Atlas Copco CD 100+ User manual

INSTRUCTION BOOK
API093050
CD 100+

Atlas Copco
CD 100+
API093050
Instruction book
Original instructions
COPYRIGHT NOTICE
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as
identified in the Declaration of Conformity.
2017 - 08
www.atlascopco.com

Table of contents
1 Safety precautions..........................................................................................................4
1.1 SAFETY ICONS................................................................................................................................... 4
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................4
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................5
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 6
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 7
2 General description........................................................................................................9
2.1 GENERAL DESCRIPTION....................................................................................................................... 9
2.2 OPERATION.....................................................................................................................................10
3 Electrical diagram.........................................................................................................15
4 Installation.....................................................................................................................17
4.1 DIMENSION DRAWINGS.......................................................................................................................17
4.2 INSTALLATION PROPOSAL................................................................................................................... 17
5 Electrical connections..................................................................................................21
6 Operating instructions................................................................................................. 24
7 Maintenance..................................................................................................................26
7.1 MAINTENANCE................................................................................................................................. 26
7.2 RESETTING THE SERVICE TIMER.......................................................................................................... 27
7.3 DISPOSAL OF USED MATERIAL............................................................................................................. 27
8 Problem solving............................................................................................................29
9 Technical data...............................................................................................................30
9.1 REFERENCE CONDITIONS................................................................................................................... 30
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9.2 LIMITATIONS FOR OPERATION..............................................................................................................30
9.3 TECHNICAL SPECIFICATIONS................................................................................................................30
10 Instructions for Use......................................................................................................31
11 Guidelines for inspection.............................................................................................32
12 Pressure Equipment Directives...................................................................................33
13 Declaration of conformity............................................................................................ 34
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1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 Safety precautions, general
General precautions
All responsibility for any damage or injury resulting from neglecting these precautions, or
non-observance of the normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
1. The dryers are designed for normal indoor use.
2. The operator must employ safe working practices and observe all related work safety
requirements and regulations.
3. If any of the following statements does not comply with the applicable legislation, the stricter
of the two shall apply.
4. Installation, operation, maintenance and repair work must only be performed by authorized,
trained, specialized personnel.
5. The dryer is not considered capable of producing air of breathing quality. To obtain air of
breathing quality, the compressed air must be adequately purified according to the
applicable legislation and standards.
6. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the
dryer, press the emergency stop button, switch off the voltage and depressurize the dryer. In
addition, the power isolating switch must be opened and locked. For plug versions, remove
the plug from the wall socket and secure it.
7. Never play with compressed air. Do not apply the air to your skin or direct an air stream at
people. Never use the air to clean dirt from your clothes. When using the air to clean
equipment, do so with extreme caution and wear eye protection.
8. The owner is responsible for maintaining the dryer in safe operating condition. Parts and
accessories shall be replaced if unsuitable for safe operation.
9. It is not allowed to walk or stand on the dryer or its components.
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1.3 Safety precautions during installation
Precautions during installation
1. The dryer must only be lifted using suitable equipment and in accordance with the applicable
safety regulations. Loose or pivoting parts must be securely fastened before lifting. It is
strictly forbidden to dwell or stay in the risk zone under a lifted load. Lifting acceleration and
deceleration must be kept within safe limits. Wear a safety helmet when working in the area
of overhead or lifting equipment.
2. Place the dryer where the ambient air is as cool and clean as possible. If necessary, install a
suction duct. Never obstruct the air inlet. Care must be taken to minimize the entry of
moisture at the inlet air.
3. Any blanking flanges, plugs, caps or desiccant bags must be removed before connecting the
pipes.
4. Air hoses must be of correct size and suitable for the working pressure. Never use frayed,
damaged or worn hoses. Distribution pipes and connections must be of the correct size and
suitable for the working pressure.
5. The aspirated air must be free of flammable fumes, vapours and particles, e.g. paint
solvents, that can lead to internal fire or explosion.
6. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that all piping is free to expand under heat and that it is not in contact with or close to
flammable materials.
8. No external force may be exerted on the air outlet valve. The connected pipe must be free of
strain.
9. If remote control is installed, the machine must bear a clear sign stating "Danger: This
machine is remotely controlled and may start without warning".
