Atlas Copco CD 110+ Instruction Book

Heatless adsorption compressed air dryers, purge control version

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Atlas Copco

Heatless adsorption compressed air dryers

CD 110+, CD 150+, CD 185+, CD 250+, CD 300+

Purge control version

Instruction book

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Page 1 Atlas Copco Heatless adsorption compressed air dryers CD 110+, CD 150+, CD 185+, CD 250+, CD 300+ Purge control version Instruction book...
Page 3 Atlas Copco Heatless adsorption compressed air dryers CD 110+, CD 150+, CD 185+, CD 250+, CD 300+ Purge control version From following serial No. onwards: API 692 000 Instruction book Original instructions Copyright notice Any unauthorized use or copying of the contents or any part thereof is prohibited.
Page 4: Table Of Contents
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 Electric diagram......................14 Elektronikon®...
Page 5 Instruction book 4.15 ........................47 ODIFYING SETTINGS 4.16 ...........................53 XTRA MENU 4.17 ..........................54 EB SERVER 4.18 .........................63 ROGRAMMABLE SETTINGS Installation........................64 ........................64 IMENSION DRAWINGS ........................69 NSTALLATION PROPOSAL .........................70 LECTRICAL CONNECTIONS Operating instructions....................72 Maintenance........................75 ..........................75 AINTENANCE ......................76 ISPOSAL OF USED MATERIAL Problem solving......................77 Technical data.......................78 ........................78 EFERENCE CONDITIONS...
Page 6: Safety Precautions
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: Safety Precautions During Installation
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: Safety Precautions During Operation
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: Safety Precautions During Maintenance Or Repair
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 • 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.
Page 11: General Description
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 standard version is intended to reach a pressure dew point (PDP) of -40 ˚C (-40 ˚F).
Page 12: Control Panel
Instruction book Rear view CD 110+ up to CD 300+ (Purge control version) reference designation reference designation Tower A Control panel Tower B Elektronikon® controller Dryer inlet Cubicle Dryer outlet Solenoid valves Inlet valve Nozzle for regeneration air Pneumatic actuator Pressure gauge tower A Pneumatic valve Pressure gauge tower B...
Page 13: Operation
Instruction book Operation The construction of the air dryer is simple, reliable and easy to service. The dryer has two towers, containing the adsorbing material or desiccant. The desiccant is a very porous grain material which can adsorb large amounts of water vapour. The operation cycle of the dryer is repetitive and is controlled by the Elektronikon regulator (2) and a PDP (Pressure Dew Point) sensor.
Page 14 Instruction book Reference Designation Reference Designation Sonic nozzle (optional) Pressure switch Outlet Manual valve Air net Pilot air filter Dryer Pressure regulator (optional) Vessel Adjustable restriction Compressor Filter with drain Pressure indicator V11/V12 Outlet valve vessel A/B Outlet filter DDp Orifice V21/V22 Safety valve (optional)
Page 15 Instruction book Reference Designation Reference Designation TT01 Inlet temperature PDP01 Pressure Dew Point 2920 7093 00...
Page 16: Electric Diagram
Instruction book Electric diagram The complete service diagram is available inside the electric cabinet. Some generally used symbols are given in below table: Reference Designation Reference Designation F1/2/... Fuses Transformer Y1/Y2 Solenoid valves MT01 PDP sensor PT01/PT02 Pressure transducer Tower A/B TT01 Temperature sensor, inlet Regulator...
Page 17: Elektronikon® Graphic Controller
The regulator has a built-in function to automatically restart the dryer if the voltage is restored after voltage failure. For dryers leaving the factory, this function is not activated. If desired, the function can be activated. Consult the Atlas Copco Customer Centre. 2920 7093 00...
Page 18: Control Panel
Instruction book If activated and provided the regulator was in the automatic operation mode, the dryer will automatically restart if the supply voltage to the module is restored within a programmed time period. The power recovery time (the period within which the voltage must be restored to have an automatic restart) can be set between 15 and 3600 seconds or to ‘Infinite’.
