CompAir A TX Series Operating Instructions Manual
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CompAir A TX Series Operating Instructions Manual

CompAir A TX Series Operating Instructions Manual

Adsorption dryer
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Adsorption dryer
A190-930TX
Operating Instructions
Revision 03—2006/EN

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  • Page 1 Adsorption dryer A190-930TX Operating Instructions Revision 03—2006/EN...
  • Page 2 Declaration of Conformity COMPAIR Drucklufttechnik GmbH Argenthaler Straße 11 55469 Simmern / Hunsrück Germany hereby declares with sole responsibility, that the products compressed air adsorption dryer series A190TX–A930TX assembly type: assembly acc. to Art. 3 No. 2.2, which this declaration refers to, conform to Directive 97/23/EC and were subjected to a conformity assessment according to Annex III Modules B + D (for assembly assessment).
  • Page 3 Machine passport Type designation A____TX Order no. Project no. Serial no. Vessel no. Vessel no. Year of manufacture 2009 Issue date of these operating instructions 2009-02 EN It is the responsibility of the owner, to enter for the first time any appliance data not stated above, to keep these appliance data up to date.

  • Page 4: Table Of Contents

    Table of contents General information .................... 6 Manufacturer's details ......................6 Details on the dryer ........................7 About these operating instructions ................... 8 For your own safety .................... 9 Signs, instruction plates and danger zones at the dryer ............9 Intended use of the dryer .......................
  • Page 5 Depressurising and shutting down the dryer ................39 If work is to be carried out on the electrical system ..............40 Restart ............................40 Maintenance and repair of the dryer..............42 Notes on maintenance......................42 Regular maintenance intervals ....................43 Instructions for use of the dongle....................44 Daily maintenance tasks......................44 Weekly maintenance tasks .....................45 Monthly maintenance tasks ....................45...

  • Page 6: General Information

    Manufacturer's details General information Manufacturer's details Name and address COMPAIR Drucklufttechnik GmbH Argenthaler Straße 11 55469 Simmern / Hunsrück 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.

  • Page 7: Details On The Dryer

    General information Details on the dryer Standard equipment Dryer, comprising 2 vessels, filled with desiccant Piping and muffler Control system Associated documents Operating instructions (present) Technical documentation (see annex) Circuit diagrams (see separate document) Warranty notes In the following cases, the warranty shall be void: If aggressive media in the compressed air and in the environment cause corrosion damage and functional faults on the dryer.

  • Page 8: About These Operating Instructions

    About these operating instructions About these operating instructions These operating instructions contain basic information on the safe useof the dryer. Characters and symbols used ► Work steps that you have to carry out in the sequence stated are marked by black triangles.

  • Page 9: For Your Own Safety

    For your own safety For your own safety The dryer has been built in accordance with the state of the art and the recognized technical safety regulations. Nevertheless, there is a risk of personal injury and damage to property when the dryer is used, if it is operated by non-qualified personnel, not used within its intended design specifications, is repaired or maintained incorrectly.
  • Page 10 Signs, instruction plates and danger zones at the dryer Hazard areas on the dryer Hazard caused by electrical voltage Hazard caused by overpressure Hazard caused by sudden air ejection during expansion Symbol in operating Hazard area instructions Warning against hazardous electrical voltage Different parts of the dryer carry electrical current.

  • Page 11: Intended Use Of The Dryer

    For your own safety Intended use of the dryer The dryer is exclusively intended for drying compressed air. Depending on defined input conditions, it dries compressed air for industrial use. The dryer is designed for compressed air, which is free from aggressive water, oil, and solid matter constituents.

  • Page 12: Safety Notes On Specific Operating Phases

    Safety notes on specific operating phases Safety notes on specific operating phases Transportation and siting Only use suitable and technically perfect lifting gear with a sufficient carrying capacity. Carefully secure the dryer during transportation. Start-up Warning against sudden air ejection! During expansion the pressure is released suddenly through the muffler: A loud expansion noise is caused which may damage your hearing.
  • Page 13 For your own safety Only operate the dryer within the permissible limits (see type plate). By operating the dryer in conditions that go beyond the defined values, the dryer is subjected to loads for which it has not been designed. This may cause functional defects.
  • Page 14 Safety notes on specific operating phases Disassembly and disposal Hazard due to a sudden release of pressure! Never remove any parts of the dryer, or manipulate the same in any way, for as long as the plant is still pressurised! A sudden escape of pressure may cause serious injuries.

