Manual Book Dryer PDF
Manual Book Dryer PDF
Instruction book
Atlas Copco
Refrigerant compressed air dryers
Instruction book
Original instructions
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as identified
in the Declaration of Conformity.
2012 - 01
No. 2920 7103 80
www.atlascopco.com
Instruction book
Table of contents
1 General description........................................................................................................5
1.1 INTRODUCTION...................................................................................................................................5
2 Controller.......................................................................................................................12
2.13 SHUT-DOWN....................................................................................................................................23
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3 Installation.....................................................................................................................34
3.4 PICTOGRAPHS.................................................................................................................................44
4 Operating instructions.................................................................................................46
4.1 WARNINGS......................................................................................................................................46
4.3 STARTING.......................................................................................................................................47
4.5 STOPPING.......................................................................................................................................48
5 Maintenance instructions............................................................................................49
6 Problem solving............................................................................................................51
7 Technical data...............................................................................................................55
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9 Declaration of conformity............................................................................................59
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1 General description
1.1 Introduction
General
FD air dryers remove moisture from the compressed air by cooling the air to near freezing point. This causes
the water to condense. The condensate is automatically drained. The dried air is warmed up before leaving
the dryer.
The dryer can be provided with an optional OSD (a device to separate the oil from the condensate) and
compressed air filters.
An Elektronikon® regulator (ER1) controls and protects the dryer.
General view
Reference Designation
AO Dry air outlet
AI Wet air inlet
ER1 Elektronikon® regulator
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Side view
The front panel and the side panel can be removed for service operations.
Reference Designation
1 Supply cable passage
Dm Manual drain valve
Da Automatic drain connection
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Reference Designation
AI Air inlet
AO Air outlet
OSD Oil/condensate separator (option)
GpOSD Pressure gauge of OSD (option)
EWD Electronic water drain
DD DD filter (option)
PD PD filter (option)
1 Service indicator (DD and PD filter)
2 Compressor
3 Condenser
4 Heat exchanger
5 Oil can (OSD and/or filters)
6 Condenser fan
7 Hot gas bypass valve
8 Capillary tube
9 Refrigerant dryer/filter
Description
Compressed air enters heat exchanger (1) and is cooled by the outgoing cold, dried air. Water in the incoming
air starts to condense. The air then flows through heat exchanger/evaporator (2) where the refrigerant
evaporates, causing the air to be further cooled to close to the evaporating temperature of the refrigerant. More
water in the air condenses. The cold air then flows through separator (3) where the condensate is separated
from the air.
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Flow diagram
Flow diagram
Operation
The liquid separator (10) ensures that only refrigerant enters the compressor.
Compressor (4) delivers hot, high-pressure refrigerant gas which flows through condenser (6) where the
refrigerant condenses.
The liquid refrigerant flows through dryer/filter (7) to the capillary tube (8). The refrigerant leaves the capillary
tube at evaporating pressure.
The refrigerant enters evaporator (2), where it withdraws heat from the compressed air by further evaporation
at constant pressure. The refrigerant leaves the evaporator and is sucked in again by the compressor.
Automatic regulation
The condenser pressure must be kept as constant as possible to obtain stable operation. The fan control switch
therefore stops and starts the condenser cooling fan (11).
If, under partial or no load, the evaporator pressure drops to 7.3 bar(e) (105.8 psig), the bypass regulator (5)
opens and hot, high-pressure gas is fed to the evaporator circuit to prevent the evaporator pressure from
dropping any further.
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Description
The dryers are equipped with an electronic water drain (EWD). The condensate from the condensate trap
accumulates in a collector. When the condensate reaches a certain level, it is discharged through the drain
outlet.
The condensate can also be drained by pressing the test button (1).
Control panel
Control panel
Reference Description
(1) Power
(2) Alarm
(3) Test
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Name Description
L1 LED "drain voltage on"
L2 LED alarm
F Funtions button
The control panel on top of the drain includes a multifunction button and two state display LED's. When LED
L1 is continuously on, this indicates that the solenoid valve is energized; when LED L1 is blinking, this
indicates that the valve is draining. If no water is supplied to the drain, the valve will make a short forced
opening every three hours. LED L2 indicates an alarm situation.
