Adec Dryers Manual Rev2
Adec Dryers Manual Rev2
PO BOX 60178
THERMI 57001
THESSALONIKI
GREECE
Tel +30 2310 463388
Fax +30 2310 464570
www.gsamaras.gr
CONTENTS
1. General information .................................................................................................................. 4
1.1. General.............................................................................................................................. 4
1.2. Safety notes ...................................................................................................................... 5
1.3. Definitions ......................................................................................................................... 6
2. Description ................................................................................................................................ 7
2.1. General.............................................................................................................................. 7
2.2. Indented use ..................................................................................................................... 7
2.3. Identification Plate ............................................................................................................. 8
2.4. Technical specifications .................................................................................................... 8
3. Technical description ................................................................................................................ 9
3.1. Function description .......................................................................................................... 9
3.2. Process flow diagram ...................................................................................................... 10
3.2.1. ADEC series ......................................................................................................... 10
3.2.2. ADEC series with ECONOMIZER option ............................................................. 11
3.2.3. ADEC series with ECONOMIZER and Filtration option........................................ 11
3.3. Control unit ...................................................................................................................... 12
3.4. LCD screen navigation .................................................................................................... 13
3.5. Settings ........................................................................................................................... 14
3.5.1. Dryer Operation mode selection ........................................................................... 14
3.5.2. IP address set up .................................................................................................. 15
3.6. Testing............................................................................................................................. 15
3.7. Alarm signal .................................................................................................................... 17
3.8. Remote control ................................................................................................................ 17
3.9. Web User Interface ......................................................................................................... 17
3.9.1. Status .................................................................................................................... 18
3.9.2. Events log file........................................................................................................ 19
3.9.3. User Configuration ................................................................................................ 19
3.9.4. Ethernet Configuration .......................................................................................... 20
3.9.5. About ..................................................................................................................... 20
3.10. Modbus TCP/IP .......................................................................................................... 21
4. Installation ............................................................................................................................... 25
4.1. Installation site ................................................................................................................ 25
4.2. Pneumatic connection ..................................................................................................... 26
4.3. Electrical connections ..................................................................................................... 26
4.4. Filter condensate drain.................................................................................................... 27
5. Start up ................................................................................................................................... 28
5.1. First start up .................................................................................................................... 28
5.2. Operation ........................................................................................................................ 29
5.3. Shutdown ........................................................................................................................ 29
5.4. Storage ............................................................................................................................ 29
6. Maintenance ........................................................................................................................... 30
6.1. General Safety advice ..................................................................................................... 30
6.2. Maintenance schedule .................................................................................................... 31
6.3. Troubleshooting .............................................................................................................. 32
7. Disposal .................................................................................................................................. 34
. ADEC, HEATLESS ADSORPTION DRYERS
1. General information
1.1. General
This instruction manual should be considered as part of the product itself. It should be kept as a
reference for the entire life of the unit until its disposal, or handed over in the event of sale.
The manual should always be kept properly and be available for consultation near the unit itself.
If lost or damaged, a new copy may be obtained from the manufacturer, specifying the details on the
Serial Number plate.
The manual exclusively concerns the product itself, and does not concern any other components or
accessories in an installation,
The manual is based on the state of the technology at the moment of sale of the product. The
manufacturer retains the right to revise it following new developments at any time, but is under no
obligation to update previous manuals, which may be done only if considered necessary or on request of
the user.
Any suggestions for improvements or modifications to the manual may be made directly to
manufacturer.
During use, care and maintenance of the product, the following fundamental safety measures must be
observed for the protection of the operator, maintenance and service engineers as well as the product:
During the development and manufacture of the product, the recognized regulations of the technical
aspects, as well as the recognized valid standards and guide-lines were taken into account and used. In
addition the product has been designed and constructed in such a way that endangerment through the
agreed use are minimized. Nonetheless we feel obliged to describe the following safety measures so the
remaining dangers can also be minimized.
Warning! When electrical equipment is being used, the basic safety precautions must be followed, to
prevent risk of fire, electric shock and personal injury.
Attention! Work on electrical equipment must only be carried out by a qualified electrician.
Warning! Components and equipment under high pressure. Compressed air is a highly hazardous
energy source. Never work on the product with parts under pressure. Never point the compressed air
or the condensate drain jet towards anybody.
Warning! The product is remotely controlled and can start without prior warning. It is also mandatory
to check that the automatic start of the unit will not pose any hazards whatever.
Caution! Take account of environmental influences! Do not operate the product in a wet or dusty
environment.