  • Page 15: Technical Product Description

    Technical product description Technical product description Summary drawing Regeneration 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 Expansion valve V4...

  • Page 16: Function Description

    Function description Function description The dryer dries the compressed air supplied by the compressor and makes it available for industrial use. If so, installed up- and downstream filters purify the compressed air, feeded to resp. dissipated from the dryer. The two vessels contain an extremely porous drying agent by means of which humidity is removed from the compressed air and stored just as in a sponge.
  • Page 17 Technical product description Expansion phase During the expansion phase the pressure in the right vessel is released via the muffler down to ambient pressure within just a few seconds. The outflow of the compressed air becomes noticeable due to a sudden powerful flow noise at the muffler.

  • Page 18: Available Options

    Available options Available options The following options are available for the dryer: Start-up device Outside installation Auxiliary heater Bypass line Signalling contacts of control system Compressor synchronisation Dewpoint-sensing control Pneumatic control Paint compatible design Pre- and after-filter Condensate drain systems for pre- and after-filter Start-up device A start-up device basically consists of a pressure holding device, which is located at the rear of the dryer.
  • Page 19 Technical product description Filters in the bypass line are meaningful so that the actual loads are largely protected against dirt, water, and oil droplets even whilst maintenance is in progress. Signalling contacts of the control system The control system is equipped with a digital input for the synchronised operation with a compressor.
  • Page 20 Available options Preliminary and afterfilter The installation of suitable preliminary filters is recommended for these reasons: Removal of dirt or oil particles contained in the compressed air to prevent contamination of the desiccant. Elimination of large water droplets and thus prevention of unnecessary use of desiccant.

  • Page 21: Transportation, Installation And Storage

    Transportation, installation and storage Transportation, installation and storage Danger due to incorrect transportation! The dryer must be transported by authorized and qualified specialist personnel only. During transportation all applicable national regulations for accident prevention must be complied with. Otherwise there is a risk of personal injury.

  • Page 22: Transporting And Installing The Dryer

    Transporting and installing the dryer Transporting and installing the dryer Requirements for the installation site The conditions at the installation site have a large influence on the functional capability of the dryer and the service life of the drying agent. In order to ensure a mode of operation, which is as continuous as possible, and low maintenance, the installation site must meet the following requirements: The installation site must be located within a building.
  • Page 23 Transportation, installation and storage Note: The vessels are filled with layers of various desiccants. They should therefore be transported in an upright position in order to prevent the mixing of these desiccants, as this could impair the operation of the dryer.

  • Page 24: Anchoring The Dryer

    Anchoring the dryer Anchoring the dryer The upright stand profiles of the dryer are provided with four pre-drilled anchorage bores. ► Use suitable attachment material to anchor the dryer to the floor (see figure). ► In the case of vibrating floors: place the dryer on suitable vibration dampers.
  • Page 25 Transportation, installation and storage 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. ►...

  • Page 26: Installation

    Preconditions for installation Installation Only authorized and qualified specialist personnel may carry out work on pipes and electrical systems. As soon as the dryer has been set up at its installation location, you can install the compressed air infeed and outlet lines make the electrical connections. Preconditions for installation For a correct installation the following preconditions must be met on the part of the owner.

  • Page 27: Installing The Electrical Connection

    Installation ► Remove plugs on the pressure inlet and outlet. All piping must be free from any stress and tension whatever! Pipes subject to stress may burst due to the load placed on them during operation. This may cause damage to property and personal injury. ►...
  • Page 28 Installing the electrical connection Installing the supply cable The components of the dryer have been connected to the control cabinet at the factory. You only need to connect the control cabinet to the electrical supply cable. The switchbox is provided with a connector where electrical power must be connected.
  • Page 29 Installation If switch S1 is in the OFF position, any regeneration process which has been started, is always continued until completed. To install the external line, proceed as follows: ► Connect the signalling line to the potential-free busbar connection of the compressor to terminals 1 and 2 on the control board (see circuit diagram).