The test button can be used in three different ways:
• When it is pressed during normal operation, it starts a manual drain test.
• When it is pressed during an alarm, it resets the control logic.
• By pressing it for at least five seconds, the self-diagnosis routing will be started. This function is very
useful when the installation is finished, to check if the installation has been successful and to simulate the
alarm situation without having to wait for condensate to build inside the dryer. To return to normal
operation, just switch the drain off and on again.
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2 Controller
Control panel
General description
The Elektronikon regulator automatically controls the dryer, i.e.:
• Monitors the pressure dew point and the digital switches to ensure safe operation.
• Stops the dryer whenever necessary.
• Restarts the dryer when required.
• Allows selection of the control mode. See section Calling up/modifying dryer regulation mode.
In order to control the dryer and to read and modify programmable parameters, the regulator has a
control panel provided with:
• LED's, indicating the status of the dryer
• A display, indicating the operating conditions or a fault
• Keys to control the dryer and to access the data collected by the regulator
• Buttons to manually start and stop the dryer
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Detailed description
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LAN control
Temperature unit
Hours
Filter
Drain
Ambient temperature
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Main screen
When the voltage is switched on, the first screen is a test screen. The next screen is the main screen, shown
automatically:
Just after starting, the timer icon is displayed during a programmed time. After this period,
the timer icon disappears again.
Scroll buttons
Scroll buttons (12) can be used to scroll through all screens. The screens are divided into register screens,
measured data screens, digital input screens (numbered as <d. in>, <d. 1>, ...), parameter screens (numbered
as <P. 1>, <P. 2>, ...), protections screens (numbered as <Pr. 1>,...) and test screens (numbered as <t. 1>,...).
During scrolling, the numbers of the screens appear in a consecutive order. For most screens, the unit of
measurement and the related pictograph are shown together with the screen number.
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The screen shows the screen number <d. 1>, the unit used <hrs> and the related icon (operation). Press Enter
key (13) to call up the number of operating hours.
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Menu flow
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In the above example, the screen shows that the ambient temperature is 25 ˚C (77 °F).
This temperature is used by the regulation algorithm to calculate a safe dew point in the energy efficient mode
(see section Calling up/modifying dryer regulation mode).
The screen shows (from left to right) the status of the remote start/stop switch, the electronic condensate drain
contact, the flow switch and the contact of the (optional) filters (1 = closed, 0 = open contact).
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The number of hours is shown in <hrs> (hours) or in <x1000 hrs> (hours x 1000). In above example, the
screen shows the dryer has been running during 100 hours.
This screen shows the number of motor starts (x 1 or - if <x1000> lights up - x 1000). In the above example,
the number of motor starts is 10100.
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In the example shown, the screen shows the unit used (hrs) and the value (5000): the regulator module has
been in service during 5000 hours.
This screen shows the unit used <hrs> (or <x1000 hrs>) and the value <1191>. In the example shown, the
compressor has run 1191 hours since the previous service (i.e. the last time the timer was reset).
Service warning
A service warning will appear when the service timer has reached the programmed time interval. See section
Calling up/modifying service timer settings.
If the service timer exceeds the programmed time interval, alarm LED (5) will light up.
Stop the compressor, switch off the voltage and carry out the required service actions. See section Maintenance
instructions.
After servicing, reset the service timer.
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Description
A shutdown warning will appear in the event of:
• A too low or too high dew point temperature
• A too high ambient temperature
• A drain fault
• Too high pressure drop over the (optional) DD and PD filter
The dryer remains running. Alarm LED (5) is lit. The alarm disappears automatically when the abnormal
condition ends.
In the example shown, the dew point is 20 °C (68 °F) and the dew point icon is flashing.
If the dew point becomes normal again, the alarm will disappear.
In the example shown, the dew point is 30 °C (86 °F) and the ambient temperature icon is flashing. See section
Calling up ambient temperature to check the temperature.
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If the ambient temperature drops again below the programmed value, the alarm will disappear.
Drain alarm
The drain alarm appears when:
• The drain is not able to drain all the condensate.
• The compressed air pressure is too low.