Page 19: Reference Designation
Instruction book Reference Designation Function Escape key To go to previous screen or to end the current action Scroll keys Keys to scroll through the menu. Stop button Button to stop the dryer. LED (7) goes out. Start button Button to start the dryer. LED (7) lights up indicating that the Elektronikon regulator is operative.
Page 20 Instruction book Input icons Icon Description Pressure Temperature Digital input Special protection System icons Icon Description Dryer Frequency converter Drain Filter Motor Failure expansion module Network problem General alarm Menu icons Icon Description 2920 7093 00...
Page 21: Navigation Arrows
Instruction book Inputs Outputs Alarms (Warnings, shutdowns) Counters Test Settings Service Event history (saved data) Access key / User password Network Setpoint Info Navigation arrows Icon Description Down 2920 7093 00...
Page 22: Main Screen
Instruction book Main screen Control panel Scroll keys Enter key Escape key Function The Main screen shows the status of the dryer operation and is the gateway to all functions implemented in the controller. The Main screen is shown automatically when the voltage is switched on and one of the keys is pushed. It is switched off automatically after a few minutes when no keys are pushed.
Page 23: Calling Up Menus
Instruction book • Section A shows information regarding the dryer operation (e.g. the Pressure in vessels A and B, the Dryer Pressure Dewpoint, the Dryer Inlet temperature). • Section B shows Status icons. Following icon types are shown in this field: •...
Page 24 Instruction book Scroll keys Enter key Escape key Description When the voltage is switched on, the main screen is shown automatically (see section Main screen): • To go to the Menu screen, highlight the Menu button (2), using the Scroll keys. •...
Page 25: Inputs Menu
Instruction book Inputs menu Control panel Scroll keys Enter key Escape key Menu icon, Inputs Function To call up information regarding the actually measured data and the status of some inputs such as the Vessel Pressure. Procedure Starting from the main screen (see Main screen), •...
Page 26 Instruction book • Press the Enter key. A screen similar to the one below appears: Text on figure Inputs Pressure vessel A Pressure vessel B Blower pressure (see note*) Inlet dryer *: only applicable to BD dryers (not applicable to CD dryers) •...
Page 27: Outputs Menu
Instruction book Outputs menu Control panel Scroll keys Enter key Escape key Menu icon, Outputs Function To call up information regarding the actual status of some outputs such as the Dryer motor, PDP alarm, General shut-down, etc. Procedure Starting from the Main screen (see Main screen), •...
Page 28 Instruction book • Move the cursor to the Outputs icon using the Scroll keys. • Press the Enter key. A screen similar to the one below appears: Outputs Dryer motor (means the dryer is operating) PDP alarm General shut-down General warning Not triggered Triggered •...
Page 29: Counters
Instruction book Counters Control panel Scroll keys Enter key Escape key Menu icon, Counters Function To call up: • The running hours • The number of dryer starts • The number of hours that the regulator has been powered • The operational state timers Procedure Starting from the Main screen (see Main...
Page 30 Instruction book • Using the Scroll keys, move the cursor to the Counters icon (see above, section Menu icon) • Press the Enter key. Following screen appears: Text on figure Counters Running hours dryer Loaded hours dryer Actual state time Programmed state time Reset The screen shows a list of all counters with their actual readings.
Page 31: Event History Menu
Instruction book • Standby time: shows how long the dryer has been in standby mode since the last reset of the energy counters. This counter will not be reset when the standby state has ended and a vessel switch is performed.
Page 32: Test Menu
Instruction book • Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Using the Scroll keys, move the cursor to the Event History icon (see above, section Menu icon). • The list of last shut-down and emergency stop cases is shown. •...
Page 33 Instruction book The vessels can only be depressurized when the dryer is stopped (off state). • The test procedure will be stopped as soon as another menu is selected on the • regulator. Procedure Starting from the Main screen (see Main screen): •...
Page 34: Service Menu
Instruction book 4.11 Service menu Control panel Scroll keys Enter key Escape key Menu icon, Service Function • To reset the service plans which are carried out. • To check when the next service plans are to be carried out. •...
