Operating Manual Adsorption Dryer DPS 120-630: Version: 11/2010/DE

Operating Manual
Adsorption Dryer
DPS 120-630 Version: 11/2010/DE
© FST GmbH 21.12.2010 DMN FST manual DPS120-630 Standard -EN-20101220-CR.docx
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 .......................................................................................................................................11
3. Safety notes ...................................................................................................................................................12
3.1 Signs and instructions ............................................................................................................................12
3.2 Danger zones at the dryer .....................................................................................................................13
3.3 General safety notes..............................................................................................................................14
4. Technical product description .......................................................................................................................16
4.1 Assembly drawing..................................................................................................................................16
4.2 Process flow diagram.............................................................................................................................18
4.3 Function description ..............................................................................................................................19
4.4 Options ..................................................................................................................................................23
5. Operating elements .......................................................................................................................................25
5.1 Power connector ...................................................................................................................................25
5.2 Pressure gauge ......................................................................................................................................26
5.3 Valve position indications......................................................................................................................26
5.4 Instrument air supply and pilot valve terminal .....................................................................................27
5.5 Control ...................................................................................................................................................28
5.6 Function keys and display......................................................................................................................28
5.7 Direct indication ....................................................................................................................................29
5.8 Menu guide............................................................................................................................................29
5.9 Parameter settings ................................................................................................................................30
5.10 Compressor synchronisation function...................................................................................................31
5.11 Dew point measurement and energy-saving function ..........................................................................31
5.12 Filters for differential pressure monitoring ...........................................................................................32
5.13 Overflow monitor ..................................................................................................................................32
5.14 Service ticket .........................................................................................................................................33
5.15 Menu structure......................................................................................................................................34
6. Error analysis table ........................................................................................................................................35
7. Transportation, setting up and storage .........................................................................................................37
7.1 Transportation .......................................................................................................................................37
7.2 Setting up...............................................................................................................................................38
7.3 Storage...................................................................................................................................................39
8. Installation .....................................................................................................................................................40
8.1 Installing the connecting pipelines ........................................................................................................40
8.2 Installing the power supply ...................................................................................................................42
9. Commissioning ..............................................................................................................................................45
9.1 Requirements for initial commissioning ................................................................................................45
Table of contents
9.2 Commissioning the dryer...................................................................................................................... 46
9.2.1 Pressurisation of the dryer ........................................................................................................... 47
9.2.2 Opening the outlet valve .............................................................................................................. 47
9.2.3 Starting the dryer.......................................................................................................................... 48
10. Shutting down and restarting the dryer ....................................................................................................... 49
10.1 Shutting down the dryer in case of emergency.................................................................................... 49
10.2 Stopping the dryer ................................................................................................................................ 49
10.3 Shutting down the dryer....................................................................................................................... 49
10.4 Depressurising the dryer ...................................................................................................................... 50
10.5 Restarting the dryer .............................................................................................................................. 50
11. Maintenance and repair ............................................................................................................................... 51
11.1 Regular maintenance intervals ............................................................................................................. 52
11.1.1 Visual check and function monitoring .......................................................................................... 52
11.1.2 Cleaning the dryer and dryer control ........................................................................................... 53
11.1.3 Checking if cable and terminals are securely fixed....................................................................... 53
11.1.4 Calibrating the dew point sensor.................................................................................................. 53
11.1.5 Replacing filter elements .............................................................................................................. 54
11.1.6 Replacing the expansion silencer ................................................................................................. 54
11.1.7 Replacing the sealing set of the valves (V3-4) and the check valves (RV1-2) ............................... 55
11.1.8 Checking and replacing the desiccant / Cleaning the strainer basket .......................................... 55
12. Appendix and technical documents ............................................................................................................. 58
12.1 General arrangement drawing ............................................................................................................. 58
12.2 Process flow diagram............................................................................................................................ 58
12.3 Pneumatic diagram ............................................................................................................................... 58
12.4 Wiring diagram ..................................................................................................................................... 58
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 12)
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 con-
tract 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 12)
1.4 Additional documents

 General arrangement drawing
 Process flow diagram
 Pneumatic diagram of the instrument air for valve actuators
 Wiring diagram
 Operating manuals of individual components
Note on additional documents
Additional documents (e.g. of the components) must be adhered to. They contain additional information, e.g.
on maintenance, and are therefore necessary for safe operation of the dryer.
The customer is provided with pressure vessel documents, if applicable.
6
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 per-
sons have to be qualified personnel who, because auf their qualification and experience, are familiar with han-
dling 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 adja-
cent 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 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 com-
ponents can be removed from the compressed air. After this pre-treatment the dryer also removes the vapor-
ous water components. The compressed air is dried until only a very low residual concentration of water va-
pour 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.
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)
 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 12).
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.
9
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 indi-
vidual 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 11)
For a dryer designed to your individual operating conditions, please refer to your contract documents or con-
tact 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 pre-
dried 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.
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 31)
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 com-
pressed 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..
10
2.2 Technical Data
vol-
Compressed air
ume flow rate
connection
Nominal
Weight
Height
Width
Depth
Dryer
V [m³/h]* [kg] [mm] [mm] [mm]

DPS 120 1200 DN 50 670 1975 1110 760
DPS 150 1480 DN 65 850 2070 1250 870
DPS 210 2080 DN 65 1080 2090 1340 920
DPS 240 2430 DN 80 1300 2185 1520 970
DPS 290 2930 DN 80 1490 2200 1585 1010
DPS 370 3700 DN 100 1930 2340 1850 1160
DPS 510 5080 DN 100 2450 2600 1850 1180
DPS 630 6290 DN 125 3050 2780 2350 1180
* = 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 DPS120: III / DPS150...630: IV

Fluid group 2
Supply voltage 230V 50-60Hz (optional 115V 50-60Hz and 24V-DC)
Class of protection IP65 (for standard dryer control type C1)
Min. / max. allowable pressure (PS) 4 to 11 bar
Min. / max. allowable temperature (TS) +1 to +60°C
Noise pressure level (free-field measurement in distance up to 115 dB(A)
of 1 m)
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.
Pressure vessel
For further technical details on the pressure vessels, please refer to the pressure vessel documen-
tation provided separately.
A routine inspection is required for the pressure vessels. In Germany, according to AD 2000 Code a
routine inspection has to be carried out every 5 years by a notified body.
Please note that different national regulations may apply in other countries.
11
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
Type plate of the vessel
The type plates show important information. Make sure that the type plates are always clearly readable.
12
Safety notes
3.2 Danger zones at the dryer
1 Risk of injury from pressure-bearing parts

2;3 Risk of injury from electric voltage
4 Risk of injury from suddenly escaping compressed air
5 Risk of slipping due to spilt desiccant
DANGER ! – Overpressure (1)

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;3)

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.
13
Safety notes
WARNING ! – Suddenly escaping compressed air (4)