• During initial start-up it may indicate that the automatic drain is connected wrongly. See section Problem
solving.
In case of a drain alarm, alarm LED (5) will light up and the related pictograph (drain) starts flashing.
Filter alarm
If the pressure drop over the DD and PD filter is too high, alarm LED (5) will light up and the related pictograph
(filter) starts flashing.
Remedy
• It remains possible to scroll through other screens (using Scroll buttons 12) to check the actual status of
the related parameters.
• If necessary, press the Stop button (11) to stop the dryer.
• If necessary, switch off the voltage, inspect the dryer and remedy.
• The warning message will disappear as soon as the warning condition disappears.
2.13 Shut-down
Description
The dryer will shut down:
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• In case the dew point temperature gets below - 0.5 °C (31.1 °F) (delay = 30 s)
• In case the ambient temperature is higher than 60 °C (140 °F) (delay = 60 s)
• In case of a problem with one of the temperature sensors
Alarm LED (5) will light up and the related icon (dew point or ambient temperature) starts flashing. The dryer
is stopped and will have to be restarted manually after remedying the problem.
After the dryer is stopped, it can take up to 5 minutes before the dryer can be restarted
(protection against too frequent starting).
The display still shows the dew point (30 °C - 86 °F), but the ambient icon is flashing.
The display shows <Err> and the dew point icon is flashing.
Press the Escape button (14) to reset and restart the dryer manually.
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To change: press Enter button (13) and - if necessary - enter the password (see section Activating password
protection). The actually selected control mode is blinking. Use Scroll button (12) to change the control mode.
Press Enter button (13) to program the new control mode or press Escape button (14) to cancel.
Calling up
Starting from the main screen, press the Scroll button (12) until <P. 2> is shown and then press Enter button
(13).
If necessary enter the password. The next screen shows that the function is ON or OFF. Press the Enter button
(13) to change this mode. Use the Scroll buttons (12) to select <On> or <OFF> and press Enter to program.
When this function is ON, use the Scroll buttons up or down (12) to see the node ID.
If desired the user can change this ID. Press the Enter button (13): the node ID value starts blinking. Use the
Scroll buttons (12) to change the node ID. Press the Enter button (13) to program the new node ID or press
the Escape button (14) to leave this screen or to cancel this operation.
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It is also possible to change the channels. The controller has 4 channels. When changing the channels, the
controller can act as a Mk IV controller (a previous version of the controller). To set the channels, go to the
screen where the node ID is visible. Press the Scroll button down (12). The following screen appears:
Press the Enter button (13) to modify the setting. The utmost left value will blink. Change this value by using
the Scroll buttons (12). Press the Enter button (13) to confirm. Change the other values in the same way, as
required.
After modifying the settings, the screen may look as follows:
Calling up
Starting from the Main screen, press the Scroll button (12) until <P. 3> is shown and then press Enter button
(13).
The next screen shows either <OFF> or <On>. If <On>, press the Enter button (13) to modify it to <OFF>.
Use the Scroll buttons Up or Down (12) to scroll between the items in this list (<IP> for IP address, <Sub>
for Subnetmask or <GAtE> for Gateway):
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Modification
Press the Enter button (13) and if necessary enter the password. The first digits are blinking. Use the Scroll
buttons Up or Down (12) to modify the settings and press Enter (13) to confirm. Modify the next digits the
same way. The standard IP address is set as 192.168.100.100.
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Description
The dryer has two regulation modes:
• Regular mode
The dryer achieves the lowest possible dew point.
• Energy efficient mode
The dryer will regulate the dew point between the best achievable dew point and a safe dew point.
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Press enter key (13) to modify this value (a password may be required), the value starts blinking. Use arrow
keys (12) to modify this setting.
Press enter key (13) to program the new value and to return to the parameter screen.
Press Escape button (14) to return to the parameter screen.
Description
The flow switch monitors the compressed air flow through the dryer. If the function is active and when no
flow is detected, the controller stops the dryer. The controller will restart the dryer when air flows through
the dryer.
If the flow switch is not active, the dryer keeps running independently from the air flow.
The option <StbY> is not used and has therefore the same result as selecting <OFF>.
