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Instruction book

Atlas Copco Air dryers

XD 1400 S, XD 1400 G,
XD 1800 S, XD 1800 G,
XD 2400 S, XD 2400 G,
XD 3000 S, XD 3000 G
CONTROL LOGIC: SCHNEIDER PLC

Instruction book

Copyright 2005, Atlas Copco Airpower n.v., Antwerp, Belgium.


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 meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines.

No. 2920 1655 00

Registration code: APC XD DRYERS / 38

2005-09 www.atlascopco.com

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Instruction book

This instruction book describes how to handle and operate the subject machine(s) to ensure safe
operation, optimum working economy and long service life.

Read this book before putting the machine into operation to ensure correct handling, operation
and proper maintenance from the beginning. The maintenance schedule contains a summary of the
measures for keeping the dryer in good repair. The maintenance procedures are simple but must be
carried out regularly.

Keep the book available for the operator(s) and make sure that the dryer is operated and that the
maintenance actions are carried out according to the instructions. Record all operating data,
maintenance work effected, etc. in an operator's logbook available from Atlas Copco. Follow all
applicable safety precautions, amongst others those mentioned in this book.

Repair operations should be performed by trained personnel from Atlas Copco who can also be
contacted if any further information is desired.

In all correspondence always mention the dryer type and the complete serial number, shown on the
data plate.

For all specific data not mentioned in the text, consult sections "Maintenance" and "Principal data".

The company reserves the right to make changes without prior notice.

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Instruction book

Contents Page

1 LEADING PARTICULARS................................................................................................................... 5
1.1 General description........................................................................................................................ 5
1.2 Operation ....................................................................................................................................... 8
1.2.1 Air circuit (Fig. 1.4) .................................................................................................................. 8
1.2.2 Regeneration circuit (Fig. 1.4)............................................................................................... 10
1.2.3 Cooling .................................................................................................................................. 10
1.2.4 Standby ................................................................................................................................. 11
1.2.5 Shifting towers (Fig. 1.4) ....................................................................................................... 11
1.2.6 Dryer starting routine............................................................................................................. 11
1.3 Regulator ..................................................................................................................................... 12
1.3.1 General description (Fig. 1.5)................................................................................................ 12
1.3.2 Control panel (Fig. 1.6) ......................................................................................................... 14
1.3.3 Keys and indicator lamps ...................................................................................................... 15
1.3.4 Menu structure ...................................................................................................................... 17
1.3.5 Manual advance and State pause......................................................................................... 17
1.3.6 External dryer status indication (Fig. 2.4).............................................................................. 18
1.3.7 Control panel operating mode............................................................................................... 18
1.3.8 Alarm history ......................................................................................................................... 18
1.3.9 Display when powered up ..................................................................................................... 18
1.4 Drain system ................................................................................................................................ 19
1.4.1 Description (Fig. 1.7) ............................................................................................................. 19
1.4.2 Testing the EWD ................................................................................................................... 19
1.4.3 Electrical connections of the EWD (Fig 1.10) ....................................................................... 19
2 INSTALLATION ................................................................................................................................. 21
2.1 Dimension drawings / installation proposal ................................................................................. 21
2.2 Installation instructions................................................................................................................. 22
2.3 Mechanical connections............................................................................................................... 24
2.4 Cubicle (Fig. 2.4).......................................................................................................................... 25
2.5 Electrical cable size and maximum fuses .................................................................................... 28
2.6 Pictographs .................................................................................................................................. 29
3 OPERATING INSTRUCTIONS .......................................................................................................... 30
3.1 Initial start..................................................................................................................................... 30
3.2 Starting......................................................................................................................................... 30
3.3 Stopping....................................................................................................................................... 30
3.4 Remote start/stop (Fig. 2.5) ......................................................................................................... 31
3.5 Emergency stop ........................................................................................................................... 31
3.6 Indication lamp............................................................................................................................. 31
3.7 Voltage failure .............................................................................................................................. 31
4 MAINTENANCE ................................................................................................................................. 32
4.1 Preventive maintenance schedule for the dryer .......................................................................... 32
4.1.1 Regular service operations ................................................................................................... 32
4.1.2 Service kits ............................................................................................................................ 33
4.1.3 Service agreements .............................................................................................................. 33
4.2 Filling instructions ........................................................................................................................ 33
4.2.1 Initial filling (desiccant is partial delivered separate)............................................................. 33
4.2.2 Replacing desiccant .............................................................................................................. 33
4.3 Transport instructions .................................................................................................................. 35
5 OPTIONAL EQUIPMENT................................................................................................................... 36
5.1 Dewpoint meter............................................................................................................................ 36
5.2 Second dewpoint read-out........................................................................................................... 36
5.3 Heater option for guaranteed dewpoint ....................................................................................... 36
5.4 Vessel isolation ............................................................................................................................ 36
5.5 Minimum pressure valve .............................................................................................................. 37
5.6 Filter option .................................................................................................................................. 37
5.7 Safety valves................................................................................................................................ 37

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6 PROBLEM SOLVING (Fig. 1.4) ........................................................................................................ 38


7 PRINCIPAL DATA ............................................................................................................................. 40
7.1 Limitations/nominal conditions..................................................................................................... 40
7.2 Specific data 1) ............................................................................................................................ 40
7.2.1 Standard variants .................................................................................................................. 40
7.2.2 Guaranteed dewpoint variants .............................................................................................. 41
8 CONVERSION LIST OF SI UNITS INTO BRITISH/U.S. UNITS ....................................................... 42
9 REGULATOR FUNCTIONS............................................................................................................... 43
9.1 Starting and stopping the dryer (F1) ............................................................................................ 43
9.2 Dryer overview (F2) ..................................................................................................................... 43
9.3 Measured data ............................................................................................................................. 44
9.4 Counters ...................................................................................................................................... 45
9.5 Test .............................................................................................................................................. 45
9.6 Settings ........................................................................................................................................ 46
9.6.1 Dryer options activation......................................................................................................... 46
9.6.2 PDP and heating temperatures............................................................................................. 46
9.6.3 PID regulation........................................................................................................................ 47
9.6.4 Control parameters................................................................................................................ 47
9.6.5 Alarm parameters.................................................................................................................. 48
9.6.6 Units ...................................................................................................................................... 48
9.7 Password ..................................................................................................................................... 48
9.8 Service ......................................................................................................................................... 48
9.8.1 Alarms ................................................................................................................................... 49
10 SETTINGS........................................................................................................................................ 50
10.1 Protections ................................................................................................................................. 50
11 PED INSTRUCTIONS ...................................................................................................................... 51

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Instruction book

1 LEADING PARTICULARS

1.1 General description

The XD air dryer removes moisture from compressed air by adsorption. The air dryer consists of two
drying towers containing desiccant. While one tower adsorbs moisture, the other is regenerating.
Every 3 hours, the tower function is reversed. When an optional pressure dewpoint meter is provided
(see section 5.1), the shift time of the towers may be extended to 24 hours in order to save energy.

Fig. 1.1 General view, XD 3000 G

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Instruction book

The desiccant consists of water resistant silica gel beads. The dryer can produce dewpoints ranging
from +10 °C up to -40 °C. Once the desiccant is saturated, it can be regenerated at temperatures in
between +90 °C and +200 °C.

Provided the dryer is maintained properly and in normal operating conditions, the drying beads can
adsorb moisture and regenerate time after time during 5 years of continuous operation.

A thermostat controls the regeneration temperature if a heater option is installed to guarantee a


dewpoint under all circumstances. Alarm functions are included for electronic water drain failure, low
working pressure, shifting failure, valve failure, sensor error, etc....

2 3 4

1
5

VESSEL A VESSEL B

6 7

8 4

11
9

10

1 Insulation vessel A (optional) 7 Desiccant removal flange, vessel B


2 Heaters vessel A (optional) 8 Cooling water outlet
3 Cubicle for electric components 9 Cooling water inlet
4 Heaters vessel B (optional) 10 Combicooler CC1
5 Insulation vessel B (optional) 11 Combicooler CC2 (optional)
6 Desiccant removal flange, vessel A

Fig. 1.2 Front view, XD 3000 G

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5
3 4 6 7 8
2 9

VESSEL B VESSEL A

10
1

12 11

13

14

15
16 17 18

1 Manhole, vessel B (XD 2400, XD 3000) 11 Blow-off valve V6 with silencer, vessel A
2 Filling flange, vessel B 12 Blow-off valve V7 with silencer, vessel B
3 Valve V4 13 Hot wet compressed air inlet for
4 Valve V2 regeneration
5 Dryer air outlet 14 Hot wet compressed air inlet for
6 Cooling air valve V12 adsorption
7 Valve V1 15 Valve V8
8 Valve V3 16 Valve V9
9 Filling flange, vessel A 17 Check valve V14
10 Manhole, vessel A (XD 2400, XD 3000) 18 Check valve V13
Fig. 1.3 Rear view, XD 3000 G

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1.2 Operation

The dryer sequence is as follows:

Step Function, Tower A Function, Tower B min max


0 Stopped Stopped
1 Shifting Shifting
2 Full flow regeneration Adsorbing 60 90 Min
3 Partial flow regeneration with Adsorbing 30 30 Min
heaters*
4 Pressure relief ** Adsorbing 5 5 Min
5 Purge cooling ** Adsorbing 30 60 Min
6 Pressure equalization ** Adsorbing 5 5 Min
7 Split flow cooling Adsorbing 5 60 Min
8 Waiting Adsorbing
9 Shifting Shifting
10 Adsorbing Full flow regeneration 60 60-90 Min
11 Adsorbing Partial flow regeneration with 30 30 Min
heaters*
12 Adsorbing Pressure relief ** 5 5 Min
13 Adsorbing Purge cooling ** 30 60 Min
14 Adsorbing Pressure equalization ** 5 5 Min
15 Adsorbing Split flow cooling 5 60 Min
16 Adsorbing Waiting 0 24 Hrs

* Only for guaranteed dewpoint variant


** Only for purge cooling variant

The regulator stops counting the operating cycle time if a compressor unload is detected by a digital
contact.