  • Page 30: Start-Up

    Requirements for initial start-up Start-up Warning! The dryer must be taken into operation by trained personnel only! Untrained personnel does not have the required knowledge. Such personnel might cause serious faults. Note: You can order the initial commissioning and start-up from the manufacturer and have your personnel trained by the manufacturer.

  • Page 31: Setting Times Of The Operating Phases

    Start-up Setting times of the operating phases In its standard version the dryer is delivered with a time-dependent control system. The phase sequence occurs in a fixed cycle. With the optional dewpoint-sensing control, the dryer can also be operated at variable cycles (depending on the dewpoint).
  • Page 32 Overview of operating and control elements Display panel The display panel at the switchbox is equipped with LEDs (light emitting diodes) and a digital display, indicating the operating status of the dryer: Display panel at the switchbox LED Power (1) LED is on when dryer is switched on.
  • Page 33 Start-up Display Explanation Default display: The figure to the left indicates the current processing step; the figure to the right shows the remaining time in seconds. In this example, step 2 is being completed, whereby there are 215 seconds remaining. After 8000 operating hours, "SEr."...

  • Page 34: Emergency Shutdown

    Emergency shutdown With an increasing duration of operation, a higher overpressure can be indicated during regeneration. This overpressure during regeneration is also designated as dam pressure. The dam pressure should not exceed 0.3 bar, otherwise read the instructions on page 45. During the pressure build-up phase the indication on the pressure gauge should again rise to operating overpressure level.
  • Page 35 Start-up Open compressed air supply and switch on dryer For start-up, please proceed in the sequence shown here. ► Ensure that the compressed air inlet and outlet valves installed by the owner are closed (see installation example on page 27). ►...

  • Page 36: Changing Cycle Mode (Optional)

    Changing cycle mode (optional) Operate dryer immediately in the compressed air system ► Ensure that the compressed air system downstream of the dryer is pressurised or that a start-up device (option, see page 18) was installed into the compressed air system directly downstream of the dryer. The importance of this increases with the size of the compressed air system downstream of the dryer.
  • Page 37 Start-up When should I change cycle mode? Cycle changes should be made during the pressure build-up phase and prior to switchover; during this phase, the pressure in both vessels is just below operating pressure so that a fast pressure build-up is prevented when the vessels are switched.

  • Page 38: Monitoring Dryer Operation

    With dewpoint-sensing control (optional) Monitoring dryer operation The dryer operates fully automatically. However, you should carry out the regular checks described in the Chapter Maintenance and repair of the dryer. Warning against sudden air ejection! During expansion the pressure is released suddenly through the muffler: A loud expansion noise is caused which may damage your hearing.

  • Page 39: Shutdown And Restart Dryer

    Shutdown and restart dryer Shutdown and restart dryer In the following cases, the dryer must be fully shut down and depressurised: In the event of an emergency or malfunction For maintenance work For dismantling Risk of injury from escaping compressed air! Never remove any parts of the dryer, or manipulate the same in any way, as long as the unit is pressurised! Suddenly escaping compressed air might cause serious injuries.

  • Page 40: If Work Is To Be Carried Out On The Electrical System

    If work is to be carried out on the electrical system Depressurise dryer ► Leave the dryer on until the expansion phase in both vessels has been completed. During the expansion phase, the vessels are completely depressurised. ► Check the pressure in the dryer at both vessel pressure gauges. The pressure gauges should show value "0".
  • Page 41 Shutdown and restart dryer If compressed air system and dryer have remained at operating pressure ► Ensure that the compressed air inlet valve (provided by the operator) is open. ► Set ON/OFF switch to I. The programme continues the cycle from the point at which it was interrupted.