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Display test
Starting from the Main screen, press Scroll buttons (12) until <t. 1> is shown and then press Enter button (13).
The display now shows all icons that can be displayed:
Description
This function allows the compressor to restart automatically after a power failure.
This parameter, accessible in screen <P. 7>, can only be modified after entering a code. Consult Atlas Copco
if this function is to be activated.
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• Password (<PASS>) appears on the screen. Press the Enter button (13).
• The screen shows the password status (ON (<On>) or OFF (<OFF>). Press Enter button (13) to modify.
• Change the value with Scroll buttons (12).
• Select <On> and press Enter button (13).
• Enter the new password and press Enter button (13) to confirm.
• Enter the password again and press Enter button (13) to confirm.
• <On> appears on the display. Press Escape button (14) to return to the previous screen.
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To change: press Enter button (13) . The actually selected alarm mode is blinking. Use Scroll button (12) to
change the alarm mode. Press Enter button (13) to program the new alarm mode. Press Escape button (14) to
return to the parameter screens.
<SEt> is the offset value that will trigger the alarm. Press Enter button (13): the programmed value starts
blinking. To change, use the Scroll buttons (12). Press Enter button (13) to modify and Escape button (14) to
return to the previous screen.
It is also possible to adjust the value when the alarm must disappear again. This is done by adjusting the
<rSEt> value. From the <SEt> screen, press the Scroll buttons (12). Following screen is shown:
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Press Enter button (13): the programmed value starts blinking. To change, use the Scroll buttons (12). Press
Enter button (13) to modify.
Press Escape button (14) to exit.
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3 Installation
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Reference Description
1 Cooling air flow
2 Air inlet
3 Air outlet
4 Manual drain valve
5 Electrical cable entry
6 Automatic drain connection
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Reference Description
7 Dryer type
8 Air connection for 50 Hz dryer
9 With integrated filter/ OSD option (male thread)
10 Air connection for 60 Hz dryer
11 Weight
12 Note: for 60 Hz dryers, use air connection (p.n. see drawing) and bushing (see drawing).
By using this bushing, the dryer height increases: see drawing
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Installation proposal
Text on drawings:
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Reference Description
(1) Installation proposal for the standard dryer (without options)
(2) Installation proposal for the dryer with options
(3) Installation proposal with reference to minimum required free area
(4) Service side
(5) Service front
(6) Ventilation proposal
(7) Air flow
(8) Floor
(9) Side view
(10) Top view
Instructions
Reference Description
1 The inlet grids and ventilation fan should be installed in such way that any recirculation of
the cooling air is avoided. The maximum air velocity through the grids is 5 m/s (16.5 ft/s).
The maximum allowable pressure drop over the cooling air ducts is 30 Pa (0.12 in wc).
When 30 Pa is exceeded a ventilation fan should be installed at the outlet of the cooling
air ducts.
2 Make sure all free water is removed from the compressed air before it enters the dryer.
The water separator and drain system of the dryer are not designed to handle the water
formed in the aftercooler of the compressor.
3 Make sure that no dirt particles (e.g. coming from corrosion in the compressed air network)
can enter the dryer. These particles may be harmful to the dryer's heat exchanger and the
condensate drain.
4 It is recommended to install bypass pipes over the dryer with bypass valves in order to
isolate the dryer during service operations, without disturbing the compressed air delivery.
5 Power supply cable to be sized and installed by a qualified electrician.
6 Filter, type DD for general purpose (optional). The filter traps solids particles down to 1
micron with a maximum oil carry-over of 0.5 mg/m3. A high-efficiency filter, type PD
(optional), may be installed downstream of a DD filter. This filter traps solid particles down
to 0.01 micron with a maximum oil carry-over of 0.01 mg/m3. Should oil vapours and odours
are undesirable, a QD type filter should be installed downstream of the PD filter.
The standard dryer is supplied without filters. Integrated DD and PD filters can be provided
as an option.
For dryers without integrated filters it is recommended to install the filters downstream the
dryer with bypass valves.
7 The condensate drain pipes must not dip into the water of the drain collector.
Do not allow untreated condensate to enter the draining system.
Optionally an integrated OSD can be provided to separate the oil from the water.
