CompAir A TX Series Page 1 Operating Instructions Manual Download

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Adsorption dryer

A190-930TX

Operating Instructions

Revision 03—2006/EN

Summary of Contents for A TX Series

Page 1: ...Adsorption dryer A190 930TX Operating Instructions Revision 03 2006 EN ...

Page 2: ... SIG 0271665 2 by Lloyd s Register Quality Assurance GmbH Hamburg is available The quality assurance system is monitored by the service provider stated below Lloyd s Register Quality Assurance GmbH identification number 0525 Mönckebergstraße 27 D 20095 Hamburg The assembly consists of pressure appliances according to the classification list attached to the technical documentation provided by the m...

Page 3: ...irst time any appliance data not stated above to keep these appliance data up to date The above stated appliance data provide for a clear identification of the dryer and its components and significantly facilitate any service measures Further important data on the dryer such as the details on the permissible operating pressure and the electrical connection are found on the type plate for position ...

Page 4: ...allation and storage 21 Information on transportation packaging 21 What to do in the case of transport damage occurring 21 Transporting and installing the dryer 22 Anchoring the dryer 24 Storing the dryer 24 Installation 26 Preconditions for installation 26 Connect piping 26 Installing the electrical connection 27 Start up 30 Requirements for initial start up 30 Setting times of the operating phas...

Page 5: ...dongle 44 Daily maintenance tasks 44 Weekly maintenance tasks 45 Monthly maintenance tasks 45 Maintenance work to be completed every 12 months 46 Maintenance work to be completed every 24 months 48 Maintenance work to be completed every 48 months 50 Identify and eliminate faults 54 Summary of faults 54 Index 58 Annex with technical documentation 61 Technical data 62 Replacement and wear parts list...

Page 6: ... Germany Telephone 49 0 6761 832 0 Telefax 49 0 6761 832 409 Internet www compair com Service and spare part order You can also use these telephone numbers to order consumables such as drying agents etc as well as replacement parts When ordering replacement parts always state the type and serial no of the dryer Both are shown on the type plate attached to the control cabinet of the dryer ...

Page 7: ...approval and confirmation in writing by the manufacturer for purposes other than those specified in these operating instructions or contractually agreed If preset parameters e g on the control system etc are changed without prior approval and confirmation in writing by the manufacturer If the dryer is transported or stored incorrectly If the dryer is sited and installed incorrectly If the dryer is...

Page 8: ...void such damage Danger These danger notes with a grey background warn against personal injury and or danger to life and limb danger notes help you to avoid serious or life threatening situations for yourself and or third parties Target group of these operating instructions These operating instructions are intended for all persons working on and using the dryer We assume that all such persons are ...

Page 9: ...onnel not used within its intended design specifications is repaired or maintained incorrectly Note For your own safety and to prevent machine damage please note the information and safety notes in these operating instructions when working with the dryer Signs instruction plates and danger zones at the dryer Signs and instructions Vessel plate Vessel plate Type plate of the dryer Front view Please...

Page 10: ...nd maintained by authorized specialist personnel only Warning against overpressure The entire dryer is under pressure Before commencing any work the plant must be depressurised Warning against sudden air ejection When the vessels are depressurised air flows suddenly out of the sound absorber This causes a sudden loud cracking noise Due to particles carried in the air flow there is a very considera...

Page 11: ... off or become damaged in another way General safety notes For your own safety when carrying out any work on the dryer comply with all applicable national safety regulations Personnel qualification Only authorized and qualified specialist personnel may be tasked with the work on the dryer described in these operating instructions Conversions and modifications Without prior approval by the manufact...

Page 12: ...he plant is still pressurised A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Carry out all prescribed tests and checks The factory settings on the control board in the switchbox must not be changed on any account without prior approval by the manufacturer Before start up ensure that no tools or other foreign parts have ...

Page 13: ...ame in any way for as long as the plant is still pressurised A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Carry out maintenance work only when the plant has been shut down and depressurised The factory settings on the control board in the switchbox must not be changed on any account without prior approval by the manuf...

Page 14: ...s still pressurised A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant Dispose all parts of the dryer the drying agent and all other operating materials in an environmentally safe way and in accordance with all current statutory regulations The waste code numbers of the drying agents can be obtained from the manufacturer fo...

Page 15: ...n gas orifice Filling point Pressure gauge PI On off switch Vessel Power supply Control box Filter for control gas Solenoid valve block Y1 Y4 Drain point Front view Check valve V3 Check valve V2 Compressed air outlet Eyebolt Compressed air inlet Expansion valve V4 Expansion valve V5 Main inlet valve V1 Muffler Rear view ...