Page 35 Instruction book • Using the Scroll keys, move the cursor to the Service icon (see above, section Menu icon). • Press the Enter key. Following screen appears: Text on figure Service Overview Service plan Next service History • Scroll through the items to select the desired item and press the Enter key to see the details as explained below.
Page 36: Service Plans
Instruction book Overview Running Hours (green) Real Time hours (blue) Example for service level (A): The figures at the left are the programmed service intervals. For Service interval A, the programmed number of running hours is 4000 hours (upper row, green) and the programmed number of real time hours is 4380 hours, which corresponds to six months (second row, blue).
Page 37: Protections Menu
Instruction book Next Service Text on figure Next service Level Running hours Actual In the example above, the A Service level is programmed at 4000 running hours, of which 8 hours have passed. History The History screen shows a list of all service actions done in the past, sorted by date. The date at the top is the most recent service action.
Page 38 Instruction book Menu icon, Protections Function • To call-up the protections. Procedure Starting from the Main screen (see Main screen): • Move the cursor to the action button Menu and press the enter key (2). Following screen appears: • Using the scroll keys (1), move the cursor to the protections icon (see above, section Menu icon). •...
Page 39: Week Timer Menu
Instruction book 4.13 Week timer menu Control panel Scroll keys Enter key Escape key Menu icon, Week timer Function • To program time-based start/stop commands for the dryer. • To program time-based change-over commands for the net pressure band. • Four different week schemes can be programmed. •...
Page 40 Instruction book • Press the Enter key on the controller. Following screen appears: Week Timer Week Action Schemes Week Cycle Status Week 1 Remaining Running Time The first item in this list is highlighted in red. Select the item requested and press the Enter key on the controller to modify.
Page 41 Instruction book Week Action Schemes Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Week Action Scheme 4 • A weekly list is shown. Monday is automatically selected and highlighted in red. Press the Enter key on the controller to set an action for this day.
Page 42 Instruction book Monday Modify • A new pop-up window opens. Select an action from this list by using the Scroll keys on the controller. When ready press the Enter key to confirm. Monday Actions Remove Start Stop Pressure Setpoint 1 Modify •...
Page 43 Instruction book Monday Start Save Modify • To adjust the time, use the Scroll keys on the controller and press the Enter key to confirm. Monday Start Save Modify • A pop-up window opens. Use the ↑ or ↓ key of Scroll keys to modify the values of the hours. Use the ← or →...
Page 44 Instruction book Monday Start Save Modify • A new pop-up window opens. Use the Scroll keys on the controller to select the correct actions. Press the Enter key to confirm. Monday Are you sure? Save Modify Press the Escape key to leave this window. •...
Page 45 Instruction book Monday - Start Tuesday Wednesday Thursday Friday Saturday Sunday Press the Escape key on the controller to leave this screen. Programming the week cycle A week cycle is a sequence of 10 weeks. For each week in the cycle, one of the four programmed week schemes can be chosen.
Page 46 Instruction book Week 3 Week 4 Modify Press twice the Enter key on the controller to modify the first week. • A new window opens. Select the action, example: Week Action Scheme 1 Week Cycle Week 1 Week Action Scheme 1 Week Action Scheme 2 Week Action Scheme 3 Modify...
Page 47 Instruction book Week Timer Week Week Timer Inactive Week 1 • Press the Escape key on the controller to leave this window. The status shows that week 1 is active. Week Timer Week Action Schemes Week Cycle Status Remaining Running Time •...
Page 48: Info Menu
Instruction book Week Timer Week Action Schemes Week Cycle Status Remaining Running Time • This timer is used when the week timer is set and for certain reasons the dryer must continue working. The remaining running time, for example 1 hour, can be set in this screen. This timer is prior to the Week Timer action.
Page 49: Modifying Settings
• Move the cursor to the action button Menu and press the Enter key. Following screen appears: • Using the Scroll keys, move the cursor to the Info icon (see above, section Menu icon). • Press the Enter key. The Atlas Copco internet address appears on the screen. 4.15 Modifying settings...