In dangerous situations or during technical problems, disconnect the product at once from the
power supply. Check regularly the power supply cable and the casings of electrical components and
if they are damaged, have them repaired by a qualified electrician. Check the electrical equipment for
external damage before work starts. Check thoroughly whether lines or cables are damaged. If there
is damage, do not operate the product.
Warning! The use of third party spare parts and other accessories may cause unpredictable danger,
damage and personal injury. Only use genuine spare parts of the manufacturer.
Read the manual, prior to installation and follow the notes and instructions. Safe and proper
operation of the product can only be guaranteed if the instructions and notes are observed. The safety
notes must be observed in particular.
Keep this manual within reach for the user and the operator. The information should be passed on to
any successor.
The manufacturer accepts no liability for damages resulting from disregard of this maintenance and
operating manual.
All the information in this manual is valid at the time that it is published. Due to component or workflow
modifications at any time affecting product maintenance, the latest information should be available
prior to maintenance work.
1.3. Definitions
User, Operator: The responsible Person who has the authorization to use the product. The user must
have been given instructions on the safe handling of the product from the appropriate authority.
Operator Authority: Responsible for the safe installation, regular servicing and cleaning of the
product.
Product: General term used for the ADEC Dryers, and/or its elements and subsystems.
Warning: this indicates procedures and operations which must be strictly observed to prevent
hazards to persons.
Caution: This indicates procedures and operations which must be strictly observed to prevent
damage to or destruction of the unit.
2. Description
2.1. General
The ADEC dryers are used to remove moisture from compressed air. The dryers are used for drying
compressed air for medical and industrial use.
During pre-treatment of the compressed air by means of separators and fine filters only the liquid
water components can be removed from the compressed air. After this pre-treatment the ADEC dryers
remove the water vapor components down to a very low residual concentration of water. This residual
moisture content is defined as the pressure Dew Point in °C.
The ADEC dryers operate completely automatically and are designed for continuous duty.
This dryer has been designed, manufactured and tested only to be used to remove the humidity from
compressed air. The dryer is exclusively designed for drying compressed air; any other use has to be
considered improper. The Manufacturer will not be responsible for any problem arising from improper use;
the user will be in any case responsible for any resulting damage.
The dryer is designed to be set up at a site that complies with the following requirements:
• Indoors
• Protected against weather impact
• Frost-free
• Dry
• Zero to low dust ambient
• No vibration via floor or connected piping
• Ambient air must be free from aggressive and corrosive substances
• Ambient air must be free from substances that damage the desiccant or influence its effectiveness
• (e.g. ammonia or other alkaline-reacting substances, oil mist, water spray or drizzle)
• Free from dangers due to explosive atmospheres inside and outside the dryer. (The standard
product version does not comply with ATEX.)
Moreover, the correct use requires the compliance with the installation conditions, in particular:
• Voltage and frequency of the mains.
• Pressure, temperature and flow-rate of the incoming air.
• Ambient temperature.
This product is supplied tested and fully assembled. The only operation left to the user is the
connection to the plant and to electrical power supply system in compliance with the instructions given in
the following chapters.
Modifications to the product or use of third-party parts may cause unpredictable danger and damage.
Only use genuine spare parts of the manufacturer.
The product identification plate shows all the primary data of the dryer. These data must always
be referred to the manufacturer or to the dealer when information or spare parts are needed, even during
the warranty period. The removal or the alteration of the identification plate will void the warranty rights.
ADEC
Type
3 5 8 12 18 25 30 40 50 60 75 90 130 160
Nominal Flow rate
Nm3/h @7bar, 35°C
19.2 31.8 45.6 72.0 111.0 150.0 180.0 234.0 300.0 372.0 450.0 540.0 768.0 972.0
Nominal Flow rate 1205.
23.8 39.5 56.6 89.3 137.6 186.0 223.0 290.0 371.7 461.0 558.0 670.0 952.0
Nm3/h @10bar, 35°C 0
Inlet/Outlet
Connection, G’’
3/8” 3/8” 3/8” ½” 3/4” 1” 1” 1½” 1½” 1½” 2 2 2 2½”
Weight, kg 55 65 71 87 111 128 161 186 232 283 305 340 403 485
Power, W 50 W
Digital outputs ALARM signal, dry contact (relay C/NO), 5A, 250 Vac, cosφ=1
Air flow capacity is a function of inlet air pressure and temperature. For calculating the air flow capacity for
a given conditions the following formula should be used:
Factor P 0.60 0.74 0.9 1.0 1.08 1.15 1.23 1.3 1.35 1.4 1.45 1.5 1.55
3. Technical description
The operation principle of the dryer is adsorption. The principle of moisture adsorption is water
molecules being attracted to a hygroscopic solid material (desiccant). This process is reversible and after
a regeneration phase, the desiccant can be reused for drying.