The dryer is depressurised approximately every 6 hours using a silencer. A loud and strong air-
stream 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 (5)

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 12).
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.
14
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.
15
Technical product description
4. Technical product description

4.1 Assembly drawing
Front View
7
5
9
4
3 10
2
11*
1 3-2-way-valvel (V1/2) 6 Regeneration gas tube with orifice (O1)

2 Desiccant drain 7 Check valves (RV1, RV2)
3 Pilot valve terminal with solenoids (Y1, 8 Upper vessel opening with strainer basket (SB1,
Y2, Y3, Y4) SB2)
With instrument air filter and shut off 9 Pressure gauge (PI01, PI02) with shut off valve
valve
4 Power Connector (power supply)) 10 Vessel (A1, A2) with sieve tray (ST1, ST2)
5 Control with display and operator keys 11 Dew point sensor (MT01) (*optional)
16
Rear view
13
14
15
12
16
12 Expansion valves (V3, V4) 15 Expansion silencers (X1, X2, …) with regen-
eration gas outlet (RO)
13 Lifting lugs 16 Earthing connection ∅10mm
14 Compressed air outlet (GO)
17
4.2 Process flow diagram

Symbolic diagram of the dryer components, their locations and interconnections.
A Dryer vessel PI Pressure gauge

V 3-2-way-valve O orifice
HV Manual shut off valve MT Dew point sensor
RV Check valve
SB Strainer basket GJ Gas inlet
ST Sieve tray GO Gas outlet
X Expansion silencer RO Regeneration gas outlet
18
4.3 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 6 hours or longer.
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) via a prefilter to the com-
pressed air inlet (GJ) of the dryer. The main valve (V1/V2)
forwards the compressed air to the vessel which is in "ad-
sorption" 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 sieve
tray (ST2) and slowly flows through the desiccant bed. The
compressed air exits the vessel via the strainer basket (SB2)
and is forwarded through the check valves (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 1 stand-by – adsorption
waits for operation.
The adsorption phase is completed and the vessels are switched over if...
 ... 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.
19
For vessel switch-over the main valve (V1/V2) is turned
form vessel (A2) to vessel (A1). The compressed air flow
changes 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 2 adsorption – switch-over
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 silencers (X1;
X2; …) the compressed air flows to the outside.
The next phase begins a after the vessel pressure has al-
most reached atmospheric pressure.
1 adsorption - expansion
20
Purging (regeneration)
Duration approx. 4 min*
When the vessel pressure drops, dry air (regeneration gas)

from vessel (A1) flows through the orifice (O1) 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 switch-over.
The regeneration air valve (V4) is closed and dry com-
pressed air continues to flow through orifice (O1) into ves-
sel (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 pres-

surisation phase is ended and the next phase begins.
5 adsorption – pressurisation
21
Standby
Duration approx. 0 minutes to max. 2 hours
Vessel regeneration is now complete and the vessel is im-

mediately ready to operate. During this phase the both
vessels stay connected via the orifice (O1) Thus he 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
(left-right inverted).
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
22
4.4 Options
Various options are available for improved operation and special installation site conditions. For detailed in-
formation 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 veloci-
ties in the dryer. There is a danger of damage to the dryer. (→ Page 47)
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 week-
end) 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).
Pneumatic dryer control

Sometimes there is no electrical power available at the place of installation or for other reasons the use of
electrical power has to be avoided.
Alternatively the dryer can be fitted with a pneumatic control. The instrument air required for the pneumatic
control is taken from dryer outlet (GO).
The pneumatic control enables the dryer for the use in ex-proof classified areas in some countries. However,
additional measures on the dryer are necessary to fulfil the requirements of the ex-proof regulations of the
European Community (“ATEX”). Please contact the manufacturer for further information.
23
Frost protection insulation with trace heating
In the event of ambient temperatures below +1°C all the wet-operated components must be protected against
freezing. After evaluating the local conditions a suitable frost protection can be provided.
Paint-compatible version
Compressed air for paint work must be free from silicone and other paint-wetting impairment substances.
For this purpose, the dryer can be manufactured with components and process materials that are free from
these substances or approved for paint work by the automotive industry.
The dryer is manufactured under normal shop-floor environments, however, with a special focus on cleanness.
The product quality can therefore be considered "technically free from paint-wetting impairment substances".
Further options include:

 Special voltages: 115V – 50-60Hz , 24V-DC
 Stainless steel versions (completely or partly)
 Alternative pressure vessel approvals (PED Module G, ASME U-Stamp, China-Stamp, GOST, …)
 Additional pressure vessel documentation (drawing, stress calculation, material certificate 3.1, cer-
tificate of hydrostatic pressure test, welding documentation, …)
 Safety valves (valve provided separately)
 Weather protection (rain protection, complete insulation, frost protection, increased class of pro-
tection (IP protection class), …)
24
Operating elements
5. Operating elements
The following sections describe the dryer components used for dryer monitoring and dryer operation.
5.1 Power connector

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 connec-
tor 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 inter-
rupting 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 31)
25
Operating elements
5.2 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.
For maintenance reasons the HV1/HV2 manual valve can be closed.
5.3 Valve position indications

All the automatically operated valves are provided with a position indication. For analysing an error the actual
state of the valve can be compared to the state set in the control system. (→ Page 28)
The position of valves V3 and V4 is indicated by means of a small, coloured

pin on the actuator.
Pin protrudes approx. 2 cm from the actuator = OPEN

Pin is almost completely inserted in the actuator = CLOSE
The position of the main valve (V1/2) is indicated by means of a black-yellow

cylinder on the actuator.
On the picture the indicator shows that the dryer inlet is connected to the
right vessel (A2).
26
Operating elements
5.4 Instrument air supply and pilot valve terminal

