Operator manual Instruction manual Heatless desiccant air dryers with Elektronikon and purge control CD 80 - CD 100 - CD 150 CD 185 - CD 230 - CD 300
ATLAS COPCO www.atlascopco.com
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
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CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
INSTRUCTION MANUAL Congratulations on the purchase of your CD 80, CD 100, CD 150, CD 185, CD 250, CD 280 or CD 300 air dryer. It is a solid, safe and reliable machine, built according to the latest technology. Follow the instructions in this booklet and we guarantee you years of troublefree operation. Please read the following instructions carefully before starting to use your machine. While every effort has been made to ensure that the information in this manual is correct, Atlas Copco does not assume responsibility for possible errors. Atlas Copco reserves the right to make changes without prior notice. The drawings of the instruction manual can be found on the fold-out pages at the back of this manual.
CONTENTS Safety precautions ..................................................................... 4 Leading particulars .................................................................... 6 General description ..................................................................... 6 Main functions ............................................................................. 6 Control panel ............................................................................... 6
Operating instructions ............................................................ 14 Initial start up .............................................................................14 Start up ......................................................................................14 During operation ........................................................................15 Stopping.....................................................................................15
Display......................................................................................... 7
Maintenance ............................................................................. 15
Calling up other menus ............................................................... 7
General recommendations and precautions..............................15
Function of control programs....................................................... 7
Maintenance activities ...............................................................15
Counters menu............................................................................ 7 Test menu.................................................................................... 7
Troubleshooting....................................................................... 16
Modify params menu................................................................... 8
Technical specifications.......................................................... 16
Modifying parameters.................................................................. 8
Usage of the correction factors..................................................18
Modifying service plans ............................................................... 8
Usage of the correction factors..................................................18
Programming Clock function ....................................................... 8
Usage of the correction factors..................................................18
To modify a command ................................................................. 9
Dryer dataplate ..........................................................................18
Configuration menu ................................................................... 11 Service menu ............................................................................ 11 Saved data menu ...................................................................... 12 Protections ................................................................................ 12
Operation...................................................................................13 Description ................................................................................ 13 Pneumatic diagram ................................................................... 13
Installation.................................................................................14 Positioning................................................................................. 14 Piping ........................................................................................ 14 Electrical wiring ......................................................................... 14
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SAFETY PRECAUTIONS ! To be read attentively and acted accordingly before lifting, operating, performing maintenance or repairing the air dryer.
Introduction The policy of Atlas Copco is to provide the users of their equipment with safe, reliable and efficient products. Factors taken into account are among others: – the intended and predictable future use of the products, and the environments in which they are expected to operate, – applicable rules, codes and regulations, – the expected useful product life, assuming proper service and maintenance. Before handling any product, take time to read the relevant instruction book. Besides giving detailed operating instructions, it also gives specific information about safety, preventive maintenance, etc. These precautions are general and some statements will therefore not always apply to a particular unit. When handling, operating, overhauling and/or performing maintenance or repair on Atlas Copco equipment, the mechanics are expected to use safe engineering practices and to observe all relevant local safety requirements and ordinances. The following list is a reminder of special safety directives and precautions mainly applicable to Atlas Copco equipment. This brochure applies to machinery processing or consuming air or inert gas. Processing of any other gas requires additional safety precautions typical to the application and are not included herein. All responsibility for any damage or injury resulting from neglecting these precautions or by non-observance of ordinary caution and due care required in handling, operating, maintenance or repair, also if not expressly mentioned in this brochure or the instruction book(s), is disclaimed by Atlas Copco. If any statement does not comply with local legislation, the stricter of the two shall be applied. Statements in this brochure should not be interpreted as suggestions, recommendations or inducements that it should be used in violation of any applicable laws or regulations. Also refer to the safety precautions of the compressor and of the equipment which is used or which is part of the installation.
8 Pressure gauges shall be checked regularly with regard to their accuracy. They shall be replaced whenever outside acceptable tolerances. 9 Parts shall only be replaced by genuine Atlas Copco replacement parts. 10 Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against toxic vapours when cleaning parts in or with cleaning products. 11 Observe scrupulous cleanliness during maintenance and repair. Keep away dirt by covering the parts and exposed openings with clean cloth, paper or tape. 12 When performing any operation involving heat, flames or sparks on a machine, the surrounding components shall first be screened with nonflammable material.
Safety during use and operation 1 To lift an air dryer, all loose or pivoting parts shall first be securely fastened. 2 Lifting acceleration and retardation shall be kept within safe limits. 3 No external force may be exerted on the air valves, e.g. by pulling on hoses or by installing auxiliary equipment directly to a valve. 4 Close the compressor air outlet valve before connecting or disconnecting a hose. Ascertain that a hose is fully depressurized before disconnecting it. 5 When blowing through a hose or air line, ensure that the open end is held securely. A free end will whip and may cause injury. 6 Never play with compressed air. Never apply it to your skin or direct an air stream at people. Never use it to clean dirt from your clothes. When using it to clean down equipment, do so with extreme caution and use eye protection. 7 Wear ear protectors when environmental noise can reach or exceed 90 dB(A). Beware of long-time exposure to noise. 8 Periodically check that: – all safety equipment is in good working order, – all hoses, cables, wiring and/or pipes are in good condition, secure and not rubbing, – there are no leaks, – all fasteners are tight,
General safety precautions 1 The owner is responsible for maintaining the air dryer in a safe operating condition. Parts and accessories must be replaced if missing or unsuitable for safe operation. 2 Maintenance, overhaul and repair work shall only be carried out by adequately trained personnel; if required, under supervision of someone qualified for the job. 3 Maintenance work, other than routine attention, shall only be undertaken when the machine is standing still. 4 Before dismantling any pressurized component, the dryer or the equipment shall be effectively isolated from all sources of pressure and be completely vented to atmosphere. In addition, a warning sign bearing a legend such as “work in progress; do not open” shall be attached to each of the isolating valves. 5 Normal ratings (pressures, etc. ) shall be durably marked. 6 Never operate a machine or equipment beyond its rated limits (pressure, etc.). 7 All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be put out of action.
