Atlas Copco MD50 User manual

Atlas Copco Air dryers
No. 2920 1443 01
Replaces No. 2920 1443 00
Registration code: APC MD / 38 / 989
2002-06
MD50
MD100-200-300-400-600 (W)
MD1000 W-1800 W
MD400-800-1300-2500 W VSD
Instruction Book
www.atlascopco.com
·Copyr ght 2002, Atlas Copco A rpower n.v., Antwerp, Belg um.
Any unauthor zed use or copy ng of the contents or any part thereof s proh b ted. Th s appl es n
part cular to trademarks, model denom nat ons, part numbers and draw ngs.
·Th s nstruct on book meets the requ rements for nstruct ons spec f ed by the mach nery d rect ve
98/37/EC and s val d for CE as well as non-CE labelled mach nes.
From follow ng ser al number onwards: AIQ-012 130

2920 1443 01
2
Instruct on book
Th s nstruct on book descr bes how to handle and operate the subject mach ne(s) to ensure safe operat on, opt mum work ng
economy and long serv ce l fe.
Read this book before putting the machine into operation to ensure correct handl ng, operat on and proper ma ntenance from
the beg nn ng. The ma ntenance schedule conta ns a summary of the measures for keep ng the dryer n good cond t on. The
ma ntenance procedures are s mple but must be carr ed out regularly.
Keep the book ava lable for the operator(s) and make sure that the dryer s operated and that the ma ntenance act ons are carr ed
out accord ng to the nstruct ons. Record all operat ng data, ma ntenance work effected, etc. n an operator's logbook ava lable at
Atlas Copco. Follow all appl cable safety precaut ons, amongst others those ment oned on the cover of th s book.
Repa r operat ons must be performed by tra ned personnel from Atlas Copco, who can also be contacted f any further nformat on
s des red.
In all correspondence always ment on the dryer type and the complete ser al number, shown on the data plate.
The company reser es the right to make changes without prior notice.
Page
3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 In t al start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2 Rout ne start ng . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3 Dur ng operat on . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4 Stopp ng . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.5 By-pass operat on . . . . . . . . . . . . . . . . . . . . . . . . 32
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5 Problem sol ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Dryer spec f cat ons . . . . . . . . . . . . . . . . . . . . . . 35
6.1.1 Reference cond t ons . . . . . . . . . . . . . . . . 35
6.1.2 L m tat ons . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.3 Typ cal data . . . . . . . . . . . . . . . . . . . . . . . 35
6.1.4 Spec f c data . . . . . . . . . . . . . . . . . . . . . . 35
6.2 Convers on l st of SI un ts nto Br t sh un ts . . . 42
CONTENTS
Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1 General descr pt on . . . . . . . . . . . . . . . . . . . . . . . . 3
1.2 A r dry ng c rcu t . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2.1 Regenerat on a r c rcu t . . . . . . . . . . . . . . . 5
1.2.2 Rotor cool ng a r c rcu t . . . . . . . . . . . . . . 5
1.3 Dra n system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.1 Descr pt on . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Test ng the EWD . . . . . . . . . . . . . . . . . . . . 5
1.3.3 Electr cal connect ons of the EWD . . . . . . 5
1.4 Electr cal system . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.4.1 MD400/800/1300/2500 W VSD . . . . . . . . 8
1.4.2 All other MD dryers . . . . . . . . . . . . . . . . . 8
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 D mens on draw ngs . . . . . . . . . . . . . . . . . . . . . . 16
2.2 Installat on proposal . . . . . . . . . . . . . . . . . . . . . . 29
2.3 Cable sect on and sett ng of the c rcu t
breaker of the fan motor on a r-cooled dryers . . 30

