Beko DRYPOINT AC Series User manual

DRYPOINT® AC 410 – 495
DRYPOINT® AC 410 – 495 MS
EN – English
06-057
Cold-regenerated adsorption dryer with dew point control
Installation and operating manual

Installation and operating manual EN
2 DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS

EN Installation and operating manual
DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS 3
Contents
1. Safety warnings and instructions.................................................................................................................. 5
1.1. Pictograms and symbols ........................................................................................................................... 5
1.2. Signal words according to ISO 3864 and ANSI Z.535............................................................................... 5
1.3. General safety instructions........................................................................................................................ 6
1.3.1. Safety precaution during plant operation ....................................................................................... 8
1.3.2. Risk of injury from electric energy .................................................................................................. 8
1.3.3. Risks from adsorbents ................................................................................................................... 9
1.3.4. Safety instructions for maintenance work .................................................................................... 10
1.4. Transport and storage ............................................................................................................................. 11
1.5. Intended use............................................................................................................................................ 13
1.5.1. Warranty and liability .................................................................................................................... 14
1.5.2. Duties of the plant operator.......................................................................................................... 14
1.5.2.1. Safety ........................................................................................................................... 14
1.5.2.2. Plant operation ............................................................................................................. 14
1.5.3. Duties of personnel ...................................................................................................................... 14
2. Product information ...................................................................................................................................... 14
2.1. Scope of delivery..................................................................................................................................... 14
2.2. Type plate................................................................................................................................................ 15
2.3. Product overview and description ........................................................................................................... 15
2.3.1. Operating principle of adsorption dryer ........................................................................................ 15
2.3.1.1. Prelter with condensate drain ..................................................................................... 15
2.3.1.2. Afterlter ....................................................................................................................... 15
2.3.2. Function of DRYPOINT®AC 410 – 495 ...................................................................................... 16
2.3.2.1. Adsorption..................................................................................................................... 16
2.3.2.2. Regeneration................................................................................................................ 16
2.3.2.3. Pressure build-up ........................................................................................................ 17
2.3.2.4. Switching over of plant ................................................................................................. 17
2.3.2.5. Intermittent operation ................................................................................................... 17
2.3.3. Control and display elements....................................................................................................... 17
2.3.4. Display (standard version) ........................................................................................................... 17
2.3.4.1. Service messages (standard version) .......................................................................... 17
2.3.4.2. Acknowledging service messages (standard version).................................................. 19
2.3.5. Text display (dew point control version) ....................................................................................... 21
2.3.5.1. Button functions............................................................................................................ 21
2.3.5.2. Display layout ............................................................................................................... 21
2.3.5.3. Second level (with SET button) .................................................................................... 23
2.4. Parts and components ............................................................................................................................ 24
2.5. Dimensions.............................................................................................................................................. 25
2.6. Technical data ......................................................................................................................................... 26
3. Installation...................................................................................................................................................... 27
3.1. Warning ................................................................................................................................................... 28
3.2. Installation area ....................................................................................................................................... 28
3.3. Bypass line (optional) .............................................................................................................................. 29
3.4. Connection to compressed air system .................................................................................................... 29
3.4.1. Compressed air quality ................................................................................................................ 29
3.5. Intermittent operation .............................................................................................................................. 29
4. Electrical installation..................................................................................................................................... 30
4.1. Warning ................................................................................................................................................... 30
4.2. Connection PCBs .................................................................................................................................... 31
4.2.1. Basic control PCB ........................................................................................................................ 31
4.3. Connection to power supply .................................................................................................................... 32
4.4. Function of electrical control.................................................................................................................... 32

