MARK
Heatless adsorption compressed air dryers
ADS 1, ADS 2, ADS 3, ADS 4, ADS 7, ADS 10
Instruction book
MARK
Heatless adsorption compressed air dryers
ADS 1, ADS 2, ADS 3, ADS 4, ADS 7, ADS 10
From following serial No. onwards: API W27 000
Instruction book
Original instructions
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as identified
in the Declaration of Conformity.
2010 - 06
No. 2920 7081 41
Replaces No. 2920 7081 40
www.mark-compressors.com
Instruction book
Table of contents
1
Safety precautions..........................................................................................................4
1.1
SAFETY ICONS...................................................................................................................................4
1.2
SAFETY PRECAUTIONS, GENERAL...........................................................................................................4
1.3
SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................5
1.4
SAFETY PRECAUTIONS DURING OPERATION..............................................................................................6
1.5
SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR...........................................................................7
2
General description........................................................................................................9
2.1
GENERAL DESCRIPTION.......................................................................................................................9
2.2
OPERATION.....................................................................................................................................12
3
Installation.....................................................................................................................13
3.1
DIMENSIONS....................................................................................................................................13
3.2
INSTALLATION INSTRUCTIONS..............................................................................................................14
4
Electrical connections..................................................................................................18
5
PC interface / Energy management............................................................................20
5.1
PC INTERFACING.............................................................................................................................20
5.2
USING THE SOFTWARE......................................................................................................................21
5.3
ENERGY MANAGEMENT.....................................................................................................................24
6
Operating instructions.................................................................................................30
7
Maintenance..................................................................................................................32
7.1
MAINTENANCE.................................................................................................................................32
7.2
RESETTING THE SERVICE COUNTER......................................................................................................33
7.3
DISPOSAL OF USED MATERIAL.............................................................................................................34
2
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8
Problem solving chart..................................................................................................35
9
Technical data...............................................................................................................38
9.1
REFERENCE CONDITIONS...................................................................................................................38
9.2
LIMITATIONS FOR OPERATION..............................................................................................................38
9.3
TECHNICAL SPECIFICATIONS................................................................................................................38
9.4
INLET FLOW CORRECTION FACTORS......................................................................................................39
10
Instructions for use......................................................................................................41
11
Guidelines for inspection.............................................................................................42
12
Pressure equipment directives...................................................................................43
13
Declaration of conformity............................................................................................44
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Instruction book
1
Safety precautions
1.1
Safety icons
Explanation
Danger for life
Warning
Important note
1.2
Safety precautions, general
General precautions
All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
1. The dryers are designed for normal indoor use.
2. The operator must employ safe working practices and observe all related work safety requirements and
regulations.
3. If any of the following statements does not comply with the applicable legislation, the stricter of the two
shall apply.
4. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
5. The dryer is not considered capable of producing air of breathing quality. To obtain air of breathing quality,
the compressed air must be adequately purified according to the applicable legislation and standards.
6. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the dryer, press
the emergency stop button, switch off the voltage and depressurize the dryer. In addition, the power
isolating switch must be opened and locked.
7. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme
caution and wear eye protection.
8. The owner is responsible for maintaining the dryer in safe operating condition. Parts and accessories shall
be replaced if unsuitable for safe operation.
9. It is not allowed to walk or stand on the dryer or its components.
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1.3
Safety precautions during installation
Precautions during installation
1. The dryer must only be lifted using suitable equipment and in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to
dwell or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within
safe limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. Place the dryer where the ambient air is as cool and clean as possible. If necessary, install a suction duct.
Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps or desiccant bags must be removed before connecting the pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint solvents, that can lead
to internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that all piping is free to expand under heat and that it is not in contact with or close to flammable
materials.
8. No external force may be exerted on the air outlet valve. The connected pipe must be free of strain.
9. If remote control is installed, the machine must bear a clear sign stating "Danger: This machine is remotely
controlled and may start without warning".
The operator has to make sure that the machine is stopped and that the isolating switch is open and locked
before any maintenance or repair. As a further safeguard, persons switching on remotely controlled
machines shall take adequate precautions to ensure that there is no one checking or working on the
machine. To this end, a suitable notice shall be affixed to the starting equipment.
10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is available and
that the exhausted cooling air does not recirculate to the inlet.
11. The electrical connections must correspond to the applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed
near the equipment.
12. On machines with automatic start-stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
13. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must be
protected by a pressure-relieving device or devices as required.
14. Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally touched
by personnel during normal operation must be guarded or insulated. Other high-temperature piping must
be clearly marked.
15. For water-cooled machines, the cooling water system installed outside the machine has to be protected by
a safety device with set pressure according to the maximum cooling water inlet pressure.
16. If no safety valve is present in the air net close to the desiccant dryer (e.g. safety valve of compressor),
full flow safety valves must be installed on the dryer vessels.
17. If the maximum pressure of the compressor is higher than the design pressure of the dryer, a full flow
safety valve must be installed between the compressor and the dryer in order to blow off the excessive
pressure in case the safety valve of the dryer should be out of order or blocked.
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Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance or repair.
These precautions apply to machinery processing or consuming air or inert gas. Processing
of any other gas requires additional safety precautions typical to the application which are not
included herein.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your machine.
