not properly secured, the indicator tube might be propelled out of its
holder.
Prior to opening the needle valve, check that the union nut at the indicator tube is properly tightened.
When working at the oil indicator, always wear protective goggles.
1) Ensure that the needle valve (3) is closed and that the indicator tube (2) is not under pressure. To
close the needle valve, turn its handle clockwise.
2) Loosen the reducer (2) below the union nut, using an appropriate tool. Fix locknut with a second
roller wrench so that the needle valve (3) is not turning.
3) Exchanging the old indicator tubes against a new indicator tube. Pull the three O-rings on the new
indicator tube, so that stands out approx. 10 mm of lower pipe end from the O-rings
4) Check the union nut and the reducer below (2) to ensure that they are properly tightened, and new
indicator tube is properly fixed.
Open the needle valve (3) for a short time and check screw connections for tightness.
10.1.5 Checking if cable and terminals are securely fixed
The cable connections may be loosened due to transportation or vibrations. To prevent malfunctions from
occurring, all the cable connections must be checked to ensure that they are securely fixed. In the event of
heavy vibrations, inspection must be carried out more frequently. The necessary actions must only be performed by a qualified electrician.
1) Decommission the dryer. (→ Page 57)
2) Depressurise the dryer. (→ Page 58)
3) Disconnect the electrical power supply from the dryer and protect it against unintentional reconnection.
4) Make sure the cables and terminals are securely fixed by tightening them, if required.
Only use tools approved for electrical work.
5) Replace any damaged or corroded components.
6) After the control box has been reclosed, the dryer can be recommissioned again.
63
Appendix and technical documents
10.1.6 Calibrating the dew point sensor
The dew point sensor (MT01) is subject to ageing which leads to inaccurate measurements over time. Oil vapour and other contamination may render the sensor unusable over time. To prevent operating errors from
occurring the dew point sensor must be calibrated regularly.
Delicate dew point sensor
The dew point sensor contains a very delicate electronic system. Vibrations and shocks may lead
to sensor damage. Handle the sensor with particular care.
1) Decommission the dryer. (→ Page 57)
2) Depressurise the dryer. (→ Page 58)
3) Loosen the screw at the sensor cable socket and remove the cable socket. The cable socket is
kept at the dryer and will be reused.
4) Unscrew the sensor from the measuring socket using an appropriate wrench. Only hold the
sensor at the hexagon of the sensor housing!
5) Insert a calibrated sensor of the same type in the measuring socket.
6) Plug the cable socket onto the calibrated sensor and tighten the cable socket.
7) Pressurise the dryer and commission the dryer again. (→ Page 57)
Replacement program
The manufacturer provides a replacement program for old dew point sensors.
1) Order a new dew point sensor.
2) Exchange the sensors upon receipt of the new sensor.
3) Send the old sensor back to the manufacturer. For this purpose, use the protective packaging
of the new sensor. Only sensors that are undamaged can be recalibrated!
4) After receipt of the old, undamaged sensor the price difference of the new sensor and calibration will be credited. The old sensor remains at the manufacturer.
10.1.7 Replacing filter elements
The filter elements in the filters prevent particles and aerosols in the compressed air flow from entering the
system. The filter elements in the filters will be clogged over time and thus the compressed air flow is throttled. To prevent operating errors from occurring, the filter elements have to be replaced regularly. Check the
differential pressure gauge at the filter (if available). When exceeding approximately 350 mbar, the elements
should be replaced. Replacement is due after one year at the latest.
1) Depressurise the filter. (→Page 58)
2) For filter replacement please proceed as described in the operating manual of the filter.
64
Appendix and technical documents
10.1.8 Replacing the expansion silencer
The expansion silencer (X1) is contaminated by dust and condensate over time and thus the expansion air flow
is throttled. To prevent operating errors from occurring, the expansion silencer has to be replaced regularly.
1) Decommission the dryer. (→ Page 57)
2) Depressurise the dryer. (→ Page 58)
3) Lock the connecting part between valve V5 and expansion silencer (X1) using an appropriate tool in
order for valve (V5) not to turn.
4) Unscrew the old expansion silencer (X1) from the connecting part using your hands or an appropriate tool.
5) Screw the new expansion silencer (X1) in the connecting part and tighten it using your hands or an
appropriate tool and some sealing tape.
6) Pressurise the dryer and commission the dryer again. (→ Page 57)
10.1.9 Replacing the sealing set of the valves (V1-4) and the check valves (RV1-2)
The valves and check valves are subject to ware. The seals must be replaced in regular intervals. Spare part kits
containing all parts required for proper maintenance can be purchased from the manufacturer or one of his
service partners.
10.1.10
Checking and replacing the desiccant
CAUTION ! – Desiccant dust
Using the desiccant may lead to mineral dust formation.