Page 16: ...he humid drying agent is prepared for another charge regeneration These two states which run in parallel during compressed air preparation are described below Adsorption Via a compressor humid compressed air is supplied to the compressed air inlet of the dryer From here the compressed air flows upwards through the absorption vessel which is pressurised In so doing the drying agent dehumidifies the...

Page 17: ...essel Pressure build up phase After dehumidification the pressure in the regenerated hollow section vessel is built up to operating pressure so that the switchover from regeneration to adsorption can take place at operating pressure level Pressure build up Standby phase only with the dewpoint sensing control option When in standby phase the fully regenerated vessel is ready for absorption operatio...

Page 18: ... stated operating pressure Outside installation As standard the dryer is not suitable for outside installation as its function and service life is influenced by the following factors Environmental humidity due to rain or other deposit Corrosion caused by environmental humidity or a salt containing environment Freezing of valves cocks flaps and other components at low temperatures Therefore a plann...

Page 19: ... become unusable prematurely The compressor synchronisation controller is a higher level controller than the pressure dew point controller see below When both options are in place the compressor synchronisation controller is treated as the prime controller Dewpoint sensing control With a dewpoint sensing control system you can operate the dryer in fixed or variable cycles In the fixed cycle switch...

Page 20: ...ant Preliminary filters should be installed as close to the dryer as possible The pipe feeding the air to the preliminary filter should be at a slight slope It is recommended to install an afterfilter behind the dryer to prevent contamination of the dried compressed air with desiccant particles Condensate drain systems for preliminary and afterfilter Condensate drain systems are installed to drain...

Page 21: ...tion packaging Depending on the type of transportation the dryer is delivered in different types of packaging All transportation types the apertures of the dryer are closed off by means of plugs In addition when transportation is effected by air the dryer is packaged in a wooden box In addition when transportation is effected by ship the dryer is packaged in a film material and in a wooden box If ...

Page 22: ...an auxiliary heater is to be provided for information on the auxiliary heater see page 18 Heed the dryer s noise emission when selecting the installation location The installation area must be level and firm It must have the necessary carrying capacity for the weight of the dryer The weight of the dryer is specified in the technical data section of the annex The dryer should be installed with suff...

Page 23: ... located in the middle of the dryer so that there is a serious risk that the unit might tilt over Therefore adhere to the transport instructions outlined as follows Transport by crane Transport the dryer in an upright position to its location of installation For this purpose attach a girder with suitable fixtures to ensure that the dryer is lifted at the centre and that the upper pipe bridge is no...

Page 24: ... or the dryer must be covered by a protective sheet The storage room must have an ambient temperature of at least 1 C 33 8 F In order to store the dryer proceed as follows Take dryer out of operation as described on page 39 Ensure that the compressed air inlet valve installed by the owner and the installed compressed air outlet valve installed by the owner are both closed and that the dryer is dep...

Page 25: ... Note If you wish to take the dryer back into service after an extended period of storage please proceed as described for its first commissioning and start up see page 35 Store drying agents Do not store drying agents in the open air Protect drying agents against humidity ...

Page 26: ...d match the operating pressure Hazard caused by exceeding the limit values A safety device must be provided in order to protect against the maximum permissible operating pressure from being exceeded The safety device must be installed so that the dryer is reliably protected from exceeding the maximum permitted operating pressure even when the temperature of the compressed gas increases The data re...

Page 27: ...er end 7 Outlet dry air 8 Bypass line option 9 Valve in bypass line option 10 Bypass filter option 11 Valve outlet bypass filter option Example of an installation with bypass line An upstream filter 3 ist to be installed The connection lines for the upstream filter 3 are to be installed at a slight incline in the direction of the upstream filter One shutdown valve each 2 6 is to be installed at th...

Page 28: ...d pull the cable through the aperture 3 The exposed phase ends should not be longer than 35 mm max Now make the cable connection as follows Earth to terminal PE L1 to terminal 1 N to terminal 2 Terminal 3 is not used Connect electrical cable to device adapter Fit terminal block into the connector and use bolt to remount the connector with seal on the switchbox In all phases the dryer must be prote...

Page 29: ...o a fault signalling system connecting the respective line to a potential free operation signalling contact With this option the following statuses and events can for example be transmitted to a remote control room Dryer on contact made Power supply disconnected no contact Dewpoint alarm only with dewpoint sensing control option no contact To install the external lines proceed as follows Connect t...