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Instruct on book
1 LEADING PARTICULARS
1.1 General description
MD are adsorpt on-type a r dryers, des gned to remove mo sture
from compressed a r del vered by Atlas Copco ZE45 up to
ZE132, ZR45 up to ZR750, ZR160 VSD up to ZR900 VSD,
ZT18 up to ZT250, ZR/ZT3, ZR4, ZR5 and ZR6 compressors.
The ma n component s a rotor (6-F g. 1.3), made of a mater al
wh ch adsorbs water.
The rotor rotates slowly and s passed by two a r flows: a flow
of cool, wet compressed a r to be dr ed and a flow of hot
compressed a r to regenerate the dry ng mater al.
An ejector (11-F g. 1.4) s f tted n the a r nlet chamber of the
dryer. The regenerat on a r system ncludes a throttle valve (8-
F g. 1.4) and a regenerat on a r cooler (17-F g. 1. 4), wh ch can
be e ther a r- or water-cooled. MD50, MD100, MD200,
MD300, MD400, MD400 VSD, MD600 and MD800 VSD are
a r-cooled dryers; MD100 W, MD200 W, MD300 W, MD400
W, MD600 W, MD1000 W , MD1800 W, MD400 W VSD,
MD800 W VSD, MD1300 W VSD and MD2500 W VSD are
water-cooled dryers.
Each dryer s prov ded w th a data plate nclud ng the type,
ser al number and max mum perm ss ble work ng pressure.
Drying circuit
The cool, wet compressed a r passes through three quarters of
the rotor. The mo sture of the compressed a r s adsorbed by
the dry ng mater al.
Regenerating circuit
Hot a r, from upstream of the compressor aftercooler, s blown
through one quarter of the rotor and regenerates the dry ng
mater al.
Pressure essel
The dryers nclude a cyl ndr cal pressure vessel, wh ch s
nstalled vert cally on a frame.
The bottom compr ses the rotor dr ve assembly. The body
ncludes the electr c motor dr ven rotor and s d v ded nto two
compartments, one for the hot regenerat on a r and one for the
a r to be dr ed.
The pressure vessel s equ pped w th two valves (1 and 2-F g.
1.2) for measur ng the pressure d fference between the
regenerat on a r nlet seal ng sector and dry a r compartment.
1 Safety valve
2 Inlet p pe, hot regenerat on a r
3 A r nlet valve
4 Control panel
5 Inlet p pe, wet compressed a r
6 Electron c Water Dra ns (EWD)
7 Rotor motor w th ncorporated gearbox
8 By-pass valve
9 Dry compressed a r outlet
10 A r outlet valve
F g. 1.1 Installat on example of ZR110 Pack/MD300 W compressor/dryer package
4
5
6
7
12
3
10
9
8
51336F

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4
Instruct on book
Rotor
The sect ons of dry ng mater al are wrapped onto a core and
conta ned n a jacket. The power of the motor s transm tted to
the rotor, through a p n-type coupl ng, a worm gear and a dr ve
shaft.
A l p-seal (29-F g. 1.4), f tted on the rotor jacket, separates the
wet and dry s des of the rotor. The l p of the seal rests on the
surface of a r ng clamped between the flanges of the vessel.
Sealing sectors
Both end faces of the rotor are prov ded w th a seal ng sector
for conduct ng the regenerat on and cool ng a r flows through
the rotor. The sector on the regenerat on a r nlet s spr ng-
loaded. Both sectors sl de on an nner and an outer r ng f xed to
the rotor. A sl ght clearance s left between the faces of the
sectors and the rotor end faces.
The regenerat on a r nlet seal ng sector covers a segment of 90
degrees of the dry s de rotor face and s prov ded w th a f lter.
The outlet seal ng sector s b gger, as t also accommodates the
cool ng sector.
An Electron c Water Dra n (EWD) s connected to the lower
part of the regenerat on a r compartment of the dryer.
Electrical control
The operat on of the rotor motor s controlled by the electr c
regulator of the compressor.
By-pass system
The dryers are standard equ pped w th a by-pass system
nclud ng an a r nlet valve, an a r outlet valve and a by-pass
valve. A regenerat on a r shut-off valve and a connect on p pe
set s also ncluded n the dryer package. A safety valve may
also be f tted.
1 Valve for (-) connect on, pressure d fferent al gauge
2 Valve for (+) connect on, pressure d fferent al gauge
3 Throttle valve
4 Regenerat on a r cooler
5 Electron c Water Dra n, nlet a r water separator
6 Electron c Water Dra n, regenerat on a r water separator
7 Rotor motor w th ncorporated gearbox
8 Manual dra n valve, dryer nlet water separator
9 By-pass valve
10 A r outlet valve
11 A r nlet valve
F g. 1.2 General v ew of MD600 W
1 Regenerat on a r sector
2 Nozzle
3 Ejector
4 Regenerat on a r cooler
5 Manual dra n valve, dryer nlet water separator
6 Rotor
F g. 1.3 Ins de v ew of MD300
765
123
4
11
10
9
8
51337F
1234
5
6
51338F