1.4
Safety precautions during operation
Precautions during operation
1. Always be careful when touching any piping or components of the dryer during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure
that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapours or
particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork closed during operation. Bodywork should be opened for short periods only, e.g. to
carry out routine checks. Wear ear protectors when removing a panel.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure-relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good condition,
free of wear or abuse
9. If warm cooling air from dryers is used in air heating systems, e.g. to warm up a working area, take
precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of, or tamper with, the sound-damping material.
11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every pressure
vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall be
protected by a pressure-relieving device or devices as required.
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Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance or repair.
These precautions apply to machinery processing or consuming air or inert gas. Processing
of any other gas requires additional safety precautions typical to the application which are not
included herein.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your machine.
1.5
Safety precautions during maintenance or repair
Precautions during maintenance or repair
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
Use only the correct tools for maintenance and repair work.
Use only genuine spare parts.
All maintenance work shall only be undertaken when the machine has cooled down.
A warning sign bearing a legend such as "Work in progress - do not start" shall be attached to the starting
equipment.
Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
starting equipment.
Close the dryer air outlet valve before connecting or disconnecting a pipe.
Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
Never weld on, or in any way modify, pressure vessels.
Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapor when air is admitted.
Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
Make sure that no tools, loose parts or rags are left in or on the machine.
All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and that
they function correctly.
Protect the motor, electrical and regulating components, etc. to prevent moisture from entering them, e.g.
when steam-cleaning.
Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork,
is in good condition. If damaged, replace it by genuine material from the manufacturer to prevent the
sound pressure level from increasing.
Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if required, use
breathing protection.
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• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with water. If
liquid refrigerant contacts the skin through clothing, never tear off or remove the latter; flush
abundantly with fresh water over the clothing until all refrigerant is flushed away; then seek medical
first aid.
21. The following safety precautions are stressed when handling desiccant:
• Take precautions not to inhale desiccant dust.
• Check that the working area is adequately ventilated; if required, use breathing protection.
• Do not overfill the dryer when replacing desiccant.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas. Processing
of any other gas requires additional safety precautions typical to the application which are not
included herein.
Some precautions are general and cover several machine types and equipment; hence some
statements may not apply to your machine.
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2
General description
2.1
General description
Introduction
The air dryers described in this book are heatless adsorption dryers, built to remove moisture from compressed
air for industrial purposes.
The dryer is intended to reach a pressure dew point of -40 ˚C (-40 ˚F). A pressure dew point of -70 °C (-94
°F) can be achieved by decreasing the inlet flow rate (see inlet flow correction factors, section Technical
data).
All units are designed for indoor use.
General view
Main parts
An overview of the main parts of the dryer is given in below figure:
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Instruction book
10
Reference
Description
Reference
Description
1
Top valve assembly
11
Multiport manifold
2
Control unit
12
Top cover
3
Bottom valve assembly
13
Top cover fixing screw
4
Bottom mounting block
14
Rear panel
5
Bottom valve fixing bolt
15
DIN connector
6
Front panel
16
Banjo fixing bolt
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Instruction book
Reference
Description
Reference
Description
7
Front panel fixing screw
17
Pressure seal
8
Pressure housing
18
Exhaust silencer
9
Pressure housing retaining bolt
19
Purge plug
10
Desiccant cartridge with dust filter
Control unit
The top and bottom valve blocks use solenoid valves to control the pressure and direction of flow into the
desiccant cartridges. Electrical signals (timing and logic) to operate the solenoid valves are provided by the
control unit.
Multiport manifold
As standard, the dryers are supplied with inlet and outlet ports configured left to right as viewed from the
front of the unit. There are several optional porting arrangements available by repositioning of port plugs. It
is also possible to switch inlet and outlet. See section Installation instructions.
Desiccant cartridge with integrated dust filter
The cartridges contain the agent (desiccant) that has been developed for the drying of compressed air. The
desiccant is housed in a clear tube that has a holder permeable to air at both ends. Located in the top of each
cartridge is a 1 micron filter for removal of residual dust from the desiccant. The length of the cartridge varies
with the flow capacity of the dryer.
Pressure housing
The cartridges are contained within an extruded aluminium pressure housing and pressure retaining end plates.
Process pressure and flow through each desiccant cartridge is controlled by means of top and bottom valve
blocks, located between the two pressure housings. The regenerating air flow (purge) is controlled by means
of a small orifice plug, located externally (front, central) on the top valve block. The plug is accessible with
the front panel removed.
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2.2
Operation
The construction of the air dryer is simple, reliable and easy to service. A dryer has basically two dessicant
chambers, containing the adsorption material or desiccant. This desiccant is a very porous grain material, able
to adsorb large amounts of water vapour.
While one chamber is drying the compressed air (adsorbing), the desiccant in the other chamber is
simultaneously being regenerated. For this purpose, a small bleed of dry air (purge air) is directed to the
opposite pressure housing. This purge air flows down through the desiccant cartridge and to atmosphere by
means of an exhaust silencer, thereby effecting regeneration of the desiccant.
After 120 seconds of operation, the cartridge under regeneration is sealed by closing of the exhaust valve and
the pressure housing is brought up to full system pressure by the purge air.
After 170 seconds, the pressure in the first housing is released to atmosphere by means of the corresponding
exhaust valve and the desiccant cartridge then operates in regeneration mode. The main air flow and drying
function is then transferred to the desiccant cartridge that was previously under regeneration.
The cycle of operation continues switching alternately between drying and regeneration.