  • Page 42: Maintenance And Repair Of The Dryer

    Notes on maintenance Maintenance and repair of the dryer In order to allow maintenance work on the dryer to be carried out efficiently and without danger for maintenance personnel, you should comply with the following instructions. Notes on maintenance Warning! Maintenance tasks may be carried out only by authorized and qualified specialist personnel, and only with the plant in a switched off and depressurised condition.

  • Page 43: Regular Maintenance Intervals

    Maintenance and repair of the dryer Regular maintenance intervals Note: If a vessel has been depressurised, e.g. after completion of the expansion phase, and the pressure remains above 0 bar, the vessel is pressurised by what is known as ram pressure. This might be due to blockage at the muffler(s), contamination of the dust sieves, spent drying agent.

  • Page 44: Instructions For Use Of The Dongle

    Instructions for use of the dongle Danger! There is a very considerable risk of personal injury, when carrying out work on the activated and pressurised dryer. Before commencing any maintenance tasks always shut down the dryer as described on page 39! Warning against electrical voltage! Only qualified specialist personnel may carry out work on the electrical system!

  • Page 45: Weekly Maintenance Tasks

    Maintenance and repair of the dryer ► Duly eliminate any defects found. If message SEr. is displayed, a routine service must be completed: ► Contact the service department of the manufacturer. Clean dryer ► Remove any loose dust by means of a dry cloth, and, if required, also by means of a moist and well wrung cloth.

  • Page 46: Maintenance Work To Be Completed Every 12 Months

    Maintenance work to be completed every 12 months Maintenance work to be completed every 12 months Renew filter element of the control air filter The control air filter is used to clean the control air and thus ensures that the valve actuators are working properly.
  • Page 47 Maintenance and repair of the dryer ► Unscrew muffler as shown in the opposite figure. ► Replace muffler and secure it. Undo muffler ► Restart dryer (see page 41). Recalibration of dewpoint sensor (optional) In order to ensure accurate dewpoint measuring, we recommend recalibrating the dewpoint sensor at least every 12 months.

  • Page 48: Maintenance Work To Be Completed Every 24 Months

    Maintenance work to be completed every 24 months Installing / dismantling pressure dewpoint sensor ► Loosen the screw at the adapter (1) and disconnect signal cable with the adapter and seal. ► Remove dewpoint sensor from the sensor cell (3) by turning the nut (2). ►...
  • Page 49 Maintenance and repair of the dryer Renew solenoid valves The pilot valves equipped with solenoids must be replaced every 2 years, even if there is no sign of wear or damage. To replace these part, proceed as follows: ► Release pressure from dryer and shut down the unit (see page 39). ►...

  • Page 50: Maintenance Work To Be Completed Every 48 Months

    Maintenance work to be completed every 48 months Maintenance work to be completed every 48 months To complete the following maintenance tasks, you must dismantle the pipe bridges and the vessels. We therefore recommend that you carry out these tasks together.
  • Page 51 Maintenance and repair of the dryer ► Unscrew flange and screw connections from the upper arch pipe system (see figure). ► Withdraw upper arch pipe complete with all mountings. ► Remove dust sieves and gaskets. ► Clean dust sieves with compressed air or a suitable tool (e.g.
  • Page 52 Maintenance work to be completed every 48 months Remove used drying agent ► Depressurise dryer and take out of service (see page 39). ► Place suitable collection vessel underneath the drain point. ► Use a suitable tool to remove the drain plug. ►...
  • Page 53 Maintenance and repair of the dryer ► Remove used drying agent (see above section) and ensure that the discharge point is closed. ► Remove the filling plug with a suitable tool (see figure). ► Fill the several drying agents in as separate layers (according to the technical data in the appendix).