1.2.1 Air circuit (Fig. 1.4)

The hot compressed air can enter the system in three ways:
1: Hot wet compressed air enters the system via the regeneration valve (V5) directly to the
cooler(s) (CC1 and CC2) for adsorption.
2: Hot wet compressed air enters the system via the inlet valve (V1 or V2) and goes through
the side inlet of the vessel (A or B) for regeneration. The air leaves at the bottom of the
vessel and goes through the check valve (V13 or V14) to the cooler(s).
3: A combination of 1 and 2 for partial flow regeneration (Guaranteed dewpoint variants only).

After passing the cooler stage, the cooled air flows to the bottom of one of the towers (A or B) and
passes the desiccant for adsorption of the moisture. The dry compressed air leaves the dryer via the
outlet valve (V3 or V4).

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CC1 Combicooler, adsorption air R3 Main heating element, vessel B


CC2 Combicooler, adsorption air (optional) R4 Main heating element, vessel B
CU01 Compressor load/unload contact R7 Regulating heating element, vessel A
FT01 Mass flow transmitter R8 Regulating heating element, vessel A
HP High pressure compression step R9 Regulating heating element, vessel B
IC Compressor intercooler R10 Regulating heating element, vessel B
LP Low pressure compression step TS01 Overheating switch, vessel A
LSxA Limit switch valve position Open TS02 Overheating switch, vessel B
LSxB Limit switch valve position Closed TT01 Compressor intercooler temperature
PDP01 Pressure dewpoint transmitter TT02 Dryer inlet temperature
(optional) TT03 Temperature, top of vessel A
PI01 Liquid pressure indicator, vessel A TT04 Temperature, top of vessel B
PI02 Liquid pressure indicator, vessel B TT05 Cooler 1 air inlet temperature
PT01 Compressor intercooler pressure TT06 Temperature, bottom of vessel A
PT02 Dryer inlet pressure TT07 Temperature, bottom of vessel B
PT03 Pressure, vessel A TT08 Mass flow transmitter temperature
PT04 Pressure, vessel B TT09 Cooler 1 water inlet temperature
R1 Main heating element, vessel A TT10 Cooler 1 water outlet temperature
R2 Main heating element, vessel A

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TT11 Cooler 2 air inlet temperature V21 Safety valve, vessel B (optional)
(optional) YxA Solenoid for valve to Open
TT12 Cooler 2 water outlet temperature YxB Solenoid for valve to Close
(optional) 1 Vessel A
TT13 Cooler 2 water inlet temperature 2 Vessel B
(optional) 3 Compressor
V1 Inlet valve, vessel A 100 Manual valve (optional)
V2 Inlet valve, vessel B 101 Filter (optional)
V3 Outlet valve, vessel A 102 Manual valve
V4 Outlet valve, vessel B 103 Filter
V5 Regeneration valve 104 Pressure regulator
V6 Blow-off valve, vessel A 105 5/3-spool valve
V7 Blow-off valve, vessel B 106 5/2-spool valve
V8 Bottom valve, vessel A 107 3/2-spool valve
V9 Bottom valve, vessel B 108 3/2-spool valve (optional)
V10 Purge flow valve, vessel A 109 Blow-off silencer
V11 Purge flow valve, vessel B 110 Electronic water drain, combicooler 1
V12 Cooling air valve 111 Electronic water drain, combicooler 2
V13 Check valve, vessel A (optional)
V14 Check valve, vessel B 114 Electronic water drain, compressor
V15 Minimum pressure valve (optional) intercooler
V20 Safety valve, vessel A (optional)

Fig. 1.4 Flow diagram

1.2.2 Regeneration circuit (Fig. 1.4)

The moist desiccant beads are dried in the regeneration stage. The hot air from the compressor is
sent through inlet valve (V1 or V2) through the vessel from top to bottom before it enters the
combicooler stage. Optional for guaranteed dewpoint dryer is an extra heating step following the full
flow regeneration step. In this extra step a part of the compressor flow will be heated to a calculated
temperature using electric heaters (R1/R2/R7/R8 or R3/R4/R9/R10) and a flow control valve, forcing
more moisture out of the vessel and making the top part of the desiccant bed extra dry. The rest of
the compressed air flow will go directly to the combicooler stage.

Sensors (TT03 and TT06) for vessel (A) and sensors (TT04 and TT07) for vessel (B) monitor the
regeneration temperatures. If the temperature difference between the top and bottom of a vessel
reaches the preset value, the cooling step will be started.

1.2.3 Cooling

After full flow regeneration without heaters, the optional partial flow regeneration with heaters and the
optional purge flow heating, the cooling step starts.

Depending on the type of XD dryer, the following cooling method is selected:

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1.2.3.1 Purge cooling (optional) (Fig. 1.4)

If the dryer is supplied with the purge cooling option, the vessel pressure will be blown off through
blow-off valve (V6 or V7). Purge flow valve (V10 or V11) opens the regeneration/cooling air outlet. If
this valve confirms opening, cooling air valve (V12) opens to start purge cooling to atmosphere. After
the defined cooling time, purge flow valve (V10 or V11) closes and the pressure in the tower
equalises.

1.2.3.2 Split flow cooling (standard) (Fig. 1.4)

The split flow cooling method can run separately or in combination with purge cooling or full flow wet
air cooling.

As an extra step after purge cooling it has three advantages:


1. Eliminating a short temperature peak at the outlet of the dryer when switching the vessels
regeneration cycle.
2. Increasing the capacity of the desiccant of the adsorbing vessel due to a period of increased
contact time of air with the desiccant.
3. Reducing the purge air consumption.

When valves (V3, V4, V8 and V9) are all open, the air flow at the outlet of the dryer combicooler stage
will split up to both vessels. After minimum time of split flow cooling to push out the last heat in the
regenerated vessel, the dewpoint will be checked. If the dewpoint is below its defined value, the split
flow cycle can be extended to the maximum defined split flow cooling time. If no dewpoint sensor is
installed, the split flow cooling stage will stop after its minimal split flow cooling time.

1.2.4 Standby

When the optional dewpoint sensor is installed, the adsorption cycle can be extended if there is still
adsorption capacity left. With the PDP sensor checking the maximum allowable value, the cycle can
be extended to a maximum of 24 hours, thereby saving considerable amounts of energy.

1.2.5 Shifting towers (Fig. 1.4)

After the standby step, the dryer will shift towers without causing a pressure drop in the air net. The
compressed air entering the dryer combicooler stage now flows to the other tower. Immediately after
the valves have changed position, inlet valve (V1 or V2) will open to start full flow regeneration.

Note: The dryer can only shift towers when the pressure difference between both towers (A and B)
is less than 0,3 bar, no valve alarms exist and the value of the sensors (TT03 and TT04) is
lower than 100 °C.

1.2.6 Dryer starting routine

If the dryer has been stopped (for example by an operator, power failure or a new download of the
controller logic), the dryer starting routine will be activated when the dryer is (re)started. The routine
prevents the dryer to start from wrong valve positions or incorrect vessel pressure when going back to
its normal regeneration routine. This routine also prevents blocking of the compressed air flow by the
dryer.

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Instruction book

1.3 Regulator

1.3.1 General description (Fig. 1.5)

The electronic regulator automatically controls and protects the dryer, i.e.:
- Keeping the pressure dewpoint stable
- Monitoring pressures, temperatures and digital switches to ensure safe operation, and stopping
the dryer whenever necessary
- Restarting the dryer when required

In order to control the dryer and to read and modify programmable parameters, the regulator has a
control panel provided with:
- A main switch (2) to disconnect the power circuit. The control circuit remains active.
- A LED (4) indicating the status of the dryer.
- A display indicating the operating conditions or a fault.
- Keys to control the dryer and to have access to the data collected by the regulator.
- An emergency stop button (6) to stop or block the dryer in unsafe situations.