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3
Installation
3.1
Dimensions
Model
Connection
Dimensions
Weight
A
B
C
ADS 1
3/8 "
445 mm
281 mm
92 mm
13 kg
ADS 1
3/8 "
17.52 in
11.06 in
3.62 in
29 lb
ADS 2
3/8"
504 mm
281 mm
92 mm
14 kg
ADS 2
3/8"
19.84 in
11.06 in
3.62 in
31 lb
ADS 3
3/8"
635 mm
281 mm
92 mm
16.5 kg
ADS 3
3/8"
25.00 in
11.06 in
3.62 in
36 lb
ADS 4
3/8 "
815 mm
281 mm
92 mm
19.5 kg
ADS 4
3/8 "
32.09 in
11.06 in
3.62 in
43 lb
ADS 7
3/8 "
1065 mm
281 mm
92 mm
24 kg
ADS 7
3/8 "
41.93 in
11.06 in
3.62 in
53 lb
ADS 10
3/8 "
1460 mm
281 mm
92 mm
31 kg
ADS 10
3/8 "
57.48 in
11.06 in
3.62 in
68 lb
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Instruction book
3.2
Installation instructions
Connecting a filter to the dryer
The mounting kit allows to couple the filter directly to the multiport manifold.
1.
2.
3.
4.
Fit a lubricated o-ring between the filter and the multiport manifold, observing the flow direction on both.
Fasten filter bolts evenly to 4 Nm.
Fit 4 mm (5/32 in) black tubing to filter and drain valve inlet.
Pipe away condensate with 4 mm (5/32 in) tubing from drain outlet. If the condensate contains oil, ensure
condensate is drained into an oil/water separator.
5. Fit any further filtration or ancillary equipment.
Piping
Make sure that all pipes, filters, valves, etc. are clean and that they are installed correctly with
or without bypass system.
Make sure that the piping is installed stress-free. For more information concerning air nets,
cooling systems etc. refer to the compressor installation manual.
Reconfiguration of inlet and outlet ports
As standard, the inlet is at the left side and the outlet is at the right side of the dryer, when facing the dryer
from the front.
To change:
• Remove the top cover (fixed by means of 2 screws).
• Remove the multiport manifold (fixed by means of 4 fixing bolts).
• Rotate the multiport manifold by 180° and fix it again. Ensure the 2 o-rings are properly seated in the
valve block.
• Reposition the top cover.
• The inlet is now at the right side and the outlet is at the left side.
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(1)
Dryer inlet
(2)
Dryer outlet
Installing the dryer in horizontal position
The dryer can be installed in horizontal position. Always observe the filters are in upright position. See
enclosed picture:
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Instruction book
When installing the dryer in horizontal position, consideration must be given to supporting and to clearance
for removal of inlet filter bowl.
General recommendations
It is recommended that a bypass line including filter is installed.
Important: Keep the following in mind when installing the dryer:
• Install the dryer at a location where the temperature never exceeds the limits, see section Limitations for
operation.
• The dryer does not require extra ventilation.
• Fix the dryer as level as possible to the floor. Make sure the fixating screws are tightened firmly and that
the floor is suitable for taking the weight of the dryer.
• Provide enough space around the dryer to install and service the filter elements.
If the filters are mounted directly on the dryer, the dryer should eventually be positioned higher to enable
servicing of the filter elements.
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• Use a water separator (1) and a high efficiency filter (2) at the inlet of the dryer. The drain pipes of the
water separator and the filters must not dip into the water. Should oil vapour and odours be undesirable,
an active carbon filter can be installed downstream the dust filter.
• When the compressor has no built-in water separator, a water separator (1) has to be installed before the
dryer in order to prevent free water from entering the dryer, as free water can damage the desiccant. If the
condensate contains oil, install an oil/water separator for draining of pure condensate water (consult your
supplier).
• It is recommended to install bypass pipes with ball valves over the filters in order to isolate the filters
during service operations without disturbing the compressed air delivery.
• It is required to install pressure relief valves on the dryer when ball valves are installed at the inlet and the
outlet of the dryer to isolate the dryer from the air net.
• If dryers are used in parallel, it is advisable to make sure that all dryers can be bypassed through one of
the other dryers.
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4
Electrical connections
General
The electrical wiring must comply with the applicable regulations. The air dryer must be protected by fuses
against short-circuiting. Consult also the electric diagram delivered with the dryer.
Power connection
The dryer is designed to operate on either AC (50 - 60 Hz) or DC supply voltage.
Ensure only one power source is connected at any one time, and that it is connected to the
correct socket!
The power supply is to be connected to the DIN plug:
DIN plug
(1)
Live wire (AC) or + (DC supply)
(2)
Neutral wire (AC) or - (DC supply)
(3)
Gasket
The dryer is double insulated. Therefore no earth wire is required. A suitable external fuse connection must
be provided.
The cable selection must suit local installation regulations and be appropriate to power consumption.
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Supply voltage
Current
Typical cable size
Typical fuse size
12 V DC
0.8 A
1.0 mm2
1A
24 V DC
0.4 A
1.0 mm2
1A
100 V AC
0.16 A
1.0
mm2
1A
115 V AC
0.14 A
1.0 mm2
1A
230 V AC
0.07 A
1.0 mm2
1A
Connection of the DIN plug to the dryer
• Connection for AC supply voltages (100 V to 230 V AC):
• Connection for DC supply voltage (12 V to 24 V DC):
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5
PC interface / Energy management
5.1
PC interfacing
Connection of the controller with a PC
The dryer controller has the ability to interface with a PC. This gives the user or the service engineer the
opportunity to interrogate the dryer to check the following:
•
•
•
•
•
•
•
•
Operating stage times
Service warnings
Operating history
Alarm settings
Fault history
Fault and service history
Real time displays
Setting Energy Management Parameters. Contact your supplier for details
PC requirements
Controller Application software: Windows 95, Windows 98,Windows 2000, Windows ME & Windows XP.