Desiccant dust may cause eye and respiratory tract irritations.
Wear eye protection and a dust mask when handling the desiccant.
WARNING ! – Risk of slipping
After desiccant replacement some amounts of desiccant may still remain on the floor.
The desiccant is very slippery and may result in serious fall injury.
Immediately remove residual desiccant properly from the floor.
65
Appendix and technical documents
The desiccant is subject to ageing and its drying performance is reduced over time. The service life of the desiccant depends on numerous operating parameters and cannot be exactly predicted. The service life is approximately 3 to 5 years. Under very favourable conditions (e.g. oil-free compressed air) the service life may be
considerably longer. The quality of the desiccant can be assessed quite well when monitoring the operating
phases. If the adsorption phase is reduced significantly during operation in the „CYCLE MODE - VAR“ mode, the
desiccant should be replaced. Desiccant replacement is generally useful as a preventive maintenance measure
in conjunction with other repair work. (See advisory note below)
WARNING ! – Risk of falls
The dryer must never be used as a climbing aid. The dryer components will not provide adequate
support and parts of the dryer may break off. Disregard may lead to dryer damages and falls with
serious injuries.
When working at height only use approved climb assist systems.
Desiccant replacement is part of a large inspection run. At the same time, other maintenance activities should
be carried out. (See maintenance table → page 60)
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
Decommission the dryer. (→ Page 57)
Depressurise the dryer. (→ Page 58)
Remove the upper check valve block. (RV1, RV2)
Replace the demister-pads (SD1)
Provide an adequately sized container for the used desiccant.
Remove the used desiccant from the vessel using a suction device (e.g. vacuum cleaner).
Remove the used desiccant from the construction site.
Provide the new desiccant. In case two different desiccants shall be used, make sure that the two
different desiccant types create two separate layers in the vessel.
Distribute the different desiccant types equally to the two vessels.
In the event you are unsure which desiccant to fill in first, please contact the manufacturer.
Fill in the liquid waterproof desiccant (silica gel WS) first. It is the lower layer in the vessel.
Fill in the desiccant (molecular sieve) last. It is the upper layer in the vessel.
Fill up the vessel almost to its full extent. Make sure that the demister-pads (SD1) can still be inserted into the vessel.
Place the upper check valve block back onto the twin vessel (A1,A2) using a new flat gasket.
Close the twin vessel with the upper check valve block. First tighten the screws only lightly. Then
tighten completely in a crosswise manner.
Clean the bottom thoroughly from desiccant residues.
Slowly pressurise the dryer again. (→ Page 55) Carry out a leak test using a leak detection spray. In
the event of leaks the dryer will have to be depressurised prior to repairing the leaks.
Please note that, directly after desiccant replacement, the dew point may become worse. The new desiccant
will reach the full drying performance only after a longer operation period.
66
Appendix and technical documents
For the time directly after desiccant replacement it may be useful to select a dew point limit value as described
Desiccant
The desiccant used is not subject to labelling requirements according to the Hazardous Substances
Ordinance. Nevertheless, the common safety measures with regard to using chemicals apply.
The manufacturer will provide safety data sheets on request.
The desiccant may accumulate contaminants from the compressed air. Depending on the type of
contamination there may be a risk of injury or damage when using the desiccant. As the type of
contamination is not known to the manufacturer, the resulting risks cannot be evaluated in this
operating manual.
Increased dust contents after desiccant replacement
Filling the new desiccant in the dryer results in increased dust contents in the vessels. In the first
weeks after recommissioning the dust is forwarded to the downstream filter and the filter elements will deteriorate faster than during later operation. We therefore recommend to recommission the dryer using the old filter elements and to use the new filter elements and the new expansion silencer only after some weeks.
in the "Properly selecting the dew point limit value" advisory note. (→ Page 11)
Disposal
Dispose of the desiccant according to the local regulations.
Waste codes according to the Waste Catalogue Ordinance:
Non-contaminated desiccant: 06 08 99
Contaminated desiccant: The waste code will have to be determined by the waste producer
taking the type of contamination into consideration. The desiccant must be disposed of in an
appropriate disposal plant.
67
Appendix and technical documents
11.
Appendix and technical documents
11.1 Manufacturer’s declaration
Manufacturer's Declaration
Herewith we declare that the below mentioned products in their conception and design in which we placed
them on the market comply with the standards and directives mentioned below.
Manufacturer/authorised representative:
FST GmbH
Weiherdamm 17
57250 Netphen, Germany
Description of the assembly:
Dryer
Type DPS1A to DPS2A
Description of the pressure equipment constituting the assembly:
The dryer is described in the operating manual in detail.