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5
2

1 Door lock 4 Indication LED (H1)


2 Main switch (S1) 5 Control panel
3 Atlas Copco logo 6 Emergency stop (S3)

Fig. 1.5 Cubicle front view

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Instruction book

1.3.2 Control panel (Fig. 1.6)

Fig. 1.6 Control panel

LEDs/buttons/keys

Reference Designation Function

Indicates messages concerning the dryer operating


1 Display
condition, a service need or a fault
Communication status LED which flashes when communicating with the
2
LED controller
3 Key stroke LED LED which flashes when a key is pressed
Keys which have variable functions depending on the
4 Control keys
displayed page
5 Menu shortcut keys Keys to make a shortcut to a menu page
6 Control system keys Keys to enter and control menu and alarm pages
7 Printing port Port to connect printer to (not supported)
Port for communication with the Programmable Logic
8 Communication port
Controller (PLC) or for downloading a new application
9 Power supply 24 V DC input

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Instruction book

1.3.3 Keys and indicator lamps

Key/indicator Lamp Function key/indicator lamp

Confirm a choice or entry; acknowledge an alarm page.

Move to page entry, password or variable field.


Move to next field each time MOD is pressed, right to left and top to bottom.

Delete an entry or suspend or stop an action in progress. Move up one level in a menu, exit
display alarm.

Accesses the dual function on the keys.

- Change page in a menu.


- Change display (concept of "turning a page" to display the list of alarms, for example).
- Change digits in a variable field.

INDICATOR LAMP STATUS:


- Off: key inactive
- On: shows that it is possible to change page in a menu (active link) or change display
- Blinking: shows that it is possible to move into the selected variable field

- Move around a page (activate the page links).


- Select the value of a digit.
- Select a value from a list.

INDICATOR LAMP STATUS:


- Off: key inactive
- On: shows that moving around a page is possible
- Blinking: shows that it is possible to modify the value of each digit

Combined with the SHIFT key, enable:


- The value of a variable field to be incremented or decremented
- Access at the top or the bottom page

INDICATOR LAMP STATUS:


- Off: key inactive
- On: shows that moving around a page is possible
- Blinking: shows that it is possible to modify the value of each digit

Deletes the character to the left of the steady digit.

Inverts the sign of the variable field being entered.

Decimal point

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Instruction book

SHIFT+ ESC: Return to the point of entry into the current menu
Example: return to the first application page

Accesses a menu containing the operating functions which are not directly accessible via
keys:
- selection of application pages
- "secondary" operating functions
SHIFT + MENU: Accesses confidential mode which contains the setup functions (protected by
a password):
- Installation and maintenance functions
- Change from running mode to confidential mode

INDICATOR LAMP STATUS:


- Off: the terminal is in running mode
- On: the terminal is in confidential mode
- Blinking: PC<-> XBT (module) transfer is in progress or no application in the terminal
INDICATOR LAMP STATUS:
- On: no cable or incorrect wiring
- Off: correct cable, no exchange with the PLC
- Blinking: exchanges with the PLC

INDICATOR LAMP STATUS:


- Off: no key pressed
- On: when any key is pressed

SHIFT+ ENTER: consult alarms

INDICATOR LAMP STATUS:


- Off: the current alarm list is empty
- On: the list contains some alarms, which have already been displayed (ignored)
- Blinking: the alarm list contains some new alarms
SHIFT+ MOD: print command

INDICATOR LAMP STATUS:


- Off: no printing in progress
- On: printing in progress
- Blinking: printing fault
(Printing option not supported on XD dryer)

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Instruction book

1.3.4 Menu structure

Level 1 page can be accessed in two ways. One is with function key F1 up to F8; the other is with the
built-in menu structure.

For the menu structure press the “Menu” key and press the right arrow for the application pages.

Function Key Level 1 Sublevel 2 Description


F1 Start/Stop dryer Start and stop the dryer + change the
dryer control mode
F2 Dryer overview State description + state times +
temperature & pressure overview
F3 Measured data Valves + limit Overview of valve positions and
switches corresponding limit switches
Digital inputs Overview of digital inputs, except valve
limit switches
Temperature inputs Overview of all temperature sensor values
Pressure inputs Overview of all pressure sensor values
Flow input Overview of the flow transmitter value
(optional)
Heater energy Overview of the current and average
consumption heater energy consumption (optional)
F4 Counters Dryer running time, loaded time, total
regeneration cycles, current + defined
cycle time
F5 Test Manual advance Activate/disable the manual advance
function
State pause Activate/disable the state pause function
F6 Settings Dryer options Configure the dryer options
activation
PDP and heating Configure wanted PDP and heating
temperatures temperature
PID regulation Overview of the flow regulation control
settings
Control parameters Overview of the state times
Alarm parameters Overview of alarm times and alarm values
Units Selection of temperature, pressure and
flow units
F7 Password
F8 Service No. of reg. cycles Overview of regeneration cycles per
vessel per 2000 running hours
No. of sensor errors Overview of the number of occurrences of
a sensor error alarm
No. of valve errors Overview of the number of occurrences of
a valve alarm

1.3.5 Manual advance and State pause

These functions are password protected and may only be used by Atlas Copco technicians.
When one of these functions is active, it will be automatically reset after 4 hours.

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Instruction book

1.3.6 External dryer status indication (Fig. 2.4)

The dryer is standard equipped with 3 potential-free alarm contactors K13, K14, K15. K13 indicates
warning alarms, K14 indicates a shut-down alarm and K15 requests the compressor to shut down.

The contact characteristics (conforming to IEC 947-5-1) of the electromechanical relay modules are as
follows:
- Rated operating voltage: up to 250V AC / 125V DC
- Rated operating current per 1 million operating cycles

Utilization category Rated operating current (A)

AC-12 230V AC 4
AC-13 230V AC 1
AC-14 230V AC 1
AC-15 230V AC 1
DC-12 24V DC 5
DC-13 24V DC 1

1.3.7 Control panel operating mode

The control panel can be used in two modes:


Running mode: The mode for standard operations (default mode).
Confidential mode: If this mode is enabled, it is possible to configure the control panel. It is
possible to configure the date + time, printer port and do self-tests.

The modes can be selected by pressing the “Shift” + “Menu” key. Arrow left and right selects the
correct mode.

1.3.8 Alarm history

If you press the “Menu” key on the control panel, mark the alarm pages test with the arrow down
button and confirm this with the arrow right button, the alarm history page of the dryer is displayed.
The memory saves the last 200 alarms with date and time.

1.3.9 Display when powered up

When it is switched on, the terminal automatically displays the system pages (duration 2 sec.):
- Display of the reference and the software version loaded
- Display of the product reference of the terminal
- Display of the reference and the version of software downloaded by XBT-L1000 (module)
- Display of the reference and the version of the protocol
- Display of the application name

The terminal then continuously displays the dryer overview page.

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Instruction book

1.4 Drain system

1.4.1 Description (Fig. 1.7)

The condensate enters the Electronic Water Drain (EWD) via inlet (1) and accumulates in collector (2).
A capacitive sensor (3) continuously measures the liquid level. As soon as the collector is filled up to
a certain level, pilot valve (4) is activated and diaphragm (5) opens outlet (6), discharging the
condensate.

When the collector has been emptied, the outlet closes quickly without wasting compressed air. When
the controller registers a malfunction, the red alarm LED (Fig 1.9) starts flashing and the electronic
drain valve will automatically change to alarm mode, opening and closing the valve according to a
sequence as shown in Fig 1.8. This condition continues until the fault is remedied. If the fault is not
remedied automatically, maintenance is required.

1.4.2 Testing the EWD

Functional test
Briefly press the TEST button (Fig 1.9) and check that the valve opens for condensate discharge.

Checking the alarm signal


• Press the test button for at least 1 minute
• Check that the alarm LED flashes
• Check the Programmable Logic Controller (PLC) for a drain alarm
• Release the test button

1.4.3 Electrical connections of the EWD (Fig 1.10)

The indications on the data label must correspond to the main supply voltage and frequency. Connect
the electrical supply to the EWD as shown in Fig 1.10. Never operate the EWD without an earth
conductor connected. An alarm device can be connected to the normally open or normally closed
contact.

1 Inlet 4 Pilot valve


2 Collector 5 Diaphragm
3 Sensor 6 Outlet
Fig. 1.7 Electronic water drain

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Instruction book

Fig. 1.8 Drain frequency during alarm condition

Fig. 1.9 EWD control panel

Fig. 1.10 EWD electrical connections

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2 INSTALLATION
2.1 Dimension drawings / installation proposal

Fig. 2.1 Dimension drawing / installation proposal, XD 3000 G variant with ZH 10000

* For dismantling

Valve
V5

Fig. 2.2 Dimension drawing / installation proposal, XD 3000 G variant

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Instruction book

2.2 Installation instructions

Attention:
- When installing the piping, make sure all pipes are clean.
- All connections to the dryer must be mounted stress-free. If necessary, additional flexible
connections and supports must be used.
- Before switching on the main power supply, check the voltage requirements in the technical
specifications or on the dryer data plate.