Installation and operating manual EN
4 DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS
4.4.1. Standard control........................................................................................................................... 32
4.4.2. Load-dependent control (dew point control)................................................................................. 32
4.4.3. Time control.................................................................................................................................. 33
4.4.4. Dew point control (optional) ......................................................................................................... 33
4.5. Alarm states............................................................................................................................................. 33
4.6. Alarm inputs............................................................................................................................................. 34
4.7. Software-generated alarms (with dew point control only) ....................................................................... 34
4.8. Intermittent operation .............................................................................................................................. 34
4.9. Behaviour in the event of a power failure ................................................................................................ 34
5. Start-up........................................................................................................................................................... 34
5.1. Commissioning........................................................................................................................................ 34
6. Operation........................................................................................................................................................ 35
6.1. Operating mode....................................................................................................................................... 35
6.2. Service mode .......................................................................................................................................... 35
7. Maintenance and servicing........................................................................................................................... 36
7.1. Maintenance intervals ............................................................................................................................. 36
7.1.1. Filter elements.............................................................................................................................. 36
7.1.2. Adsorbent ..................................................................................................................................... 36
7.1.3. Service inspection tasks .............................................................................................................. 36
7.1.4. Service intervals........................................................................................................................... 36
7.1.5. Service tasks................................................................................................................................ 36
7.2. Maintenance schedule ............................................................................................................................ 37
7.3. Replacing lter elements ......................................................................................................................... 37
7.4. Maintenance of BEKOMAT®20 FM condensate drain............................................................................ 39
7.5. Maintenance of 2/2-way solenoid valve .................................................................................................. 40
7.5.1. Installation .................................................................................................................................... 40
7.5.2. Electrical connection .................................................................................................................... 40
7.5.3. NC function .................................................................................................................................. 41
7.5.4. Troubleshooting............................................................................................................................ 41
7.5.4.1. Replacing solenoid ....................................................................................................... 41
7.5.4.2. Replacing diaphragm ................................................................................................... 41
7.5.4.3. Replacing magnet armature (NC function)................................................................... 42
7.5.4.4. Replacing manual assisted actuation device ............................................................... 42
7.5.4.5. Figure: Spare parts ...................................................................................................... 42
7.6. Maintenance of shuttle valves ................................................................................................................ 43
7.7. Replacing adsorbent ............................................................................................................................... 45
7.8. Spare parts.............................................................................................................................................. 46
8. Troubleshooting and repair .......................................................................................................................... 47
8.1. Possible causes of faults......................................................................................................................... 47
8.2. Troubleshooting of BEKOMAT®20 FM ................................................................................................... 49
9. Shutting down plant...................................................................................................................................... 49
9.1. Depressurising plant................................................................................................................................ 50
10. Dismantling and disposal........................................................................................................................... 50
11. Declaration of Conformity........................................................................................................................... 51

EN Installation and operating manual
DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS 5
1. Safety warnings and instructions
1.1. Pictograms and symbols
In this documentation
General instructions
Observe installation and operating instructions
General hazard symbol (danger, warning, caution)
Warning: electric voltage
Wear respiratory protection mask
Wear hearing protection
Wear safety goggles
About the plant
Observe installation and operating instructions
(on type plate)
1.2. Signal words according to ISO 3864 and ANSI Z.535
DANGER Imminent danger
Consequences of non-compliance: serious or even fatal injury
WARNING Potential danger
Consequences of non-compliance: possible serious or fatal injury
CAUTION Imminent danger
Consequences of non-compliance: injury and/or damage to property
NOTE Additional notes, tips and hints
Consequences of non-compliance: ine󰀩cient operation, extra maintenance work.
No risk to persons.