  • Page 54: Identify And Eliminate Faults

    Summary of faults Identify and eliminate faults The following table provides information on what designatory abbreviations are to be used for the various components. These designations are also found in the technical documentation. Abbreviation Component Pressure gauge V1 (Y1–Y2) Main inlet valve (solenoid valves) V2–V3 Check valves V4–V5 (Y3–Y4)
  • Page 55 Identify and eliminate faults Table of possible faults Fault Possible cause Remedy Excessive dam pressure Muffler or filter element of the muffler Check mufflers or filter elements for during regeneration is contaminated. contamination, clean if nec., and poss. renew. Expansion valve V4/V5 does not open Check expansion valve for correctly.
  • Page 56 Summary of faults Fault Possible cause Remedy Dryer is continuously Solenoid valve Y3/Y4 cannot be Check supply voltage. bled closed properly (audible humming Check solenoid valve; replace, if sound or valve flapping). necessary. Expansion valve V4/V5 does not close Check gaskets for contamination, if nec. correctly.
  • Page 57 Identify and eliminate faults With dewpoint-sensing control (optional) Fault code Description of fault Possible cause Remedy Upper measuring range Drying capacity See instructions for commissioning. limit exceeded exceeded. If the drying agent is wet, replace it. Error in programme. Restart programme. Dewpoint sensor Sensor defective or Replace sensor.

  • Page 58: Index

    Index explanation ............17 Design paint compatible ..........19 Abbreviation Detour line...........see bypass line Components............54 Dew point sensor Address, manufacturer ..........6 maintenance interval ........... 43 Adsorption, explanation..........16 Dewpoint-sensing control ........19 air ejection Digital display hazard ..............10 explanation ............32 Auxiliary heater ............18 Documentation, technical ........
  • Page 59 Index minimum, maximum..........62 Operating pressure ..........35 hazard areas............10 permissible ............3 Humidity ..............62 safety device............26 Operating signalling contact installation............29 Operation signalling Installation area ............22 contact ..............19 Installation example..........27 Orders, telephone number......... 6 Installation site, requirements ........
  • Page 60 Specialist personnel ..........8, 26 Standard equipment ..........7 Use, intended ............11 Start-up device ............18 Use, safe ..............8 Start-up, requirements ..........30 Storage room requirements ............24 Supply cable, electrical ..........28 Variable cycle............19 Supply lines..............26 Vessel pressure gauge symbols, explanation..........10 maintenance interval ...........

  • Page 61: Annex With Technical Documentation

    Annex with technical documentation 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 A190-930TX_EN_03_ 2009-02-06...

  • Page 62: Technical Data

    Technical data Technical data Capacity* Length Height Width Weight Type 1200 1060 2080 A190TX 1550 1270 2120 A250TX 2000 1350 2160 A320TX 2500 1530 2210 1040 1095 A390TX 3000 1600 2227 1100 1300 A490TX 3800 1875 2385 1200 1590 A630TX 4850 1900 2640...

  • Page 63: Replacement And Wear Parts List

    Annex with technical documentation Replacement and wear parts list Note: When exchange or replacement parts are ordered, always state the dryer type and the build no. of the dryer. These data are found on the type plate. Service kits * Type Service kit Order no.

  • Page 64: Logic Control Diagram

    Logic control diagram Logic control diagram Adsorption in B1 and regeneration in B2 A190-930TX_EN_03_ 2009-02-06...
  • Page 65 Annex with technical documentation Regeneration in B1 and adsorption in B2 A190-930TX_EN_03_ 2009-02-06...

  • Page 66: Flow Diagram

    Flow diagram Flow diagram Pos. Designation Pos. Designation Dust sieve Muffler Stop valve for pressure gauge Control system Pressure gauge PI Control air filter Main inlet valve V1 Solenoid valve block Y1–Y4 Check valve V2/V3 Options: Regeneration gas orifice plate Dewpoint-sensing unit Expansion valve V4/V5 Start-up device...

  • Page 67: Dimensional Drawings

    Annex with technical documentation Dimensional drawings A190-930TX Type A...TX Dimensions 1060 1270 1350 1350 1600 1875 1904 2155 1000 1000 1160 2080 2120 2160 2210 2247 2385 2640 2816 1990 2027 2065 2108 2127 2275 2530 2713 1040 1100 1200 1250 1304 1095...

This manual is also suitable for:

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