Shut-off valve for instrument air
Instrument air inlet (from dryer outlet GO)
Valve connector with cable to dryer control
Pilot valve terminal
Plug screw (for the option „dew point control“ the plug
screw is replaced by a throttle valve to generates flow on
the dew point sensor)
Exhaust silencer
Instrument air going to valve actuators
Instrument air filter
Air-bleed valve
(for option „dew point control“ the bleed valve will be
Similar illustration!
replaced by the dew point sensor).
The instrument air is supplied internally, i.e. from the dryer outlet, and forwarded to the pilot valve terminal
via an instrument air filter and a pressure reducer. The electrical control signals from the dryer control system
are pneumatically amplified using the pilot valve terminal and transferred to the valve actuators.
1) For maintenance of the instrument air supply cut off the instrument air at the small shut-off valve.
2) Open the air-bleed valve on the instrument air filter in order to depressurise the pilot valve termi-
nal and the valve actuators. (for the option “dew point control” the pilot valve terminal is depres-
surised via the throttle valve.) Please wait until you can hear no more flow noise of escaping air.
3) After maintenance work the air-bleed valve must be reclosed and the shut-off valve reopened.
(for the option “dew point control” please make sure that a small flow of air passes through the
throttle valve in the pilot valve terminal to the ambient. The throttle valve shall never be entirely
closed. Otherwise there is no flow on the dew point sensor and the measurement will be faulty.)
For a schematic diagram of the instrument air supply, please refer to the pneumatic diagram in the → appen-
dix.
Abbildung ähnlich!
27
Operating elements
5.5 Control
The dryer is operated via the display and tree function key on the dryer control.
5.6 Function keys and display
function display runtime of cycle phase
mode of vessel 1 mode of vessel 2
"Up" key
dew point
value "Enter" key
status LED "Down" key
mains
connector
The appliance connector is used to supply the C1 control system with the operating voltage. Following
voltage connection the display will indicate the software version number for approximately 5 seconds.
The control system then immediately changes to the operating mode and starts in the program step at
which it was last shut down. As a rule, all the operating states and settings are memory-resident, i.e. the
control system will automatically continue the control program after a power failure.
The function display indicates all the relevant operating situations and the associated residual runtime
and the pressure dew point*. After pressing a key the display backlight is on for 2 minutes. The status
LED additionally informs you about the energy-saving mode and the alarm states.
Operation and entry of the setting values is carried out using the 3 keys. For further information, please
refer to the menu structure. The language used for the control system is "easy" English.
Mode Function Display Status

ADS vessel adsorption 5:00 min - cannot be read Input valves at vessel 1 or 2 opened
REG regeneration 3:59 min - residual time indication Expansion valves at vessel 1 or 2 opened
REP repressurisation 0:59 min - residual time indication Expansion valves at vessel 1 or 2 closed
phase
CHG vessel changeover 0:03 min - residual time indication no valve activated
ECO economy mode xx:xx min - time indication Expansion valves at vessel 1 or 2 closed
STB standby mode no time indication Expansion valves at vessel 1 or 2 closed
LED status indication
Green normal operation
Orange economy mode ECO is indicated for one vessel
Red alarm, flashing message/dew point value Acknowledge alarm manually via "Enter"
key
28
Operating elements
5.7 Direct indication

Pressing the arrow keys allows for directly accessing additional information on the operating mode, en-
ergy savings and service monitor.
"Cycle Mode" indicates the VAR or FIX operating modes as well as the number of
days, hours and minutes the dryer was in economy mode.
"Next Service" indicates the time (as a percentage value) elapsed for the next ser-
vice message to be shown. This value depends on the actual utilisation of the
dryer. For this value, the pure operating hours are counted which the dryer used
for regeneration. Depending on the operation intensity the time to reach the per-
centage value = 100% and to display the service message may be different.
5.8 Menu guide

Access to the menu structure and thus to the parameter settings is generally password-protected
against unauthorised access. Keep this operating manual in a safe place and make sure it is available for
maintenance.
The password is:
The menu is structured in two paths. Pressing the "Up" arrow key selects the service section. Pressing
the "Down" key selects the parameterisation section.
Pressing the "Down" key selects the corresponding menu item. Pressing the "Enter" key opens the
parameterisation level. On this level, the setting value can be changed using the "Up" and "Down" keys.
Confirm the settings entered using the "Enter" key. The display returns to the menu item.
The numeric codes in the service section are also set using the arrow keys. When entering a digit the
cursor jumps to the next position until the code has been entered completely.
29
Operating elements
5.9 Parameter settings

The table shows all the parameters, their default settings and their function.
Menu Default Value range Function

settings
CYCLE MODE VAR FIX In FIX mode the control time program is executed
VAR without being affected.
VAR mode provides the energy-saving function.
Internal dew point measurement or an external
signal (IN2) will affect the control time.
CYCLE STOP FINISH CY- FINISH CYCLE When opening the compressor synchronisation
CLE DIRECT STOP contact in DIRECT STOP mode the expansion
valves open immediately and vessel change will be
prepared. In FINISH CYCLE mode the regeneration
cycle started will be completed. Please note that
the dryer still requires compressed air for this
purpose! See also compressor synchronisation.
PDP SET -40°C * 20°C * to -100°C* Threshold value for dew point control.
PDP ALARM SET -25°C * 20°C * to PDP SET Threshold value for dew point alarm.
PDP SENSOR ON ON Switches internal dew point measurement on/off.
OFF
PDP DISPLAY ON ON Switches dew point value indication on/off
OFF (4-20 mA signal at X10 is not affected).
ALARM PDP ON ON When ON, the dew point alarm controls the alarm
OFF relay. When OFF, the relay is not controlled.
PDP ALARM DELAY 00:10 s 00:00 .. 20:00 Alarm relay control can be delayed for up to 20
minutes. In the event the dew point alarm falls
again within the delay time, the alarm relay will
not be switched.
TEMP UNIT °C °C (degrees Celsius) Changes the temperature indication.
°F (degrees Fahren-
heit)
ALARM FILTER1 OFF ON Input IN3 can be used to evaluate the threshold
OFF switch of a differential pressure gauge on the
upstream filter. The result can be indicated in the
form of an alarm.
ALARM FILTER2 OFF ON Input IN4 can be used to evaluate the threshold
OFF switch of a differential pressure gauge on the
downstream filter. The result can be indicated in
the form of an alarm.
FILTERALARM DLY 00:20 s 00:00 .. 20:00 Delay time for the filter alarm up to 20 minutes.
This function can be used to suppress alarm acti-
vation caused by rapid volume flow changes
(peaks).
ALARM OVERFLOW OFF ON "Overload" of the dryer can be detected by simul-
OFF taneously monitoring the differential pressure
monitors on the upstream and downstream filters.
An overflow alarm is activated when the signals
from IN3 and IN4 are present during the alarm
delay time.
30
Operating elements
5.10Compressor synchronisation function

The CYCLE STOP menu item is used to select the control system behaviour for the signal at the digital in-
put IN1. By default, IN1 is provided with a jumper. If the jumper is opened, the control program is set to
the standby mode. There are two options:
In DIRECT STOP mode the control system is stopped immediately and outputs
Y3 and Y4 are not (no longer) controlled. All the time values expired until then
will be "frozen" (stored).
In FINISH CYCLE mode the control system will only be stopped after completing
the regeneration cycle, and outputs Y3 and Y4 are not (no longer) controlled.
All the count values will also be "frozen".
Independent of the type of cycle completion "STB" is indicated for both vessels on the display.
Example: IN1 can be connected to the auxiliary contacts of a compressor. This synchronises the dryer
with the compressor. The dryer only regenerates with compressed air being produced. The influencing
compressor synchronisation contact does not affect the input valves. The compressor synchronisation
contact can also be used as a remote switch and can, for example, be connected to higher-level time or
emergency control systems.
5.11Dew point measurement and energy-saving function

