Atlas Copco CD 1+ Instruction Book

Heatless adsorption compressed air dryers

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Atlas Copco

Heatless adsorption compressed air dryers

CD 1+, CD 2+, CD 3+, CD 5+, CD 7+, CD 10+, CD 12+, CD 1.5+,

CD 17+, CD 22+, CD 2.5+

Instruction book

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Summary of Contents for Atlas Copco CD 1+

Page 1 Atlas Copco Heatless adsorption compressed air dryers CD 1+, CD 2+, CD 3+, CD 5+, CD 7+, CD 10+, CD 12+, CD 1.5+, CD 17+, CD 22+, CD 2.5+ Instruction book...
Page 3 Atlas Copco Heatless adsorption compressed air dryers CD 1+, CD 2+, CD 3+, CD 5+, CD 7+, CD 10+, CD 12+, CD 1.5+, CD 17+, CD 22+, CD 2.5+ From following serial No. onwards: API W55 400 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.
Page 4 Instruction book Table of contents Safety precautions......................4 ........................... 4 AFETY ICONS ......................4 AFETY PRECAUTIONS GENERAL ................... 5 AFETY PRECAUTIONS DURING INSTALLATION ....................6 AFETY PRECAUTIONS DURING OPERATION ................7 AFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR General description......................9 ........................9 ENERAL DESCRIPTION .............................11 PERATION...
Page 5 Instruction book Problem solving......................52 Technical data.......................54 ........................54 EFERENCE CONDITIONS ......................54 IMITATIONS FOR OPERATION ........................54 ECHNICAL SPECIFICATIONS Instructions for Use......................58 Guidelines for inspection.....................59 Pressure Equipment Directives...................60 Declaration of conformity.................... 61 2920 7083 21...
Page 6 Instruction book Safety precautions Safety icons Explanation Danger for life Warning Important note 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.
Page 7 Instruction book 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.
Page 8 Instruction book Also consult following safety precautions: Safety precautions during operation 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.
Page 9 Instruction book Also consult following safety precautions: Safety precautions during installation 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.
Page 10 Instruction book 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. •...
Page 11 Instruction book General description 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).
Page 12 Instruction book CD 5 up to CD 22 , General view Main parts An overview of the main parts of the dryer is given in below figures: CD 1 up to CD 22 , Front view 2920 7083 21...
Page 13 Instruction book CD 1 up to CD 22 , Back view Reference Description Reference Description Tower A Solenoid valve Tower B Silencers Air inlet Valve block Air outlet Controller Operation General The construction of the air dryer is simple, reliable and easy to service. A dryer has basically two towers, containing the adsorption material or desiccant.
Page 14 Instruction book Flow diagram Reference Designation Reference Designation Air inlet Electrical control line Controller Flow restriction Left desiccant tower Check valve Right desiccant tower Selector valve Air outlet Pneumatic silencer Flow line Solenoid valve Operation principle The operation cycle of the dryer is repetitive and is controlled by a factory-set timer. While the desiccant in one tower dries the compressed air, the desiccant in the second tower is being regenerated.
Page 15 Instruction book A small portion of the dried air passes a nozzle, expands to atmospheric pressure and flows downwards through the other tower, regenerating (drying) the desiccant. A nozzle for operation of the dryer at 7 bar is installed as standard. Alternative nozzles for use at other operating pressures are available as sales kit. Please consult the spare parts list for specific information.
Page 16 Instruction book Reference Designation Reference Designation LED <Service alarm> Service reset Air inlet Pictographs Description Pictographs Reference Designation Caution, possibility of electric shock MUST NOT be disposed of with regular consumer waste and must be collected separately for proper recycling in accordance with local regulations (WEEE) 2920 7083 21...
Page 17 Instruction book Electrical diagram Controller connections X3 (Freeze contact): to freeze the regeneration cycle when the compressor runs unloaded, remove the jumper wire and connect pin 1 and 2 of connector X3 with the potential free contact of the compressor (contact open = freeze).
Page 18 Instruction book Alarm contact: When the controller is switched on, the contacts remain closed unless an alarm contact is required. The contacts open if the mains power fails, or the internal power supply fails. 2920 7083 21...
Page 19 Instruction book Installation Dimension drawings Dimensions CD 1 up to CD 3 2920 7083 21...
Page 20 Instruction book Dimensions CD 5 up to CD 22 Reference Designation Inlet Outlet Removable panels Electrical connection options Filter mounting holes 2920 7083 21...
Page 21 Instruction book Installation proposal 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.
Page 22 Instruction book X3 is used If the X3 connection is used, the correct installation sequence is compressor - dryer - air receiver. Installation in case the X3 connection with the compressor is used Reference Designation Reference Designation Compressor PD filter Water separator Dryer DD filter (not required)
Page 23 Never overload the dryer as this will damage the desiccant. It may be recommended to install the air dryer upstream of the air receiver to prevent overload (e.g. after extending the dry air circuit). Consult Atlas Copco if in doubt. 2920 7083 21...