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– all electrical leads are secure and in good order, – air outlet valves and manifold, hoses, couplings, etc. are in good repair, free of wear or abuse. 9 Execute each vessel of pressure relief valve when dryer outlet valves are installed. 10 When the air is foreseen to be used as breathing air, provide adequate filters at the outlet of the dryer.
Safety during maintenance and repair Maintenance and repair work shall only be carried out by adequately trained personnel; if required, under supervision of someone qualified for the job. 1 Use only the correct tools for maintenance and repair work. 2 Before removing any pressurized component, effectively isolate the dryer from all sources of pressure and relieve the entire system of pressure. Do not rely on non-return valves (check valves) to isolate pressure systems. 3 Never weld on, or in any way modify, pressure vessels.
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4 Special service tools are available for specific jobs and should be used when recommended. The use of these tools will save time and prevent damage to parts. 5 When jobs on desiccant are executed, always wear dust masks.
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LEADING PARTICULARS
General description
Control panel
The CD air dryers are built to remove moisture from compressed air for industrial purposes. All units are designed for indoor use.
The control panel of the Elektronikon II regulator is shown in figure 2:
An overview of the main parts of the dryer units is given in figure 1A . 1 .....Tower A
10... Pressure dewpoint sensor
2 .....Tower B
11 ... Air inlet
3 .....3-way valve
12... Air outlet
4 .....Non-return valves
13... Pneumatic actuator
5 .....Solenoid valves
14... Pressure transmitters
6 .....Elektronikon® controller
15... Pneumatic valves
7 .....Silencers
16... Control air valve
8 .....Cubicle
17... Purge line
9 .....Display
1 .... Stop button Push button to stop the dryer. LED (8) goes out. 2 .... Start button Push button to start the dryer. LED (8) lights up indicating that the regulator is operative (in automatic operation). 3 .... Display Indicates messages concerning the dryer operating condition, a service need or a fault. 4 .... Scroll keys Keys to scroll through the display. 5 .... Tabulator key Key to select the parameter indicated by a horizontal arrow. Only the parameters followed by an arrow pointing to the right are accessible for modifying.
Main functions
6 .... Voltage on LED Indicates that the voltage is switched on.
Automatic control of the dryer
7 .... General alarm LED Is alight if a warning, service warning or shut-down warning condition exists or if a sensor is out of order. Blinks in case of an emergency stop.
The regulator maintains the pressure dewpoint between programmable limits automatically by defining the switching time. A number of programmable settings, are taken into account.
! A number of time-based automatic start/stop commands may be programmed (See page 8). Take into account that a start command will be executed (if programmed and activated), even after manually stopping the dryer. Protecting the dryer Shut-down warning
8 .... Automatic operation LED Indicates that the regulator is automatically controlling the dryer. 9 .... Function keys Keys to control and program the dryer. 10 .. Pictograph - Alarm 11... Pictograph - Automatic operation 12 .. Pictograph - Voltage on
If the dryer inlet temperature exceeds a programmed value, this will be indicated to warn the operator.
Function keys
Service warning
The keys are used:
A number of service operations are grouped in plans (called Service plans A, B and C). Each Service plan has a programmed time interval. If a time interval is exceeded, a message will appear on display to warn the operator to carry out the service actions belonging to that plan.
–
Warning A warning message also appears if: –
The pressure dewpoint exceeds a programmed value.
–
The pressure status in the dryer vessels is not correct.
To call up or to program settings.
–
To reset service message or an emergency stop.
–
To have access to all data collected by the regulator.
The functions of the keys vary depending on the displayed menu. The actual function is abbreviated and indicated on the bottom line of the display just above the relevant key. The most common abbreviations are listed below. Abbreviation Add
Add
To add dryer start/stop commands (day/hour)
Back
Back
To return to a previously shown option or menu
Canc
Cancel
To cancel a programmed setting when programming parameters
Delete
To delete dryer start/stop commands
Automatic restart after voltage failure For dryers leaving the factory, this function is made inactive. If desired, the function can be activated. Consult Atlas Copco.
Del
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Designation Function
Help
Help
To find the Atlas Copco internet address
Lim
Limits
To show limits for a programmable setting
Main
Main
To return from a menu to the main screen
Menu
Menu
Starting from the main screen: to have access to submenus
Menu
Menu
Starting from a submenu, to return to the previous menu
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Abbreviation
Designation Function
Mod
Modify
Prog
Program
To modify programmable settings To program modified settings
Rset
Reset
To reset a timer or message
Rtrn
Return
To return to a previously shown menu
Xtra
Extra
To find the module configuration of the regulator
Display
Program/ Function
Description
Saved data
Calling up the saved data: last shut-down, last emergency stop data
Counters menu Function
Normally, the display shows the operation status of the dryer, the pressure in the vessels and the abbreviations of function keys F1, F2 and F3. The main screen looks as follows: Vessel
A
B
bar
7.0
0.5
Regenerating
B
Menu
Unld
F1
F2
To allow the operator to call up the: –
running hours
–
regulator (module) hours (the hours the module has been under tension)
Procedure
~
1.
Starting from the Main screen: – press the key "Menu" (F1) – press the ~ key until the option "Counters" is followed by a horizontal arrow
F3 Main screen
– press the tabulator key to activate the menu By pressing the ~ key, the above-mentioned data can be found.