Harmonised standards applied:
DIN EN ISO 12100-1; DIN EN ISO 12100-2; DIN EN ISO
14121-1; DIN EN 55011; DIN EN 61000-6-2; DIN EN
61000-3-2; DIN EN 61000-3-3
Other European Commission directives applied:
97/23/EC annex I
2004/108/EG
2006/95/EG
In case changes are made to the product without prior consultation and written approval of the manufacturer
this declaration will become void.
Signature
_________________________
Norbert Hannen
General Manager
68
Appendix and technical documents
11.2 Declaration of conformity
EC – Declaration of Conformity
acc. to the pressure equipment directive 97/23/EG
Herewith we declare that the below mentioned products in their conception and design in which we placed
them on the market have undergone the procedures of conformity assessment acc. to annex III of the above
mentioned directive and are in conformity with this directive.
Manufacturer/authorised representative:
FST GmbH
Weiherdamm 17
57250 Netphen, Germany
Description of the assembly:
Dryer
Type DPS3A to DPS8A
Description of the pressure equipment constituting
the assembly:
The dryer is described in the operating manual in
detail.
Conformity assessment procedure followed:
Module A
Harmonised standards applied:
DIN EN ISO 12100-1; DIN EN ISO 12100-2; DIN EN ISO
14121-1; DIN EN 55011; DIN EN 61000-6-2; DIN EN
61000-3-2; DIN EN 61000-3-3
Other Community Directives applied:
97/23/EC annex I
2004/108/EG
2006/95/EG
In case changes are made to the product without prior consultation and written approval by the manufacturer this declaration will become void.
Signature:
_________________________
Norbert Hannen, General manager
69
Appendix and technical documents
11.3 Tables for oil indicator
11.3.1 ≥ 7 bar (g)
Residual oil content in ppm (parts per million) at an operating pressure of 7 bar(g) and higher:
Scale
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
4,2
0,548
1,096
1,644
2,192
2,740
3,288
3,836
4,384
4,5
0,496
0,992
1,488
1,984
2,480
2,976
3,472
3,968
5
0,452
0,904
1,356
1,808
2,260
2,712
3,164
3,616
5,6
0,404
0,808
1,212
1,616
2,020
2,424
2,828
3,232
6,3
0,358
0,716
1,074
1,432
1,790
2,148
2,506
2,864
7,2
0,312
0,624
0,936
1,248
1,560
1,872
2,184
2,496
8,4
0,270
0,540
0,810
1,080
1,350
1,620
1,890
2,160
10
0,224
0,448
0,672
0,896
1,120
1,344
1,568
1,792
12,5
0,180
0,360
0,540
0,720
0,900
1,080
1,260
1,440
16,6
0,136
0,272
0,408
0,544
0,680
0,816
0,952
1,088
25
0,090
0,180
0,270
0,360
0,450
0,540
0,630
0,720
33
0,068
0,136
0,204
0,272
0,340
0,408
0,476
0,544
50
0,045
0,090
0,135
0,180
0,225
0,270
0,315
0,360
56
0,040
0,079
0,119
0,158
0,198
0,238
0,277
0,317
63
0,036
0,072
0,109
0,145
0,181
0,217
0,253
0,290
72
0,032
0,064
0,096
0,128
0,160
0,192
0,224
0,256
84
0,027
0,055
0,082
0,110
0,137
0,164
0,192
0,219
100
0,023
0,045
0,068
0,090
0,113
0,136
0,158
0,181
125
0,018
0,036
0,055
0,073
0,091
0,109
0,127
0,146
166
0,014
0,028
0,041
0,055
0,069
0,083
0,097
0,110
250
0,009
0,018
0,026
0,035
0,044
0,053
0,062
0,070
500
0,004
0,009
0,013
0,018
0,022
0,026
0,031
0,035
1000
0,002
0,004
0,006
0,008
0,010
0,012
0,014
0,016
[h]
Duration
70
Appendix and technical documents
11.3.2 6 bar (g)
Residual oil content in ppm (parts per million) at an operating pressure of 6 bar(g) :
Scale
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
4,2
0,640
1,280
1,920
2,560
3,200
3,840
4,480
5,120
4,5
0,580
1,160
1,740
2,320
2,900
3,480
4,060
4,640
5
0,524
1,048
1,572
2,096
2,620
3,144
3,668
4,192
5,6
0,454
0,908
1,362
1,816
2,270
2,724
3,178
3,632
6,3
0,416
0,832
1,248
1,664
2,080
2,496
2,912
3,328
7,2
0,364
0,728
1,092
1,456
1,820
2,184
2,548
2,912
8,4
0,312
0,624
0,936
1,248
1,560
1,872
2,184
2,496
10
0,266
0,532
0,798
1,064
1,330
1,596
1,862
2,128
12,5
0,210
0,420
0,630
0,840
1,050
1,260
1,470
1,680
16,6
0,160
0,320
0,480
0,640
0,800
0,960
1,120
1,280
25