If the internal dew point measuring system is used with a pressure dew point sensor or if an external
measuring instrument is used with a 4-20 mA signal output, it must be registered to the control system.
For this purpose the option in the PDP SENSOR menu must be set to ON.
The working point of the dryer is specified by the dew point threshold value. It can be set in the PDP SET
menu using the arrow keys. The default setting is -40°C *.
Every time the dryer is not operating at the performance limit (i.e. at maximum volume flow rate), a
better (lower) pressure dew point value can be achieved than specified by the threshold value set. The
dryer then switches to the ECO mode and delays the next vessel change or regeneration phase until the
measured dew point value exceeds the threshold value. For information on the total time the dryer was
in ECO mode, please use the direct indication method and refer to 3.2.
The dew point alarm is preferably set with a distance of 10° to 20° to the dew point threshold value. This
prevents hypersensitive reactions of the alarm messages from occurring. Spontaneous fluctuations of
the measured dew point value caused by pressure or load variations within the system are inevitable.
31
Operating elements
Direct activation of the dew point alarm sensor in the event of dew point peaks can also be suppressed
by setting a longer delay time. This rule applies: For the entire delay time the measured dew point must
be worse than the alarm value set.
5.12Filters for differential pressure monitoring

The pre- and afterfilters of an adsorption dryer can optionally be provided with differential pressure
gauges with an integrated differential pressure monitoring contact. Using the C1 control system the con-
tact signals can be separately evaluated and indicated for the upstream and downstream filters. The
connections are provided via switching inputs IN3 and IN4. You can individually switch the alarms on or
off and delay their evaluation.
5.13Overflow monitor
If the pre- and afterfilters are provided with differential pressure monitors (as described in 3.7), the
overflow can be evaluated by means of common interrogation of both contacts. It can be assumed that
the dryer will be strongly overloaded (internal flow rates too high), if the differential pressure monitors
on the upstream and downstream filters are activated simultaneously.
The ALARM-OVERFLOW monitor is switched off by default. The delay time should always be shorter
than the delay time of the separate differential pressure monitor on the filters.
32
Operating elements
5.14Service ticket
The control system program counts the switching cycles of the dryer. This allows for representing the
vessel load changes on the one hand and for calculating the actual capacity utilisation or the desiccant
and upstream/downstream filter wear using the count values in relation to the duty cycle on the other
hand. After reaching a threshold value (66,400 complete load changes (corresponds to approx. 1 year)
under normal operating conditions) a service warning message is indicated.
To acknowledge the service warning message a 4-digit numeric code ("service ticket") must be entered.
Every time buying service parts and filter elements the customer is provided with a new service ticket
including the numeric code. Once a numeric code has been used it cannot be entered again. Upon indi-
cation of the next service warning message the control system expects a new code to be entered.
The path for entering the service parameters and monitoring functions can be accessed by entering the
password and pressing the "Up" arrow key.
The number of the ticket code is entered digit by digit using the arrow keys. The cursor moves to the
next digit by pressing the "Enter" key.
When the correct ticket code has been entered TIMER RESET DONE is indicated. When the wrong code
has been entered TIMER RESET FAIL is indicated.
If the ticket code has not been entered correctly, it can be entered again after approximately 2 minutes.
If, after this try, the ticket code is not entered correctly again and again, the waiting time for the next try
doubles each time until the correct code is entered.
33
Operating elements
5.15 Menu structure
34
Operating elements
6. Error analysis table

Error Cause Measure
Control system not Voltage supply missing Check voltage supply and switch on, if necessary.
ready to operate /
LED not on Appliance connector installed incorrectly Check cable connections on appliance connector.
Fine-wire fuse defective Replace fine-wire fuse (500 mA, slow-blowing).
Valve not working Cable connection to magnetic coil defec- Check cable connection and reinstall, if neces-
tive sary.
Magnetic coil defective Check magnetic coil using ohmmeter.
No voltage at valve output Switching transistor of output may be defective.
No dew point value Sensor not registered Register pressure dew point sensor to control
on display system, see 3.6.
Indication Sensor cable connected incorrectly Remove contact problems and check wiring, see
ALARM SENSOR table 2.6, X9.
Sensor defective Check dew point sensor and send it back to be
inspected, if necessary.
Too much moisture in sensor The sensor was in contact with splash water. Dry
the sensor slowly. Never dry the sensor using
compressed air!
Dew point Signal of dewpoint transmitter Indicates heavy dirt accumulation on the active
indication below 4 mA sensor surface. The sensor has to be replaced.
---°C * Signal of dewpoint transmitter 4-20 mA signal adjusted incorrectly during con-
below 4 mA nection of external dew point measuring instru-
ments.
Dew point Signal of dewpoint transmitter Active sensor surface is very moist and must be
indication above 20 mA dried carefully.
+++°C *
Signal of dewpoint transmitter 4-20 mA signal adjusted incorrectly during con-
above 20 mA nection of external dew point measuring instru-
ments.
Dew point Possible only if external dew point Adjust 4-20 mA scaling (by manufacturer service
indication incorrect measuring instruments are connected. only).
Default scaling of 4-20 mA signal not Set 4-20 mA output of external measurement
matching. system.
Indication Differential pressure monitor has been Acknowledge alarm using "Enter" key.
ALARM FILTER triggered
Cable connection from/to differential Check cable connection from control system
pressure monitor defective (open) using a continuity tester. In normal state the
contact loop needs to be closed.
Indication Differential pressure monitor has been Acknowledge alarm using "Enter" key. Frequent
ALARM OVERFLOW triggered. The upstream and down- overloading of the dryer considerably damages
stream filters have been triggered simul- the desiccant.
taneously. Dryer has been overloaded.
Indication Dew point value above the alarm value Acknowledge alarm using "Enter" key. Dew point
ALARM DEWPOINT alarms occurring more frequently after some
years of operation indicate that the desiccant
capacity is exhausted.
Indication Internal monitoring function of the con- Disconnect control system from voltage and
ALARM 24VDC trol system has been triggered restart after approx. 30 seconds.
Contact manufacturer service in the event the
control system fails to restart.
35
Operating elements
Error Cause Measure

Dryer switches over Supply lines of input valves and ex- Check installation according to table in 2.6 and
without pressurisa- pansion valves mixed up diagram in 2.5.
tion phase (one
side or two sides)
Expansion noise of Supply lines of input valves V1 and Check installation according to table in 2.6 and
dryer is too loud V2 mixed up diagram in 2.5. Try to change the connections, if
and, at the same necessary.
time, there is pres-
sure loss in the
system
36
Transportation, setting up and storage
7. Transportation, setting up and storage