Calling up other menus
2.
Starting from the Main display:
Test menu
–
Use the ~ key for a quick look at the actual dryer status
–
Press the key Menu (F1). The option "Status data" will be followed by a horizontal arrow: – Press the tabulator key to select this menu. – Use the ~ key to scroll until the desired submenu is followed by a horizontal arrow and then press the tabulator key to select this menu.
Function To carry out a display test, i.e. to check whether the display and LEDs are still intact. Procedure 1.
For detailed instructions, consult the User manual for Elektronikon regulator.
– press the key "Menu" (F1) – press the ~ key until the option "Test" is followed by a horizontal arrow
Function of control programs Program/ Function
Description
Main
Shows in short the operation status of the dryer. It is the gateway to all functions.
Status data
- Protections - Service - Expansion Mods
Starting from the Main screen:
– press the tabulator key to activate the menu 2.
The option "Display test" will be followed by a horizontal arrow.
3.
After pressing the tabulator key, the regulator will generate a series of patterns on the display which enable the operator to check that each pixel still functions normally; at the same time the LEDs are lit.
Measured data Calling up: - actually measured data - status of some inputs Counters
Calling up the: - running hours - regulator (module) hours
Test
Allows a display test.
Modify params
Modifying the settings for: - parameters - protections - service plans - clock functions - configuration (time, date, display language, …)
Service
Calling up service plans and resetting the timers.
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Modify params menu Function
Programming Clock function To program time-based start/stop commands for the dryer.
The menu allows the operator to program:
Programming start/stop commands
–
Parameters.
In this example, the dryer will be programmed as follows:
–
Protection settings.
–
On Monday at 06:15 starting
–
Service plan settings.
–
On Saturday at 18:00 stopping
–
Clock settings.
1.
Starting from the Main screen:
–
Configuration settings.
– press the key "Menu" (F1) – press the ~ key until the option "Modify params" is followed by a horizontal arrow
Modifying parameters
– press the tabulator key to activate the menu Function
2.
To modify a number of parameters.
Use the ~ key to scroll until the option "Clock function" is followed by a horizontal arrow. Press the tabulator key, following screen appears:
Procedure 1.
Clock Function
Starting from the Main screen:
}
– press the key "Menu" (F1)
Not activated
– press the ~ key until the option "Modify params" is followed by a horizontal arrow
Menu
Mod
Del
– press the tabulator key to activate the menu
F1
F2
F3
2.
The first option ("Parameters") will be followed by a horizontal arrow.
3.
Press the tabulator key: the first item ("PDP level") and its setting will appear.
4.
Use the ~ key to scroll until the parameter to be modified is followed by a horizontal arrow.
3.
}
Monday Tuesday
~
Wednesday
Modifying service plans Function
Press the tabulator key, following screen appears:
4.
To modify the hour intervals for the Service plans. Service plans The service operations to be carried out are grouped in plans, called Service plan A, B or C. When reaching an interval, a message will appear on the screen indicating which Service plans are to be carried out.
! Always consult Atlas Copco in case any timer setting should be changed. The intervals must not exceed the periods below and must coincide logically. 5.
Menu
Mod
Del
F1
F2
F3
Use the | or ~ key until the day on which a command must be programmed is followed by a right pointing arrow. Press the tabulator key, following screen appears: --:--
-----------
--:--
-----------
} ~
--:--
-----------
Menu
Mod
Del
F1
F2
F3
Press the key "Mod" (F2). The first two dashes will flash. Use the
| or ~ key to enter "06". Press the tabulator key to jump to the following two dashes. Use the | or ~ key to enter "15". Press the tabulator key to jump to the row of dashes. Use the | or ~ key to enter the command Start. Press the key "Prog" to program the command: 06:15 Start 6.
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Programming the command to stop on Saturday at 18:00 is carried out in a similar way as described above.
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To activate/deactivate the timer 1.
To modify a command
Starting from the Main screen: – press the key "Menu" (F1)
Suppose the command to stop the dryer on Saturday 18:00 is to be modified: stopping at 17 o'clock instead of 18 o'clock:
– press the ~ key until the option "Modify params" is followed by a horizontal arrow
1.
– press the key "Menu" (F1)
– press the tabulator key to activate the menu 2.
– press the ~ key until the option "Modify params" is followed by a horizontal arrow
Use the ~ key to scroll until the option "Clock function" is followed by a horizontal arrow. Press the tabulator key, following screen appears:
– press the tabulator key to activate the menu 2.
Clock Function
}
Not activated
Starting from the Main screen:
Use the ~ key to scroll until the option "Clock function" is followed by a horizontal arrow. Press the tabulator key, following screen appears: Clock Function
Menu
Mod
Del
F1
F2
F3
3.
Press the key "Mod", "Not activated" starts blinking.
4.
Press the ~ key, "Not activated" changes into "Activated".
5.
Press the key "Prog".
}
Not activated
3.
Menu
Mod
Del
F1
F2
F3
Press the tabulator key, following screen appears:
Important:
Monday
1.
Tuesday
It is necessary to program the start/stop commands in successive order timewise, e.g.:
} ~
Wednesday
– 07.30 start
Menu
Mod
Del
– 17.00 stop
F1
F2
F3
– etc. 2.
Make sure that the clock function is activated (indicated as "Activated"). If not, the programmed start/stop commands will not be executed.
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4.
Scroll through the display until "Saturday" is followed by a horizontal arrow. Press the tabulator key. If necessary, scroll through the dryer start/stop commands until the command to be modified is followed by the horizontal arrow on the screen. Press the key "Mod", the first two digits of the command start blinking. Modify as required using the scroll keys, i.e. in the example above change "18" into "17" using the | key.