Page 50: Menu Icon, Settings
Instruction book Enter key Escape key Scroll keys Menu icon, Settings Function To display and modify a number of settings (e.g. Time, Date, Date format, Language, units ...) Procedure Starting from the Main screen (see Main screen), • Move the cursor to the action button Menu and press the Enter key. Following screen appears: •...
Page 51: Modifying Network Settings
Instruction book Icon Function Network settings General settings Regulation settings Automatic restart after voltage failure settings Access key User password • Move the cursor to the icon of the function to be modified and press the Enter key. Modifying network settings •...
Page 52: General Settings
Instruction book Screen for Ethernet settings Screen for CAN settings • Press the Enter button; a red selection bar is covering the first item (Ethernet). • Using the Scroll keys, move the cursor to the setting to be modified (e.g. Ethernet) and press the Enter button (2).
Page 53: Regulation Settings
Instruction book Text on figure General Language in use Time Date Date format • The screen shows the first items of a list of all settings. Use the scroll button the see the other items in the list. • Press the Enter button (2); a red selection bar is covering the first item (Language in use). Use the ↓...
Page 54: Automatic Restart
Instruction book PDP Alarm offset Heatless backup mode (see note *) Not activated Modify *: only applicable to BD dryers (not applicable to CD dryers) • The screen shows the list of all settings. • Press the Enter button (2); a red selection bar is covering the first item (PDP extended cycle). Use the ↓...
Page 55: Extra Menu
Instruction book • A pop-up screen appears. Use the ↑ or ↓ key to select the required parameter and press the Enter key to confirm. Access key Different security levels are programmed in the regulator (e.g. user, service technician, etc). This menu item is used to change the security level.
Page 56: Web Server
Instruction book • Move the cursor to the action button Menu and press the enter key (2). Following screen appears: • Using the scroll keys (1), move the cursor to the Extra icon (see above, section Menu icon) • Press the enter key (2). A screen showing the actual readings for the pressure dewpoint, the relative humidity and the LAT setpoint appears.
Page 57 Instruction book USB to LAN adapter • Use a UTP cable (CAT 5e) to connect to the controller (see picture below). Configuration of the network card • Go to My Network places (1). • Click on View Network connections (1). 2920 7093 00...
Page 58 Instruction book • Select the Local Area connection (1), which is connected to the controller. • Click with the right button and select properties (1). • Use the checkbox Internet Protocol (TCP/IP) (1) (see picture). To avoid conflicts, de-select other properties if they are selected.
Page 59: Configuration Of The Web Server
Instruction book • Use the following settings: • IP Address 192.168.100.200 • Subnetmask 255.255.255.0 Click OK and close network connections. Configuration of the web server Configure the web interface The internal web server is designed and tested for Microsoft® Internet Explorer 6, 7 and 8.
Page 60 Instruction book • In the Proxy server Group box, click on the Advanced button (1). • In the Exceptions Group box, enter the IP address of your controller. Multiple IP addresses can be given but they must be separated with semicolons (;). Example: Suppose that you already added two IP addresses (192.168.100.1 and 192.168.100.2).
Page 61 Instruction book Click OK (2) to close the window. Viewing the controller data • Open your browser and type the IP address of the controller you want to view in your browser (in this example http://192.168.100.100). The interface opens: 2920 7093 00...
Page 62 Instruction book Navigation and options • The banner shows the dryer type and the language selector. In this example, three languages are installed on the controller. • On the left side of the interface you can find the navigation menu (see picture below). If a license for ESi is foreseen, the menu contains 3 buttons.
Page 63: Digital Inputs
Instruction book Dryer settings All dryer settings can be hidden or shown. Put a mark for each setting. Only the machine status is fixed and can not be removed from the main screen. Analog inputs (The units of measure can be changed in the preference button from the navigation menu). Counters Counters give an overview of all actual counters from controller and dryer.
Page 64: Digital Outputs
Instruction book Digital outputs Shows a list of all digital outputs and their status. Special protections Give an overview of all special protections of the dryer. Service plan Shows all levels of the service plan and status. This screen only shows the running hours. It is also possible to show the actual status of the service interval.