For compressed air drying the compressed air flow is led through a vessel containing the
desiccant and brought into intensive contact with the desiccant. The desiccant removes moisture from the
compressed air and stores it in its internal structure. With continuous moisture loading of the desiccant the
dryer performance is reduced until the desiccant is saturated with moisture. The saturated desiccant then
requires regeneration, i.e. the moisture stored in the inner desiccant structure is removed again. The
desiccant can then be reused for drying.
Continuous operation of the heatless adsorption dryer is accomplished using two vessels that are
operated alternately. One vessel is used for drying the compressed air (adsorption phase), while the other
vessel is used for the regeneration phase of the saturated desiccant and so on.
●DPD (Dew Point Dependant), where the adsorption/regeneration cycle is variable according to
Dew Point set point and load conditions. This is the ECONIMIZER function, based on decreasing the
average regeneration air consumption when partial outlet air consumption exists.
5 9 10
2
3
11 12
4
6 7 8
1`
Description 13
1 POWER , Visual Green Indicator, solid light on when normal electrical power supply exists
2 SYSTEM, Visual Green Indicator, flashing light when internal microprocessor is in normal condition
3,4 LINK / ACT Green and red visual indicators that are lighting according to communication data traffic
5 LCD screen (2X16 characters), for displaying measurements and text messages
6
Press instantly for moving down / scroll down the LCD display
8
Press instantly for moving up / scroll up the LCD display
Press and hold for displaying current Version, IP address and light ON all visual indicators
INLET AIR PRESS, inlet air pressure level
9 ●Green Indicator lights on, when pressure is normal
● Red Indicator light son, when pressure is out of range (over / under pressure)
DRYER STATUS:
●RUN, Green Indicator lights on, when dryer is in operation mode
●STAND BY, Green Indicator lights on, when dryer is in standby (STOP REMOTELY) by applying remotely stop signal
10 ●ALARM, Red Indicator lights on, when there is a fault condition in the dryer
●SERVICE, Red Indicator lights on, , when service needed
●AUTO, Green Indicator lights on, when dryer is in DPD cycle/ ECONOMIZER mode
●FIX, Red Indicator lights on, when dryer is in FIX cycle mode
LEFT COLUMN/BED STATUS:
11 ● ADSORPTION, Green Indicator lights on, when left column/bed is in adsorption mode
● REGENERATION, Red Indicator lights on, when left column/bed is in regeneration mode
RIGHT COLUMN/BED STATUS:
12 ● ADSORPTION, Green Indicator lights on, when right column/bed is in adsorption mode
● REGENERATION, Red Indicator lights on, when right column/bed is in regeneration mode
13 FAULT status bar. A red visual indicator lights on, when respective fault condition exists.
The LCD screen is a user friendly way to provide all necessary information about operation,
status, measurements, service timers as well as basic settings and testing procedures.
Navigation by using buttons and selection/enter function by using MENU button. Below is
described all the available information in LCD screen.