For units without integrated OSD, an OSC separator can be installed to separate the oil
from the water.
8 The refrigerant air dryer should be installed on a level floor suitable for taking the weight
of the dryer.
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• All pipes to be installed stress-free to the dryer. Do not use the dryer as support for
external pipes.
• Avoid installation of the dryer in corrosive atmosphere.
• The dryer is not designed for outdoor use.
• Install a safety valve on the connection pipe between the compressor and the dryer!
Electrical connections
1. Provide an isolating switch nearby the dryer.
2. Check that the electric cables and wires inside the electric cabinet are clamped tight to their terminals.
3. Check the fuses and the setting of the overload relay. See section Settings of fuses.
4. On single-phase units: connect the power supply cables to terminals L1, L2 of terminal strip (1X0).
5. On three-phase units: connect the power supply cables to terminals L1, L2, L3 of terminal strip (1X0).
6. Connect the earth conductor to earth bolt (1X3).
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Reference Designation
(1) Customer’s installation
(2) Flow switch
(3) Alarm EWD
(4) Remote start/stop
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Reference Designation
(5) Option filters
B1 Electronic drain
1X0/6 Terminals
F1-6 Fuses
F23 Internal protection
K02 Relay ON/OFF compressor and fan
K03 Auxiliary relay, general warning
K04 Auxiliary relay, general shut-down
K05/6 Auxiliary relay, forced drain
K11 Contactor compressor
K12 Contactor fan motor
K25 Phase sequence relay
K5 Auxiliary relay (alarm functions)
M1 Compressor
M2 Fan motor
PDS10 Δp switch, DD filter
PDS11 Δp switch, PD filter
PSHH13 High pressure switch
PSR12 Fan switch
S1’ Remote start/stop
S2 Flow switch
X209 Connector
3.4 Pictographs
Pictographs
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Reference Description
1 Dryer outlet
2 Dryer inlet
3 Automatic condensate drain
4 Warning: switch off the voltage, depressurise the compressor and read the instruction book
before carrying out maintenance work.
5 Warning, voltage
6 Information label refrigerant: Contains fluorinated greenhouse gases covered by the Kyoto
Protocol.
Reference Description
1 Oil
2 Oil outlet
3 Condensate outlet
4 Pressure
5 Inlet
6 Service point drain
7 Separator inlet pressure
8 Oil gasket, screw on filter and tighten by hand (approx. half a turn)
9 Consult instruction leaflet before carrying out maintenance or repair
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4 Operating instructions
4.1 Warnings
Safety precautions
The operator must apply all relevant safety precautions, including those mentioned in this manual.
Altitude operation
Consult your supplier if operating above 3000 m (9843 ft).
Procedure
Step Action
1 A few minutes before starting, the main supply to the dryer must be switched on to initialize
the Elektronikon and the flow switch.
2 Press start button (10).
After a few seconds the dryer is started.
Three-phase units are provided with a phase sequence relay. When the dryer does not
start, switch off the voltage and reverse two incoming electric lines.
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4.3 Starting
Control panel
Procedure
To prevent that wet air gets into the compressed air circuit, it is advised to follow next procedure:
Step Action
1 Switch on the main supply to the dryer a few minutes before starting, to allow the
Elektronikon and the flow switch to initialize.
2 If installed, close the dryer bypass valve and the dryer outlet valve (customers installation).
3 Open the dryer air inlet valve (customers installation) and pressurize the dryer.
4 Press start button (10).
After a few seconds the dryer is started.
5 Approximately 5 minutes later, open the dryer air outlet valve (customers installation).
6 Approximately 10 minutes later, the dew point will be stabilized.
Description
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Regularly check:
• The pressure dew point on the display of the control panel. The pressure dew point will deviate from
nominal if the air inlet conditions or volume flow differ from nominal.
• That condensate is discharged. The amount depends on the operating conditions.
4.5 Stopping
Control panel
Procedure
Step Action
1 Close dryer inlet and outlet valves (customer's installation).
2 Press stop button (11).
The dryer stops. Voltage on LED (4) remains lit. Leave the voltage on if the dryer has to
remain on stand-by.