The operator has to make sure that the machine is stopped and that the isolating switch is
open and locked before any maintenance or repair. As a further safeguard, persons
switching on remotely controlled machines shall take adequate precautions to ensure that
there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the starting equipment.
10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted cooling air does not recirculate to the inlet.
11. The electrical connections must correspond to the applicable codes. The machines must be
earthed and protected against short circuits by fuses in all phases. A lockable power
isolating switch must be installed near the equipment.
12. On machines with automatic start-stop system or if the automatic restart function after
voltage failure is activated, a sign stating "This machine may start without warning" must be
affixed near the instrument panel.
13. Never remove or tamper with the safety devices, guards or insulation fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
atmospheric pressure must be protected by a pressure-relieving device or devices as
required.
14. Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be
accidentally touched by personnel during normal operation must be guarded or insulated.
Other high-temperature piping must be clearly marked.
15. For water-cooled machines, the cooling water system installed outside the machine has to
be protected by a safety device with set pressure according to the maximum cooling water
inlet pressure.
16. If no safety valve is present in the air net close to the desiccant dryer (e.g. safety valve of
compressor), full flow safety valves must be installed on the dryer vessels.
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API093050 5

17. If the maximum pressure of the compressor is higher than the design pressure of the dryer,
a full flow safety valve must be installed between the compressor and the dryer in order to
blow off the excessive pressure in case the safety valve of the dryer should be out of order
or blocked.
18. When unit is not permanently secured to the floor in the vertical position or mounted
horizontally, access to electrical equipment is feasible through the unit base. In this case
additional barriers must be provided during installation. Tag with "warning high voltage"
symbol
Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance or repair.
These precautions apply to machinery processing or consuming air or inert gas. Processing
of any other gas requires additional safety precautions typical to the application which are
not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.4 Safety precautions during operation
Precautions during operation
1. Always be careful when touching any piping or components of the dryer during operation.
On dryers using heat to regenerate the desiccant, some parts will become very hot.
2. Use only the correct type and size of hose end fittings and connections. When blowing
through a hose or air line, ensure that the open end is held securely. A free end will whip
and may cause injury. Make sure that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes,
vapors or particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork closed during operation. Bodywork should be opened for short periods
only, e.g. to carry out routine checks. Wear ear protectors when removing a panel.
7. People staying in environments or rooms where the sound pressure level reaches or
exceeds 90 dB(A) shall wear ear protectors.
8. Periodically check that:
• All guards are in place and securely fastened
• All hoses and/or pipes inside the machine are in good condition, secure and not
rubbing
• There are no leaks
• All fasteners are tight
• All electrical leads are secure and in good order
• Safety valves and other pressure relief devices are not obstructed by dirt or paint
• Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in
good condition, free of wear or abuse
9. If warm cooling air from dryers is used in air heating systems, e.g. to warm up a working
area, take precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of, or tamper with, the sound dampening material.
11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine.
Every pressure vessel or auxiliary installed outside the machine to contain air above
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atmospheric pressure shall be protected by a pressure relieving device or devices as
required.
12. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book
must be respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance or repair.
These precautions apply to machinery processing or consuming air or inert gas. Processing
of any other gas requires additional safety precautions typical to the application which are
not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
1.5 Safety precautions during maintenance or repair
Precautions during maintenance or repair
1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes,
etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress - do not start" shall be attached
to the starting equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to
ensure that there is no one checking or working on the machine. To this end, a suitable
notice shall be affixed to the remote starting equipment.
7. Close the dryer air outlet valve before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all
sources of pressure and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapours of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by
covering the parts and exposed openings with a clean cloth, paper or tape.
11. Never weld on, or in any way modify, pressure vessels.
12. Whenever there is an indication or any suspicion that an internal part of a machine is
overheated, the machine shall be stopped but no inspection covers shall be opened before
sufficient cooling time has elapsed; this to avoid the risk of spontaneous ignition of the oil
vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure
vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. All regulating and safety devices shall be maintained with due care to ensure that they
function properly. They may not be put out of action.
16. Before clearing the machine for use after maintenance or overhaul, check that operating
pressures, temperatures and time settings are correct. Check that all control and shut-down
devices are fitted and that they function correctly.