1 Install the dryer under a roof, where the ambient air is as clean as possible and where the
temperature of the air will never exceed the limits (see section 7.1). If installed in a room,
ventilation must be provided to avoid a temperature increase and moisture collection during purge
cooling. It is recommended to lead the purge air outdoors.

It is desirable to lead the regeneration/cooling outlet air via a pipe to another location; it is
important to take into consideration the maximum allowable pressure drop. If the length of the
additional pipe exceeds 5 m, the diameter must be 1.5 times larger than the original regeneration
pipe. For longer pipe installations, consult Atlas Copco.

(3)
Regeneration
air

(3)
Regeneration
air

Regeneration
(1)
air outlet Drain (2)

55505D

Fig. 2.3 Piping of regeneration air outlet

Text on Fig. 2.3

(1) Regeneration air outlet


(2) Drain
(3) Regeneration air

If the pipe is led upwards, provide a drain hole at the lowest point to remove condensate
water and prevent water lock.

Warning:
- The temperature of the regeneration outlet air can rise up to 140 °C; take care that the hot air
is never pointed to personnel or inflammable objects.
- Adequate protection must be provided to protect personnel from touching the hot surfaces of
the dryer.

2 Check that the air intake of the compressor is positioned so that volatile gases or other flammable
elements cannot be taken in to avoid concentration of these elements in the desiccant beads.

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Instruction book

3 Enough space must be provided around dryer and filters to allow maintenance and filter
replacement. The minimum distance between the top of the dryer and the ceiling must allow
disassembly of the dryer heating elements and desiccant filling.

4 If the air from the compressor contains oil drops or oil vapour, a de-oiling filter of the PD type
should be installed upstream of the dryer. The filter should be fitted with an automatic drain for
condensate water and oil. If there is no automatic drain, the filter should be emptied several times
a day manually. An optional QD filter may be installed upstream of the dryer.

5 It is recommended to install a dust filter of the DD(p) type downstream of the dryer, as the drying
medium can release a small amount of dust.

6 Connect the compressed air lines to the dryer INLET and OUTLET.

Blow any welding waste and other impurities from the lines before connecting them. A by-pass
line is often a useful addition to the equipment.

7 Connect the dryer to the main supply via an isolation switch. Check that the primary side of
transformer T1 corresponds to the supply voltage. Check that the electrical installation
corresponds to the local codes. The dryer must be earthed and protected against short circuit by
fuses of the inert type in all phases.

8 After replacement of the drying medium, the amount of dust released can increase. Therefore, it
is recommended to replace the dust filter one week after replacing the desiccant and close the air
inlet for the PDP sensor for the first 24 hours.

9 If two dryers should be connected in parallel (which is not recommended), measures must be
taken to ensure an equal distribution of the air flow between the dryers.

10 During regeneration, the surface temperature of the tower will be very high. Special precautions
must be taken to protect personnel from touching the hot surface.

11 For optimal regeneration of the dryer, the piping between the compressor and the dryer
regeneration air inlet piping should be isolated.

12 All inlet piping of the dryer will reach temperatures up to 150 °C. Special precautions must be
taken to protect personnel from touching the hot surface.

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Instruction book

2.3 Mechanical connections

The table below gives an overview of the mechanical connections of the inlet piping, the outlet pipe
and the regeneration/cooling outlet pipe.

CE unit ANSI unit


XD 1400 Inlet 1, regeneration air DIN DN150 PN16 ANSI 6" 150#
Inlet 2, adsorption air DIN DN150 PN16 ANSI 6" 150#
Outlet DIN DN150 PN16 ANSI 6" 150#
Regeneration/cooling outlet DIN DN80 PN16 ANSI 3" 150#
Cooling water inlet and outlet DIN DN80 PN16 ANSI 3" 150#
XD 1800 Inlet 1, regeneration air DIN DN150 PN16 ANSI 6" 150#
Inlet 2, adsorption air DIN DN150 PN16 ANSI 6" 150#
Outlet DIN DN150 PN16 ANSI 6" 150#
Regeneration/cooling outlet DIN DN80 PN16 ANSI 3" 150#
Cooling water inlet and outlet DIN DN80 PN16 ANSI 3" 150#
XD 2400 Inlet 1, regeneration air DIN DN150 PN16 ANSI 6" 150#
Inlet 2, adsorption air DIN DN150 PN16 ANSI 6" 150#
Outlet DIN DN150 PN16 ANSI 6" 150#
Regeneration/cooling outlet DIN DN80 PN16 ANSI 3" 150#
Cooling water inlet and outlet DIN DN80 PN16 ANSI 3" 150#
XD 3000 Inlet 1, regeneration air DIN DN200 PN16 ANSI 8" 150#
Inlet 2, adsorption air DIN DN150 PN16 ANSI 6" 150#
Outlet DIN DN200 PN16 ANSI 8" 150#
Regeneration/cooling outlet DIN DN80 PN16 ANSI 3" 150#
Cooling water inlet and outlet DIN DN80 PN16 ANSI 3" 150#

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Instruction book

2.4 Cubicle (Fig. 2.4)

25
Instruction book

EM1 Digital input module K9 Contactor, heater R9 (optional)


EM2 Digital input module K10 Contactor, heater R10 (optional)
EM3 Relay output module K11 Auxiliary relay, overheating switches
EM4 Relay output module (optional)
EM5 Analog input module (optional) K12 Auxiliary relay, overheating switches
F1 Circuit breaker, main heaters 1 (optional)
(R1/R3) K13 Remote alarm signal contact
F2 Circuit breaker, regulating heaters 1 K14 Remote shut-down signal contact
(R2/R4) K15 Compressor shut-down contact
F3 Circuit breaker, main heaters 2 K16 Compressor loaded signal
(R7/R9) PLC Programmable logic controller
F4 Circuit breaker, regulating heaters 2 S1 Main switch (optional)
(R8/R10) T1 Main transformer
F5 Circuit breaker, control circuit (primary) T2 Power supply, 24 V DC
F6 Fuse, control circuit 115 V AC T3 Power supply, 24 V DC (optional)
F7 Fuse, control circuit 24 V AC (not TS1 Overheating switch, vessel A (optional)
connected) TS2 Overheating switch, vessel B (optional)
F8 Fuse, control circuit 24 V AC (not Yx Contact, solenoid for valve x
connected) 1X3 Terminal strip, PE (earth/ground)
F9 Fuse, EWD 1 1X4 Terminal strip, 115 V AC
F10 Fuse, EWD 2 (optional) 1X6 Terminal strip, 24 V DC
K1 Contactor, heater R1 (optional) 1X11 Terminal strip
K2 Contactor, heater R2 (optional) 1X12 Terminal strip
K3 Contactor, heater R3 (optional) 1X13 Terminal strip
K4 Contactor, heater R4 (optional) 1X14 Terminal strip
K7 Contactor, heater R7 (optional) 1X15 Terminal strip
K8 Contactor, heater R8 (optional)

Fig. 2.4 Cubicle, XD dryer

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Instruction book

F1 Circuit breaker, main heaters 1 K1 Contactor, heater R1 (optional)


(R1/R3) K2 Contactor, heater R2 (optional)
F2 Circuit breaker, regulating heaters 1 K3 Contactor, heater R3 (optional)
(R2/R4) K4 Contactor, heater R4 (optional)
F3 Circuit breaker, main heaters 2 K7 Contactor, heater R7 (optional)
(R7/R9) K8 Contactor, heater R8 (optional)
F4 Circuit breaker, regulating heaters 2 K9 Contactor, heater R9 (optional)
(R8/R10) K10 Contactor, heater R10 (optional)
F5 Circuit breaker, control circuit (primary) R1/R3/R7/R8 Heater elements, tower A
F6 Fuse, control circuit 115 V AC R2/R4/R9/R10 Heater elements, tower B
F7 Fuse, control circuit 24 V AC (not S1 Main switch (optional)
connected) T1 Main transformer
F8 Fuse, control circuit 24 V AC (not 1X3 Terminal strip, PE (earth/ground)
connected)

Fig. 2.5 Electrical diagram, XD dryer

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Instruction book

2.5 Electrical cable size and maximum fuses

Remarks
- The size is valid for cable PVC 70 °C, at ambient temperature 40 °C according to EN60204.
- Local regulations remain applicable if they are stricter than the values proposed below.
- The voltage drop must not exceed 5 % of the nominal voltage. It may be necessary to use cables
with a larger size than those stated to comply with this requirement.