5.
If necessary, press the tabulator key to go to the next field to be modified, the minutes indication and the start/stop indication.
6.
Press the key "Prog" to program the new command or the key "Canc" to quit without reprogramming.
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To add a command
Adding a command between two existing commands
Adding a command at the end of an existing list
1.
The regulator does not allow to enter a new command which is situated timewise before the last command in the list.
2.
Scroll through the display until the command before which the new command must be entered is followed by the horizontal arrow and press the key "Mod". Change this command to the new command and press the "Prog". Press the ~ key, add the last command of the list and press the key "Prog".
1.
Starting from the Main screen: – press the key "Menu" (F1) – press the ~ key until the option "Modify params" is followed by a horizontal arrow – press the tabulator key to activate the menu
2.
Use the ~ key to scroll until the option "Clock function" is followed by a horizontal arrow. Press the tabulator key, following screen appears:
To delete commands 1.
Starting from the Main screen: – press the key "Menu" (F1)
Clock Function
– press the ~ key until the option "Modify params" is followed by a horizontal arrow
}
Not activated
– press the tabulator key to activate the menu Menu
Mod
Del
F1
F2
F3
2.
Suppose the command to stop the dryer at 18:00 must be added to the list of Monday:
Use the ~ key to scroll until the option "Clock function" is followed by a horizontal arrow. Press the tabulator key, following screen appears: Clock Function
}
Not activated
– 06:15 start 3.
Press the tabulator key, following screen appears:
}
Monday
Menu
Mod
Del
F1
F2
F3
Tuesday
~
Wednesday Menu
Mod
Del
F1
F2
F3
Deleting all commands Press the key "Del" (F3) in the screen above. A question to confirm the deleting operation will appear. Deleting all commands related to a specific day
4.
Scroll through the display until "Monday" is followed by a horizontal arrow. Press the tabulator key. Scroll through the dryer start/stop commands until the first empty command line is indicated by the horizontal arrow on the screen.
5.
Press the key "Mod", the first two digits of the command start blinking. Enter "18:00 stop" using the scroll keys | or ~ to modify a field and the tabulator key to jump from one field to another.
6.
Press the key "Prog" to program the new command or the key "Canc" to quit without reprogramming.
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Scroll through the display until the desired day is followed by a horizontal arrow. Press the key "Del" (F3). A question to confirm the deleting operation will appear. Deleting a specific start/stop command Scroll through the display until the desired start or stop command line is followed by a horizontal arrow. Press the key "Del" (F3). A question to confirm the deleting operation will appear.
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Configuration menu
Service menu
Function
Function
To reprogram a number of parameters.
–
To reset the service plans which are carried out.
–
To check for both the next service plans to be carried out and to find which service plans were carried out previously.
Procedure 1.
Starting from the Main screen: – press the key "Menu" (F1)
Service plans
– press the ~ key until the option "Modify params" is followed by a horizontal arrow
–
– press the tabulator key to activate the menu 2. 3.
Use the ~ key to scroll until the option "Configuration" is followed by a horizontal arrow. Press the tabulator key: The first option shown is "Time". If another option is desired, scroll through the display (using | or ~ keys) and select it using the tabulator key.
See Maintenance activities to find which service actions are related to these plans.
When the service plan interval is reached, a message will appear on the screen. Example Programmed service plan intervals ex-factory Service plans
Intervals
Service plan A
Every 4.000 running hours
4.
In case of option "Time", the second line on the screen indicates the actual setting, e.g. 14:30.
Service plan B
Every 8.000 running hours or yearly
5.
If it is desired to modify the time, press the key "Mod". If not, press the key "Menu" to return to the submenu.
Service plan C
Every 40.0000 running hours
6.
After pressing the key "Mod", the first field will blink. Modify the hours using the | or ~ keys. Then press the tabulator key to go to the next field (i.e. 30). The setting of this field can now be modified with the | or ~ keys.
Resulting service actions to be carried out
The bottom line of the display will show two options:
7.
Service actions according to
At
Service plan A, B and C
40.000 running hours
…
….
– "Prog" to program the new setting – "Canc" to cancel the new setting 8.
Proceed in a similar way for the other parameters to be modified.
Procedure 1.
Starting from the Main screen: – press the key "Menu" (F1) – press the ~ key until the option "Service" is followed by a horizontal arrow – press the tabulator key to activate the menu
2.
A screen similar to the one below appears: Service Timer
}
Running Hours hrs
3971
~
Menu F1
F2
F3 Service menu
The screen shows that the total compressor running time is 3971 hrs.
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3.
Press the tabulator key:
Saved data menu
Next Timer Level
Function
ABC
hrs
4000
Back
Rset
F1
F2
~
–
Last emergency stop data
Procedure
F3
1.
Service menu
4.
To call up some dryer data saved by the regulator. These data are:
Starting from the Main screen:
The screen shows that the next service plans to be carried out are plans A, B and C and that these plans are to be carried out each 4000 running hours.
– press the key "Menu" (F1)
Press the ~ key to find which service plans were carried out previously:
– press the tabulator key to activate the menu
|
Previous Timer Level
2.
The list of last emergency stop cases is shown.
3.
Scroll through the items to select the desired emergency stop item.
4.
Press the tabulator key to find the date, time and other data reflecting the status of the compressor at the last shut-down occurred.
AB
hrs F1
– press the ~ key until the option "Saved data" is followed by a horizontal arrow
2008 F2
F3 Service menu
The screen shows that service plans A and B were carried out at 2008 running hours.
Protections Minimum
Nominal
Maximum
5.