7.1 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; lifting lugs at the top of the vessel) (→ see Figure).
 Transport the dryer in upright position. Horizontal transportation may lead to mixing of the differ-
ent desiccant layers thus causing malfunctions. Please contact the manufacturer first if the dryer
needs to be tilted for transportation.
 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.
37
7.2 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 11).
Additional requirements on the installation site:
 The ground for dryer installation must be level and capable to carry heavy loads. Ground irregulari-
ties must be levelled in order for tensional forces not to occur in the piping of the dryer. When cal-
culating the total weight, please take the additional load during a hydrostatic pressure test into ac-
count. The volume information on the vessel helps when calculating the additional weight.
 Because of noise emissions the installation site should not be in the vicinity of stationary work-
places.
 Keep a service distance to walls and other systems around the dryer of 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 inexperi-
enced persons.
 Set up the dryer such that the pressure gauge and the control system are clearly visible and can be
operated properly.
We recommend anchoring the dryer into the ground using the holes in the vessel supports.
38
7.3 Storage
To maintain the dryer quality the dryer must be stored at a suitable location and properly prepared for stor-
age.
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 addi-
tional 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 31)
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 49)
5) Depressurise the dryer. (→ Page 50)
6) Disconnect the dryer from the electrical supply. (→ Page 25)
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 46)
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 electri-
cian.
39
Installation
8. Installation
8.1 Installing the connecting pipelines
DANGER ! – Overpressure
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 12).
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 addi-
tional 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. Transmis-
sion 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 pro-
tected against unintentional opening. (2) + (8)
 The compressed air source (e.g. compressor) must be safe-guarded against exceeding of the maxi-
mum 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 open-
ing behaviour (e.g. shut-off valves with stem or gear handwheel). This valve behaviour avoids sud-
den 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 of flanged connections) 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.
40
Installation
 Wet pipelines upstream of the dryer (4) should be installed at a slope in order for condensate (wa-
ter and oil) in the line to be discharged in flow direction. If installation of an upright pipeline is in-
evitable, a condensate drain must be provided at the lowest point of the pipeline. This avoids con-
densate 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 12)
Never fill the dryer with water when performing a pressure test. Liquids will destroy the desiccant!
Installation example
1 Compressed air inlet 9 Compressed air outlet

2 Valve at compressed air inlet 10 Bypass valve at inlet
3 Compressed air pipeline at inlet 11 Bypass line
4 Pre-filter with condensate drain 12 Bypass filter with condensate drain
5 Dryer 13 Bypass valve at outlet
6 After-filter with manual drain 14 Expansion silencer
7 Compressed air pipeline at outlet 15 Condensate line
8 Valve at compressed air outlet 16 Pressure maintaining valve
Please note that the standard scope of supply only comprises the dryer (5) in the grey outline.
41
Installation
8.2 Installing the power supply
DANGER ! – Electric voltage

The dryer is operated at electric voltages up to 230 V.
CAUTION ! – Qualification and experience required

Persons working on and with the dryer have to be qualified personnel who, because of their quali-
fication 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 unpredict-
able 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 con-
necting 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 25)
42
Installation
4) Remove the mounting screw (1) from the connector 1

housing (2) first.
(The mounting screw serves as locking device for the
8
connector insert (3). The connector insert cannot be re- 5 6 7
2
moved from the housing of the power connector before
the mounting screw has been removed.)
5) Carefully lift the connector insert (3) out of the connec- 3
tor housing using a small screw driver.
6) Lead the cable (8) through the various components of
the cable gland: 4
(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 informa-
tion in the wiring diagram.
8) Put the connector insert (3) back into the connector
housing (2). Put the connector seal (4) back onto the fe-
male power connector and tighten the cable gland (5).
Communication interfaces
The dryer is provided with different signal inputs and outputs for dryer control and dryer monitor-
ing. 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 discon-
nect the dryer control from the power supply. (→Page 25)
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.
43
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 connec-
tor plugs and cable glands can be found in the parts list of the wiring diagram.
44
Commissioning
9. Commissioning
9.1 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 re-
quired 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 40)
 The dryer is connected electrically and voltage supply is ensured.
(→ Page 42)
 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 na-
tional 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 25)
 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 con-
nections, screwed joints and pneumatic lines are tightly secured. Tighten loose connections using
the appropriate tools.
45
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 unpredict-
able 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.
9.2 Commissioning the dryer

WARNING ! – Suddenly escaping compressed air (3)

The dryer is depressurised approximately every 6 hours using a silencer. A loud and strong air-
stream 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.
46
Commissioning
9.2.1 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. Pres-
sure 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 move-
ment.
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 50)
5) If flow noise and a pressure increase is no longer present when further opening the valve, it can be
opened completely.
9.2.2 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, com-
missioning 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 rec-
ommend using an automatic start-up device. (→ Page 23)
The automatic start-up device prevents pressure blows and increased flow speeds from occurring
even when the compressor is started automatically.
47
Commissioning
9.2.3 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 25)
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 solenoid valve terminal.
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 35)
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 19)
48
Shutting down and restarting the dryer
10. Shutting down and restarting the dryer

10.1 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 25)
2) Close the valves upstream and downstream of the dryer.
3) The dryer has now been shut down.
10.2 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 31)
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
10.3 Shutting down the dryer

1) Stop the dryer as described in the above section.
2) Pull the power connector off the control box.
4) The dryer has now been shut down.
5) Prior to working on the dryer it has to be depressurised.
49
Shutting down and restarting the dryer
10.4 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.

2) Open the valve on the after-filter (→ Page 40)
3) Monitor the pressure on the pressure gauges of the dryer.
4) Wait until the pressure has dropped to 0 bar on both pressure gauges.
10.5 Restarting the dryer

Please proceed as described in chapter "Commissioning". (→ Page 46)
If the relevant requirements have already been fulfilled, the corresponding steps of the chapter can be
skipped.
50
Maintenance and repair
11. Maintenance and repair



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 12, 14)
 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 46.
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 in-
formation can be found on the type plate on the control box of the dryer. (→ Page 12)
51
11.1 Regular maintenance intervals

The following table gives an overview of routine maintenance tasks. The required activities are described on
the following pages.
See page
Every day
Every
year
Component Maintenance activity
Every 2
Every 4
month
years
Every
years
Dryer and Visual check and function
dryer control monitoring  52
Dryer Clean  53
Check if cable and termi-
Control box
nals are securely fixed  53
Dew point sensor (MT01) Calibration required  53

Pre- and after-filter
(option)
Replace filter element  53
Expansion silencer
(X1,X2,...)
Replace  * 54
valves
(V3-V4)
Replace sealing set  55
Strainer basket (SB1,SB2) clean * 55
Desiccant Check/replace * 55
Check valves
(RV1-RV2)
Replace sealing set * 55
* = These activities should be carried out at the same time.
11.1.1 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 par-
ticular). (→ Page 11)
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 35)
5) Check if the condensate drains on the compressor and on the upstream filters are working prop-
erly.
6) Check the dew point.
52
11.1.2 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 sol-
vents.
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.
11.1.3 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 per-
formed by a qualified electrician.