50/60 Hz IEC versions

Standard variant (no heaters installed)

Nominal
Voltage Frequency Maximum
Dryer type Current Cable size (mm²)
(V) (Hz) fuse (A)
(A)
XD 1400 400 50 0.5 2 x 1.5 + 1.5 2
500 50 0.5 2 x 1.5 + 1.5 2
380 60 0.5 2 x 1.5 + 1.5 2
XD 1800 400 50 0.5 2 x 1.5 + 1.5 2
500 50 0.5 2 x 1.5 + 1.5 2
380 60 0.5 2 x 1.5 + 1.5 2
XD 2400 400 50 0.5 2 x 1.5 + 1.5 2
500 50 0.5 2 x 1.5 + 1.5 2
380 60 0.5 2 x 1.5 + 1.5 2
XD 3000 400 50 0.5 2 x 1.5 + 1.5 2
500 50 0.5 2 x 1.5 + 1.5 2
380 60 0.5 2 x 1.5 + 1.5 2

Guaranteed Pressure dewpoint variant (electric heaters installed)

Nominal
Dryer Voltage Frequency Maximum
Current Cable size (mm²)
type (V) (Hz) fuse (A)
(A)
XD 1400 400 50 * * *
500 50 * * *
380 60 * * *
XD 1800 400 50 * * *
500 50 * * *
380 60 * * *
XD 2400 400 50 * * *
500 50 * * *
380 60 * * *
XD 3000 400 50 * * *
500 50 * * *
380 60 * * *
* Contact your Atlas Copco Customer Centre for details

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Instruction book

60 Hz UL versions

Standard variant (no heaters installed)

Nominal
Voltage Frequency Maximum
Dryer type Current Cable size (mm²)
(V) (Hz) fuse (A)
(A)
XD 1400 440/460 60 0.5 * *
575 60 0.5 * *
XD 1800 440/460 60 0.5 * *
575 60 0.5 * *
XD 2400 440/460 60 0.5 * *
575 60 0.5 * *
XD 3000 440/460 60 0.5 * *
575 60 0.5 * *
* Contact your Atlas Copco Customer Centre for details

Guaranteed Pressure dewpoint variant (electric heaters installed)

Nominal
Voltage Frequency Maximum
Dryer type Current Cable size (mm²)
(V) (Hz) fuse (A)
(A)
XD 1400 440/460 60 * * *
575 60 * * *
XD 1800 440/460 60 * * *
575 60 * * *
XD 2400 440/460 60 * * *
575 60 * * *
XD 3000 440/460 60 * * *
575 60 * * *
* Contact your Atlas Copco Customer Centre for details

2.6 Pictographs

1 Data plate
2 Warning, heated surface
3 Warning, explosion danger if
2 pressurised (not applicable for
XD dryers)
1 4 Air outlet
5 Air inlet
55506P

6 Emergency stop

6
5 4 3

Fig. 2.6 Pictographs on dryer

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Instruction book

3 OPERATING INSTRUCTIONS

Safety precautions
The operator must apply all relevant safety precautions, including those mentioned in this book.
Safety valves are available as an option; make sure that the air net is protected by safety valves of the
correct size and opening pressure.

3.1 Initial start

The dewpoint of the air leaving the dryer will be higher than normal after starting. If the air net is to
remain dry, run the dryer approximately 7 hours (complete cycle for both towers) with the outlet air
blown off to make sure that the desiccant is properly regenerated.

3.2 Starting

1. Check if all fuses in the cubicle are turned on.


2. Check if the overheating switches in the cubicle are set to 450 °C (optional).
3. Switch on the voltage (customer’s installation). The control panel shows that the dryer is
STOPPED.
4. Switch on the voltage to the dryer by means of the main switch (optional).
5. Check if the correct options are active in the “Settings - dryer options” activation menu.
6. Check if all sensors give correct values in the measured data page.
7. Check that the pilot air valve (102-Fig. 1.4) is open.
8. Check if the cooling water supply is opened.
9. While the dryer outlet valve (customer’s installation) is closed, open the air inlet valve (customer’s
installation) slowly and wait until the dryer has pressurised.
10. Check for leakage.
11. Start the dryer by pressing the start button on the control panel.
12. If necessary, reset any alarm on the control panel.
13. Open the dryer air outlet valve slowly (customer's installation).
14. Close the by-pass valve (if provided).
15. If a dewpoint meter is installed:
- it is recommended to run the dryer for 1 day before opening the valve to the dewpoint meter
- the dryer must run in a fixed cycle for 1 day before switching over to "PDP control" (dewpoint
meter control)

3.3 Stopping

1. Stop the dryer by pressing the stop button on the control panel.
In case of emergency: push emergency stop button (6-Fig. 1.5). See also section 3.5.
2. Close the dryer inlet and outlet valves (customer's installation).

ATTENTION: Make sure that the outlet valve of the dryer is closed or the air net behind the dryer
depressurises slowly preventing high air speeds and thus desiccant floating.
A minimum pressure valve can be used to prevent this problem.

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Instruction book

3.4 Remote start/stop (Fig. 2.5)

The XD dryer can be started and stopped from a remote location by means of a digital switch S2
(customer’s installation).

Procedure
1. Stop the dryer (see section 3.3).
2. Put the main switch (S1) in position “0”. This will switch off the main power supply to the dryer,
only the 24 V AC control voltage to the regulator remains. Switching off S1 enables you to open
the cubicle door.
3. Connect a digital switch (customer’s installation) in between clamps 201 and 101 of rail 6X2 inside
the cubicle (see Sheet 3 of Service Diagram 9827 1719 00). The switch should be of the Normally
Open (NO) type.
4. Close the cubicle door, switch S1 back to position “I”.
5. Enter the “Start and stop the dryer” menu. Change the setting from “Local Control” to “Remote
Control”. Note that activating the “Remote Control” feature will disable the Start/Stop buttons on
the control panel.
6. To start the dryer, close switch S2. To stop the dryer, open switch S2.

3.5 Emergency stop

In case of an emergency stop (S3) (6-Fig. 1.5), the main switch (S1) (2-Fig. 1.5) of the dryer will
automatically disconnect. This is an added safety feature that ensures a proper shut-down of the
dryer irrespective of the operation of the contactors. Note that the 24V AC control circuit of the
electronic regulator remains powered, and the control panel will indicate an emergency stop shut-
down.

To clear the shut-down:


- Unlock the emergency stop button (S3)
- Reset the main switch (S1), i.e. completely disconnect the switch (position “0”), then turn the
switch back on (position “I”)
- Reset the shut-down on the control panel

3.6 Indication lamp

Above the control panel the dryer status lamp (H1) (4-Fig. 1.5) is indicated.

The following indications are possible:


ON: Dryer stopped, no alarms are active
OFF: Dryer running, no alarms are active
1 sec ON; 1 sec OFF: Dryer running, a warning or shut-down warning alarm is active
0,5 sec ON; 0,5 sec OFF: Dryer stopped, a shut-down alarm is active

3.7 Voltage failure


In case of a voltage failure, the main switch (S1) (2-Fig. 1.5) of the dryer will automatically disconnect.
As the power to the electronic regulator is taken before the main switch, the regulator will resume
operation as soon as the power to the dryer is restored. Via the dryer starting routine the program will
jump to the cycle step in which the voltage failure occurred. However, the main switch (S1) needs to
be reset manually by switching it off completely (position “0”) and back on (position “I”).

Valves (V10, V11, V6 and V7-Fig. 1.4) will automatically close when a voltage failure occurs to prevent
air losses.

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Instruction book

4 MAINTENANCE

Warning
- Before starting any maintenance or repair, stop the dryer as described in section 3.3, press
emergency stop button (6-Fig. 1.5), switch off the voltage, depressurise the dryer and close
the cooling water supply.
- Safeguard against unintentional "switch-on". Apply all relevant safety precautions, including
those mentioned in this book.

4.1 Preventive maintenance schedule for the dryer

4.1.1 Regular service operations

- To ensure safe operation and long service life carry out following operations at the interval. Note
that the "longer interval" checks must also include the "shorter interval" checks.
- The local Atlas Copco Customer Centre may overrule the maintenance schedule depending on the
environmental and working conditions of the dryer.
- During servicing, replace all removed gaskets, O-rings and washers.

Running
Period Operation
hours
- Check that the compressed air temperature does not exceed
the limits (see section 7).
- Check that XD discharge pressure does not drop below
minimum allowed pressure.
Daily -
- Check for alarms on the display and confirm them.
- Check dewpoint and working state on display.
- Check the regeneration/cooling air outlet for proper working.
- Check the working of the EWD’s.

- Check filter of the dryer inlet and outlet.


- Check the filter of the PDP sensor for dust and clean it if
necessary.
Weekly -
- Check the filter of the pilot air.
- Check for water or air leaks.
- Check for abnormal noise.

- Check all dryer components. Replace worn-out parts.


- Clean the silencers.
- Measure the heating element current consumption (optional).
- Re-calibrate the dewpoint meter (optional).
Yearly 8000
- Replace filter cartridges of the filter(s) (optional).
- Have the condition of the desiccant checked.
- Inspect seats of check valves, replace if necessary.
- Clean and service the EWD’s with EWD service kits.