Installation of the application software
Simply insert the CD into the PC and the software will automatically load-up and complete installation. The
logo of the dryer application software will become visible on your desktop when installation is completed.
Connecting the PC to the controller
Remove the screw on the front panel of the dryer and remove the panel. Use the lead supplied (kit p.n. 8092
2616 95) to connect the PC to the controller.
The RS232 connector is located on the underside of the controller. Remove the blanking plug, taking care not
to lose it and connect the RS232 connector with the latch to the front of the dryer.
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Controller (shown in inverted position)
5.2
1
Condensate solenoid valve
5
Energy management DIN connection
2
Tower 1 solenoid pilot valve
6
Controller clear LED cover
3
Tower 2 solenoid pilot valve
7
RS 232 connection
4
DIN connections (AC and DC supply)
8
Alarm DIN connection
Using the software
Starting the program
If not already done, connect the RS232 serial link cable between the controller and the host PC.
Switch on the power to the controller. Launch the application software by either double clicking the Dryer
Application Software icon found on the PC desktop or by clicking Start > Programs > Dryer Application
Software.
The first time the software is used the following window will appear:
Choose your preferred language by clicking the appropriate flag.
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Establish communication (1)
With the power to the dryer switched on and the lead connecting the controller to the PC, double click the
Dryer Application Software icon on the screen. This will display the screen below. If the language is not as
you require it, simply click the appropriate flag and the next time the application software starts, the language
will be in the requested language.
Next, click the <Establish Communication> button (1) on the screen. The serial number on the software must
match the serial number on the controller to allow communication to be established.
If communication cannot be made, a warning will appear at the bottom of the screen.
This may be due to the following:
• Poor connections between controller and PC
• Controller switched off
• Application software/controller serial number mismatch
Once communication has been established, click the <Read> button (2) on the screen. This will display the
default setting from the factory or the last setting made by the Service Engineer. It is possible to change some
of the controller settings from the factory default settings on the screen. This should only be done by a qualified
service engineer.
Read (2)
This button is used to read the current settings of the controller.
Program (3)
To program the controller with new settings.
Real Time View (4)
This screen can be opened by clicking the <Real Time View> button (4). In addition to the main display panel
shown previously, there is also a real time view, which illustrates the operation of the dryer valves while it
happens. It also counts down the remaining time to run on the valve operation. This is useful in confirming
faults, which are displayed with the LED's on the front display panel.
To view the status of the controller in real time, click the <Real Time View> button. A new window will
appear, animating the controller status in real time.
The following information is shown:
• The stage the controller is in through its cycle, including remaining time on the particular stage
• Valve conditions
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•
•
•
•
Power condition
Cartridge and valve service conditions
Energy management condition
Alarm condition
Load settings (5)
Allows previously stored settings to be loaded into the controller.
Stage Times (6)
• Tower 1 and Tower 2: indicates the time that a tower is depressurised.
• Re-pressurisation 1 and 2: indicates the re-pressurisation time set on the controller.
• Link: enables or disables the Tower 1 and Tower 2 settings to be linked.
Drain Valve (7)
• Here you can choose whether the drain should operate after Tower 1 only or after Tower 1 and 2.
• Drain valve pulse: sets the drain operation time in seconds.
Alarm Settings (8)
Allows the service Engineer to Toggle and adjust the remote alarm activation values from the default values.
Energy Management (9)
Allows the user to set application parameters to save energy during periods of low demand when kit 8092
2616 95 is purchased.
Service Information (10)
Indicates the default settings at which the cartridge and valve service indicators will illuminate. The service
history of the machine is logged, giving total hours run and hours run since the last service. The reset buttons
provide an alternative method of resetting service hours than using the reset disc after a service has been
carried out.
Address (11)
Indicates the network address of networked dryers.
Faults (12)
The first column indicates the number of faults (up to 50). The information is refreshed every 30 minutes.
The second column indicates the type of fault and the hour it occurred from start-up.
Serial numbers (13)
Indicates software and dryer serial number to ensure they correspond.
Programming
Once it has been decided to change the default settings, and when communications have been established and
the values appear on the screen of the PC, the procedure for change is:
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•
•
•
•
•
Click into the box you wish to change.
Overwrite with the items you require (note that stage times are in 10 second intervals).
Click the <Program> button (3). A warning will appear, asking to confirm the change.
Click to confirm and the operating parameter will be changed.
Click the <Real Time View> button (4) to check set up.
Remote fault alarm
A remote alarm relay is built into the controller to facilitate an alarm connection remote from the dryer. This
can activate at the service due period or with a pre-defined number of electrical faults or both.
This function can be enabled or disabled using the software interface. The alarm requires a power source to
be brought to the controller and on activation the controller will switch on in an alarm condition. This in turn
can be used to activate a remote audible or visual indicator.
5.3
Energy Management
Description
The purpose of the Energy Management (EM) feature is to save energy by reducing compressed air
consumption during periods of low demand by interrupting the normal purge cycle. This can be activated
with a link from the receiver upper and lower pressure switches, normally fitted to receivers.