RUN DPD2 -40 C 1st line: Dryer Status, Operating Mode and set point of Dew Point
DPoint: -48.3 C 2nd line: Dew Point on line measurement or NO SENSOR if Dew Point sensor not installed [1]
Dpoint: -48 C 1st line: Dew Point on line measurement or NO SENSOR if dew point sensor not installed [1]
Min-58. Max-26. 2nd line: Min and Max values measured
Inlet: 8.8bar 1st line: Inlet air pressure on line measurement or NO SENSOR if transducer not installed [1]
Min 6.9 Max 9.8 2nd line: Min and Max values measured
LeftB: 8.6bar 1st line: Left bed/column air pressure on line measurement or NO SENSOR if transducer not
installed [1]
PrDrop: 0.2bar
2nd line: Pressure drop of Left bed/column compared to inlet air pressure
RightB: 8.6bar 1st line: Right bed/column air pressure on line measurement or NO SENSOR if transducer not
installed [1]
PrDrop: 0.2bar
2nd line: Pressure drop of Right bed/column compared to inlet air pressure
Outlet: 8.4bar 1st line: Outlet air pressure on line measurement or NO SENSOR if transducer not installed [1]
PrDrop: 0.2bar 2nd line: Min and Max values measured
Flow:28.9Nm3/h 1st line: Air flow rate on line measurement or NO SENSOR if transducer not installed [1]
Max:40.5 2nd line: Max values measured
TOTAL AIR VOLUME 1st line: Total Air volume counter [1]
12345.78Nm3 2nd line: Numeric value of total volume measured
O2 Pur:20.9% 1st line: Oxygen concentration on line measurement or NO SENSOR if transducer not installed [1]
Min20.8 Max20.9 2nd line: Min and Max values measured
CO: 2.0ppm 1st line: CO concentration on line measurement or NO SENSOR if transducer not installed [1]
CO2: 100ppm 2nd line: CO2 concentration on line measurement or NO SENSOR if transducer not installed [1]
DIG-DP:-48 C 1st line: Dew Point on line measurement or NO SENSOR if DIG-DP transducer not installed [2]
18.6C 0.3% 2nd line: Temperature (°C) and Relative Humidity (%) of outlet air measurement
Tinl: 17.5C 1st line: Temperature (°C ) of inlet air or NO SENSOR if temperature transducer not installed [1]
Tamb: 18.0C 2nd line Temperature (°C ) of ambient or NO SENSOR if temperature transducer not installed [1]
PWR=00000:29:19 1st line: Electrical Power ON timer (reset every time electrical power removed)
RUN=00210:46:26 2nd line: RUN timer (working hours), the timer value is stored in internal memory
RUN TIME SERV #1 1st line: Run Time Service countdown timer (timer #1)
IN 03997:39:48 2nd line: Value of Run Time Service countdown timer (timer value is stored in internal memory)
YEARLY SERV #2 1st line: Yearly Service countdown timer (timer #2)
IN 08549:02:18 2nd line: Value of Run Time Service countdown timer (timer value is stored in internal memory)
#ENTER SETTINGS#
Entry to SETTINGS menu (see chapter 3.7)
#ENTER TESTING #
Entry to TESTING menu (see chapter 3.8)
3.5. Settings
The Dryer operation mode is factory preset according to design parameters, although there is the
capability of selection a new operation mode by the user on site. The procedure is described below:
Press button as many times as required, until the message #ENTER SETTINGS# reached
Press MENU button,
#ENTER PASSWORd#, appeared with the most significant digit flashing, with buttons select
digit 9, then press MENU button, then with buttons select digit 6 and so on, in order to
compose 9691 code number. When 9691 selected press MENU to insert
The message ##DRYER MODE## appeared, press MENU and then with buttons select the
desired operating dryer mode and finally press MENU to save selection (a short audible signal
generated for confirmation)
with buttons select ## exit ## and press MENU to escape
with buttons go to desired screen.
●The Dryer operation mode is factory preset according to design parameters. Do not modify
st
●On normal operation it is recommended to view the main screen, 1 screen
The dryer is factory preset to IP address 192.168.2. XXX, where XXX is a number in the range of
50 to 120. In order to view the current IP address, press and hold TEST button.
The procedure to set a new IP address is described below:
Press button as many times as required, until the message #ENTER SETTINGS# reached
Press MENU button,
#ENTER PASSWORd# ,appeared with the most significant digit flashing, with buttons select
digit 9, then press MENU button, then with buttons select digit 6 and so on, in order to
compose 9691 code number. When 9691 selected press MENU to insert
Press button, the message ## IP ADDRESS ## appeared, press MENU and then with
buttons select the desired number for the first field
Press MENU to save selection, and then with buttons select the desired number for the
second field and so on until the last field
with buttons select ## exit ## and press MENU to escape
with buttons go to desired screen.