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5 Maintenance instructions
Attention
Cooling dryers of FD type contain refrigerant HFC.
Safety precautions
When handling refrigerant, all applicable safety precautions must be observed. Please be aware of the
following points:
• Contact of refrigerant with the skin will cause freezing. Special gloves must be worn. In case of contact
with the skin, the skin should be rinsed with water. On no account may clothing be removed.
• Fluid refrigerant will also cause freezing of the eyes; safety glasses must hence be worn.
• Refrigerant is harmful. Do not inhale refrigerant vapours. Check that the working area is adequately
ventilated.
When removing the service panels of the dryer, be aware that internal elements such as the pipes can reach a
temperature of 110˚C (230˚F). Therefore, wait until the dryer has cooled down before removing the panels.
Before starting any maintenance or repair work, switch off the voltage and close the air inlet and outlet valves.
Mind the sharp edges of the fan blades in case the condenser fan needs to be replaced. The use of hand
protection is a requisite.
Local legislation
Local legislation may stipulate that:
• Work on the refrigerant circuit of the cooling dryer or on any equipment which influences its function
must be undertaken by an authorised control body.
• The installation should be checked once a year by an authorised control body.
General
The following remarks should be kept in mind:
• Keep the dryer clean.
• The dryer is equipped with a new condenser technology, which provides the best efficiency on condition
that the condenser maintenance instructions are followed closely.
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Period Operation
Daily Check that condensate is discharged during operation
Weekly Drain cleaning: open the manual drain valve during a few seconds. Hold a towel against
the drain outlet when opening.
Monthly Drain inspection: press the test button on top of the electronic water drain (EWD)
Condenser cleaning: proceed as follows:
• Stop the dryer and turn off the supply voltage.
• Remove the front service panel.
• Remove dust from the condenser surface using a vacuum cleaner.
• Clean the condenser by blowing compressed air from outside to inside. Keep the
compressed air nozzle more than 30 cm away from the condenser to avoid damaging
of the condenser fins.
• Remove dust from inside the dryer, e.g. with vacuum cleaner.
• Close the front service panel
• Start up the dryer.
Do not use water or solvents to clean the condenser.
Yearly/every Replace the wearing parts of the electronic water drain (service kit)
8000 hours
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6 Problem solving
Warnings
• Before starting any maintenance or repairs, close the air outlet valve and press the
test button on top of the electronic water drain to depressurise the air system.
• Apply all relevant instructions in section Safety precautions during maintenance or
repair.
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Dew point alarm visible (red light and blinking dew point icon)
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7 Technical data
Reference conditions
Unit 50 Hz 60 Hz
Compressed air inlet pressure bar(e) 7 7
Compressed air inlet pressure psig 101.53 101.53
Compressed air inlet temperature °C 35 38
Compressed air inlet temperature °F 95 100.4
Ambient temperature °C 25 38
Ambient temperature °F 77 100.4
Relative humidity at inlet % 100 100
Pressure dew point °C 3 4
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Unit 50 Hz 60 Hz
Pressure dew point °F 37.4 39.2
Cooling air inlet temperature °C 25 38
Cooling air inlet temperature °F 77 100.4
Limits
Unit 50 Hz 60 Hz
Maximum compressed air inlet pressure bar(e) 14 14
Maximum compressed air inlet pressure psig 203 203
Minimum ambient air temperature °C 1 1
Minimum ambient air temperature °F 34 34
Maximum ambient air temperature °C 50 50
Maximum ambient air temperature °F 122 122
Minimum compressed air inlet temperature °C 1 1
Minimum compressed air inlet temperature °F 34 34
Maximum compressed air inlet temperature °C 60 60
Maximum compressed air inlet temperature °F 140 140
Specific data
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Overall rating
The dryer is conform to PED category II.
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9 Declaration of conformity
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In order to be First in Mind—First in Choice® for all your quality
compressed air needs, Atlas Copco delivers the products and
services that help to increase your business’ efficiency and
profitability.
Atlas Copco's pursuit of innovation never ceases, driven by our
need for reliability and efficiency. Always working with you, we are
committed to providing you the customized quality air solution that
is the driving force behind your business.
www.atlascopco.com