Professional Documents
Culture Documents
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
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.
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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Instruction book
1 LEADING PARTICULARS
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.
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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.
2 3 4
1
5
VESSEL A VESSEL B
6 7
8 4
11
9
10
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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 regulator stops counting the operating cycle time if a compressor unload is detected by a digital
contact.
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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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)
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.
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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.
The split flow cooling method can run separately or in combination with purge cooling or full flow wet
air cooling.
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.
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.
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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1.3 Regulator
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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2
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LEDs/buttons/keys
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Delete an entry or suspend or stop an action in progress. Move up one level in a menu, exit
display alarm.
Decimal point
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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
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Instruction book
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.
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
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
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
The modes can be selected by pressing the “Shift” + “Menu” key. Arrow left and right selects the
correct mode.
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.
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
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Instruction book
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.
Functional test
Briefly press the TEST button (Fig 1.9) and check that the valve opens for condensate discharge.
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.
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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
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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
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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The table below gives an overview of the mechanical connections of the inlet piping, the outlet pipe
and the regeneration/cooling outlet pipe.
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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.
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
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
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
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
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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.
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
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
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.
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.
Above the control panel the dryer status lamp (H1) (4-Fig. 1.5) is indicated.
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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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.
- 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.
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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.
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.
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.
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
If the dryer will not be used for a long period, contact your Atlas Copco Customer Centre for detailed
instructions.
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5 OPTIONAL EQUIPMENT
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.
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.
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.
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
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.
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.
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Instruction book
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
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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7 PRINCIPAL DATA
Nominal conditions
Limitations
* Pressure drop when one combicooler is used. For optional second combicooler add 0.1 bar.
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* 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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Footnote, chapter 8
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9 REGULATOR FUNCTIONS
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.
NOTE: The control mode can only be changed if the dryer is stopped and can only be
changed to local through this screen.
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.
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
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.
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
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
9.5 Test
5. TEST
R1 R2
R1 MANUAL ADVANCE
R2 STATE PAUZE
R3
R4
R3 R4
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
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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
The values in this page are usable as an indication when there are problems with the partial flow
regeneration state.
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.
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Instruction book
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
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.
16-06-04 19:31
WARNING
R1 R2
Sensor error or out of range
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.
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10 SETTINGS
10.1 Protections
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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.
XD 1400 1514 IV
XD 1800 1847 IV
XD 2400 2617 IV
XD 3000 3557 IV
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