- Replace seats of butterfly valves.


Every 2 years 16000 - Check correct positioning of limit switches of butterfly valves.
- Replace PLC backup battery.

- Replace desiccant (depending on the working conditions).


Every 5 years 40000
- Check vessel internal strainers if desiccant is removed.

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Instruction book

4.1.2 Service kits

Atlas Copco Customer Centres will be glad to provide you with a wide range of service kits. Service
kits comprise all parts needed for servicing components and offer the benefits of genuine Atlas Copco
parts while keeping the maintenance budget low.

4.1.3 Service agreements

Atlas Copco Customer Centres have a range of service agreements to suit your needs:

- An Inspection plan
- A Preventive maintenance plan
- A Total responsibility plan

Contact your Customer Centre to agree on a tailor-made service agreement. It will ensure optimum
operational efficiency, minimize downtime and reduce the total life cycle costs.

4.2 Filling instructions

4.2.1 Initial filling (desiccant is partially delivered separately)

1. Open the desiccant filling flanges (2 and 9-Fig. 1.3).


2. Fit a large funnel to the filling hole of one of the drying towers; the size of the narrow part should
be 35 - 40 mm.
3. Gently pour the correct amount of desiccant Type 1, part 2 (see section 4.2.2) into the tower. Use
a vacuum cleaner to control dust escaping from the filling hole. The desiccant level must reach
just above the top strainer level.
4. Repeat steps 2 and 3 for the other tower; the amounts of desiccant must be equal in both towers.
5. Do not use any mechanical or pneumatic means for filling; this may destroy the desiccant.
6. Refit the filling flanges. The dryer is now ready to be started (see section 3 for starting
instructions).

4.2.2 Replacing desiccant

Emptying
1. Let the dryer program run to the end of the split flow cooling or to the waiting or shifting step.
2. Stop the dryer.
3. Shut off the power supply.
4. Close the pilot air valve (102-Fig. 1.4). Isolate the dryer from the air net by closing the air inlet and
outlet valves. Depressurise the towers slowly.
5. Install a suitable collector underneath the desiccant removal flange for emptying; note that the
desiccant may be very hot (150 °C).
6. Remove the plugs or flanges (6 and 7-Fig. 1.2) and let the desiccant pour out into the collector. A
vacuum cleaner may be used to speed up the process and control dust.
Use a vacuum cleaner to clean the bottom strainer.
7. Check the bottom strainer of the vessels through the manhole (XD 2400 and XD 3000) (1 and 10-
Fig. 1.3) or removal flange.

Attention:
When replacing desiccant, make sure that the desiccant is disposed of according to the local
regulations.

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Instruction book

Filling
1. Once the vessels are empty and the strainers are checked, refit the desiccant removal flange or
manhole (XD 2400 and XD 3000).
2. Open the desiccant filling flange (2 and 9-Fig. 1.3).
3. Fit a large funnel to the filling hole of one of the drying towers; the size of the narrow part should
be 35-40 mm.
4. Gently pour the correct amount of desiccant Type 1 (see section 7.2) into the tower. The
desiccant level must reach just above the top strainer level.
Use a vacuum cleaner to control dust escaping from the filling hole.
5. Repeat steps 3 and 4 for the other tower; the amounts of desiccant Type 1 must be equal in both
towers.
6. Do not use any mechanical or pneumatic means for filling; this may destroy the desiccant.
7. Refit the filling plugs or flanges. Close the pilot air valve (102-Fig. 1.4), the dryer is now ready to
be started (see section 3 for starting instructions).

Notes:
- When replacing the desiccant, never use an ejector or similar equipment as this might shatter
the beads. The beads must be gravity fed into the tower.

If a dewpoint meter is installed:


- It is recommended to run the dryer for 1 day before opening the valve to the dewpoint meter.
- The dryer must run in a fixed cycle for 1 day before switching over to "PDP control" (dewpoint
meter control).

Desiccant can be ordered in following quantities:

Desiccant type Quantity Ordering number

Type 1 45 kg 2906 7500 00


Type 1 130 kg 2906 7501 00
Type 1 750 kg 2906 7502 00

Amount of desiccant for single vessel:

Dryer Type 1, part 1 Type 1, part 2

XD 1400 275 kg 575 kg


XD 1800 300 kg 750 kg
XD 2400 420 kg 1100 kg
XD 3000 530 kg 1365 kg

Note:
XD dryers are delivered with only part 1 of Type 1 filled in the vessel. The other part (part 2) will
be delivered separately together with the dryer.

After replacing the drying medium, the amount of dust released can increase. Therefore, it is
recommended to replace the dust filter downstream of the dryer one week after replacing the
desiccant and close the air inlet of the PDP sensor for 24 hours.

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Instruction book

4.3 Transport instructions

When transporting the dryer, a few points must be kept in mind:


1. The bottom drain outlet of the combicooler must be opened to prevent water staying in the
cooler for a long period.
2. Only 1/3 of the desiccant may remain in the dryer to prevent problems with the vessel internal
bottom strainers.

If the dryer will not be used for a long period, contact your Atlas Copco Customer Centre for detailed
instructions.

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Instruction book

5 OPTIONAL EQUIPMENT

5.1 Dewpoint meter

Installing a dewpoint meter will increase the accuracy and lower the operation costs.

The dewpoint meter monitors the dewpoint and shows it continuously on the display.

The dewpoint meter controls the dryer operating cycle. As long as the outlet pressure dewpoint is
better, that is below the preset value (e.g. -40 °C), the regulator will extend the dryer adsorption
sequence (maximum 24 hours). See section 1.2.

When activating the "PDP control" in the “Settings - dryer options” menu (see section 9.6.1) it is
possible to choose whether the dryer should shift towers according to a preset time program or
according to a preset value. However, the dryer can never shift towers less frequent than 24 hours,
regardless of the control system used.

The sensor must be calibrated once a year. It is recommended to replace the in-line air filter in the
sensor block once a year.

Notes:
- It is recommended to run the dryer in a fixed cycle for 1 day when starting up after a long stand-
still period.
- It is recommended to isolate the PDP sensor (PDP01-Fig. 1.4) by means of shut-off valve (100)
immediately after initial start-up of the dryer, or after refilling, as dust from the desiccant filling
will contaminate the filter and sensor.

5.2 Second dewpoint read-out

If a dewpoint meter is installed, the analog signal of the pressure dewpoint can be externally read out.
This module allows the customer to have the measured pressure dewpoint value available as a 4-20
mA signal.

5.3 Heater option for guaranteed dewpoint

To guarantee a constant dewpoint through summer and winter, extra heating of the regeneration air
could be needed. A part of the compressor flow will be heated to make the top part of the desiccant
extra dry and so as energetic as possible. To regulate the flow, a flow transmitter and an analog
controller for regeneration valve (V5-Fig. 1.4) are required.

5.4 Vessel isolation

To prevent heat loss of the compressor outlet air, the piping towards the dryer regeneration inlet must
be isolated. An extra option isolates the vessels, the inlet valves and the inlet piping of the dryer.

Both methods optimise the quality of regeneration and thus results in a better dewpoint.

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Instruction book

5.5 Minimum pressure valve

Excessively high air velocity (e.g. due to low inlet pressure) may cause the desiccant to “float” in the
vessels. The desiccant beads scrape against each other, creating additional dust. High-speed flow
occurs when a compressor starts against an empty air net or when working at a discharge air pressure
that is too low. A high volume of compressed air output can result in a pressure drop, which in turn
increases the speed.

Therefore, the air net should be filled by slowly opening the valve towards the dryer.

Alternatively, a minimum pressure valve which automatically regulates the pressure, can be installed
downstream of the dryer. The opening pressure of the minimum pressure valve must be set to a
pressure equal to the operating pressure minus 1 bar.

Refer to the instruction delivered with the minimum pressure valve to install and adjust the valve.

5.6 Filter option

To protect the desiccant from contaminating fluids or particles, an inlet filter can be mounted upstream
of the dryer. On the outlet side of the dryer, a particle filter can be mounted to prevent dust particles,
emerging from the desiccant bed, from entering the air net.

The XD filter option consists of a DDp outlet filter, as well as all the relevant piping and instructions.
An adjustable space of approx. 25 mm is provided on the support of the filter inlet pipe to account for
unevenness in the floor and/or tolerances on the dryer piping. The statuses of the filters are read into
the regulator, which will display an alarm message in case of filter fouling.

The filter element of a DDp outlet filter should be replaced one week after initial start-up or
replacement of the desiccant.

In case an extra afterfilter is installed (customer’s installation), it is important to mount it always


downstream of the DDp particle filter.

5.7 Safety valves


Safety valves are available as an option; make sure that the air net is protected by safety valves of the
correct size and opening pressure.