Notice that IP address can be also modified using Web User Interface(see Chapter 3.11.4 )
st
On normal operation it is recommended to view the main screen, 1 screen
3.6. Testing
The controller provides TESTING function for checking correct operation of visual signal (Led) and
pressurizing and regenerating functions of both columns individually. To insert TESTING function the
procedure is:
Press button as many times as required, until the message #ENTER TESTING# reached
Press MENU button,
#ENTER PASSWORd# appeared with the most significant digit flashing, with buttons select
digit 9, then press MENU button, then with buttons select digit 6 and so on, in order to
compose 9691 code number. When 9691 selected press MENU to insert
The TESTING mode consisted of 6 discreet steps. Use buttons to execute steps as follows:
Test of right column regeneration state and respective solenoid valve correct operation
RIGHT REGEN
3 (valve is ON ). Pressure in right column should be close zero and should be a small air
Prev Exit Next
leakage in right silencer
Test of right column pressurization state and respective solenoid valve correct operation
RIGHT PRESS
4 (valve is OFF ). Pressure in right column should rise slowly up to inlet pressure and
Prev Exit Next
should not be any air leakage in right silencer
Test of left column regeneration state and respective solenoid valve correct operation
LEFT REGEN
5 (valve is ON ). Pressure in left column should be close zero and should be a small air
Prev Exit Next
leakage in left silencer
Test of left column pressurization state and respective solenoid valve correct operation
LEFT PRESS
6 (valve is OFF ). Pressure in left column should rise slowly up to inlet pressure and
Prev Exit Next
should not be any air leakage in left silencer
When TESTING is executed, the dryer stops running normally and the cycle function is
manual. On EXIT of TESTING mode the dryer automatically returns to normal operation
and initially START UP cycles are executed
A relay output signal (dry contact) is provided for signaling an alarm or/and fault condition. The
contact is closed (relay is activated) on NORMAL condition.
Capability of Remote Control is provided using the dedicated digital input DL5. By connection DL5
(X5.24) to GND (X5.21) dryer stops operation, the message stop remotely is displayed and the
green led indicator ●STAND-BY lights on.
By removing the connection DL5 (X5.24) to GND (X5.21), the dryer automatically returns to
normal operation and initially START UP cycles are executed.
Caution! REMOTE CONTROL, digital input must be connected only to dry contacts.
Otherwise, severe and permanent damage may occur. It is recommended to use shielded
cable, with shield connected to Protective Earth, PE.
3.9.1. Status
STATUS page is used for in line viewing and monitoring the whole system: Information that provided
is:
Synoptic panel full emulation ,
Power on, Run, Service, volume timers, competed cycle counter and regeneration/pressurization
timers
Dew point live measurement and MIN/MAX values recorded
Live measurement and fault condition of all analog transducers
Digital input and output status
Events log file is the page where all events are logged. For each event there is a message and time
stamp. Up to 200 records supported (if records are greater than 200, then older records are deleted).
Configure Dryer Operation Mode and LCD contrast. After any modification, press SAVE Config.
The Dryer operation mode is factory preset according to design parameters. Do not modify.
Notice that IP address can be also modified using keyboard (see Chapter 3.7.2)
3.9.5. About
Information about Firmware/HTML version and G.SAMARAS SA contact details.
Modbus TCP/IP communication protocol is provided as standard. The port 502 is used.
MODBUS FUNCTION
Function Description Register Data type Description
CODE
HEX DEC
1=output is activated,
01 1 Read Output Status 0 Single Bit Digital output OD1 0=output is
deactivated
1=output is activated,
01 1 Read Output Status 1 Single Bit Digital output OD2 0=output is
deactivated
1=output is activated,
01 1 Read Output Status 2 Single Bit Digital output OD3 0=output is
deactivated
1=output is activated,
01 1 Read Output Status 3 Single Bit Digital output OD4 0=output is
deactivated
1=output is activated,
01 1 Read Output Status 4 Single Bit Digital output OD5 0=output is
deactivated
1=output is activated,
01 1 Read Output Status 5 Single Bit Digital output OD6 0=output is
deactivated
1=output is activated,
01 1 Read Output Status 6 Single Bit Digital output OD7 / K7 0=output is
deactivated
1=output is activated,
01 1 Read Output Status 7 Single Bit Digital output OD8 / K8 0=output is
deactivated
MODBUS FUNCTION
Function Description Register Data type Description
CODE
1=output is activated,
01 1 Read Output Status 8 Single Bit Digital output OD9 / K9 0=output is
deactivated
1=output is activated,
Digital output OD10 /
01 1 Read Output Status 9 Single Bit 0=output is
K10
deactivated
MODBUS FUNCTION
Function Description Register Data type Description
CODE
Left Bed/Column
16-bit word, signed Analog input 3, mA
04 4 Read input registers 2 Pressure mA value
integer measurement
multiplied by 100
Right Bed/Column
16-bit word, signed Analog input 4, mA
04 4 Read input registers 3 Pressure mA value
integer measurement
multiplied by 100
16-bit word, signed Analog input 2, scaled Inlet Air Pressure bar
04 4 Read input registers 10