0,105
0,210
0,315
0,420
0,525
0,630
0,735
0,840
33
0,078
0,156
0,234
0,312
0,390
0,468
0,546
0,624
50
0,053
0,106
0,158
0,211
0,264
0,317
0,370
0,422
56
0,047
0,093
0,140
0,186
0,233
0,280
0,326
0,373
63
0,042
0,083
0,125
0,166
0,208
0,250
0,291
0,333
72
0,037
0,074
0,110
0,147
0,184
0,221
0,258
0,294
84
0,032
0,064
0,096
0,128
0,160
0,192
0,224
0,256
100
0,027
0,054
0,080
0,107
0,134
0,161
0,188
0,214
125
0,020
0,041
0,061
0,082
0,102
0,122
0,143
0,163
166
0,016
0,032
0,048
0,064
0,080
0,096
0,112
0,128
250
0,011
0,021
0,032
0,042
0,053
0,064
0,074
0,085
500
0,005
0,010
0,016
0,021
0,026
0,031
0,036
0,042
1000
0,003
0,005
0,008
0,010
0,013
0,016
0,018
0,021
[h]
Duration
71
Appendix and technical documents
11.3.3 5 bar (g)
Residual oil content in ppm (parts per million) at an operating pressure of 5 bar(g) :
Scale
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
4,2
0,700
1,400
2,100
2,800
3,500
4,200
4,900
5,600
4,5
0,700
1,400
2,100
2,800
3,500
4,200
4,900
5,600
5
0,636
1,272
1,908
2,544
3,180
3,816
4,452
5,088
5,6
0,568
1,136
1,704
2,272
2,840
3,408
3,976
4,544
6,3
0,500
1,000
1,500
2,000
2,500
3,000
3,500
4,000
7,2
0,438
0,876
1,314
1,752
2,190
2,628
3,066
3,504
8,4
0,380
0,760
1,140
1,520
1,900
2,280
2,660
3,040
10
0,316
0,632
0,948
1,264
1,580
1,896
2,212
2,528
12,5
0,254
0,508
0,762
1,016
1,270
1,524
1,778
2,032
16,6
0,190
0,380
0,570
0,760
0,950
1,140
1,330
1,520
25
0,126
0,252
0,378
0,504
0,630
0,756
0,882
1,008
33
0,096
0,192
0,288
0,384
0,480
0,576
0,672
0,768
50
0,062
0,124
0,186
0,248
0,310
0,372
0,434
0,496
56
0,057
0,114
0,172
0,229
0,286
0,343
0,400
0,458
63
0,050
0,101
0,151
0,202
0,252
0,302
0,353
0,403
72
0,044
0,088
0,132
0,176
0,220
0,264
0,308
0,352
84
0,038
0,076
0,114
0,152
0,190
0,228
0,266
0,304
100
0,032
0,064
0,096
0,128
0,160
0,192
0,224
0,256
125
0,026
0,051
0,077
0,102
0,128
0,154
0,179
0,205
166
0,018
0,037
0,055
0,074
0,092
0,110
0,129
0,147
250
0,013
0,027
0,040
0,054
0,067
0,080
0,094
0,107
500
0,006
0,012
0,018
0,024
0,030
0,036
0,042
0,048
1000
0,003
0,006
0,009
0,012
0,015
0,018
0,021
0,024
[h]
Duration
72
Appendix and technical documents
11.3.4 4 bar (g)
Residual oil content in ppm (parts per million) at an operating pressure of 4 bar(g) :
Scale
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
4,2
0,940
1,880
2,820
3,760
4,700
5,640
6,580
7,520
4,5
0,860
1,720
2,580
3,440
4,300
5,160
6,020
6,880
5
0,780
1,560
2,340
3,120
3,900
4,680
5,460
6,240
5,6
0,700
1,400
2,100
2,800
3,500
4,200
4,900
5,600
6,3
0,624
1,248
1,872
2,496
3,120
3,744
4,368
4,992
7,2
0,550
1,100
1,650
2,200
2,750
3,300
3,850
4,400
8,4
0,470
0,940
1,410
1,880
2,350
2,820
3,290
3,760
10
0,390
0,780
1,170
1,560
1,950
2,340
2,730
3,120
12,5
0,310
0,620
0,930
1,240
1,550
1,860
2,170
2,480
16,6
0,236
0,472
0,708
0,944
1,180
1,416
1,652
1,888
25
0,156
0,312
0,468
0,624
0,780
0,936
1,092
1,248
33
0,116
0,232
0,348
0,464
0,580
0,696
0,812
0,928
50
0,080
0,160
0,240
0,320
0,400
0,480
0,560
0,640
56
0,073
0,146
0,219
0,292
0,365
0,438
0,511
0,584
63
0,062
0,124
0,186
0,248
0,310
0,372
0,434
0,496
72
0,055
0,110
0,165
0,220
0,275
0,330
0,385
0,440
84
0,047
0,095
0,142
0,190
0,237
0,284
0,332
0,379
100
0,039
0,078
0,117
0,156
0,195
0,234
0,273
0,312
125
0,032
0,063
0,095
0,126
0,158
0,190
0,221
0,253
166
0,024
0,048
0,072
0,096
0,120
0,144
0,168
0,192
250
0,016
0,032
0,048
0,064
0,080
0,096
0,112
0,128
500
0,007
0,014
0,022
0,029
0,036
0,043
0,050
0,058
1000
0,004
0,008
0,012
0,016
0,020
0,024
0,028
0,032
[h]
Duration
73
Appendix and technical documents
11.4 General arrangement drawing
Separate document
11.5 Process flow diagram
11.6 Wiring diagram
74
GJ
CO
RO
D1
F1
PDI
01
X1
N8
N1
N10
RV1
N3
N6
V3
V1
A1
PI
01
SD1
O1
SD1
O1
SD1
SD1
O2
V4
V2
A2
N7
PI
02
N5
N2
N11
N9
O1
RV2
N4
MT
01
SD2
SD2
N12
HVX
SO
PC1
QI
01
A3
HV2
OPTION
B
A
Rev.