Stop the dryer, switch off the voltage and carry out the service operations related to plans A, B and C.
Protection Dryer inlet pressure for 11 bar units
3.5 bar
7 bar
11 bar
Dryer inlet pressure for 16 bar units
10.5 bar
12.5 bar
16 bar
6.
Switch on the voltage and scroll to the service screen. Press the "Rset" button (F3) to reset the timer. Confirm the question for resetting.
Dryer inlet temperature
1 °C
35 °C
45 °C
Dryer regenerating pressure
0 bar
0,7 bar
1 bar
Pressure dewpoint
-45 °C
-40 °C
-20 °C
Notes –
The "Rset" button only appears when the next Timer level is almost reached (from 400 running hours before elapsing of the service plan interval).
–
After pressing the | key, the Life time hours are shown (i.e. the number of hours elapsed since initial programming ex-factory). This counter is not taken into account.
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OPERATION
Pneumatic diagram Figure 3A shows the pneumatic diagram:
Description The construction of the air dryer is simple, reliable and easy to service. The dryer has two towers containing the adsorbing material or desiccant. This desiccant is a very porous grain material which can adsorb large amounts of water vapour. The operation cycle of the dryers is repetitive and is controlled by a factory-set timer and a PDP-sensor. While the desiccant in the first tower dries the compressed air, the desiccant in the second tower is being regenerated and vice versa. Regeneration of the desiccant is achieved by means of purge air from the drying tower.
A .... Tower A
PA ..Pneumatic actuator
AF .. Air filter
PR ..Pressure regulator
B .... Tower B
.......(only for 16 bar units)
CA . Control air valve
PV ..Pneumatic valve
IV ... 3-way valve
S.....Silencer
N .... Nozzle
SV ..Solenoid valve
NV . Non-return valve
TV ..Pneumatic valve
P1 .. Pressure transmitter 1 P2 .. Pressure transmitter 2
The compressed air entering the dryer is led to one of the towers by means of the inlet valve which is controlled by the pneumatic actuator. As the air flows upwards through the tower, the desiccant adsorbs the water vapours and the compressed air is dried. Once the top of the tower is reached, the air leaves the dryer via the non-return valve A small portion of the dried air does not leave the dryer immediately via the non-return valve but is expanded to atmospheric pressure and flows downwards through the other tower, regenerating the desiccant. This regenerating air is finally released via the exhaust valve and the silencer. A second small portion of the dried air flows via the control air valve, an air filter and the pressure regulator (only for the 16 bar units) to the solenoid valves which are controlled by the Elektronikon® and to the PDP-sensor The air leaving the solenoid valves (when energized) is used to control the pneumatic actuator and the pneumatic valves. After a certain period, the cycle will restart. The fully regenerated tower will now dry the air whereas the other tower will be regenerated. The PDP-sensor measures the pressure dewpoint of the air wich is leaving the drying tower. When the PDP temperature is below the set point then the drying tower will keep on drying until the PDP temperature exceeds the set point. Then the regenerated tower will start drying the compressed air and the other tower will be regenerated.
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INSTALLATION
Positioning It is important to keep the following in mind when installing the dryer: –
Place the dryer at a location where the temperature never exceeds the limits.
–
Provide enough space (approximately 80 cm) around the dryer for maintenance operations.
–
Place the dryer as level as possible and fix it firmly to the concrete.
–
When the compressor has NO built-in water separator, a water separator has to be installed before the CD dryer, in order to prevent free water from entering the dryer.
OPERATING INSTRUCTIONS ! In your own safety interest, always observe all relevant safety instructions.
! Some of the components mentioned in the operating instructions were not mentioned before in this manual, e.g. external inlet valve and external outlet valve. Refer to the chapter “Installation – Piping” for more detailed information.
Initial start up To start up the dryer for the first time or after a long period of standstill, proceed as follows: 1.
If installed, open the bypass valves of the dryer.
2.
Close the air supply towards the PDP-sensor and unplug the PDP-sensor.
3.
Cut off the air supply from the compressor towards the dryer by closing the external inlet valve.
4.
If installed, close the external outlet valve.
5.
Start the compressor and wait for pressure.
6.
Slowly open the external inlet valve.
7.
Check the connections of the dryer for air leaks and repair if necessary.
8.
Switch on the voltage to the dryer.
9.
Switch the dryer on by pushing button I on the Elektronikon.
Piping ! When installing the piping, make sure that all pipes are clean. To ensure correct operation of the dryer, it has to be fitted properly into the compressed air system consisting of a compressor, the dryer and an application. The recommended installation, as shown in figure 4, can only be used in case the particular application allows to bypass the dryer. AR .......Air receiver BV .......Bypass valves Together with the external inlet valve and the external outlet valve, the bypass valves allow the dryer and the filters to be serviced while non-dried air flows through the bypass system. D .........Dryer EIV ......External inlet valve To cut off the air supply towards the dryer. EOV ....External outlet valve To cut off the air supply towards the air consumer. If installed, provide each vessel with pressure relief valves. WSD....Water separator (optional) To prevent free water from entering the dryer. The water separator must always be installed in case of 'Standard Pack Units'.
10. Let the dryer operate for several hours with the external outlet valve closed. 11. Gradually open the external outlet valve. 12. As required, close the bypass valves of the dryer. 13. Press the stop button 0 and switch off the voltage to the dryer. 14. Plug the PDP-sensor. 15. Open the air supply towards the PDP-sensor.
! If the application allows air that is not dried optimally, the valve towards the air consumer may be opened even when the PDP temperature is too high. In this case, it will take more time for the desiccant to dry completely.