Page 30: ...ements for initial start up For the first start up the following preconditions must have been met The pipe system is free from scales thread abrasions welding beads and other contaminations All shutdown valves of the compressed air inlet and outlet valves installed by the owner in the bypass line if available are closed The dryer is correctly sited and installed Checks before start up Ensure that ...

Page 31: ... min 4 min of which pressure build up 1 min 1 min Standby 55 min maximum Overview of operating and control elements ON OFF switch The ON OFF switch 2 is located to the side of the control cabinet and above the mains plug 1 see figure If it is set to 0 the power supply is disconnected and the dryer is switched off The expansion valves are normally closed If the switch is set to I the dryer is switc...

Page 32: ...nt operating phases of the dryer are indicated by means of 4 LEDs Vessel B1 Vessel B2 Regeneration 1 Regeneration 2 Adsorption 1 Adsorption 2 Depending on the operating phase the following LEDs might be on simultaneously Adsorption B1 and regeneration B2 or regeneration B1 and adsorption B2 Digital display 3 The digital display shows the individual programme steps and the respective remaining time...

Page 33: ... the optional dewpoint sensing control the following error messages might be displayed Display Cause 20 Upper measuring range limit exceeded 999 Dewpoint sensor defective sens or 999 Dewpoint sensor not powered Cable defective or disconnected Sensor defective LED Economy cycle 4 This LED is only relevant in units that are equipped with the optional dewpoint sensing control The diode lights up when...

Page 34: ...ame in any way for as long as the plant is still pressurised A sudden escape of pressure may cause serious injuries Before carrying out any work on the dryer first depressurise the plant The more powerful the dryer is the more noise may be generated during operation Therefore the operator must provide suitable protective equipment e g ear protection Only operate the dryer within the permissible li...

Page 35: ...lowing intermediate step can be skipped Operating the dryer for the first time or after a change of drying agent separately Depending on the transportation and storage conditions the drying agent in the vessels can already be loaded with humidity from the environment At each first start up it makes sense therefore to operate the dryer from some time separately from the compressed air system This c...

Page 36: ...e vessel pressure gauge of the pressurised vessel The pressure should not drop below the operating pressure if poss If necessary keep the compressed air outlet valve in a slightly open position until the compressed air system downstream of the dryer has filled up completely only then should the valve be opened fully The dryer has then be taken into operation within the compressed air system In the...

Page 37: ... compressor synchronisation optional If compressor synchronisation is enabled the dryer can only be operated in conjunction with the compressor As soon as the compressor is switched off the dryer is automatically set to standby mode In standby mode the control system remains on and the dryer is ready for the next switchover which is made as soon as the compressor is switched on With dewpoint sensi...

Page 38: ... the switchbox shows the currently measured dewpoint The range of display is 100 C 148 F to 20 C 68 F If the set dewpoint is exceeded the system automatically completes a switchover between the vessels The dewpoint at which a switchover is made is preset at the factory After commissioning or extensive maintenance work check the dewpoint display at the dryer Under certain circumstances the desired ...

Page 39: ...tem first switch off the compressor and then wait until the dryer has reached the standby phase before switching it off with the ON OFF switch This ensures that the regeneration cycle is completed and that the pressure in both vessels is at the same level Note As soon as the dryer is switched on again the programme continues the cycle from the point at which it has been stopped Emergency shutdown ...

Page 40: ...ly cable and external power lines are live even after the dryer is switched off and in the event of body contact may cause serious injury Before carrying out any work on the electrical system the electrical supply cable and all external power lines must be made voltage free Make the electrical supply cable to the dryer voltage free Secure the electrical supply cable to the dryer against switch on ...

Page 41: ...let valve installed by the owner Observe the vessel pressure gauge of the pressurised vessel The pressure should not drop below the operating pressure if poss If necessary keep the compressed air outlet valve in a slightly open position until the compressed air system downstream of the dryer has filled up completely only then should the valve be opened fully If available block off bypass line The ...

Page 42: ...ance work only when the plant has been shut down and depressurised Bolt connections must be undone with care Note ram pressure values Otherwise emerging media may cause personal injury Do not modify the factory settings of the control system in any way without prior consultation with the manufacturer Never carry out welding work on a vessel or modify the same in any way Following maintenance work ...