integer value measurement value multiplied by 10
Left Bed/Column
16-bit word, signed Analog input 3, scaled
04 4 Read input registers 11 Pressure bar value
integer value measurement
multiplied by 10
Right Bed/Column
16-bit word, signed Analog input 4, scaled
04 4 Read input registers 12 Pressure bar value
integer value measurement
multiplied by 10
16-bit word, signed Analog input 5, scaled Outlet Air pressure bar
04 4 Read input registers 13
integer value measurement value multiplied by 10
16-bit word, signed Analog input 6, scaled Flow rate Nm3/h value
04 4 Read input registers 14
integer value measurement multiplied by 10
CO concentration
16-bit word, signed Analog input 8, scaled
04 4 Read input registers 16 ppm value multiplied
integer value measurement
by 10
CO2 concentration
16-bit word, signed Analog input 9, scaled
04 4 Read input registers 17 ppm value multiplied
integer value measurement
by 10
DEW POINT DIG-DP
16-bit word, signed Analog data 10, scaled
04 4 Read input registers 18 in ºC value multiplied
integer value measurement
by 10
Inlet Air Temperature
16-bit word, signed Analog data 11, scaled
04 4 Read input registers 19 ºC value multiplied by
integer value measurement
10
Ambient Temperature
16-bit word, signed Analog data 12, scaled
04 4 Read input registers 20 ºC value multiplied by
integer value measurement
10
MODBUS FUNCTION
Function Description Register Data type Description
CODE
Error Codes
Function Code Not
01
Supported
Note
3
* Total Volume Nm (multiplied by 100) = 65536* MS word + LS word
4. Installation
Caution! The ambient temperature must be in the range of +1ºC and +50 ºC
The dryer is designed to be set up at a site that complies with the following requirements:
Indoors
Protected against weather impact
Frost-free
Dry
Zero to low dust ambient
No vibration via floor or connected piping
Ambient air must be free from aggressive and corrosive substances
Ambient air must be free from substances that damage the desiccant or influence its effectiveness
Free from dangers due to explosive atmospheres inside and outside the dryer. (The standard
product version does not comply with ATEX.)
The ground for dryer installation must be level and capable to carry heavy loads. Ground
irregularities must be leveled in order for tensional forces not to occur in the piping of the dryer.
Keep a service distance to walls and other systems around the dryer of 1 m, minimum.
Set up the dryer such that the pressure gauge and the control system are clearly visible and can
be operated properly.
Anchoring the dryer into the ground using the holes is recommended.
The temperature and the amount of air entering the dryer must comply with the limits reported on
the data plate. In case of treatment of air at particularly high temperature, the installation of a final
refrigerator could result necessary.
The cross section of the connecting piping, which must be free from dust, rust, chips and other
impurities, and must be suitable with the flow-rate of the dryer.
The threaded of flanged connections have to be compatible to the dryer inlet and outlet with
regard to nominal width, nominal pressure and type.
Any vibrations or pulsation must not be transmitted to the dryer via the piping. This may damage
the desiccant, the dryer control system or other components. If required, install compensators or pulsation
absorbers in the pipelines to be connected.
Wet pipelines upstream of the dryer should be installed at a slope in order for condensate (water
and oil) in the line to be discharged in flow direction. If installation of an upright pipeline is inevitable, a
condensate drain must be provided at the lowest point of the pipeline. This avoids condensate from being
accumulated in the pipeline and suddenly being swept away by the compressed air flow. These kinds of
water shocks may damage the filter and dryer and must be avoided.
When checking the installation for leaks the maximum allowable operating pressure of the dryer
must not be exceeded
Warning! The dryer is operated at electric voltages up to 230 V. Touching live parts may
result in serious injury or death. Work on electrical components must only be carried out by
qualified and authorized personnel.
Warning! The connection to the mains, to be carried out by qualified personnel, and the
safety systems must comply with local rules and laws
When connecting the unit to the electrical supply, check direction of rotation for agreement with
arrow on unit.
Before connecting the unit to the electric power, verify that the voltage and the frequency available on
the mains correspond to the data reported on the data plate of the dryer. In terms of voltage, a ±5%
tolerance is allowed. The dryer comes with a mains connecting cable already installed (3m long).
The mains socket must be provided with a mains magneto-thermal differential breaker (IDn=0.3A).
The cross section of the power supply cables must comply with the consumption of the dryer, while
keeping into account also the ambient temperature, the conditions of the mains installation, the length of
the cables, and the requirements enforced by the local Power Provider.
The dryer is already designed to be connected to the condensate collecting plant through a
flexible plastic pipe, 10mm in diameter. Connect and properly fasten the condensate drain to a collecting
plant or container. The drain cannot be connected to pressurized systems.