! Never overload the dryer as it will damage the desiccant. It may be recommended to install the air dryer upstream of the air receiver to prevent overload (e.g. after extending the dry air system). Consult Atlas Copco if in doubt. Concerning the piping, following checks should be carried out: –
plugs and pipes must be removed before connecting the pipes,
–
make sure that all pipes, filters, valves, etc. are clean and are installed correctly with or without bypass system,
–
make sure that no external force is exerted on the piping.
Start up If the dryer has not been used for more than 3 months, refer to the chapter “Initial start up”. In all other cases proceed as follows: 1.
Cut off the air supply from the compressor towards the dryer by closing the external inlet valve.
2.
Cut off the air supply towards the PDP-sensor.
3.
If installed, close the external outlet valve between the dryer unit and the dry air consumer.
4.
Slowly open the external inlet valve.
5.
Switch the dryer on.
! Before switching on the main power supply, check the
6.
Gradually open the air outlet valve.
voltage requirements in the technical specifications or on the dryer’s data plate.
7.
As required, close the bypass valves of the dryer.
8.
Open the air supply towards the PDP-sensor.
Electrical wiring The electrical wiring must comply with the local regulations. The air dryer must be earthed and protected by fuses against short-circuiting.
2920 7012 00
14
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
! Close the external inlet valve in case the compressor needs
MAINTENANCE
to be restarted. The air speed in the start-up phase of the compressor may damage the desiccant.
General recommendations and precautions During operation At regular intervals, check the PDP temperature. If the PDP temperature is too high let the dryer regenerate (by closing the outlet valve).
Stopping To stop the dryer proceed as follows: 1.
If installed and if necessary, open the bypass valves of the dryer so that the application will still receive compressed air.
2.
Close the external inlet valve between the compressor and the dryer and the external outlet valve between the dryer and the dry air consumer.
3.
Let the dryer run for a period without consumption, to depressurize the vessels.
4.
Switch the dryer off .
The dryer does not need any specific maintenance. Nevertheless, before carrying out any maintenance or corrective activity, read the following recommendations and safety precautions and act accordingly: –
Check that the dryer is switched off.
–
Disconnect pressure sources and vent the internal pressure of the system before dismantling any pressurized component.
–
Use original Atlas Copco spare parts only.
–
Check the correct operating after maintenance.
! Filters and valves installed between the compressor, the dryer and the air consumer may need other maintenance activities than those mentioned below (e.g. draining the filters and replacing the filter elements). Refer to the appropriate manual for more information.
Maintenance activities
! If the dryer is stopped for a longer period, close the inlet and outlet valve to avoid moisture from entering the dryer.
Daily –
Check PDP temperature.
Service plan A, at least once a year –
Replace the silencers.
–
Replace the filter elements DD/PD.
–
Exchange the dewpoint sensor: certificate is only one year valid. For updating, contact Atlas Copco customer center.
Twice a year –
Check for damaged wiring or loose connections.
–
Check for air leaks.
Service plan B
2920 7012 00
–
Replace the desiccant. In normal working conditions, the lifetime of the desiccant is approximately 5 years. It is recommended to have the desiccant replaced by an Atlas Copco service technician.
–
Replace the silencers.
–
Replace the filter elements DD/PD.
–
Exchange the dewpoint sensor: certificate is only one year valid. For updating, contact Atlas Copco customer center.
15
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
TROUBLESHOOTING Symptom
Possible cause
The PDP temperature is too high
The drain is not working correctly.
Corrective action Check the drain valve of the filter.
The air flow through the dryer is too high.
Check for correct application.
The outlet pressure is too low.
Check whether the compressor provides enough air for the application.
The inlet temperature is too high.
Check the compressor aftercooler.
The dryer produces a lot of noise
Check the silencer and its fixation to the unit.
Replace the silencer if necessary or correct its fixation.
Insufficient air leaves the dryer
Too much purge air escapes.
Check the condition of the solenoid valve and replace it if necessary. Also check the pneumatic valves and the 3-way valve.