Page 43: ...k to be carried daily weekly monthly 12 months 24 months 48 months see page Complete dryer Carry out visual and function checks 44 Vessel pressure gauge Check dam pressure For a dam pressure exceeding 0 3 bar Check muffler Check dust sieve Check drying agent 45 Upstream and downstream filters option Check differential pressure on the upstream and downstream filters 45 Upstream filter option Check ...

Page 44: ...sage from the display A dongle is enclosed with every service kit You can also order dongles individually from the manufacturer Each dongle can only be used once Switch off the controller Caution The electric line is still live Do not touch live parts Open the lid to the Multitronic controller The circuit board in housed underneath it Slot the dongle into the dongle interface X9 PC Press and hold ...

Page 45: ... a residual pressure designated as dam pressure in the vessel Check for dam pressure if the dryer functions correctly the respective pressure gauge indicates 0 bar Then there is no dam pressure If the dam pressure is greater than 0 3 bar Depressurise the dryer and shut it down see page 39 Dam pressure can be caused by a blocked muffler a blocked dust sieve or drying agent which is too old The resp...

Page 46: ... work is required Restart dryer see page 41 Check filter for leaks Open control air filter Renew mufflers The dryer is equipped with a muffler If the muffler becomes blocked a dam pressure is generated which in extreme cases may cause the muffler to burst Hazard caused by blocked muffler Blocked mufflers can cause a dangerous overpressure to build up which may cause the mufflers to burst Flying fr...

Page 47: ...Warning The dew point sensor is a sensitive measuring device It can be damaged if subjected to forceful vibrations or shocks Therefore please handle the dew point sensor with great care at all times For calibration the pressure dewpoint sensor must be dismantled In order to limit the impact on the dryer operation to a minimum we recommend that you contact the manufacturer well in advance for conta...

Page 48: ...ewpoint sensor must be equipped with protective caps and placed in a solid box Place the protective caps 4 5 onto the old dewpoint sensor and pack it properly in the box Send the old dewpoint sensor to the manufacturer Maintenance work to be completed every 24 months Service expansion valves Replace the seals of the expansion valves every 2 years even if there is no sign of wear or damage Please o...

Page 49: ...lve with coil 2 Loosen both screws 4 to remove the pilot valve with solenoid 2 from the solenoid valve Repeat above steps for all solenoid valves Mount new pilot valves with solenoids and tighten the screws To replace a complete solenoid valve proceed as follows Loosen both Allen screws 5 Replace solenoid valve 2 3 Secure it by retightening the Allen screws Finally Reconnect all cable adapters Sol...

Page 50: ...he condition of all fittings such as e g sieve bottoms and dust sieves including gaskets If necessary these fittings must be cleaned or renewed In the event of comprehensive maintenance or repair tasks contact the manufacturer see page 6 Replace dust sieve Between vessel and upper arch pipe dust sieves are fitted which retain the drying agent dust If these dust sieves become blocked a dam pressure...

Page 51: ...t a substantially later date for notes on the installation site see also page 22 The change interval depends very significantly from the degree of contamination in the compressed air or the quality of the compressed air upstream filters Oil dust and dirt particles cover the drying agent surface and reduce its effective surface in part quite irreversibly If in doubt have a sample of your drying age...

Page 52: ...ontamination or deposits Re fix drain plug as well renew the gasket Repeat the process on the second vessel Remove drain plug Warning If the dryer is not used within specifications the drying agent can be contami nated with pollutants Always take this into account for the environmentally safe disposal of the drying agent The waste code numbers of the drying agent can be obtained from the manufactu...

Page 53: ...the next step Provide for a high bulk density in the vessel Remove filling plug Note To achieve an optimum bulk density we recommend using a snowstorm filling pipe available from the manufacturer Otherwise use a rubber hammer to tap regularly against the vessel wall during filling or use a rod to distribute and compact the drying agent through the vessel opening Re mount the filling plug as well r...

Page 54: ...Expansion valves solenoid valves RV1 RV2 Check valves of regeneration gas return line optional Summary of faults There are different fault types In the case of most electrical faults e g short circuit defective fuse etc the expansion valves V4 V5 close the programme is interrupted In the case of some process faults the dryer will continue to operate for some time Faults on the dryer become noticea...

Page 55: ... renew Excessive compressed air consumption Leakage Check condensate trap at the upstream filter option clean if necessary Solenoid valve Y1 Y2 does not open Check supply voltage cable contacts and solenoid replace if necessary Main inlet valve V1 does not switch correctly Check operating pressure of control air if nec restore Otherwise check function easy switching of main inlet valve if nec rene...