In the case where the compressor is a continually running type or if the dryer is remote from the receiver, a
dewpoint dependent switch can be used to activate the energy management feature.
As standard, the energy management feature is supplied activated on all controllers. When connected to an
external switching system, the energy management process will become operational. For systems where
energy management will not be required, a jumper link is fitted to the supplied DIN plug.
24
Control
Logic
User interface
Compressor unload switch
Compressor loaded = air demand Connection of EM contacts to the
= normal dryer cycle
compressor
Compressor unloaded = no air
Unload switch contacts
demand = EM dryer cycle
Dewpoint switch
Specified dewpoint = normal
Hygrometer or dewpoint switch
loading = normal dryer cycle
connected to EM contacts
Dry dewpoint = low loading = EM
dryer cycle
System pressure switch
Normal system pressure = normal Pressure switch on system and EM
demand = normal dryer cycle
contacts connected
High system pressure = low
demand = EM dryer cycle
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Energy Management connection
1.
2.
3.
4.
5.
6.
Remove the DIN plug from the EM connection on the controller.
Remove the blanking plug from the cable entry nut on the DIN plug.
Remove fixing screw and gasket from the DIN plug body.
Separate the DIN plug body internal from the cover.
Remove jumper wire from pins 1 & 2 on the DIN plug body internal.
Connect the external switching device cable (compressor unload switch, dewpoint switch or pressure
switch) to pins 1 and 2 on DIN plug body internal, ensuring that cable entry nut, washer and seal are in
place.
7. Assemble DIN plug body internal into cover and reconnect the DIN plug to the EM connection on
controller, ensuring that screw and gasket are fitted.
8. The controller gives a +5 V DC signal from pin 1 on the EM DIN. Operation of the EM feature is by
opening and closing of the circuit.
Opening the circuit with an appropriate external relay or switch will activate the EM feature.
The user must ensure that the EM DIN plug as supplied with jumper wire, or an external
switching arrangement is in place before the dryer becomes operational.
Ensure the EM switching arrangement is in place before activating the EM feature and before
air is flowing through the dryer.
Energy management application selection
For correct energy management operation it is important to select the correct mode of operation for the
application.
For applications where the compressor, receiver and the dryer are in the same location linking the controller
energy management into the compressor pressure limit switch, an effective method of energy saving is offered.
For applications where the compressor is continuously operating or if the dryer is the point of use or if the
dryer is remote from the receiver, a dewpoint dependant method of switching should be employed.
This links the operation of the energy management to the outlet dewpoint from the dryer.
The flow diagram below illustrates the correct selection:
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Instruction book
1
Energy management required
9
Dry receiver application
2
Point of use dryer application (remote from
compressor)
10
15 second default EM delay
3
Dewpoint dependant energy management
switch
11
Wet receiver application
4
Dewpoint monitoring
12
Input compressor/receiver operating parameters
5
Continuously running compressor
13
Calculated EM delay
6
Dewpoint dependant energy management
switch
14
Compressor
7
Dryer directly connected to local compressor 15
and receiver
Dry air receiver
8
Compressor load energy management
switching
Wet air receiver
16
Connecting the PC to the controller
See section PC interfacing for connecting the PC to the controller. Start the Dryer Application Software and
check the <Energy Management Active> box. Note that a default delay of 15 seconds is operational. If the
figure is considered suitable for the application, no further set-up is necessary. If the application requires
dedicated settings to be entered, follow the rest of the instructions in this section. If necessary, the energy
management feature can be deactivated by unchecking the box. Alternatively, the DIN plug with jumper link
will override the energy management feature provided it is left in place.
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Select Dry or Wet Receiver System from the illustration given in the set-up screen by selecting the appropriate
box.
Note: for point of use dryers or constant running dryers utilising dewpoint monitoring, the Dry Receiver
System should be activated regardless of the installation.
For Wet Receiver applications select the Wet Receiver box. To calculate the necessary delay it is necessary
for the installer to enter the high and low pressure set points for the compressor switch, the internal volume
of the receiver and the flow rate of the dryer. The purpose of the delay is to prevent dryer saturation when
using a large receiver with large range of set pressures.
Once the application conditions have been entered, click OK. This will return the screen to main application
software. <Program> will set and fix the previously defined conditions.
The RS232 connection can be removed by using a small screw driver to depress the retaining tang on the
connector.
Replace the push-in cover and put the front panel back in place.
Energy Management (EM) memory retention
Energy savings are made in the dryer by interrupting the normal purge operation during periods of low demand.
To maintain the equilibrium of the dryer towers, the dryer has a memory retention feature. This allows the
dryer to remember the point in the operating cycle when the EM feature was activated and return to it to
complete the cycle.
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Instruction book
From new or service delay
To allow conditioning of the dryer desiccant beds to the optimum condition, a 6-hour delay has been
programmed into the controller to delay EM operation from new or from a service. Once this time has elapsed,
the EM facility can be operated.
Alarm connection details
To enable the alarm facility it is recommended that a suitable cable is brought into the controller via the rear
panel and a grommet. An external power source is required.
1. Connect the switching pole to terminals 1 and 2 on a DIN 43650 industrial type connector.
2. With the power removed from the dryer and the alarm lead wired, remove the cover from the DIN marked
<Alarm> (see chapter Schematic wiring and fault diagrams) and connect the wired DIN socket ensuring
the seal and screw are fitted.