TECHNICAL SPECIFICATIONS Specifications of CD 80 up to CD 300
APPLICABLE FOR 11 BAR AND 16 BAR UNITS
CD 80
CD 100
CD 150
CD 185
CD 250
CD 300
Nominal conditions Compressed air inlet temperature
35 °C
35 °C
35 °C
35 °C
35 °C
35 °C
Outlet pressure dewpoint
-40 °C
-40 °C
-40 °C
-40 °C
-40 °C
-40 °C
Outlet pressure dewpoint with “-70 °C” option
-70 °C
-70 °C
-70 °C
-70 °C
-70 °C
-70 °C
Humidity
100 %
100 %
100 %
100 %
100 %
100 %
Maximum ambient temperature
40 °C
40 °C
40 °C
40 °C
40 °C
40 °C
Minimum ambient temperature
1 °C
1 °C
1 °C
1 °C
1 °C
1 °C
Maximum compressed air inlet temperature
50 °C
50 °C
50 °C
50 °C
50 °C
50 °C
Minimum compressed air inlet temperature
1 °C
1 °C
1 °C
1 °C
1 °C
1 °C
Pressure drop through dryer
0.1 bar
0.15 bar
0.16 bar
0.2 bar
0.14 bar
0.19 bar
Pressure drop through dryer with “-70 °C” option
0.07 bar
0.1 bar
0.11 bar
0.14 bar
0.09 bar
0.13 bar
1 1/2 “
1 1/2 “
1 1/2 “
1 1/2 “
2“
2“
260 kg
300 kg
Limit values
Specific data
In- and outlet connection Desiccant type
Activated aluminium Al2O3
Desiccant type with “-70 °C” option Total amount of desiccant Recommende filter size
Molucular sieves 112 kg PD/DD/DDp 120
140 kg
10 W
10 W
Dimensions (LxWxH)
728x950x1695
728x950x1695
320 kg
340 kg
2920 7012 00
200 kg
PD/DD/DDp 120 PD/DD/DDp 150 PD/DD/DDp 175 PD/DD/DDp 280
Power consumption Mass
170 kg
10 W
10 W
10 W
PD/DD/DDp 280 10 W
848x1089x1731 848x1089x1731 960x1106x1816 1116x11173x1854 415 kg
445 kg
600 kg
650 kg
16
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
APPLICABLE FOR 11 BAR UNITS ONLY
CD 80
CD 100
CD 150
CD 185
CD 250
CD 300
7 bar
7 bar
7 bar
7 bar
7 bar
7 bar
Maximum compressed air inlet pressure (e)
11 bar
11 bar
11 bar
11 bar
11 bar
11 bar
Minimum compressed air inlet pressure (e)
4 bar
4 bar
4 bar
4 bar
4 bar
4 bar
Nominal capacity at dryer inlet
80 l/s
100 l/s
150 l/s
185 l/s
250 l/s
300 l/s
Nominal capacity at dryer inlet with “-70 °C” option
64 l/s
80 l/s
120 l/s
148 l/s
200 l/s
240 l/s
Purge air consumption (average during 1/2 cycle)
18 %
18 %
18 %
18 %
18 %
18 %
Purge air consumption with “-70 °C” option (average during 1/2 cycle)
23 %
23 %
23 %
23 %
23 %
23 %
Nominal conditions Compressed air inlet pressure (e) Limit values
Specific data
Time of a half cycle
180 s
180 s
180 s
180 s
180 s
180 s
Purge time
145 s
145 s
145 s
145 s
145 s
145 s
Correction factors for inlet flow Inlet pressure (bar) Correction factor Kp Inlet temperature (°C) Correction factor Kt
4
5
6
7
8
9
10
11
0.47
0.68
0.84
1
1.1
1.2
1.3
1.38
20
25
30
35
40
45
1
1
1
1
0.84
0.71
APPLICABLE FOR 16 BAR UNITS ONLY
CD 80
CD 100
CD 150
CD 185
CD 250
CD 300
12.5 bar
12.5 bar
12.5 bar
12.5 bar
12.5 bar
12.5 bar
Maximum compressed air inlet pressure (e)
16 bar
16 bar
16 bar
16 bar
16 bar
16 bar
Minimum compressed air inlet pressure (e)
11 bar
11 bar
11 bar
11 bar
11 bar
11 bar
Nominal capacity at dryer inlet
96 l/s
120 l/s
180 l/s
220 l/s
300 l/s
360 l/s
Purge air consumption (average during 1/2 cycle)
11 %
11 %
11 %
11 %
11 %
11 %
Nominal conditions Compressed air inlet pressure (e) Limit values
Specific data
Time of a half cycle
250 s
250 s
250 s
250 s
250 s
250 s
Purge time
195 s
195 s
195 s
195 s
195 s
195 s
Correction factors for inlet flow Inlet pressure (bar) Correction factor Kp Inlet temperature (°C) Correction factor Kt
2920 7012 00
11
12.5
13
14
15
16
0.89
1
1.04
1.11
1.19
1.24
20
25
30
35
40
45
1
1
1
1
0.84
0.71
17
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
Usage of the correction factors When the actual inlet pressure or inlet temperature differs from its nominal value, multiply the nominal capacity with the corresponding correction factor to obtain the correct capacity.
Dryer dataplate The dryer dataplate is shown in figure 5: 1.......Dryer type 2.......Dryer serial number
2920 7012 00
3.......Maximum pressure 4.......Year of construction
5.......CE mark
18
b
a
: : : : : : : : : : : : : : : : : : :
1X3 PE
2 4
U1
Q1
A
1 3
DOOR
UL : Class K5
A
Main switch: customers installation Main fuses : customers installation Main circuit breaker Circuit breaker control circuit Transformer for control voltage Elektronikon analog input module Remote START/STOP Emergency stop Inlet temperature sensor Pressure sensor tower A Pressure sensor tower B Solenoid valve 1 Solenoid valve 2 pressure dewpoint sensor Supply 24V/DC terminal strip (supply) terminal strip (earth) terminal strip (24V/AC) terminal strip (24V/DC)
4
1X6
3
1X6
b
T1
24V
1X0
L N
1 3
Q2
Maximum fuse with regards to shortcircuit protection of starter. Cable section may impose a fuse a smaller size. For correct transfo connections: see on trafo.