O1
N13
PDI
02
F2
GO
3/8“
3/8“
3/8“
3/8“
N11
N12
N13
N14
1/2"
1/2"
1/2"
1/2"
1/2"
erstellt/design
geprüft/checked
C.Ruff, 01.09.10
T.Tappe, 01.09.10
Ersetzt/replacing:
ZPI-S-100079
1
A2
R&I-Fließbild DPS 1 bis 8 A
P&I-Diagram DPS 1 to 8 A
function
inlet
outlet
condensate outlet
inlet dryer
outlet dryer
inlet dryer, alternative 2
connection dew point sensor MT01, alternative 2
pressure gauge vessel A1
pressure gauge vessel A2
inlet dryer, alternative 3
expansion
regeneration air outlet
expansion - regeneration air outlet, alternative 2
inlet adsorber
outlet adsorber
outlet adsorber, alternative 2
Stuzentabelle / nozzle table
= DPI nur bei DPS 6 bis 8
= DPI only for DPS 6 to 8
Gas-Eintritt
Gas-Austritt
Regenerationsgas-Austritt
Kondensat-Austritt
Messluft-Austritt
GJ
GO
RO
CO
SO
gas inlet
gas outlet
regeneration gas outlet
condensate outlet
sample air outlet
Öl-Indikator mit Strömungsregelung oil indicator with flow control
Druckminderer 7bar[ü]
pressure reducer 7bar[g]
Drucktaupunkttransmitter
pressure dew point transmitter
QI
PC
MT
adsorber vessel
filter
valve
manual shut off valve
non-return valve
throttle valve with silencer
wire mesh / demister
exhaust silencer
condensate drain
orifice for regeneration flow
pressure gauge
differential pressure gauge
Trocknerbehälter
Filter
Ventil
Handabsperrventil
Rückschlagventil
Drosselschalldämpfer
Drahtgewebe / Demister
Expansionsschalldämpfer
Kondensatableiter
Lochblende / Reg.Gas-Düse
Manometer
Differenzdruckmanometer
A
F
V
HV
RV
HVX
SD
X
D
O
PI
PDI
Funktion
Eintritt
Austritt
Kondensat Austritt
Eintritt Trockner
Austritt Trockner
Eintritt Trockner, Alternative 2
Anschluss Taupunktsensor MT01, Alternative 2
Manometer Behälter A1
Manometer Behälter A2
Eintritt Trockner, Alternative 3
Expansion
Regenerationsluft Austritt
Expansion - Regenerationsluft Austritt, Alternative 2
Eintritt Adsorber
Austritt Adsorber
Austritt Adsorber, Alternative 2
26.07.12
CR
12.05.2011 TT
Datum/date Name
3/8“
N10
DPS 1-4 DPS 6-8
GJ
3/8“
1/2"
GO
3/8“
1/2"
CO
1/8“
1/8"
N1
3/8“
1/2"
N2
3/8“
1/2"
N3
3/8“
1/2"
N4
3/8“
1/2"
N5
3/8“
1/2"
N6
1/8“
1/8“
N7
1/8“
1/8“
N8
3/8“
1/2"
N9
3/8“
1/2"
HV1
Reg.Rück. entf.