17. Protect the motor, electrical and regulating components, etc. to prevent moisture from
entering them, e.g. when steam-cleaning.
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18. Make sure that all sound-damping material and vibration dampers, e.g. damping material on
the bodywork, is in good condition. If damaged, replace it by genuine material from the
manufacturer to prevent the sound pressure level from increasing.
19. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate
bowls.
20. The following safety precautions are stressed when handling refrigerant:
• Never inhale refrigerant vapours. Check that the working area is adequately ventilated;
if required, use breathing protection.
• Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin
with water. If liquid refrigerant contacts the skin through clothing, never tear off or
remove the latter; flush abundantly with fresh water over the clothing until all refrigerant
is flushed away; then seek medical first aid.
21. The following safety precautions are stressed when handling desiccant:
• Take precautions not to inhale desiccant dust.
• Check that the working area is adequately ventilated; if required, use breathing
protection.
• Do not overfill the dryer when replacing desiccant.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during operation.
These precautions apply to machinery processing or consuming air or inert gas. Processing
of any other gas requires additional safety precautions typical to the application which are
not included herein.
Some precautions are general and cover several machine types and equipment; hence
some statements may not apply to your machine.
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2 General description
2.1 General description
Introduction
The air dryers described in this book are heatless adsorption dryers, built to remove moisture
from compressed air for industrial purposes.
The standard version is intended to reach a pressure dew point of -40 ˚C (-40 ˚F). There is also a
version available for a pressure dew point of -70˚C (-94 ˚F).
All units are designed for indoor use, and altitude up to 2000 m.
CD 25+ up to CD 145+, general view
Main parts
An overview of the main parts of the dryer is given in below figures:
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Reference Description Reference Description
1 Tower A 5 Solenoid valve
2 Tower B 6 Control cubicle
3 Air inlet 7 Silencers
4 Air outlet
2.2 Operation
General
The construction of the air dryer is simple, reliable and easy to service. A dryer has basically two
towers, containing the adsorption material or desiccant. This desiccant is a very porous grain
material, able to adsorb large amounts of water vapour.
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Flow diagram CD 25+ up to CD 50+
Reference Designation Reference Designation
1 Air inlet 7 Air outlet
2 Inlet selector valve 8 Left solenoid valve
3 Left desiccant tower 9 Right solenoid valve
4 Right desiccant tower 10 Silencer
5 Purge nozzle 11 Silencer
6 Outlet selector valve PI Pressure gauge
Operation principle basic control version
The operation cycle of the dryer is repetitive and is controlled by a factory-set timer. While the
desiccant in one tower dries the compressed air, the desiccant in the second tower is being
regenerated. Regeneration of the desiccant is achieved by means of purge air from the drying
tower.
The compressed air entering the dryer is led to one of the towers by means of the bottom
selector valve. The position of the selector valve depends on the condition (activated or not) of
the solenoid valves. As the air flows upwards through the tower, the desiccant adsorbs the water
vapour and the compressed air is dried.
Once the top of the tower is reached, the air leaves the dryer via the outlet valve (= top selector
valve).
A small portion of the dried air passes a nozzle, expands to atmospheric pressure and flows
downwards through the other tower, regenerating (drying) the desiccant. A nozzle for operation of
the dryer at 7 bar is installed as standard. Alternative nozzles for use at other operating
pressures are available as sales kit, see section Technical data. The regeneration air is released
via the corresponding solenoid valve and the silencer. The solenoid valves are controlled by the
timer.
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API093050 11

After a pre-set period, the function of the towers is reversed. The fully regenerated tower will now
dry the air, while the desiccant in the other tower will be regenerated.
By default, the regeneration timer will restart from the beginning of the cycle in case of a power
failure during operation or in case the on/off switch was put in position 0.
However, in case the input of remote control connector X3 (old denomination: P4 - freeze
contact, see section Electric diagram) opens (by the freeze contact), the dryer will "freeze" the
drying cycle: purge air flow stops, both solenoid valves are closed. When the contact, connected
to connector X3 closes, the dryer will switch towers and will continue normal operation. This
feature can prevent loss of compressed air (purge air) when the compressor is not continuously
running loaded. On compressors with load/unload regulation, X3 can be connected to a voltage
free contact of the compressor (contact open when the compressor runs unloaded). If no free
contact is available, an additional voltage free contact should be installed on the load/unload
contactor of the compressor to use this feature. See section Electrical connections for more
details.