NOTES:
SO FO Q1 Q2 T1 E1 S1' S3 T01 P01 P02 Y1 Y2 PDP01 U1 1X0 1X3 1X5 1X6
Legend:
2 4
L N
1X0
A F0
a MAX. FUSE CSA : HRC Form II
5
1X5
2 4
6
1X5
20
1X5
2X10:8
K01
2X10:9
1X5 2
1X5 2
Y1 A2
A1
9
1
8
1
1X5
7
10
1
1X5
1X6
21
1X5
2X10:5
K02
2
1X5
Y2 A2
A1
12
2X10:6
11
13
gnd/V+
gnd
14
NO C NC NO C NC NO C NC
2X11
NO C NC NO C NC NO C NC
Y1
1
18
19
22
22
2
1
22
21
2
E1
9
8
7
1 1
16
1000
2 2
10
P
P
P02
1 2 3 1 2 3
1 2 3 1 2 3
P01
22
17
Mk IV B
1 2 3 4 5 6 7 8 9 10 11 12
T01
Pt
2X5
22 22
11
18
1X6 1X6 1X6
6
14
5
13
4
12
25
1X6 1X6 1X6
3
11
24
PDS11 PDS12 PDS13 DP DP DP
4
23
1
9
PDP01
sign gnd V+ sign gnd V+
2X2
NO C NC NO C NC NO C NC
2X3
K09
K08
sign
27
2X12
13
K07
12
26
29
30
31
32
33
34
Marking of connectors 2X5 to 2X12
General shutdown
General warning
Automatic operation
Manual operation
250VAC 10A AC11
AUXILIARY CONTACTS
28
36
1
1
4X4 9
AIE2
9
38
Gnd 4X3 I01 Gnd I02 Gnd I03 Gnd I04
37
sign
gnd
V+
Pressure transducer pin configuration
35
8 7 6 5 4 3 2 1 4X5
20
1X6 1X6 1X6 1X6
10
1X6
12
S3 11 S1' S4'
22
1X6 1X6 1X6
17
Y2
K06
K05
K04
K03
K02
K01
24 Vac
1
16
2
2X10
2X9
15
DI01
1 3
4
DI02
S0
3
DI03
2
DI04
a MAX. FUSE IEC : Class gL/gG
L1L2
DI05
1
5
6
emergency stop
DI06
L N PE
3
4
7
8
DP DD filter 2067 DI08
1 2
DP PD filter 2068 DI09
1 21
DP DDP filter 2069 DI010
remote START/Pr. STOP
DI07
Gnd Temp01 Gnd Temp02 Gnd Temp03 Gnd V+ P01 Gnd V+ P02
Supply
1 20
1 1 1 2 2 2 20 21
1 2 3 4 5 6 7 8 9 9 8 7 6 5 4 3 2 1
3 4 10 11 12 13 14 16 17 18 22 22 22
10 9 8 7 6 5 4 3 2 1 9 1
2920 7012 00 1 2 3 4 5 6 7
Customer's Installation
39
40
41
42
43
44
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300 9827 1207 00
19
800
1000
1000
800
2920 7012 00
Minimum free area to be reserved for the dryer installation.
5
- All pipes should be installed stress-free to the compressor unit. - For more information concerning air nets, cooling systems, etc. refer to the compressor installation manual.
Notes
2 3
6
8
7
1 4
The drainpipes (8) to the drain collector must not dip into the water. For draining of pure condensate water, install an oil/water separator. Consult Atlas Copco.
Waterseparator (7) : High efficiency waterseparator removes 90% in the compressor air when by-passing the dryer. If the WSD is not mounted in the compressor, a WSD need to be added in the installation downstream the vessel.
The installation sequence is Compressor (5) -vessel (6) -dryer. For the dryer there is no extra ventilation needed.
It is recommended to install pressure relief valves on each vessel of the dryer when there are ball valves installed at the inlet and the outlet of the dryer to isolate the dryers from the air net.
It is recommended to install by-pass pipes over each filter together with ball valves in order to isolate the filters during service operations, without distrubing the compressed air delivery.
An outlet dust filter type DDp (4) (particle removal down to 1micron) installed downstream the dryer. Should oil vapour and odours be indesirable, a QD carbon filter should be installed downsteam the DDp filter.
The inlet filter type DD (2) for general-purpose filtration (particle removal down to 1micron with a maximum oil carry-over of 0.5 ppm). A high efficiency PD-filter (3) installed downstream the DD- filter (particle removal down to 0.01 micron and max. oil carry - over of 0.01 ppm).
On both inlet filters a drain tube must be installed. The drainpipes to the drain collector must not dip into the water. For draining of pure condensate water, install an oil/water separator (Consult Atlas Copco).
The dryer unit (1) must be installed on a level floor suitable for taking the weight of the dryer. There must be a free space of 800mm around the dryer.
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300 Fig. 4 9827 1492 00
20
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
1A
2 1
2
3
4 5 4 9 9 9
2920 7012 00
8
11
10
7
12
6
21
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
5 1 2 3 4
Product type Serial number Max. work pressure(e)
bar
Year of manufacture
20
MADE BY ATLAS COPCO n.v. WILRIJK - BELGIUM
5 1617 5664 00
0038 3A
NV
NV
P1
N P2
CA AF
A
B
PR
SV
SV
PA IV PV
PV
TV
80 cm
TV
S
CD .. 80 cm
2920 7012 00
22
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
1 bar = 14.504 psi
1 m = 3.281 ft
1 g = 0.035 oz
1 mm = 0.039 in
1 kg = 2.205 lb
1 m³/min = 35.315 cfm
1 km/h = 0.621 mile/h
1 mbar = 0.401 in wc
1 kW = 1.341 hp (UK and US)
1 N = 0.225 lbf
1 l = 0.264 US gal
1 Nm = 0.738 lbf.ft
1 l = 0.220 lmp gal (UK)
t°F = 32 + (1.8 x t°C)
1 l = 0.035 cu.ft
t°C = (t°F - 32)/1.8
2920 7012 00
23
What sets Atlas Copco apart as a company is our conviction that we can only excel in what we do if we provide the best possible know-how and technology to really help our customers produce, grow and succeed.
There is a unique way of achieving that - we simply call it the Atlas Copco way. It builds on interaction, on long-term relationships and involvement in the customers' process, needs and objectives. It means having the flexibility to adapt to the diverse demands of the people we cater for.
It's the commitment to our customers' business that drives our effort towards increasing their productivity through better solutions. It starts with fully supporting existing products and continuously doing things better, but it goes much further, creating advances in technology through innovation. Not for the sake of technology, but for the sake of our customer's bottom line and peace-of-mind.
That is how Atlas Copco will strive to remain the first choice, to succeed in attracting new business and
No. 2920 7012 00 / DC 2006.12
to maintain our position as the industry leader.