Page 24 Instruction book Horizontal installation Description Figure Inlet filter as fitted to the dryer in vertical orientation. A mounting kit allows to couple the filter directly to the inlet manifold (CD 1 up to CD 3 ). For CD 5 up to CD , an adaptor nipple is supplied as standard.
Page 25 Instruction book Electrical connections General The electrical wiring must comply with the local regulations. The air dryer must be earthed and protected by fuses against short-circuiting. Consult the electric diagram delivered with the dryer. Before switching on the main power supply, check the voltage requirements in the technical specifications or on the dryer’s data plate.
Page 26 Instruction book Timing cycle Controller specifications • Ambient temperature: 1.5 °C to 50 °C (35 °F to 122 °F) • Maximum relative humidity (RH): 80% for temperatures up to 31 °C, decreasing linearly to 50% at 50 °C • Input voltage: 110 or 230 VAC, 50-60 Hz •...
Page 27 Instruction book Controller connections Controller connections Mains connection The mains cable is included with the product. The mains plug needs to be installed during commissioning. Cable specification according to IEC60227 (for polyvinyl chloride insulated cables) or IEC60245 (for rubber insulated cables) Equipment intended for use in the EU does not have a fuse fitted to the mains plug and therefore requires a separate fuse in the mains line.
Page 28 Instruction book A circuit breaker or switch must be installed near the air dryer, shall be easy to reach, and shall be certified according to EN60947-1 and EN60947-3. The switch or circuit breaker shall be marked as the disconnection device for the air dryer and needs to be marked with On and Off positions. DIN connector wiring For permanently electrical connection of the dryer, consult the electrical diagram.
Page 29 Instruction book Picture of jumper wire Reference Designation Pin 1 Pin 2 Jumper wire Alarm contact When the controller is switched on, the contacts close and remain closed unless an alarm condition is required, as follows: • The contacts open if the main power fails, or the internal power supply fails. There is no LED indication on the control unit.
Page 30 Instruction book Mains cable Controller display LED no. Function Indication Remark Power off No LED's illuminated. Power supply disconnected. No alarm contact switched. Power on Red LED continuous Left tower pressurised Green LED continuous Left tower drying Right tower pressurised Green LED continuous Right tower drying 2920 7083 21...
Page 31 Instruction book LED no. Function Indication Remark 2 and 3 Both towers pressurised Green LED continuous One tower drying, the other tower repressurising Left solenoid failure Left tower LED turns red instead of green Right solenoid failure Right tower LED turns red instead of green Service warning Orange flashing LED...
Page 32 Instruction book Operating instructions Safety Always observe all relevant safety instructions. Initial start-up To start up the dryer for the first time or after a long period of standstill, proceed as follows: 1. If installed, open the bypass valves of the dryer. 2.
Page 33 Instruction book Close the external inlet valve in case the compressor needs to be restarted. The high air speed in the start-up phase of the compressor may damage the desiccant. During operation At regular intervals, check the status of the LED's on the control panel. If the Warning/Alarm LED is lit, consult the section Problem solving.
Page 34 • Disconnect all pressure sources and vent the internal pressure of the system before dismantling any pressurized component. • Use genuine Atlas Copco spare parts only. Consult the Spare Parts List for part numbers. For preventive maintenance, dedicated Service kits are available.
Page 35 Instruction book Desiccant replacement procedure CD 1 up to CD 3 Step Description Figure Completely depressurise the dryer. Consult Stopping the dryer in section Operating instructions. Remove the four M8 bolts from the top manifold of the dryer. 2920 7083 21...
Page 36 Instruction book Step Description Figure Remove the dryer from the air net (the top manifold is still connected to the piping.) Remove the cartridges. 2920 7083 21...
Page 37 Instruction book Step Description Figure Turn the valve locking caps a quarter turn and lift to release them. Take out purge plugs. Remove the label from the top of the new cartridges. Insert the old purge nozzles into the new cartridges, making sure the O-rings are in place at the bottom of the plugs.
Page 38 Instruction book Step Description Figure Insert the cartridges into the dryer. Connect the dryer to the top manifold making sure the O-rings are in place. 2920 7083 21...
Page 39 Instruction book Step Description Figure Tighten the M8 bolts, making sure there are no leaks. Follow the start-up procedure described in section Operating instructions. CD 5+ up to CD 22+ Step Description Figure Completely depressurise the dryer. Consult Stopping the dryer in section Operating instructions.
Page 40 Instruction book Step Description Figure Remove the four M10 bolts from the top cover of one tower of the dryer. Remove the top cover plate and O-ring from the dryer. 2920 7083 21...
Page 41 Instruction book Step Description Figure Remove the cartridge from the dryer. Take off the handle from the old cartridge by unscrewing the M4 bolts and take out the spring and nozzle. 2920 7083 21...
Page 42 Instruction book Step Description Figure Remove the label on top of the new cartridge. Insert the nozzle in the new cartridge. Place the spring on the top, and screw the handle back in place. Insert the new cartridge into the dryer. 2920 7083 21...