Position dew point sensor (MT01)
Änderung/change
N14
Steigrohr
riser tube
Fallrohr
downcomer
F
E
D
C
B
A
1
1
4
IP 65
DPS
1-8 ::
<< 50VA
DPS1-8
50 VA
DPS
10-100 :: << 35
35VA
DPS10-100
VA
DPS
120-630
:
<
10VA
DPS120-630 : < 10 VA
DHW
10VA
DHM :8-66 : << 80
VA
DHM
:
80 VA
VA
DTC 45-1100
: << 10
DTC :
< 10 VA
0,5 A träge / slow-blow
Schutzart:
protection class
Leistungsaufnahme :
(abh. vom Trocknertyp)
power consumption
(depending on dryer type)
Anmerkung:
Note
2
EMV Prüfbericht:
EMV test report
Angewandte Richtlineien
und Normen :
applied guidelines
and standards
3
4
Nicht geeignet für Ventilstecker mit Gleichrichter.
Hierfür bitte Sonderplatine anfordern.
Not suitable for valve connectors with rectifyer. In this
case please ask for a special circuit board.
2010-2536-3871-RDE
2009/95/EG
EN 55011
EN 61000-3-2
EN 61000-3-3
EN 61000-6-2
230 V / 115V (+/-10%) 50/60 Hz
L1 / N / PE
Sicherung intern :
internal fuse
5
6
19.09.13
TT
5
6
A Filterkontakt = Öffner (NC) 08.08.11 CR
Rev.
Änderung / change
Datum/date Name
B Klemmen X9 +24 und GND
7
8
7
(Ers.f / repl.for:
-
)
A3
(Ers.d / rep.by:
ZEP-S-100064
-
Deckblatt /cover sheet
(Zeichnungsnummer / drawing no.)
)
4
von/of
1
Blatt/sheet
C1 Stromlaufplan 230/115V-AC
C1 wiring diagram 230/115V-AC
Datum/date Name (Benennung / title)
bear./design 07.09.10 C.Ruff
gepr./check 07.09.10 T.Tappe
4 Stückliste
parts list
3 Platine / Klemmenbelegung
circuit board / wire terminal
2 Aufbauplan
general arrangement
1 Deckblatt
cover sheet
Inhaltsverzeichnis
list of content
Stromlaufplan für Trocknersteuerung C1
Wiring Diagram for Dryer Control C1
3
Elektrische Anschlussdaten :
(= Ventil-Spannung)
power supply
(= solenoid valve voltage)
2
F
E
D
C
B
A
F
E
D
C
B
1
Vorderansicht
front view
188
150
3
2
3
Deckel mit Steuerung (innen)
box lid with control (inside)
Gerätesteckdose DIN EN 175301-803,
niedriges Gehäuse, für 6-8mm Kabel
female power connector DIN EN 175301-803,
low housing, for 6-8mm cable
2
4
4
4,2
6
19.09.13
TT
5
6
A Filterkontakt = Öffner (NC) 08.08.11 CR
Rev.
Änderung / change
Datum/date Name
B Klemmen X9 +24 und GND
(The number of glands varies with the application.
Free openings might be closed using blind plugs.)
4-port cable glands M25x1,5,
for cable 6-8mm
(Die Anzahl der Verschraubungen variiert je nach Anwendung.
Ggf. werden freie Öffnungen durch Blindstopfen verschlossen.)
4-fach Kabelverschraubungen M25x1,5,
für Kabel 6-8mm
Gehäuse (innen)
box (inside)
5
3
57,5
120
138
8
7
(Ers.f / repl.for:
-
)
A3
(Ers.d / rep.by:
ZEP-S-100064
(Zeichnungsnummer / drawing no.)
-
)
4
von/of
2
Blatt/sheet
Aufbauplan / gen. arrangement
C1 Stromlaufplan 230/115V-AC
C1 wiring diagram 230/115V-AC
Datum/date Name (Benennung / title)
bear./design 07.09.10 C.Ruff
gepr./check 07.09.10 T.Tappe
max. Durchmesser des Schraubenkopfes = 7mm
max. diameter of bolt head = 7mm
4,2
7
Seitenansicht
side view
2
A
1
1
180
150
F
E
D
C
B
A
F
E
COM
NC
NO
1
[max. 5A/250V-AC
max. 5A/30V-DC]
Alarmkontakt
alarm contact
A1
+24V
Sensor
GND
V1
X2
N
N
L
L
Y2
V2
PE
PE
max.
2,5mm²
X3
2
NO-valve=left vessel
NC-valve=right vessel
NO-valve=right vessel
NC-valve=left vessel
main valve V1 main valve V2
X4
(not for all dryers)
right vessel
left vessel
3
linker Behälter
4
pressurisation or
blow off valve V5
expansion
valve V4
expansion
valve V3
V5
(nicht für alle Trocknertypen)
Y5
rechter Behälter
V4
X5
max.
2,5mm²
[je max. 25 VA]
Druckaufbau- o.
Abblassventil V5
Y4
max.
2,5mm²
[each max. 25 VA]
Expansionsventil V4
Y3
V3
L
L
max.