3. Connection to the alarm supply is made with a DIN connection on the controller body.
Alarm relay setting
3 A max (DC)
Alarm connection type
DIN 43650 Industrial type
Schematic wiring and fault diagrams
• General wiring diagram
1
Ensure correct supply connection. Fit only 4
one power source
Switch mode power supply
2
External power source - 3 A max.
5
Controller front
3
Energy management signal link
6
Application diagnostic PC interface
• Remote alarm wiring diagram
28
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1
Remote alarm device
3
Terminal 2
2
Terminal 1
4
Controller front
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Instruction book
6
Operating instructions
Start-up
Ensure that the purge plug fitted to the dryer is the correct one for the operating conditions.
Depending from the operating pressure, different purge plugs are available.
In your own safety interest, always observe all relevant safety instructions.
Start the dryer as follows:
1.
2.
3.
4.
5.
Close valves A, B, C and D
Switch on the compressor
Open valve A slowly
Check there are no leaks from the dryer
Switch on the electric power of the dryer. All four display panel LED’s will flash simultaneously green
four times, then simultaneously red four times to acknowledge application of power and readiness to
function. Observe display panel for one complete cycle.
Note: cycle described is factory setting.
a.
b.
c.
d.
e.
Power LED D illuminates green and tower LED A illuminates green.
After 120 seconds, tower LED A switches off and drain LED C illuminates green.
After a further 50 seconds, drain LED C switches off and tower LED B illuminates green.
After another 120 seconds, tower LED B switches off.
After a further 50 seconds, tower LED A illuminates green again. This is (a) in the cycle described
above.
f. The above cycle (steps a-d) repeats.
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6. Run the dryer for a minimum of 6 hours to ensure the dewpoint is adequate.
7. Open valve B slowly.
If the application allows air that is not dried optimally, the valve towards the air consumer
may be opened even before the optimal PDP is reached. In this case however it will take
more time for the desiccant to dry completely.
At initial start-up, and specially when the dryer is loaded from the beginning, it can take
a long time before the dewpoint is reached. For a dewpoint of -70 ˚C (-94 ˚F), it can take
up to more than 10 days before this value is reached.
It is therefore recommended to operate the dryer for a number of days with the outlet
valve closed.
Dryer in operation
At regular intervals, check the status of the LED’s on the control panel. If the PDP temperature is too high,
let the dryer regenerate by closing the outlet valve. Check the table in section Fault diagnosis for information
and correct action.
Stopping
To stop the dryer, proceed as follows:
1. If installed and if necessary, open the bypass valves of the dryer so that the application will still receive
compressed air.
2. Close the external inlet valve between the compressor and the dryer and the external outlet valve between
the dryer and the dry air consumer.
3. Let the dryer run for a period without consumption, to depressurize the vessels.
4. Switch off the power to the dryer.
If the dryer is stopped for a longer period, keep the inlet and outlet valve closed to avoid
moisture from entering the dryer.
Under no circumstances must compressed air be allowed to flow through the dryer when
the electrical power is switched off. This will result in terminal failure of the desiccant
cartridges and regeneration will not be possible.
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7
Maintenance
7.1
Maintenance
General recommendations and precautions
The dryer does not need any specific maintenance. Nevertheless, before carrying out any maintenance or
corrective activity, read the following recommendations and safety precautions and act accordingly:
•
•
•
•
Close valve B and valve A.
Leave the dryer operating during 15 minutes to fully depressurise.
Switch off all electrical power to the dryer.
Use original spare parts only. Consult the Parts List for part numbers. For preventive maintenance,
dedicated service kits are available.
• Check for correct operation after maintenance.
Under no circumstances must compressed air be allowed to flow through the dryer when
the electrical power is switched off. This will result in terminal failure of the desiccant
cartridges and regeneration will not be possible.
Filters and valves installed between the compressor, the dryer and the air consumer
may need other maintenance activities than those mentioned below (e.g. draining the
filters and replacing the filter elements). Refer to the appropriate manual for more
information.
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Scheduled maintenance
Frequency
Service kit
Activity
Daily
Check the display panel. Information on service
messages can be found here. See section Fault
diagnosis for details
Every two years or every 12000 kit A - 12000
hours of operation (1)
hours kit
Pre-filter kit
• Replace the desiccant cartridges
• Replace the inlet filter cartridges (pre-filter kit).
• Reset the controller.
Every four years or every 24000 kit B - 24000
hours of operation (1)
hours kit
Pre-filter kit
• Service plan 12000 hours
• Have exhaust valve diaphragms and solenoids
•
replaced (2)
Replace shuttle valves
(1): whichever comes first
(2): consult your supplier
For part numbers and for details on the composition of the service kits: consult the Parts list.
7.2
Resetting the service counter
Resetting the controller
After maintenance, it is necessary to reset the controller. This is done as follows, using the reset disc (supplied
with a 12 000 hour service kit):
1. Hold the disc against the blue pad on the front display of the dryer panel during 5 seconds.
2. During the five second period, the power LED D will flash green. When the reset has been successful,
LED B will flash red once to confirm that it has been completed successfully.
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Instruction book
7.3
Disposal of used material
Used filters or any other used material (e.g. desiccant, lubricants, cleaning rags, machine parts, etc.) must be
disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and
environmental legislation.