Page 65: Programmable Settings
Instruction book A possible ESi screen 4.18 Programmable settings Description The regulation and safety devices are factory-adjusted to obtain optimum performance of the dryer. No adjustments are required. 2920 7093 00...
Page 66: Installation
Instruction book Installation Dimension drawings CD 110+ Dryer outlet Dryer inlet Dimension of inlet and outlet connection 2920 7093 00...
Page 67 Instruction book CD 150+ Dryer outlet Dryer inlet Dimension of inlet and outlet connection 2920 7093 00...
Page 68 Instruction book CD 185+ Dryer outlet Dryer inlet Dimension of inlet and outlet connection 2920 7093 00...
Page 69 Instruction book CD 250+ Dryer outlet Dryer inlet Dimension of inlet and outlet connection 2920 7093 00...
Page 70 Instruction book CD 300+ Dryer outlet Dryer inlet Dimension of inlet and outlet connection 2920 7093 00...
Page 71: Installation Proposal
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.
Page 72: General Recommendations
Instruction book Compressed air prefilter for general purpose filtration, particle removal down to 1 micron, maximum oil carry-over 0.5 ppm This filter provides extra protection of the dryer and extends the lifetime of the high efficiency filter cartridge (4). High efficiency filter, particle removal down to 0.01 micron, maximum oil carry-over 0.01 ppm To remove remaining impurities.
Page 73 Instruction book Before switching on the main power supply, check the voltage requirements in the technical specifications or on the dryer’s data plate. 2920 7093 00...
Page 74: Operating Instructions
Instruction book Operating instructions In your own safety interest, 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 75: Normal Start
Instruction book If the application allows air that is not completely dry, the valve towards the dry 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 dew point is reached.
Page 76 Instruction book 4. Stop the dryer by pushing the Stop button (13) on the Elektronikon controller. If the dryer is stopped for a longer period, keep the external 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.
Page 77: Maintenance
• 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 78: Preventive Maintenance Schedule
(1) whichever comes first In normal working conditions, the lifetime of the desiccant is approximately 5 years. It is recommended to have the desiccant replaced by a qualified Atlas Copco service technician. Reset the service timer after a maintenance intervention. See section Service menu.
Page 79: Problem Solving
Instruction book Problem solving Symptom Possible cause Corrective action PDP temperature too high The dryer has not had the time to Close the valve installed between the regenerate completely. dryer and the application (if permitted) and have the desiccant regenerated. The silencers are clogged.
Page 80: Technical Data
Instruction book Technical data Reference conditions 11 bar 16 bar Compressed air effective inlet pressure 12.5 Compressed air effective inlet pressure 101.5 181.3 Compressed air inlet temperature ˚C Compressed air inlet temperature ˚F Relative humidity of the air at inlet Pressure dewpoint (PDP), standard version ˚C Pressure dewpoint (PDP), standard version...
Page 81 Instruction book CD 110+ CD 150+ CD 185+ CD 250+ CD 300+ Max. volume flow at dryer inlet l/s Max. volume flow at dryer inlet cfm Regeneration air consumption average at max. inlet flow Total amount of desiccant Total amount of desiccant Recommended filter size DD/PD/DDp Mass...
Page 82 Instruction book CD 110+ CD 150+ CD 185+ CD 250+ CD 300+ Mass Mass 1323 1433 Time of half a cycle Regeneration time Installed power Special version (PDP -70 ˚C) - 16 bar Desiccant type: molecular sieves CD 110+ CD 150+ CD 185+ CD 250+ CD 300+...
Page 83: Instructions For Use
Instruction book Instructions for use Instructions The dryer vessels can contain pressurised air. This can be potentially dangerous if the equipment is misused. The dryer vessels must only be used as a compressed air vessel and must be operated within the limits specified on the data plate.
Page 84: Guidelines For Inspection
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 85: Pressure Equipment Directives
Instruction book Pressure equipment directives Components subject to 97/23/EC Pressure Equipment Directive 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.
Page 86 Instruction book 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. 2920 7093 00...
Page 87: Declaration Of Conformity
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 2920 7093 00...
Page 90 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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