3) Disconnect the electrical power supply from the dryer and protect it against unintentional recon-
nection.
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.
11.1.4 Calibrating the dew point sensor

The dew point sensor (MT01) is subject to ageing which leads to inaccurate measurements over time. Oil va-
pour 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.
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 49)
53
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 cali-
bration will be credited. The old sensor remains at the manufacturer.
11.1.5 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 throt-
tled. 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 50)

2) For filter replacement please proceed as described in the operating manual of the filter.
11.1.6 Replacing the expansion silencer

The expansion silencers (X1, X2, …) are contaminated by dust and condensate over time and thus the expan-
sion air flow is throttled. To prevent operating errors from occurring, the expansion silencers have to be re-
placed regularly.

3) Unscrew the old expansion silencers (X1, X2, …) from the
connecting part using your hands or an appropriate tool.
4) Screw the new expansion silencers (X1, X2, …) into the
connecting part and tighten it using your hands or an ap-
propriate tool and some sealing tape.
5) Pressurise the dryer and commission the dryer again. (→
Page 49)
54
11.1.7 Replacing the sealing set of the valves (V3-4) 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
11.1.8 Checking and replacing the desiccant / Cleaning the strainer basket
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.
The desiccant is subject to ageing and its drying performance is reduced over time. The service life of the des-
iccant depends on numerous operating parameters and cannot be exactly predicted. The service life is ap-
proximately 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 51)

3) Provide adequate support for the pipelines connected to the dryer and make sure the connection
points are not subject to stress.
4) The pipe elbow is very heavy. Connect the pipe elbow to the lifting equipment suitable for lifting
the load.
55
5) Remove the pipe elbows above the vessels. (To main-
tain stability of the piping system it is possible to only
remove one pipe elbow and to carry out maintenance
on one vessel after the other.)
6) Remove the strainer basket (SB1, SB2) and clean it
from desiccant residues.
7) Remove the seals and clean the flange surfaces from
residues of the seals.
8) Provide an adequately sized container for the used
desiccant. (Make sure to observe the volume informa-
tion given on the vessel plate.)
9) Remove the used desiccant from the vessel using a
suction device.
10) As an alternative, the desiccant can also be drained by opening the desiccant drain installed on the
side of the vessel. The residues in the container can be removed using a conventional industrial
vacuum cleaner.
11) Clean the nozzle of the desiccant drain and reclose the nozzle while using a suitable sealant.
12) Remove the used desiccant from the construction site.
13) Provide the new desiccant *. Make sure to use two different desiccant types which 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.
14) Fill in the liquid waterproof desiccant first (e.g. silica gel WS *). It is the lower layer in the vessel.
15) Fill in the non-liquid-waterproof desiccant last (e.g. molecular sieve *). It is the upper layer in the
vessel. This type of desiccant will disintegrate when getting in contact with liquid water.
16) Fill up the vessel almost to its full extent. Make sure that the strainer basket (SB1, SB2) can still be
inserted in the vessel opening by slightly pressing on it. During operation the desiccant will be com-
pressed to some extent and the desiccant volume will be slightly reduced
17) Reinsert the strainer basket (SB1, SB2) into the vessel using two new seals.
18) Reclose the vessel using the pipe elbow. First tighten the screws only lightly. Then tighten com-
pletely in a crosswise manner.
19) Clean the bottom thoroughly from desiccant residues.
20) Slowly pressurise the dryer again. (→ Page 47) 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.
(* = Different applications require different desiccant fillings. Even a filling with only one type of desiccant is possible and common.
Please investigate for the correct type and quantity of desiccant before you order the replacement desiccant. The manufacturer holds
records of the desiccant filling used for each individual dryer(→ Page 5). Please state the dryer serial number in your correspondence.
(→ Page 12))
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.
For the time directly after desiccant replacement it may be useful to select a dew point limit value as described
in the "Properly selecting the dew point limit value" advisory note. (→ Page 9)
56
Taking the inspection intervals for the vessels into account

A routine inspection is required for the pressure vessels. In Germany, according to AD 2000 Code a
routine inspection has to be carried out every 5 years by a notified body.
Please note that different national regulations may apply in other countries.
We recommend replacing the desiccant in the course of this inspection run at the latest.
Combine desiccant replacement and vessel inspection. The manufacturer provides desiccant re-
placement in conjunction with "measures parallel to approval".
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 ele-
ments will deteriorate faster than during later operation. We therefore recommend to recommis-
sion the dryer using the old filter elements and to use the new filter elements and the new expan-
sion silencer only after some weeks.
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.
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.
57
Appendix and technical documents
12. Appendix and technical documents
12.1 General arrangement drawing
Separate document
12.2 Process flow diagram
12.3 Pneumatic diagram
12.4 Wiring diagram
58
A Trocknerbehälter adsorber vessel
V Absperrventil / 3-2-Wegeventil Shut off or 3-2-way valve
HV Handabsperrventil manual shut off valve
RV Rückschlagarmatur non-return valve
SB Siebkorb sieve basket
ST Siebboden sieve tray
X Schalldämpfer silencer
PI Manometer pressure gauge
GO O Lochblende / Reg.Gas-Düse orifice for regeneration flow
MT Drucktaupunkttransmitter pressure dew point transmitter
GJ Gas-Eintritt gas inlet

GO Gas-Austritt gas outlet
RO Regenerationsgas-Austritt regeneration gas outlet
RV1 RV2
MT
01
SB1 (OPTION) SB2
A1 O1 A2
PI PI
01 02
HV1 HV2
RO RO
X1 X2,...,Xn
ST1 ST2
V3 V4
V1/2
GJ
erstellt/design C.Ruff, 01.02.10

geprüft/checked T.Tappe, 01.02.10
R&I-Fließbild ab DPS 120
P&I-Diagram from DPS 120
B Details hinzugefügt / details added 07.09.10 CR 1
A Schalld. zusammengefasst 15.07.10 TT DP-PI-00015 A2
Rev. Änderung/change Datum/date Name
1
1
3
3
5
5
12*
Y3 Y4 Y1 12*
* = ohne Funktion / without function
14* 14*
4
5
4
5
4
5
1
1
1
2
3
2
3
2
3
Y2
4 2 4 2 4 2
auf auf
A open A
A open
V3 V4 V1/2
N.C. N.C.
Wenn Y1 angesteuert ist,

dann ist der Trocknereintritt (GJ) auf
Behälter A1 (links) verbunden.
When Y1 is energised vessel A1 (left)
is connected to the dryer inlet (GJ)
erstellt/design C.Ruff, 25.10.2010