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Instruction book

6 PROBLEM SOLVING (Fig. 1.4)

1 Poor dewpoint
a Ineffective cooler or high cooling water temperature
a Check that condensate separators and drains upstream of the dryer are operative
b Working pressure low
b Check pressure drop in filter, etc.
c Poor regeneration
c See 5
d Dryer fails to shift
d See 2
e Poor desiccant (older than 5 years, contamination in desiccant, too low working pressure)
e Replace desiccant

2 Dryer fails to shift


a Pilot air missing
a Check for pressure in the operating lines. Clean pilot air filter (103)
b Temperature in one of the vessels above 100 °C
b Wait until vessel is cooled down enough. (Search for reason)
c A valve alarm is active
c Check alarms and check if all the dryer options are configured correctly
d Dewpoint is below defined value
d Wait unit vessel becomes saturated or disable the PDP extended cycle option
e Pressure difference between vessels is greater than 0,3 bar
e Check if cooling air valve (V12) is opened and valves (V1,V2, V6, V7, V10 and V11) are 100%
closed

3 Unusually large flow through regeneration valve(s) during cooling


a Valve (V1 or V2) leaks
a Disassemble and check; replace seals
b Cooling air valve (V12) opens too much
b Adjust opening settings

4 Regeneration temperature too low


a One of the connectors of the heating element (optional) burnt off
a Check; replace
b A heating element (optional) burned out
b Replace
c Too much regeneration air
c Check regeneration valve (V5) (standard) and flow transmitter (optional)
d Bad isolation of piping between compressor and dryer
d Check isolation

5 Regeneration temperature too high


a Too little regeneration air
a Check regeneration valve (V5) (standard) and flow transmitter (optional)

6 Too high dryer outlet temperature


a Too high adsorption air temperature
a Check adsorption air inlet temperature after cooling stage, check cooling water temperature
b. Bad cooling sequence
b. Check cooling times, follow cooling state

7 Dryer fails to relieve pressure needed for purge cooling and purge heating
a Solenoid valve defective
a Check if solenoid is defective and replace if necessary
b Silencer clogged
b Replace silencers

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Instruction book

8 A lot of dust in the air net


(The outlet filter element needs to be replaced too often)
a Desiccant floating due to constant working pressures lower than 4.5 bar
a Contact your Atlas Copco Customer Centre
b. Many starts and stops of compressor causing pressure drops
b. Use a minimum pressure valve

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Instruction book

7 PRINCIPAL DATA

7.1 Limitations/nominal conditions

Nominal conditions

Compressed air inlet pressure bar(e) 7


Compressed air inlet temperature °C 100
Inlet relative vapour pressure % 7
Pressure dewpoint
- Pressure dewpoint 0 °C variant °C 0
- Pressure dewpoint - 20 °C variant °C - 20
- Pressure dewpoint - 40 °C variant °C - 40

Limitations

Unit XD 1400 XD 1800 XD 2400 XD 3000

Maximum compressed air inlet


bar(e) 11 11 11 11
pressure
Minimum compressed air inlet
bar(e) 4.5 4.5 4.5 4.5
pressure
Minimum ambient air temperature °C 5 5 5 5
Maximum ambient air temperature °C 40 40 40 40
Minimum compressed air inlet
°C 70 70 70 70
temperature

7.2 Specific data 1)

7.2.1 Standard variants


Unit XD 1400 S XD 1800 S XD 2400 S XD 3000 S

Volume flow at dryer inlet l/s 1400 1800 2400 3000


Pressure drop over dryer bar 0.35* 0.35* 0.35* 0.35*
Electric power input kW 0.5 0.5 0.5 0.5
Recommended filter size DD/PD 1400 1800 2700 3150
Desiccant silica gel silica gel silica gel silica gel
Amount of desiccant per
tower
- Type 1 kg 850 1050 1520 1895

* Pressure drop when one combicooler is used. For optional second combicooler add 0.1 bar.

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Instruction book

7.2.2 Guaranteed dewpoint variants


Unit XD 1400 G XD 1800 G XD 2400 G XD 3000 G

Volume flow at dryer inlet l/s 1400 1800 2400 3000


Pressure drop over dryer bar 0.35* 0.35* 0.35* 0.35*
Electric power input kW 68 68 81.5 96.5
Recommended filter size DD/PD 1400 1800 2400 3000
Desiccant silica gel silica gel silica gel silica gel
Amount of desiccant per tower
- Type 1 kg 850 1050 1520 1895

* Pressure drop when one combicooler is used. For optional second combicooler add 0.1 bar.

Footnote, chapter 7

1) At nominal conditions

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Instruction book

8 CONVERSION LIST OF SI UNITS INTO BRITISH/U.S. UNITS

1 bar = 14.504 psi


1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 m = 3.281 ft
1 mm = 0.039 in
1 m3/min = 35.315 cfm
1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x °C = (32 + 1.8x) °F 1)

Footnote, chapter 8

1) A temperature difference of 1 °C = a temperature difference of 1.8 °F.

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Instruction book

9 REGULATOR FUNCTIONS

See section 1.3 for more regulator details.

9.1 Starting and stopping the dryer (F1)

2. START AND STOP THE DRYER


R1 R2
DRYER STATUS <STARTED> CHANGE
DRYER STATUS

CONTROL MODE <LOCAL> CHANGE


R3 R4
CONTROL MODE
(ONLY POSSIBLE WHEN THE DRYER IS STOPPED)
Fig. 9.1 Starting and stopping the dryer screen, typical example

Dryer status: Indicates started or stopped.


With dynamic key R2 the dryer can be started or stopped if the control mode is local.

NOTE: After a new download of the controller logic, the control mode will
automatically be local.

Control mode: Indicates the control mode of the dryer to start and stop the dryer and can be changed
through key R4.

There are three modes:


LOCAL The dryer can be started and stopped through this screen
REMOTE The dryer can be started and stopped by means of a digital input
LAN The dryer can be started and stopped through an industrial network
interface (optional)

NOTE: The control mode can only be changed if the dryer is stopped and can only be
changed to local through this screen.

9.2 Dryer overview (F2)

When the voltage is switched on, this screen is shown automatically, showing the operation status of
the dryer.

2. DRYER OVERVIEW
R1 R2
Vessel A 42 degC Vessel A 7.0 Bar
Vessel B 100 degC Vessel B 7.3 Bar
Tinlet 104 degC PDPout -24,1 degC
Vessel A Adsorbing 01:01:34
R3 R4
Vessel B FF reg no heat (01:30:00)
STATE PAUZE* MANUAL ADVANCE*
* Optional (see section 9.5)
Fig. 9.2 Dryer overview screen, typical example

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Instruction book

The figure shows the temperatures at the top of the vessels, the vessel pressures, the dryer inlet
temperature (compressor outlet temperature) and the pressure dewpoint.
The current state of the dryer is also visible with the current and defined state time.

With dynamic key R3, the current state time can be paused and with manual advance R4 the dryer will
go to its next state. These functions are for test and service purposes.
See section 9.5 for more information.

9.3 Measured data

3. MEASURED DATA
R1 R2
R1 VALVES + LIMIT SWITCHES
R2 DIGITAL INPUTS EXCEPT VALVE POSITIONS
R3 TEMPERATURE INPUTS
R4 NEXT PAGE
R3 R4
NEXT PAGE
Fig. 9.3 Measured data page, page 1 of 2, typical example

3. MEASURED DATA
R1 R2
R1 PRESSURE INPUTS
R2 FLOW INPUT
R3 HEATER ENERGY CONSUMPTION
R4
R3 R4

Fig. 9.4 Measured data page, page 2 of 2, typical example

With the dynamic keys R1 up to R4 the submenu pages can be selected. Key R3 in Fig. 9.3 gives the
temperature inputs page in Fig. 9.6.

3.1. MEASURED DATA - VALVE POSITIONS


R1 R2
V1A <ACTIVATED> LS1A <CLOSED>
V1B <NOT ACTIVE> LS1B <OPENED>

V2A <NOT ACTIVE> LS2A <OPENED>


R3 R4
V2B <NOT ACTIVE> LS2B <CLOSED>
NEXT PAGE
Fig. 9.5 Measured data page, valve positions, typical example

Fig. 9.5 presents the digital outputs of the valve and the corresponding limit switches.
Valve V1 is now activated to open V1A and limit switch LS1A is closed. This confirms that valve V1 is
opened (Limit switches are Normally Open (NO) contacts).
Valve V2 isn’t activated, but limit switch LS2B is closed, which means that the valve is in closed
position.
With dynamic key R4 it is possible to go to the next page with valve positions.

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Instruction book

3.1. MEASURED DATA - TEMP INPUTS


R1 R2
TT01 COMP INTERCOOL TEMP 45,2 degC
TT02 DRYER INLET TEMP 103,9 degC
TT03 TEMP TOP VESSEL A 100,1 degC
TT04 TEMP TOP VESSEL B 38,2 degC
R3 R4
NEXT PAGE
Fig. 9.6 Measured data page, temp inputs, typical example

Fig. 9.6 shows the measured temperature inputs. A sensor error will give ### on the screen.
With dynamic key R4 it is possible to go to the next page with temperature inputs.