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8
Problem solving chart
Survey
Following chart shows the different possibilities:
1
OK (green)
9
Service warning every 11 500 hours (yellow
+ green)
2
Warning (yellow)
10
Service due every 12 000 hours (red + green)
3
Action (red)
11
Repressurisation including second drain (red
+ green)
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Instruction book
4
Power Off
12
Right hand / Left hand solenoid fault (red +
green)
5
Left hand tower purge cycle (green)
13
Drain valve fault (red + green)
6
Repressurisation cycle (green)
14
Controller fault (red)
7
Right hand tower purge cycle (green)
15
Low power fault (red)
8
Repressurisation including second drain
(green)
Problem solving
Before specific identification of any fault is looked for, the following general points must
be verified:
• Has the unit been damaged externally or are any parts missing?
• Is power being supplied to the unit?
• Was start-up carried out in accordance with the instructions in this manual?
• Are all external valves correctly set for operation?
• Do the operational conditions meet those specified at time of ordering and used for
product selection?
The table below gives possible causes and corrective actions to faults that may occur on the dryer:
Problem
Posiible cause
Action
Poor dewpoint
Liquid water at dryer inlet
Check pre-filtration and drains
Excessive flow
Check actual flow against maximum specified
Low inlet pressure
Check against specification
High inlet temperature
Check against specification
Silencer blocked or damaged
Replace silencer
Air leaks
Tighten joints or fit new seals
Jammed shuttle valves or faulted
electrical components
See electrical operation trouble shooting
Incorrect dryer
operation
Electrical trouble shooting
Problem
Possible cause Display
Priority
Location
No dryer function No power supply None
Incorrect dryer
operation
36
Action
Check supply
Blown fuse
(external)
None
Replace fuse
(external)
Energy
management
active
None
Check
installation
Left solenoid
open or short
circuit
Flashing red
P1
A
Replace
solenoid valve
Right solenoid
open or short
circuit
Flashing red
P1
B
Replace
solenoid valve
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Problem
Drain not
operating
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Possible cause Display
Priority
Location
Action
Controller fault
Flashing red
P2
D
Replace
controller
Lower power
fault
Continuous red
P1
D
Check supply
Energy
management
active
None
Drain solenoid
open or short
circuit
Flashing red
P1
C
Replace
solenoid valve
Controller fault
Flashing red
P2
D
Replace
controller
Check
installation
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Instruction book
9
Technical data
9.1
Reference conditions
9.2
9.3
Compressed air effective inlet pressure
bar
7
Compressed air effective inlet pressure
psi
101.5
Compressed air inlet temperature
˚C
35
Compressed air inlet temperature
˚F
95
Relative humidity of the air at inlet
%
100
Pressure dew point (standard version)
˚C
-40
Pressure dew point (standard version)
˚F
-40
Pressure dew point (with decreased inlet flow)
˚C
-70
Pressure dew point (with decreased inlet flow)
˚F
-94
Time of half a cycle
s
170
Regeneration time
s
120
Maximum compressed air effective inlet pressure
bar
16
Maximum compressed air effective inlet pressure
psi
232
Minimum compressed air effective inlet pressure
bar
4
Minimum compressed air effective inlet pressure
psi
58
Maximum ambient air temperature
˚C
50
Maximum ambient air temperature
˚F
122
Minimum ambient air temperature
˚C
5
Minimum ambient air temperature
˚F
41
Maximum compressed air inlet temperature
˚C
50
Maximum compressed air inlet temperature
˚F
122
Minimum compressed air inlet temperature
˚C
1.5
Minimum compressed air inlet temperature
˚F
35
Limitations for operation
Technical specifications
Specific data (standard version, PDP - 40 °C)
Desiccant type: molecular sieves
Maximum volume
flow at dryer inlet
38
l/s
ADS 1
ADS 2
ADS 3
ADS 4
ADS 7
ADS 10
1.9
2.8
4.7
7.1
11.8
16.5
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Instruction book
ADS 1
ADS 2
ADS 3
ADS 4
ADS 7
ADS 10
Maximum volume
flow at dryer inlet
cfm
4.0
5.9
10.0
15.0
25.0
35.0
Total amount of
desiccant
kg
1.2
1.6
3
4
7
8.8
Total amount of
desiccant
lb
2.6
3.5
6.6
8.8
15.4
19.4
Regeneration air
%
consumption average
at max. flow
18
18
18
18
18
18
Recommended filter
size
FMO/
FMM/
FPRE
10
10
10
10
10
10
Mass
kg
13
14
16.5
19.5
24
31
Mass
lb
28.7
30.9
36.4
43.0
52.9
68.3
Installed power
VA
5.7
5.7
5.7
5.7
5.7
5.7
ADS 1
ADS 2
ADS 3
ADS 4
ADS 7
ADS 10
Specific data (PDP - 70 °C)
Desiccant type: molecular sieves
9.4
Maximum volume
flow at dryer inlet
l/s
1.3
2.0
3.3
5.0
8.3
11.6
Maximum volume
flow at dryer inlet
cfm
2.7
4.2
7.0
10.6
17.6
24.6
Regeneration air
%
consumption average
at max. flow
26
26
26
26
26
26
Total amount of
desiccant
kg
1.2
1.6
3
4
7
8.8
Total amount of
desiccant
lb
2.6
3.5
6.6
8.8
15.4
19.4
Recommended filter
size
FMO/
FMM/
FPRE
10
10
10
10
10
10
Mass
kg
13
14
16.5
19.5
24
31
Mass
lb
28.7
30.9
36.4
43.0
52.9
68.3
Installed power
VA
5.7
5.7
5.7
5.7
5.7
5.7
Inlet flow correction factors
Data valid at reference conditions (see section Reference conditions) and air inlet pressure as stated below .