The condensate collected in the dryer contains oil particles released in the air by the compressor.
It is strongly recommended to install a water-oil separator where to convey all the condensate
drain coming from compressors, dryers, tanks, filters, etc
Don’t dispose the condensate in the environment. Dispose the condensate in compliance
with the local rules.
5. Start up
Before delivery, each product is subjected to full operation tests and tested in real operating
conditions. Nevertheless, the product could be damaged during transportation. Therefore it is strongly
recommended to check the integrity of the product upon arrival and to keep it under supervision during the
first hours of operation.
Warning! At the first start-up, or in case of start-up after a long inactivity period or following
to maintenance operations, comply with the instructions given below. The start-up must be
performed by qualified personnel.
Warning! The user and/or the personnel that intervene to the dryer must wear hearing
protection before any operation to the dryer. Each user / personnel must use proper PPE
(Personal Protection Equipment) hearing protector (earmuffs, ear canal caps and earplugs)
in order to prevent any uneasiness that could cause dangerous situation.
First start up sequence:
Verify that all the steps of the “Installation” chapter have been observed.
Verify that the connection to the compressed air system is correct and that the piping is suitably
fixed. Before starting the dryer the compressor should be running and the air system pressurized.
Verify that the condensate drain pipe is properly fastened and connected to a collection system or
container.
Verify that both inlet and outlet ball valves of dryer are closed.
Remove any packaging and other material which could obstruct the area around the dryer.
Pressurize the dryer by SLOWLY open the inlet isolation ball valve, admitting compressed air to
the dryer. It is important to pressurize the dryer slowly to prevent fluidization of the desiccant
column/bed. The dryer outlet isolation ball valve should remain closed at this time.
Activate the mains switch, Switch ON electrical power.
Verify that the control unit is ON.
Check the piping for air leakage.
Check the pressure level of DEW POINT sensor sampling network. Readjust if necessary to 7 bar.
Check the exhaust air flow of DEW POINT sensor sampling network. Readjust if necessary to
about 1 LPM.
Test the drain of the inlet filter.
After 120 seconds of initialization, the dryer will begin to cycle. At this point one column/bed will
exhaust its air to atmosphere. See cautionary statement above.
2 full start up cycles are executed and then automatically returns to normal operation (FIX or
AUTO depending on configuration, Dew Point measurement and type).
Slowly open the dryer outlet isolation ball valve.
●During the first working hours, the Dew Point is not ensured because the adsorption
material may contain humidity. Dryers may require up to 24 hours of operation to reach
normal operating Dew Points. Therefore, indicators and/or alarms should not be recognized
until that time
●At the first start-up, or in case of start-up after a long inactivity period or following to
maintenance operations, it is recommended to use the dryer at a reduced nominal flow
during the first working hours
DOC. ADEC 4.0/1215 REV 2 Page 28 of 34
. ADEC, HEATLESS ADSORPTION DRYERS
5.2. Operation
Warning! The user and/or the personnel that intervene to the dryer must wear hearing
protection before any operation to the dryer. Each user / personnel must use proper PPE
(Personal Protection Equipment) hearing protector (earmuffs, ear canal caps and earplugs)
in order to prevent any uneasiness that could cause dangerous situation.
Start up sequence:
Pressurize the dryer by SLOWLY open the inlet isolation ball valve, admitting compressed air to
the dryer. It is important to pressurize the dryer slowly to prevent fluidization of the desiccant
column/bed. The dryer outlet isolation ball valve should remain closed at this time.
Activate the mains switch, Switch ON electrical power.
Verify that the control unit is ON.
Check the pressure level of DEW POINT sensor sampling network. Readjust if necessary to 7 bar.
Check the exhaust air flow of DEW POINT sensor sampling network. Readjust if necessary to
about 1 LPM.
Test the drain of the inlet filter.
After 120 seconds of initialization, the dryer will begin to cycle. At this point one column/bed will
exhaust its air to atmosphere. See cautionary statement above.
2 full start up cycles are executed and then automatically returns to normal operation (FIX or
AUTO depending on configuration, Dew Point measurement and type).
Slowly open the dryer outlet isolation ball valve.
5.3. Shutdown
Warning! The user and/or the personnel that intervene to the dryer must wear hearing
protection before any operation to the dryer. Each user / personnel must use proper PPE
(Personal Protection Equipment) hearing protector (earmuffs, ear canal caps and earplugs)
in order to prevent any uneasiness that could cause dangerous situation.