9.4 Counters

4. COUNTERS
R1 R2
CURRENT CYCLE TIME 02:00:43
DEFINED CYCLE TIME 03:00:00
TOTAL RUNNING HOURS 2560:44
TOTAL LOADED HOURS 2556:21
R3 R4
TOTAL REG CYCLES A 368
TOTAL REG CYCLES B 365
Fig. 9.7 Counter page, typical example

Current cycle time: The current regeneration cycle time


Defined cycle time: The defined regeneration cycle time
Total running hours: The total running time of the dryer
Total loaded hours: The total running time of the dryer with the compressor loaded
(Sensed by digital input)
Total reg. cycles A: The total of regeneration cycles of vessel A
Total reg. cycles B: The total of regeneration cycles of vessel B

9.5 Test

5. TEST
R1 R2
R1 MANUAL ADVANCE
R2 STATE PAUZE
R3
R4
R3 R4

Fig. 9.8 Test page, typical example

Both functions of the test page are password protected and should only be used by an Atlas Copco
service technician. If the functions are activated (see section 9.7), they are visible in the dryer
overview page (F2).

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Instruction book

9.6 Settings

The settings page contains the following subpages:


- Dryer options activation
- PDP and heating temperatures
- PID regulation
- Control parameters
- Alarm parameters
- Dryer units

9.6.1 Dryer options activation

6.1 SETTINGS - DRYER OPTIONS


R1 R2
PDP SENSOR <ACTIVE>
PDP EXTENDED CYCLE <ACTIVE>
HEATER OPTION <ACTIVE>
OUTLET FILTER 1 <NOT ACTIVE>
R3 R4
OUTLET FILTER 2 <NOT ACTIVE>
NEXT PAGE
Fig. 9.9 Settings - Dryer options, typical example

PDP sensor: Activate the PDP sensor reading


PDP extended cycle: Activate the PDP extended adsorption cycle
(only works if PDP sensor is activated)
Heater option: Activate the Partial flow regeneration step for guaranteed dewpoint
Outlet filter 1: Activate the alarm for the first outlet filter pressure drop measurement
Outlet filter 2: Activate the alarm for the second outlet filter pressure drop
measurement
Minimum pressure valve: Activate the minimum pressure valve regulator and indicator
Valve V5 limit switches: Activate the limit switch option for valve V5
Combicooler 2 drain failure: Activate the alarm for the second combicooler electronic water drain
Combicooler 2 temp inputs: Activate the temperature reading of the second combicooler cooling
water temperature

9.6.2 PDP and heating temperatures

6.2 SETTINGS – PDP AND HEATING TEMPERATURES


R1 R2
CALCULATED PDP REGEN AIR 35,1 degC
CALCULATED BED TEMP 35,0 degC
WANTED OUTLET AIR PDP -30,0 degC
HEATING TEMPERATURE <AUTOMATIC>
R3 R4
HEATING TEMPERATURE 141 degC
PDP SWITCHING TEMPERATURE -20,0 degC
Fig. 9.10 Settings - PDP and heating temperatures, typical example

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Instruction book

Calculated PDP regen air: Calculated dewpoint of the dryer inlet air
Calculated Bed temp: Adsorption air temperature after dryer combicooler stage
Wanted outlet air PDP: Wanted dryer PDP used for calculating heating temperature
(Equal or lower than PDP switching temperature)
Heating temperature: Automatically calculated from PDP regeneration air or manual setting
through the control panel
Heating temperature: Current heating temperature set point. If setting is manual, the value
can be changed
PDP switching temperature: Wanted PDP used for extended adsorption cycles

9.6.3 PID regulation

6.3 SETTINGS - PID REGULATION


R1 R2
PID setpoint SP 4500 Nm3/h
Proportional gain Kp 60 *100
Integration time Ti 30 *0.1 s
Differentiation time Td 0 *0.1 s
R3 R4
Sampling time Ts 15 *0.01 s

Fig. 9.11 Settings - PID regulation, typical example

The values in this page are usable as an indication when there are problems with the partial flow
regeneration state.

9.6.4 Control parameters

These screens contain the state times of each regeneration step. They cannot be modified.
Times equal to zero mean that the state is not used in the current application.

Minimal half cycle time: The minimal regeneration sequence time


Maximal half cycle time: The maximal regeneration cycle time if the PDP extended cycle
option is activated
FF reg no heat time: Full flow regeneration time
PF reg no heat time: Partial flow regeneration time without extra heating (optional)
PF reg with heat time: Partial flow regeneration time with extra heating (optional)
PF cooling time: Partial flow cooling time (optional). Used to cool down the heating
elements after partial flow regeneration with heat
Pressure relief time: Pressure relief of vessel (optional)
Minimal purge cooling time: Minimal purge air cooling time (optional)
Maximal purge cooling time: Maximal purge air cooling time (optional)
Blower cooling time: Cooling with blower (optional)
Pressure equalisation time: Pressure equalization of vessels
FF wet air cooling time: Full flow wet air cooling (optional)
Minimal split flow cooling time: Minimal split flow cooling/split flow adsorption time (optional)
Maximal split flow cooling time: Maximal split flow cooling/split flow adsorption time (optional)
Minimal waiting time: Minimal waiting time to stabilize the dewpoint after split flow cooling

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Instruction book

9.6.5 Alarm parameters

Alarm mode: PDP PRIORITY: dewpoint may never be higher than defined value
COOLING PRIORITY: outlet air may never be too hot, even if it will
cause a dewpoint higher than the defined
value
EWD1 shutdown delay: Shutdown delay after an electronic water drain failure of combicooler
1
EWD1 shutdown delay: Shutdown delay after an electronic water drain failure of combicooler
2 (optional)
Minimal compressor out temp: Minimal compressor outlet air temperature
Maximal compressor out temp: Maximal compressor outlet air temperature
Minimal working pressure: Minimal dryer working pressure
Maximal working pressure: Maximal dryer working pressure
Maximal adsorption air temp: Maximal adsorption air temperature after dryer combicooler stage
Maximal cooling water temp: Maximal cooling water temp of dryer combicooler
Maximal dryer outlet temp: Maximal outlet air temperature of dryer

9.6.6 Units

In this page the unit of temperature, pressure and flow can be selected.

Default values:
Temperature degC Degrees Celsius
Pressure Bar Effective pressure in Bar
Air flow Nm3/h Normal cubic meters per hour

9.7 Password

7. PASSWORD PROTECTED PAGES


(PLEASE ENTER 4 DIGIT PASSWORD)
R1 R2

PASSWORD <INCORRECT>
R3 R4
(AUTOMATIC DISABLED IN 4 HOURS)
Fig. 9.12 Password page, typical example

If a correct password is entered, it is possible to activate the test functions in the test page (F5).

9.8 Service

In the service page it is possible to check the number of regeneration cycles each vessel made every
2,000 loaded hours with a maximum of 40,000 hours. With this method the desiccant aging process is
visible.

The number of valve alarms and sensor errors are also visible; this makes it easy to see which part
needs servicing.

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Instruction book

9.8.1 Alarms

The alarm LED blinks on the control panel if a new alarm occurs. If an operator has acknowledged the
alarm, but it is still active, the LED will burn continuously.

Every new alarm will be displayed on the control panel. It can be acknowledged with the ENTER
button and can be ignored with the ESC button.

Example of the indication in case of a Warning:

16-06-04 19:31
WARNING
R1 R2
Sensor error or out of range

TT02 Dryer inlet temp


R3 R4

Fig. 9.13 Warning screen, typical example

There are three types of alarms:


Warning alarm There is a problem with the dryer that should be solved, but it has no
safety risk. It could have consequences on the dryer dewpoint or
energy consumption.

Example: Sensor TT02 fails. The heating temperature of the dryer


cannot be calculated anymore and results in higher
energy consumption.

Shutdown-warning alarm There is a problem that will give problems in an other state or will be
followed by another alarm that could cause a shutdown alarm.

Example: A valve did not close properly.

Shutdown-alarm The dryer will stop due to safety or dewpoint precautions.

Example: Emergency stop by operator or failed EWD.

See section 1.3.6 for external indication of the alarms.

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Instruction book

10 SETTINGS

10.1 Protections

Settings of the temperature switches (TS1 and TS2)

Temperature switch Unit Setting


TS1 and TS2 °C 450

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Instruction book

11 PED INSTRUCTIONS

The pressure vessels are the only pressure bearing parts of category higher than I. Pressure vessels
are designed according to ASME Section VIII, div. 1. The design pressure is 11 bar(e). The category
according to 97/23/EC of the pressure assembly, as well as the volume in litres, is indicated in the
table 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.

Machine Type Content [l] PED Category of pressure assembly

XD 1400 1514 IV
XD 1800 1847 IV
XD 2400 2617 IV
XD 3000 3557 IV

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