Page 56: ...duce compressed air volume flow Compressed air inlet temperature is too high Reduce compressed air inlet temperature or pre connect a compressed air cooler Control board is defective Check control board if nec renew Differential pressure on the upstream filter option is too high Check differential pressure on the upstream filter if nec renew filter element Condensate trap on the upstream filter op...

Page 57: ...ed Replace sensor sens or 999 Sensor not powered or cable or sensor defective Sensor sensor cable or sensor adapter defective Visual inspection check power supply 24 V to terminals 4 and 6 Replace defective component s SEr Display for service interval Regular maintenance tasks must be carried out The display appears after every 8000 operating hours Inform the manufacturer s service staff and order...

Page 58: ...n 36 D Danger notes Danger 8 Danger warning maintenance 44 Date of manufacture 3 Dehumidification explanation 17 Design paint compatible 19 Detour line see bypass line Dew point sensor maintenance interval 43 Dewpoint sensing control 19 Digital display explanation 32 Documentation technical 61 Dongle use 44 Dryer maintenance interval 43 drying agent service life 51 Drying agent charging 19 mainten...

Page 59: ...rating overpressure minimum maximum 62 Operating pressure 35 permissible 3 safety device 26 Operating signalling contact installation 29 Operation signalling contact 19 Orders telephone number 6 Original replacement parts 13 42 Outside installation 18 overpressure hazard 10 P Packaging 21 Parameters preset 7 Personnel qualification 7 9 11 44 Pressure build up explanation 17 sudden 35 pressure vess...

Page 60: ...24 Supply cable electrical 28 Supply lines 26 symbols explanation 10 T Target group 8 Temperature ambient minimum maximum 62 Transport damage 21 Type plate 9 U Use intended 11 Use safe 8 V Variable cycle 19 Vessel pressure gauge maintenance interval 43 vibration dampers 24 Visual inspection 44 Voltage electrical 27 W Warranty 7 Waste code numbers 14 ...

Page 61: ...0 930TX_EN_03_ 2009 02 06 61 Annex with technical documentation This annex comprises the following information and technical documentation Technical data Replacement and wear parts list Logic control diagram Flow diagram Dimensional drawing ...

Page 62: ...erating pressure and a feed temperature of 35 C 95 F Type A190 930TX Fluid group acc to 97 23 EC 2 max operating overpressure 10 bar min operating overpressure 6 bar min ambient temperature 1 C 33 8 F max ambient temperature 50 C 122 F Rel humidity 60 Noise level 3 dB A relative to free field measurement 1 m surr field 65 105 dB A Mains voltage see type plate Protection class IP 54 Filling quantit...

Page 63: ... for 24 months 100014771 A490 770TX Service kit for 24 months 100014772 A930TX Service kit for 24 months 100014773 A190 390TX Service kit for 48 months 100014776 A490 770TX Service kit for 48 months 100014777 A930TX Service kit for 48 months 100014778 The service kits do not include filter elements or mufflers Those parts have to be ordered separately Drying agent kits including dust sieve and gas...

Page 64: ...Logic control diagram 64 A190 930TX_EN_03_ 2009 02 06 Logic control diagram Adsorption in B1 and regeneration in B2 ...

Page 65: ...Annex with technical documentation A190 930TX_EN_03_ 2009 02 06 65 Regeneration in B1 and adsorption in B2 ...

Page 66: ...5 Stop valve for pressure gauge 300 Control system 7 Pressure gauge PI 304 Control air filter 55 Main inlet valve V1 308 Solenoid valve block Y1 Y4 60 Check valve V2 V3 Options 100 Regeneration gas orifice plate 350 Dewpoint sensing unit 150 Expansion valve V4 V5 450 Start up device 550 Regeneration gas return line ...

Page 67: ...0 930 A1 1060 1270 1350 1350 1600 1875 1904 2155 A2 600 740 740 870 870 1000 1000 1160 B1 2080 2120 2160 2210 2247 2385 2640 2816 B2 1990 2027 2065 2108 2127 2275 2530 2713 C1 840 900 990 1040 1100 1200 1250 1304 Weight Kg 640 765 955 1095 1300 1590 1950 2850 Connection Inlet DN 50 DN 65 DN 80 DN 100 DN 125 Outlet DN 50 DN 65 DN 80 DN 100 DN 125 ...

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CompAir A TX Series, Operating Instructions Manual

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