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Instruct on book
1.2 Air drying circuit (Fig. 1.4)
Wet a r from the compressor aftercooler (2) enters the dryer
nlet, passes through nlet valve (5) and the nozzle of ejector
(11) nto a r nlet water separator (26). The a r leav ng the
aftercooler s normally saturated and has a temperature of approx.
10°C above that of the nlet cool ng water on water-cooled
compressors or above that of the amb ent temperature on a r-
cooled compressors.
In the dem ster (27), the water droplets are removed from the
a r. The a r s then led through rotor (12), wh ch adsorbs the
water vapour. The dr ed a r then flows nto a r outlet
compartment (30) and leaves the dryer through outlet valve (33).
1.2.1 Regeneration air circuit
Hot regenerat on a r s branched off from p pe (1) upstream of
the compressor aftercooler. Th s a r s unsaturated and has a
temperature of 130-190°C, depend ng on the operat ng pressure,
the cool ng water nlet temperature or amb ent temperature and
the a r nlet temperature.
The regenerat on a r passes through shut-off valve (7), throttle
valve (8) and stra ner (9) to nlet seal ng sector (10), and s
blown through the wet rotor channels. S nce the hot a r has a
lower vapour pressure than the wet rotor channels, t w ll dry,
.e. regenerate, the rotor.
The wet regenerat on a r leav ng the rotor s collected n outlet
seal ng sector (14).
The hot saturated a r s then cooled down n regenerat on a r
cooler (17) and passed to water separator (18), where the free
water s evacuated by the dra n system.
The regenerat on a r s then led to the suct on chamber (28) of
ejector (11), where t s m xed w th the wet compressed a r from
the compressor aftercooler. In the ejector the veloc ty of the
wet compressed a r s ncreased, result ng n a pressure drop n
the suct on chamber of the ejector and the ent re regenerat on
a r c rcu t up to throttle valve (8). The pressure drop prevents
regenerat on a r from enter ng the dry a r outlet compartment.
1.2.2 Rotor cooling air circuit
After regenerat on, the hot channels of the rotor are cooled by
a r from the dry a r compartment (30). The cool ng a r flow s
trapped by the regenerat on a r outlet seal ng sector (14) and
m xed w th the wet regenerat on a r.
1.3 Drain system
1.3.1 Description (Fig. 1.5)
The condensate enters the Electron c Water Dra n (EWD) v a
nlet (1) and accumulates n collector (2). A capac t ve sensor
(3) cont nuously measures the l qu d level. As soon as the
collector s f lled up to a certa n level, p lot valve (4) s act vated
and d aphragm (5) opens outlet (6), d scharg ng the condensate.
When the collector has been empt ed, the outlet closes qu ckly
w thout wast ng compressed a r.
When the controller reg sters a malfunct on, the red alarm LED
(F g. 1.7) starts flash ng and the electron c dra n valve w ll
automat cally change to the alarm mode, open ng and clos ng
the valve accord ng to a sequence as shown n (F g. 1.6). Th s
cond t on cont nues unt l the fault s remed ed. If the fault s not
remed ed automat cally, ma ntenance s requ red.
1.3.2 Testing the EWD
Functional test
Br efly press the TEST button (F g. 1.7) and check that the valve
opens for condensate d scharge.
Checking the alarm signal
- Press the test button for at least 1 m nute
- Check that the alarm LED flashes
- If an alarm dev ce s connected to the NO or NC contact
(see sect on 1.3.3), check ts operat on.
- Release the test button.
1.3.3 Electrical connections of the EWD (Fig. 1.8)
The nd cat ons on the data label must correspond to the ma ns
supply voltage and frequency. Connect the electr cal supply to
the EWD as shown n F g. 1.8. Never operate the EWD w thout
an earth conductor connected. An alarm dev ce can be connected
to the normally open or normally closed contact; see F g 1.8.

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Instruct on book
1 Compressor HP a r del very p pe
2 Aftercooler, compressor
3 Float valve, aftercooler water separator of compressor
4 Manual dra n valve, dryer nlet water separator
5 A r nlet valve
6 By-pass valve
7 Shut-off valve, hot regenerat on nlet a r
8 Throttle valve, regenerat on nlet a r
9 Stra ner
10 Seal ng sector, regenerat on a r nlet (unsaturated s de)
11 Ejector
12 Rotor
13 A r dryer pressure vessel (rotor hous ng)
14 Seal ng sector, regenerat on a r outlet (saturated s de)
15 Shut-off valve, regenerat on a r cooler water outlet
16 Shut-off valve, regenerat on a r cooler water nlet
17 Regenerat on a r cooler
18 Water separator, regenerat on cooler outlet a r
19 Vent ng tube, EWD regenerat on a r
20 EWD regenerat on a r
21 Dra n tube, water separator regenerat on a r
22 Rotor dr ve assembly
23 Dra n p pe, water separator nlet a r
24 EWD, nlet a r
25 Vent ng tube, EWD nlet a r
26 Water separator, nlet a r
27 Dem ster
28 Suct on chamber
29 Rotor seal ng arrangement
30 Dry a r outlet compartment
31 Valve for (-) connect on, pressure d fferent al gauge
32 Valve for (+) connect on, pressure d fferent al gauge
33 A r outlet valve
F g. 1.4 A r flow d agram of MD100 W, MD200 up to MD1000 W and MD400 W VSD up to MD2500 W VSD
1 Inlet
2 Collector
3 Sensor
4 P lot valve
5 D aphragm
6 Outlet
F g. 1.5 Electron c water dra n
12345 6
7
51340F