geprüft/checked T.Tappe 25.10.2010
Pneumatikplan DPS 120 - 630
Pneumatic diagram DPS 120 - 630
1
A Position 5-2-W-Venitl geändert 19.11.10 CR ZPP-S-100095 A2
Rev. Änderung/change Datum/date Name ersetzt/replacing:
1 2 3 4 5 6 7 8
A A
Stromlaufplan für Trocknersteuerung C1
Wiring Diagram for Dryer Control C1
Elektrische Anschlussdaten : 230 V / 115V (+/-10%) 50/60 Hz Inhaltsverzeichnis
B (= Ventil-Spannung) L1 / N / PE list of content B
power supply
(= solenoid valve voltage) 1 Deckblatt
cover sheet
Schutzart: IP 65
protection class 2 Aufbauplan
general arrangement
Leistungsaufnahme : DPS1-8 : < 50 VA
C C
(abh. vom Trocknertyp) DPS10-100 : < 35 VA 3 Platine / Klemmenbelegung
power consumption DPS120-630 : < 10 VA circuit board / wire terminal
(depending on dryer type) DHM 8-66 : < 80 VA
DTC 45-1100 : < 10 VA 4 Stückliste
parts list
Sicherung intern : 0,5 A träge / slow-blow
internal fuse
D D
Angewandte Richtlineien 2009/95/EG

und Normen : EN 55011
applied guidelines EN 61000-3-2
and standards EN 61000-3-3
EN 61000-6-2
E E
EMV Prüfbericht: 2010-2536-3871-RDE
EMV test report
Anmerkung: Nicht geeignet für Ventilstecker mit Gleichrichter. Datum/date Name (Benennung / title)
Note Hierfür bitte Sonderplatine anfordern. bear./design 07.09.10 C.Ruff C1 Stromlaufplan 230/115V-AC
gepr./check 07.09.10 T.Tappe C1 wiring diagram 230/115V-AC
Not suitable for valve connectors with rectifyer. In this
case please ask for a special circuit board. Deckblatt /cover sheet
(Zeichnungsnummer / drawing no.) Blatt/sheet
F 1 F
ZEP-S-100064 von/of
4
Rev. Änderung / change Datum/date Name (Ers.f / repl.for: - ) (Ers.d / rep.by: - )
1 2 3 4 5 6 7 A3
1 2 3 4 5 6 7 8
Vorderansicht Gehäuse (innen) Seitenansicht
A front view box (inside) side view A
188
4,2
150 57,5
B B
150
180
3
1
C C
4-fach Kabelverschraubungen M25x1,5,

Gerätesteckdose DIN EN 175301-803, für Kabel 6-8mm 120
niedriges Gehäuse, für 6-8mm Kabel (Die Anzahl der Verschraubungen variiert je nach Anwendung.
female power connector DIN EN 175301-803, Ggf. werden freie Öffnungen durch Blindstopfen verschlossen.)
low housing, for 6-8mm cable 4-port cable glands M25x1,5,
for cable 6-8mm
(The number of glands varies with the application.
D Free openings might be closed using blind plugs.)
D
138
Deckel mit Steuerung (innen)

box lid with control (inside)
4,2
E E
max. Durchmesser des Schraubenkopfes = 7mm
max. diameter of bolt head = 7mm
Datum/date Name (Benennung / title)
bear./design 07.09.10 C.Ruff C1 Stromlaufplan 230/115V-AC
Aufbauplan / gen. arrangement
F 2 F
ZEP-S-100064 von/of
4
1 2 3 4 5 6 7 A3
1 2 3 4 5 6 7 8
A X7 A
N
F3 L1
3
Sannungsversorgung
1
0,5AT L1 N power supply
230V, +/-10%, 50-60Hz
2
115V, +/-10%, 50-60Hz
115 V
230 V
only one jumper is set

nur eine Brücke gesetzt
B max. 1,5mm² PE B
X8
C C
+24VDC
_
1
2
1
2
1
2
1
2
+
GND
SENSOR
+24V
D X9 X10 X11 X12 X13 X14

D
4-20mA IN IN 1 IN 2 IN 3 IN 4
max. 1,5mm²
max. 1,5mm² max. 1,5mm²

gn
wh
bl
4-20mA
_ out + OUT
°C tp
PE I
K1
X15
IN1...IN4:
NO
COM
NC
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
E X6 X1 X2 X3 X4 X5 E
Taupunkt
dew point
max. max. max. max. max. max.

filter 1
filter 2
Filter 1
Filter 2
4mA = -100°C tp
2,5mm² 2,5mm² 2,5mm² 2,5mm² 2,5mm² 2,5mm²

20mA = +20°C tp
Standard Range :
[24VDC; max. Bürde 250 Ohm]
potential free contact
potentialfreier Kontakt
Taupunktsensor
dew point sensor

Taupunkt-extern
dew point-extern
[24VDC; max. ohmic resistance 250 Ohm]
L
N
PE
L
N
PE
L
N
PE
L
N
PE
L
N
PE
Reange enspr. Sensor / range equ. to sensor
[24VDC; max. Leitungswiderstand 1 kOhm]
[24VDC; max. allowable resistivity 1 kOhm]
compressor contact
Komperssor Kontakt

[je max. 25 VA]
gepr./check 07.09.10 T.Tappe

[each max. 25 VA]
A1 Y1 V1 Y2 V2 Y3 V3 Y4 V4 Y5 V5 C1 wiring diagram 230/115V-AC

Alarmkontakt Hauptventil V1 Hauptventil V2 Expansions- Expansions- Druckaufbau- o. Stromlaufplan /circuit diagram
NO-Ventil=linker Beh. NO-Ventil=rechter Beh. ventil V4 (Zeichnungsnummer / drawing no.) Blatt/sheet
alarm contact NC-Ventil=rechter Beh. NC-Ventil=linker Beh.
ventil V3 Abblassventil V5
F F
typical installation -
[max. 5A/250V-AC linker Behälter rechter Behälter (nicht für alle Trocknertypen) 3
max. 5A/30V-DC] main valve V1 main valve V2
for details see dryer manual
NO-valve=left vessel NO-valve=right vessel

expansion expansion pressurisation or ZEP-S-100064 von/of
Betriebsanleitung des Trockner
NC-valve=right vessel NC-valve=left vessel valve V3 valve V4 blow off valve V5 4