Do not connect X3 when an air receiver is installed before the dryer.
X3 should only be connected when the air receiver is installed downstream of the dryer.
Flow diagrams
Depending on the dryer size, the dryer can be composed of a single dryer module (flow diagram:
see above), or of two or three dryer modules in parallel (see below):
Flow diagram CD 60+ up to CD 100+
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Flow diagram CD 145+
Reference Designation Reference Designation
1 Air inlet 7 Outlet selector valve
2 Connecting tube 8 Air outlet
3 Inlet selector valve 9 Left solenoid valve
4 Left desiccant tower 10 Right solenoid valve
5 Right desiccant tower 11 Left silencer
6 Purge nozzle 12 Right silencer
PI Pressure gauge
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Control panel
Control panel with flow diagram
S1 On/Off switch 9 LED <Service warning>
1 LED <Power On> 10 LED <Service alarm>
2 LED <In Operation> 11 Timer countdown (Indication of PDP in option)
3 LED < Left tower drying> 12 Air Inlet
4 LED <Left tower regenerating> 13 Air Outlet
5 LED <Right tower drying> 14 Outlet selector valve
6 LED <Right tower regenerating> 15 Inlet selector valve
7 LED <PDP warning> see note 16 Solenoid valves
8 LED <PDP alarm> see note
Note: The LED indication of the dew point (PDP) (LED’s 7 and 8) is only operational when the
dryer is equipped with an electronic dew point indicator (available as option).
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3 Electrical diagram
Service diagram (typical)
Reference Explanation
(1) Customer's installation
(a) Maximum fuses with regard to circuit protection. Cable section may impose fuses of smaller
value
(b) Supply settings for X9
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API093050 15

Reference Explanation
(c) Connection for remote control (X3): to NO contact of compressor
(d) Supply connection for 115 V and 230 V
(f) Time setting solenoid valves
(g) Connection PDP sensor
Reference Designation Reference Designation
E1 Controller card E2 LED/Display card
PDP Pressure Dew Point sensor
(optional)
X9 Supply connections
K01 Alarm relay K02 Warning relay
K03 Solenoid relay, left tower K04 Solenoid relay, right tower
Y1-(Y3)-(Y5) Solenoid valve(s) left tower Y2-(Y4)-(Y6) Solenoid valve(s) right tower
X1 Input PDP X2 Input On/Off contact
X3 Input Freeze contact S1 On/Off switch
X4 Input Ext 1 contact X5 Input Ext 2 contact
X8 CAN-Bus X11 Output alarm relay
X12 Output warning relay
X13 Output solenoid (left tower) X15 Output solenoid (right tower)
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4 Installation
4.1 Dimension drawings
CD 80+ and CD 100+
4.2 Installation proposal
Piping
Make sure that all pipes, filters, valves, etc. are clean and that they are installed correctly
with or without bypass system.
Make sure that the piping is installed stress-free. For more information concerning air nets,
cooling systems etc., refer to the compressor installation manual.
To ensure correct operation of the dryer, it has to be fitted properly into the compressed air
circuit. Depending from the fact if the remote control connector X3 is used or not (see section
Operation), there are two possibilities:
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X3 is not used
If the X3 connection is not used, the correct installation sequence is compressor - air
receiver - dryer.
Installation without use of the X3 connection with the compressor
COMP Compressor
AR Air receiver
D Dryer
EIV External inlet valve
To cut off the air supply towards the dryer
EOV External Outlet Valve
To cut off the air supply towards the air consumer
BV Bypass valves (not shown on the drawings)
Together with the external inlet valve and the external outlet valve, the bypass valves
allow the dryer and the filters to be serviced while non-dried air flows through the
bypass system.
WSD Water separator (optional)
To prevent free water from entering the dryer.
DD Compressed air prefilter DD: general purpose filtration, particle removal down to 1
micron, maximum oil carry-over 0.5 ppm
This filter is not included in the scope of supply, but recommended to provide extra
protection of the CD dryer and extend the lifetime of the PD filter cartridge.
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18 API093050