2,5mm²
N
N
Hauptventil V1 Hauptventil V2 ExpansionsNO-Ventil=linker Beh.
NO-Ventil=rechter Beh.
ventil V3
NC-Ventil=rechter Beh.
NC-Ventil=linker Beh.
Y1
X1
L
L
max.
2,5mm²
N
N
max.
2,5mm²
PE
PE
X6
PE
PE
K1
L
L
X15
out
°C tp
+_
max. 1,5mm²
X9
4-20mA IN
nur eine Brücke gesetzt
only one jumper is set
19.09.13
TT
5
6
A Filterkontakt = Öffner (NC) 08.08.11 CR
Rev.
Änderung / change
Datum/date Name
B Klemmen X9 +24 und GND
PE
X8
230 V
I
-+
+24V
GND
gn
br
Taupunktsensor
dew point sensor
115 V
SENSOR
wh
+24V
Sensor
GND
GND
+24V
3
_
max. 1,5mm²
4-20mA
OUT
max. 1,5mm²
X10
+
L1
X11
IN 1
PE
potential free contact
X12
IN 2
X13
IN 3
N
X14
IN 4
+24VDC
Sannungsversorgung
power supply
230V, +/-10%, 50-60Hz
115V, +/-10%, 50-60Hz
7
(Ers.f / repl.for:
-
)
A3
(Ers.d / rep.by:
ZEP-S-100064
(Zeichnungsnummer / drawing no.)
-
)
4
von/of
3
Blatt/sheet
Stromlaufplan /circuit diagram
C1 Stromlaufplan 230/115V-AC
C1 wiring diagram 230/115V-AC
Datum/date Name (Benennung / title)
bear./design 07.09.10 C.Ruff
gepr./check 07.09.10 T.Tappe
Taupunkt
dew point
gn
br
bl
Standard Range :
4mA = -100°C tp
20mA = +20°C tp
2
Reange enspr. Sensor / range equ. to sensor
[24VDC; max. Bürde 250 Ohm]
[24VDC; max. ohmic resistance 250 Ohm]
0,5AT
L1
potentialfreier Kontakt
1
Komperssor Kontakt
F3
2
compressor contact
X7
potentialfreier Kontakt
1
Taupunkt-extern
8
potentialfreier Kontakt
N
2
dew point-extern
7
potential free contact
6
filter 1
1
Filter 1
D
5
potential free contact
C
N
N
2
potentialfreier Kontakt
1
Filter 2
B
PE
PE
2
filter 2
A
L
L
4
N
N
3
PE
PE
2
Typische Installation - Für Details siehe
Betriebsanleitung des Trockner
typical installation for details see dryer manual
max. 1,5mm²
potential free contact
1
IN1...IN4:
[24VDC; max. Leitungswiderstand 1 kOhm]
[24VDC; max. allowable resistivity 1 kOhm]
1
F
E
D
C
B
A
F
E
D
C
B
A
2
3
4
1
5
(max. 6)
1
1
2
(max. 5)
2
(max. 3)
2
(max. 3)
ca. 4
7
8
9
10
11
ca. 1
1
14
15
13
12
1
6
2
3
4
Gerätestecker-Flachdichtung, 30x30x1,5mm, NBR beige
(z.B. BINDER 16-8090-000)
Steckerteil (X1...X5: "Ventile" / X7: "Spannnungsversorgung"), PA
2 Pole, Raster 5mm, Schraube M3, Drehmoment 0,5Nm
Nennquerschnitt 2,5mm² (Leiter 0,2...2,5mm² /mit Endhülse 0,25...2,5mm²)
(z.B. Phoenix Contact MSTB 2,5/2-ST)
Steckerteil (X6: "Alarmkontakt"), PA
3 Pole, Raster 5mm, Schraube M3, Drehmoment 0,5Nm
Nennquerschnitt 2,5mm² (Leiter 0,2...2,5mm² /mit Endhülse 0,25...2,5mm²)
(z.B. Phoenix Contact MSTB 2,5/3-ST)
Steckerteil (X9: "Taupunktsensor"), PA
3 Pole, Raster 3,5mm, Schraube M2, Drehmoment 0,22...25Nm
Nennquerschnitt 1,5mm² (Leiter 0,14...1,5mm² /mit Endhülse 0,25...1,5mm²)
(z.B. Phoenix Contact MC1,5/3-ST-3,5)
Steckerteil (X10...14: "Signalkontakte"), PA
2 Pole, Raster 3,5mm, Schraube M2, Drehmoment 0,22...25Nm
Nennquerschnitt 1,5mm² (Leiter 0,14...1,5mm² /mit Endhülse 0,25...1,5mm²)
(z.B. Phoenix Contact MC1,5/2-ST-3,5)
Kabelverschraubung M25x1,5, lichtgrau RAL7035, PA
(z.B. SKINTOP® ST-M 25x1,5 Art.: 53111430)
Dichteinsatz für Kabelverschraubung M25, 4x5mm, NBR schwarz