Typische Installation - Für Details siehe
left vessel right vessel (not for all dryers) Rev. Änderung / change Datum/date Name (Ers.f / repl.for: - ) (Ers.d / rep.by: - )
1 2 3 4 5 6 7 A3
1 2 3 4 5 6 7 8
Pos. Anzahl / qty Beschreibung description
1 1 Gehäuse, 150x150x57, RAL7035 lichtgrau, ABS (Dichtung: Neoprene) housing, 150x150x57, light grey RAL7035, ABS (seal: neoprene)
A (BOPLA Euromas II - ET218-LP) (BOPLA Euromas II - ET218-LP) A
2 1 Steuerplatine FST/FMW A0891010 control circuit board FST/FMW A0891010
3 1 Gerätesteckdose DIN EN 175301-803, niedriges Gehäuse, 3+PE, PA female power connector DIN EN 175301-803, low housing, 3+PE, PA
(z.B. BINDER 43-1702-000-04) (e.g. BINDER 43-1702-000-04)
4 1 Gerätesteckdosen-Profildichtung, NBR schwarz profiled seal for female power connector, NBR black
Nennquerschnitt 1,5mm² / Kabeldurchmesser 6-8 mm nom. cross section 1,5mm² / cable diameter 6-8 mm
(z.B. BINDER 16-8088-000) (e.g. BINDER 16-8088-000)
5 1 Gerätestecker DIN EN 175301-803, quadratisch, 4 Befestigungslöcher, 3+PE, PA male power connector DIN EN 175301-803, rectengular, 4 mounting holes, 3+PE, PA
B (z.B. BINDER 43-1715-000-04) (e.g. BINDER 43-1715-000-04) B
6 1 Gerätestecker-Flachdichtung, 30x30x1,5mm, NBR beige gasket for male power connector, 30x30x1,5mm, NBR beige
(z.B. BINDER 16-8090-000) (e.g. BINDER 16-8090-000)
7 5 Steckerteil (X1...X5: "Ventile" / X7: "Spannnungsversorgung"), PA plug connector (X1...X5: "valves" / X7: "power supply"), PA
(max. 6) 2 Pole, Raster 5mm, Schraube M3, Drehmoment 0,5Nm 2 pole, pitch 5mm, screw M3, torque 0,5Nm
Nennquerschnitt 2,5mm² (Leiter 0,2...2,5mm² /mit Endhülse 0,25...2,5mm²) nom. cross section 2,5mm² (conductor 0,2...2,5mm² /with ferrule 0,25...2,5mm²)
(z.B. Phoenix Contact MSTB 2,5/2-ST) (e.g. Phoenix Contact MSTB 2,5/2-ST)
8 1 Steckerteil (X6: "Alarmkontakt"), PA plug connector (X6: "alarm contact"), PA
C 3 Pole, Raster 5mm, Schraube M3, Drehmoment 0,5Nm 3 pole, pitch 5mm, screw M3, torque 0,5Nm C
(z.B. Phoenix Contact MSTB 2,5/3-ST) (e.g. Phoenix Contact MSTB 2,5/3-ST)
9 1 Steckerteil (X9: "Taupunktsensor"), PA plug connector (X9: "dew point sensor"), PA
3 Pole, Raster 3,5mm, Schraube M2, Drehmoment 0,22...25Nm 3 pole, pitch 3,5mm, screw M2, torque 0,22...25Nm
(z.B. Phoenix Contact MC1,5/3-ST-3,5) (e.g. Phoenix Contact MC1,5/3-ST-3,5)
10 2 Steckerteil (X10...14: "Signalkontakte"), PA plug connector (X10...14: "signal contacts"), PA
D (max. 5) 2 Pole, Raster 3,5mm, Schraube M2, Drehmoment 0,22...25Nm 2 pole, pitch 3,5mm, screw M2, torque 0,22...25Nm D
(z.B. Phoenix Contact MC1,5/2-ST-3,5) (e.g. Phoenix Contact MC1,5/2-ST-3,5)
11 2 Kabelverschraubung M25x1,5, lichtgrau RAL7035, PA cable gland M25x1,5, light grey RAL7035, PA
(max. 3) (z.B. SKINTOP® ST-M 25x1,5 Art.: 53111430) (SKINTOP® ST-M 25x1,5 Art.: 53111430)
12 2 Dichteinsatz für Kabelverschraubung M25, 4x5mm, NBR schwarz seal inlay for cable gland M25, 4x5mm, NBR black
(max. 3) (z.B. SKINTOP® DIX-M Art.: 53325450) (e.g. SKINTOP® DIX-M Art.: 53325450)
13 ca. 4 Verschlussstopfen für Kabeldurchführung D=5,5 x L=11mm, PA plug for seal inlay D=5,5 x L=11mm, PA
(z.B. SKINTOP® DIX-DV 5,5x11 Art.: 53100055) (e.g. SKINTOP® DIX-DV 5,5x11 Art.: 53100055)
E 14 ca. 1 Blindstopfen für freie Gehäuseöffnung M25x1,5, lichtgrau RAL7035, PA blind plug for free housing opening M25x1,5, light grey RAL7035, PA
E
(z.B. SKINDICHT® BLK-M, Art.: 52006630) (e.g. SKINDICHT® BLK-M, Art.: 52006630)
15 1 Sicherung, 0,5 A, träge, 5x20mm fuse, 0,5 A, delayed, 5x20mm
Stückliste / parts list
F 4 F
ZEP-S-100064 von/of
4
1 2 3 4 5 6 7 A3

Operating Manual Adsorption Dryer DPS 120-630: Version: 11/2010/DE

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Operating Manual

1. General information ........................................................................................................................................5

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

1.2 Dryer data

Vessel no. (left/right):

1.3 Contact data

1.4 Additional documents

Note on additional documents

The customer is provided with pressure vessel documents, if applicable.

1.5 Warranty notes

In the following cases the warranty shall be void:

1.6 About this operating manual

Using the operating manual

Signs and symbols used

 Boxes are used for bulleted lists.

→ Cross references refer to information on a different page or in a different document.

Tips and hints!

2.1 Intended use

The supplied compressed air must be of the following quality:

 Free from aggressive and corrosive substances

In the event of pre-dried compressed air

2.2 Technical Data

V [m³/h]* [kg] [mm] [mm] [mm]

Classification acc. to PED 97/23/EG DPS120: III / DPS150...630: IV

Individual operating conditions

3.1 Signs and instructions

Type plate of the dryer

Type plate of the vessel

3.2 Danger zones at the dryer

1 Risk of injury from pressure-bearing parts

DANGER ! – Overpressure (1)

DANGER ! – Electric voltage (2;3)

WARNING ! – Suddenly escaping compressed air (4)

WARNING ! – Risk of slipping (5)

3.3 General safety notes

DANGER ! – Unauthorised modifications

DANGER ! – Suspected misuse

Please also refer to section "Intended use" (→ page 9).

WARNING ! – Risk of falls

Additional safety notes

4. Technical product description

1 3-2-way-valvel (V1/2) 6 Regeneration gas tube with orifice (O1)

4.2 Process flow diagram

A Dryer vessel PI Pressure gauge

4.3 Function description

The moist compressed air is supplied from a compressed

The optional dew point sensor (MT01) checks the dryer

After the "wet" vessel (A2) has completed the adsorption

Regeneration is divided into the following phases:

After vessel switch-over the expansion valve (V4) is opened

When the vessel pressure drops, dry air (regeneration gas)

The dry and pressureless regeneration gas is distributed

4 adsorption – purging (regeneration)

The pressurisation phase ensures that the two vessels have

After a preset time of app. 1 minute* has expired the pres-

Vessel regeneration is now complete and the vessel is im-