Correction factor in function of the air inlet pressure
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Instruction book
Pressure
bar
4
5
6
7
8
9
10
Pressure
psi
58.0
72.5
87.0
101.5
116.0
130.5
145.0
0.62
0.75
0.87
1.0
1.12
1.25
1.37
Correction
factor
Correction factor in function of the air inlet pressure
Pressure
bar
11
12
13
14
15
16
Pressure
psi
159.5
174.0
188.5
203.0
217.5
232.0
1.50
1.62
1.75
1.87
2.00
2.12
Correction
factor
Correction factor in function of the air inlet temperature
Temperature
°C
20
25
30
35
40
45
50
Temperature
°F
68
77
86
95
104
113
122
1.07
1.06
1.04
1.0
0.88
0.78
0.55
Correction factor
Correction factor in function of the pressure dewpoint (PDP)
PDP
°C
-40
-70
PDP
°F
-40
-94
1.0
0.7
Correction factor
40
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10
Instructions for use
Instructions
1
The dryer vessels can contain pressurised air. This can be potentially dangerous if the
equipment is misused.
2
The towers of the dryer consist of an extruded profile, which must only be used as a
compressed air vessel and must be operated within the limits specified. See section Pressure
Equipment Directives, table A.
3
No alterations must be made to the vessels by welding, drilling or other mechanical methods
without the written permission of the manufacturer.
4
The design pressure and temperature of this pressure bearing part must be clearly indicated
on the data label.
5
The safety valve must correspond with pressure surges of 1.1 times the maximum allowable
operating pressure. This should guarantee that the pressure will not permanently exceed the
maximum allowable operating pressure of the vessel.
6
Original bolts have to be used after opening for inspection. The maximum torque has to be
taken into consideration (see table below).
Maximum bolt torque
Thread size
Tightening torque
Nm
Allowed deviation
Nm
M3
1
0.3
M4
2.4
0.6
M5
5
1.2
M6
8
2.1
M8
20
5
M10
41
10
M12
73
18
M14
115
29
M16
185
46
M18
238
60
M20
335
84
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11
Guidelines for inspection
Guidelines
On the Declaration of Conformity / Declaration by the Manufacturer, the harmonised and/or other standards
that have been used for the design are shown and/or referred to.
The Declaration of Conformity / Declaration by the Manufacturer is part of the documentation that is supplied
with this air dryer.
Local legal requirements and/or use outside the limits and/or conditions as specified by the manufacturer may
require other inspection periods as mentioned below.
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12
Pressure equipment directives
Components subject to 97/23/EC Pressure Equipment Directive
The drying towers, consisting of extruded profiles, are the only pressure bearing parts of category I. The
category according to 97/23/EC of the pressure assembly, as well as the volume, is indicated in Table A (see
below).
Parts of article 3.3 of 97/23/EC are subject to good engineering practice.
Parts of category I according to 97/23/EC are integrated into the machine and fall under the exclusion of article
I, section 3.6.
Parts subject to the Simple Pressure Vessel Directive 87/404/EEC are excluded from 97/23/EC according to
article I, section 3.3.
The following table contains the necessary information for the inspection of all pressure equipment according
to the Pressure Equipment Directive 97/23/EC.
Design criteria for pressure equipment:
Table A
Dryer
type
Tube drawing
p.n.
Design
pressure
bar(e)
Design temperature
°C
PED
category
Tube wall
thickness
mm
Tube
diameter
mm
Tube
internal
volume
l
ADS 1
1624 0116 00
16
-10 to +80
I
3.25
80
1.8
ADS 2
1624 0117 00
16
-10 to +80
I
3.25
80
2.1
ADS 3
1624 0118 00
16
-10 to +80
I
3.25
80
2.8
ADS 4
1624 0184 00
16
-10 to +80
I
3.25
80
3.7
ADS 7
1624 0185 00
16
-10 to +80
I
3.25
80
5.6
ADS 10 1624 0186 00
16
-10 to +80
I
3.25
80
7.6
Recommendation of the manufacturer for the re-inspection time
Following actions are to be executed by authorised service personnel, unless stated differently in the applicable
legislation. The stated time interval has as reference the day of start-up of the unit.
• Every 6 months: visual check of tube (tower) material on the outside (exposed) for traces of strong
corrosion. Consult the service department of your supplier if necessary.
• Every 2 years or 12000 hours: when replacing the desiccant, following inspections are to be carried out:
• Inspection of outside and inside of the material for excessive and local corrosion,
• Inspection of outside and inside of the material for fissures, leaks, damage.
Consult the service department of your supplier if necessary.
• Every 10 years: hydrostatic test according to the Pressure Equipment Directive 97/23/EC. Consult the
service department of your supplier if necessary.
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13
Declaration of conformity
Typical example of a Declaration of Conformity document
(1): Contact address:
C. Aria C. S.p.A.
Via Soastene , 34
I 36040 BRENDOLA (VICENZA)
Italy
44
2920 7081 41
www.mark-compressors.com
No. 2920 7081 41 / 2010 - 06 - Printed in Belgium