(z.B. SKINTOP® DIX-M Art.: 53325450)
Verschlussstopfen für Kabeldurchführung D=5,5 x L=11mm, PA
(z.B. SKINTOP® DIX-DV 5,5x11 Art.: 53100055)
Blindstopfen für freie Gehäuseöffnung M25x1,5, lichtgrau RAL7035, PA
(z.B. SKINDICHT® BLK-M, Art.: 52006630)
Sicherung, 0,5 A, träge, 5x20mm
Pos. Anzahl / qty Beschreibung
1
1
Gehäuse, 150x150x57, RAL7035 lichtgrau, ABS (Dichtung: Neoprene)
(BOPLA Euromas II - ET218-LP)
2
1
Steuerplatine FST/FMW A0891010
3
1
Gerätesteckdose DIN EN 175301-803, niedriges Gehäuse, 3+PE, PA
(z.B. BINDER 43-1702-000-04)
4
1
Gerätesteckdosen-Profildichtung, NBR schwarz
Nennquerschnitt 1,5mm² / Kabeldurchmesser 6-8 mm
(z.B. BINDER 16-8088-000)
5
1
Gerätestecker DIN EN 175301-803, quadratisch, 4 Befestigungslöcher, 3+PE, PA
(z.B. BINDER 43-1715-000-04)
1
6
7
19.09.13
TT
5
6
A Filterkontakt = Öffner (NC) 08.08.11 CR
Rev.
Änderung / change
Datum/date Name
B Klemmen X9 +24 und GND
8
7
(Ers.f / repl.for:
-
)
A3
(Ers.d / rep.by:
ZEP-S-100064
(Zeichnungsnummer / drawing no.)
Stückliste / parts list
-
)
4
von/of
4
Blatt/sheet
C1 Stromlaufplan 230/115V-AC
C1 wiring diagram 230/115V-AC
Datum/date Name (Benennung / title)
bear./design 07.09.10 C.Ruff
gepr./check 07.09.10 T.Tappe
gasket for male power connector, 30x30x1,5mm, NBR beige
(e.g. BINDER 16-8090-000)
plug connector (X1...X5: "valves" / X7: "power supply"), PA
2 pole, pitch 5mm, screw M3, torque 0,5Nm
nom. cross section 2,5mm² (conductor 0,2...2,5mm² /with ferrule 0,25...2,5mm²)
(e.g. Phoenix Contact MSTB 2,5/2-ST)
plug connector (X6: "alarm contact"), PA
3 pole, pitch 5mm, screw M3, torque 0,5Nm
nom. cross section 2,5mm² (conductor 0,2...2,5mm² /with ferrule 0,25...2,5mm²)
(e.g. Phoenix Contact MSTB 2,5/3-ST)
plug connector (X9: "dew point sensor"), PA
3 pole, pitch 3,5mm, screw M2, torque 0,22...25Nm
nom. cross section 1,5mm² (conductor 0,14...1,5mm² /with ferrule 0,25...1,5mm²)
(e.g. Phoenix Contact MC1,5/3-ST-3,5)
plug connector (X10...14: "signal contacts"), PA
2 pole, pitch 3,5mm, screw M2, torque 0,22...25Nm
nom. cross section 1,5mm² (conductor 0,14...1,5mm² /with ferrule 0,25...1,5mm²)
(e.g. Phoenix Contact MC1,5/2-ST-3,5)
cable gland M25x1,5, light grey RAL7035, PA
(SKINTOP® ST-M 25x1,5 Art.: 53111430)
seal inlay for cable gland M25, 4x5mm, NBR black
(e.g. SKINTOP® DIX-M Art.: 53325450)
plug for seal inlay D=5,5 x L=11mm, PA
(e.g. SKINTOP® DIX-DV 5,5x11 Art.: 53100055)
blind plug for free housing opening M25x1,5, light grey RAL7035, PA
(e.g. SKINDICHT® BLK-M, Art.: 52006630)
fuse, 0,5 A, delayed, 5x20mm
description
housing, 150x150x57, light grey RAL7035, ABS (seal: neoprene)
(BOPLA Euromas II - ET218-LP)
control circuit board FST/FMW A0891010
female power connector DIN EN 175301-803, low housing, 3+PE, PA
(e.g. BINDER 43-1702-000-04)
profiled seal for female power connector, NBR black
nom. cross section 1,5mm² / cable diameter 6-8 mm
(e.g. BINDER 16-8088-000)
male power connector DIN EN 175301-803, rectengular, 4 mounting holes, 3+PE, PA
(e.g. BINDER 43-1715-000-04)
5
F
E
D
C
B
A