Shutdown sequence:
Disconnect the compressed air flow from the dryer by closing the downstream/outlet isolation ball
valve of the dryer.
Operate the dryer for at least 4 more hours without compressed air flowing through the dryer. This
ensures that the dryer that is to be stored with dry vessels. Therefore, the more regeneration
cycles that executed, the more dry the desiccant and vessel will be.
Depressurize the dryer by closing the upstream/inlet ball valve and let it ON for 1 hour more.
Switch OFF the dryer and disconnect from the electrical supply.
5.4. Storage
To maintain the dryer quality the dryer must be stored at a suitable location and properly prepared
for storage. The place of storage has to fulfill the following requirements:
Indoors
Protected against weather impact
Frost-free
DOC. ADEC 4.0/1215 REV 2 Page 29 of 34
. ADEC, HEATLESS ADSORPTION DRYERS
Dry
If the dryer is to be stored immediately after delivery, it must only be protected against dust using an
additional cover.
If the dryer has already been used for drying compressed air, proceed as follows:
Disconnect the compressed air flow from the dryer by closing the downstream/outlet ball valve of
the dryer.
Operate the dryer for at least 4 more hours without compressed air flowing through the dryer. This
ensures that the dryer that is to be stored with dry vessels. Therefore, the more regeneration
cycles that executed, the more dry the desiccant and vessel will be.
Depressurize the dryer by closing the upstream/inlet ball valve and let it ON for 1 hour more.
Switch OFF the dryer and disconnect from the electrical supply.
Disconnect the dryer from the compressed air system.
Verify that inlet and outlet ball valves are closed.
Protect the dryer against dust using a cover.
To reuse after storage, proceed as described for first start up. (see chapter 5.1)
6. Maintenance
Warning! Components and equipment under high pressure Never service the Dryer or Filters
without first relieving pressure.
Warning! After desiccant replacement some amounts of desiccant may still remain on the floor.
The desiccant is very slippery and may result in serious fall injury.
Immediately remove residual desiccant properly from the floor.
Warning! The dryer is operated electric voltages up to 230 V. Touching live parts may result in
serious injury or death.
Warning! Switch off the product and unplug from the mains before any maintenance work.
Warning! Hearing protectors must be worn when working on a machine which is running.
Warning! The maintenance works must be performed by qualified personnel and must only
be carried out if the dryer is depressurized and disconnected from the power supply.
Warning! Prior to any maintenance work ensure there is no part of the machine is powered
and that it cannot be connected to the mains supply.
Warning! Prior to any maintenance work ensure there is no part of the machine is under
pressure and that it cannot be connected to the compressed air.
Warning! The user and/or the personnel that intervene to the dryer must wear hearing
protection before any operation to the dryer. Each user / personnel must use proper PPE
(Personal Protection Equipment) hearing protector (earmuffs, ear canal caps and earplugs)
in order to prevent any uneasiness that could cause dangerous situation.
For communication purposes, please specify the type and the manufacturing number. This information
can be found on the type plate on the control box of the product.
Daily
1. Check if the inlet filter condensate drain works regularly.
2. Check differential pressure across Pre-Filter & After-Filter elements. Replace if required.
3. Check that the tower switching operation takes place correctly and in the set cycle times.
4. Ensure there is no backpressure in the regenerating tower (Pressure = 0 bar).
The estimated average life of the adsorption material is 3-5 years, with 10-minute cycle times and
4000 hours/year, in any case it depends on the quality and temperature of the inlet air and on the correct
programmed maintenance.
6.3. Troubleshooting
Warning! Troubleshooting and any eventual check must be carried out by qualified
personnel.
Warning! The user and/or the personnel that intervene to the dryer must wear hearing
protection before any operation to the dryer. Each user / personnel must use proper PPE
(Personal Protection Equipment) hearing protector (earmuffs, ear canal caps and earplugs)
in order to prevent any uneasiness that could cause dangerous situation.
7. Disposal
IMPORTANT INFORMATION:
Most of the components of this product are manufactured with recyclable
material.
In the event that this product is withdrawn from service and destined to be dismantled, the following
materials must be disposed of as follows:
:
- rubber hosing, electrical cable and plastic parts: to be collected separately from to the
other materials ;
- filters: to be disposed as “special refuse” ;
- metal components (motor, vessels, frame etc.): recycle in authorized centres
-desiccant and filter cartridges may contain oil. Do not dispose these materials in the
environment. Delivered them to an appropriate disposal plant.