Page 43 Instruction book Step Description Figure Put the top cover back on, making sure the O- ring is in place. Finally tighten the M10 bolts, making sure there are no leaks. Repeat steps 2 to 9 for the other tower of the dryer.
Page 44 Instruction book Purge nozzle replacement procedure CD 1+ up to CD 3+ Step Description Figure Completely depressurise the dryer. Consult Stopping the dryer in section Operating instructions. Remove the four M8 bolts from the top manifold of the dryer. 2920 7083 21...
Page 45 Instruction book Step Description Figure Remove the dryer from the air net (leave top manifold connected to the piping). Turn the valve locking caps a quarter turn and lift to release them. 2920 7083 21...
Page 46 Instruction book Step Description Figure Remove the purge nozzles. Insert the new purge nozzles, making sure the O-rings are in place at the bottom of the plugs. 2920 7083 21...
Page 47 Instruction book Step Description Figure Put the locking caps back in place and turn a quarter turn to tighten. Connect the dryer to the top manifold making sure the O-rings are in place. 2920 7083 21...
Page 48 Instruction book Step Description Figure Tighten the M8 bolts, making sure there are no leaks. Follow the start-up procedure described in section Operating instructions. CD 5 up to CD 22 Step Description Figure Completely depressurise the dryer. Consult Stopping the dryer in section Operating instructions.
Page 49 Instruction book Step Description Figure Remove the four M10 bolts from the top cover of one tower of the dryer. Remove the top cover plate from the dryer. 2920 7083 21...
Page 50 Instruction book Step Description Figure Remove two M4 bolts and take out the handle. Remove the purge nozzle and spring. 2920 7083 21...
Page 51 Instruction book Step Description Figure Insert the new purge nozzle with the spring on top. Put the handle back on top of the purge nozzle and tighten the two bolts. 2920 7083 21...
Page 52 Instruction book Step Description Figure Put the top plate back on, making sure the O- ring is in place. Finally tighten the M10 bolts making sure there are no leaks. Repeat steps 2 to 9 for the other tower of the dryer.
Page 53 Instruction book Resetting the service timer Timer card resetting procedure To reset the timer card, continue as follows: • At 11500 hours, the orange service warning LED (4) will flash, indicating that service will be needed soon. • At 12000 hours, the red service alarm LED (5) will flash, indicating that service is required. •...
Page 54 Instruction book Problem solving Overview Symptom Possible cause Corrective action Poor dew point The dryer has not had the time to Close the valve installed between the dryer regenerate completely. and the application (if permitted) and have the desiccant regenerated. Liquid water at dryer inlet Check pre-filtration and drains.
Page 55 Instruction book Symptom Possible cause Corrective action Low outlet pressure Blocked filter Check/replace filter elements. Blocked filter desiccant cartridge Check/replace desiccant cartridge. Excessive purge air flow See excessive purge air flow. Dryer won't Incorrect start-up Keep downstream isolation valve closed. pressurize Open upstream valve slowly.
Page 56 Instruction book Technical data Reference conditions Condition Unit Value Compressed air effective inlet pressure barg psig 101.5 Compressed air inlet temperature ˚C ˚F Relative humidity of the air at inlet Pressure dew point (standard version) ˚C ˚F Limitations for operation Limitation Unit Value...
Page 57 Instruction book Specification Unit CD 1 CD 1.5 CD 2 CD 2.5 CD 3 Mass 15.5 17.6 19.8 24.2 Installed power (max) Time of half a cycle Regeneration time Specification Unit CD 5 CD 7 CD 10 CD 12 CD 17 CD 22 Max.
Page 58 Instruction book Specification Unit CD 5 CD 7 CD 10 CD 12 CD 17 CD 22 Filter size Mass 41.9 48.5 55.1 63.9 77.1 Installed power (max) Time of half a cycle Regeneration time Correction factors Flow correction factors due to air inlet pressure Operating pressure (barg)
Page 59 Instruction book Operating pressure Part number purge nozzle kit 11.5 14.5 barg barg barg barg barg barg barg barg barg 8092 3458 03 CD 1 8092 3458 11 CD 1.5 8092 3458 29 CD 2 8092 3458 37 CD 2.5 8092 3458 45 CD 3 8092 3458 52...
Page 60 Instruction book Instructions for Use Instructions Description The dryers can contain pressurized air. This can be potentially dangerous if the equipment is misused. 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.
Page 61 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 Atlas Copco may require other inspection periods as mentioned below.
Page 62 Instruction book Pressure Equipment Directives Components Subject to 97/23/EC Pressure Equipment Directive 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 Sound Engineering Practice (SEP). 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.
Page 63 Instruction book Declaration of conformity Typical example of a Declaration of Conformity document (1): Contact address: Atlas Copco Airpower n.v. P.O. Box 100 B-2610 Wilrijk (Antwerp) Belgium (2): Applicable directives (3): Standards used 2920 7083 21...
Page 64 Instruction book On the Declaration of Conformity / Declaration by the Manufacturer, the harmonized 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 device.
Page 66 Atlas Copco delivers the products and services that help to increase your business’ efficiency and profitability. Atlas Copco's pursuit of innovation never ceases, driven by our need for reliability and efficiency. Always working with you, we are committed to providing you the customized quality air solution that is the driving force behind your business.

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