2920 1443 01
8
Instruct on book
1.4 Electrical system
The motor must be w red to the electr cal equ pment of the
compressor as shown on the relevant c rcu t d agram.
1.4.1 D400/800/1300/2500 W VSD (Figs. 1.13 up
to 1.15)
The worm gear motor must be connected to the frequency
converter for the dryer (A21) n the electr cal cab net of the
compressor. The rotor speed of the dryer depends on the speed
of the compressor motor. When the compressor runs at
max mum speed, the dryer w ll also run at max mum speed and
v ce versa. The dryer motor stops when the compressor runs
unloaded.
1.4.2 All other D dryers (Figs. 1.9 up to 1.12)
The worm gear motor (M40) s connected n the c rcu t of the
compressor a r pressure sw tch or, n case of an Elektron kon-
controlled compressor, n ser es w th a contact of the load ng/
unload ng relay. Thus the worm gear motor stops runn ng when
the compressor s unloaded. Th s cond t on s requ red s nce
hot compressed a r for regenerat ng the rotor s not ava lable
when the compressor runs unloaded.
F g. 1.6 Dra n frequency dur ng alarm cond t on
F g. 1.7 Control panel
0.0 L ne term nal
0.1 Neutral term nal
0.2 Earth term nal
0.6 Normally closed term nal
0.7 Common term nal
0.8 Normally open term nal
F g. 1.8 Electr cal connect ons

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Instruct on book
F g. 1.9 Electr cal c rcu t d agram of MD50 connected to ZT18/37

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10
Instruct on book
F g. 1.10 Electr cal c rcu t d agram of MD300 (W)/MD1000 (W) connected to ZR/ZT3, ZR/ZT4 and ZR5 w th pneumat c
regulator

2920 1443 01 11
Instruct on book
A double-pole c rcu t breaker must be nstalled n the cab net of
the compressor regulator and connected to the term nals as
shown on the c rcu t d agram. One pole s connected n the
c rcu t of the rotor motor. On compressors w th relay-controlled
regulators, the other pole of the c rcu t breaker s connected n
the c rcu t of the "MD-ON" nd cator lamp (H12).
When voltage s suppl ed to a compressor w th a relay-controlled
regulator, the lamp w ll l ght up (lamp test). If the contacts are
closed and the compressor subsequently started, the lamp w ll
rema n al ght, thus nd cat ng that the dryer w ll be operat ve
when the compressor s loaded. If, on the other hand, the contacts
are open, the lamp w ll go out when the compressor s started,
nd cat ng that the dryer s out of serv ce. Th s w ll also be the
case f, dur ng operat on, the c rcu t breaker should tr p due to
an overload.
For a r-cooled dryers, a c rcu t breaker must be nstalled n the
cab net of the compressor. Consult sect on 2.3 for the correct
sett ng.
F g. 1.11 Electr cal c rcu t d agram of MD300 W/MD1000 W connected to ZR3, ZR4 and ZR5 w th Elektron kon regulator
w th LED d splay as shown above

2920 1443 01
12
Instruct on book
F g. 1.12 Electr cal c rcu t d agram of MD300 W/MD1000 W connected to ZR5-ZR6 and ZR110 up to ZR750 w th
Elektron kon regulator as shown above

2920 1443 01 13
Instruct on book
F g. 1.13 Electr cal d agram of MD400 W VSD/MD800 W VSD connected to ZR160 VSD/ZR 315 VSD
A21 Frequency converter, dryer control
F41 C rcu t breaker, worm gear motor of dryer
H12 "MD-ON" nd cator lamp
M40 Worm gear motor
M41 Fan motor
Q2 C rcu t breaker, dryer control
Q41 C rcu t breaker, fan motor
F gs. 1.9 up to 1.15 Electr cal c rcu t d agrams of MD50 up to MD1000 W and MD400 W VSD up to MD2500 W VSD

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14
Instruct on book
F g. 1.14 Electr cal d agram of MD1300 W VSD connected to ZR500 VSD

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Instruct on book
F g. 1.15 Electr cal d agram of MD2500 W VSD connected to ZR900 VSD

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16
Instruct on book
2 INSTALLATION
2.1 Dimension drawings (Figs. 2.1 up to 2.13)
F g. 2.1 D mens on draw ng of MD50 a r-cooled

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Instruct on book
F g. 2.2 D mens on draw ng of MD100/200 a r-cooled

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18
Instruct on book
F g. 2.3 D mens on draw ng of MD100/200 water-cooled

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Instruct on book
F g. 2.4 D mens on draw ng of MD300/400 a r-cooled

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20
Instruct on book
F g. 2.5 D mens on draw ng of MD300/400 water-cooled and MD400 VSD water-cooled