Installation and operating manual EN
6 DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS
1.3. General safety instructions
NOTE Installation and operating manual
Before reading this manual, make sure that it refers to your plant model. This document
contains important information and instructions for the safe operation of the plant. Before
carrying out any work with or on the plant, all specialist technical personnel ¹ must have read
this manual.
A copy of this operating manual must be kept near the plant where it is at all times accessible
to sta󰀨.
In addition to the instructions in this document, always comply with the statutory regulations
for machine operation, accident prevention and safety. This also applies to the use of
accessories and spare parts.
DANGER Insu󰀩cient qualication
Improper handling and operation of the plant might result in serious or even fatal injury, and/
or damage to property.
• All tasks described in this installation and operating manual must be performed by
specialist technical personnel1who meet the following criteria:
• Before carrying out any work with or on the plant, all specialist technical personnel¹ must
have read and understood the contents of this installation and operating manual. It is the
responsibility of the owner of the plant to ensure that the above requirement is complied
with.
DANGER Escaping compressed gas
Risk of serious or even fatal injury from contact with escaping compressed gas or unsecured
plant components.
• Before carrying out any installation or maintenance work, depressurise the system.
• Use only pressure-resistant installation material and suitable tool that are in proper
working order.
• Before pressurising the system, check all plant components and repair them, if necessary.
Open valves slowly to prevent pressure blows during operation.
• The feed pipes must be permanently installed. Drain pipe: short, properly secured
pressure hose attached to pressure-resistant pipe.
• Make sure that no persons can be injured or objects damaged by condensate or escaping
compressed gas.
• Prevent transmission of vibration and impacts on plant components.
• Perform a leakage test.
DANGER Use of unsuitable tools
If unsuitable tools are used, there is a risk of plant malfunction, potentially resulting in injury
and/or damage to property.
• When serving and repairing the plant, use only tools that are in proper working order and
have been approved for the respective task.
• If you require special tools for certain tasks, contact the manufacturer.
DANGER Modications to the plant
Structural modications to the plant might result in serious injury and/or damage to property.
• Any modications to the plant must be made by the manufacturer, or after consultation
with the manufacturer.
• Work on pressure vessels and pipelines such as welding, structural modications,
assembly work, etc. is prohibited, unless you have obtained the prior consent of the
manufacturer and, if required, of the notied body. Such modications shall void the
Declaration of Conformity.
1 Specialist technical personnel
Specialist technical personnel are persons who, due to their professional qualication and knowledge in the eld of measuring,
control and pneumatic technology, and their knowledge of the applicable statutory regulations, guidelines and standards are in
a position to foresee potential dangers in relation to the use of the plant, and who are qualied to perform the tasks described
in this manual. Special operating conditions (e.g. plant operation with aggressive media) require additional knowledge.

EN Installation and operating manual
DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS 7
DANGER Disabling of safety devices
If safety devices are disabled or not working properly, there is a risk of serious injury, plant
malfunction and/or damage to property.
• Never disable or bridge the safety devices of the plant.
• Safety devices that prevent operation of the plant at inadmissible conditions (e.g.
excessive pressure or temperature) are not included in the standard scope of delivery.
• Should they be supplied as installed accessories, they must never be disabled
• or bridged.
DANGER Excessive pressure / temperature
Suitable measures must be taken to ensure that the pressure in the plant components does
not exceed the permissible operating pressure.
• It is the responsibility of the plant operator to protect the plant against excessive pressure
build-up.
• Take suitable measures to protect the compressor and the compressed air system
downstream of the adsorption dryer.
• Take suitable technical precautions to ensure that the temperature at operating pressure
does not exceed the maximum permissible operating temperature of the individual
components.
• The plant operator must take suitable measures to ensure that the temperature of the
incoming gas does not exceed the maximum permissible operating temperature of the
plant.
• If the plant is pressurised to operating pressure, the operator must ensure that the
maximum permissible operating temperature is not inadvertently exceeded by ambient
conditions at the site of installation.
DANGER Fire safety
A re in the plant might result in serious injury or damage to materials.
• Safety devices that prevent excessive pressure build-up as a consequence of a re are
not included in the standard scope of delivery.
• If there are potential ignition sources at the place of installation of the plant, the operator
must take suitable safety measures to ensure that the permissible operating parameters
of the plant are not exceeded.
NOTE Pressure vessel – stress from alternating loads
The alternating load rate per year depends on the plant cycle times and the type of the plant.
The plant design is based on a service life of 10 years.
• In Germany, the pressurised walls must be tested at least every 5 years (internal test),
and strength test (pressure test) must be completed at least every 10 years.
• Observe the statutory regulations that apply at the place of installation of the plant and
schedule all necessary tests with the respective notied body.

Installation and operating manual EN
8 DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS
1.3.1. Safety precaution during plant operation
Compliance with the statutory safety and operating regulations is a prerequisite for trouble-free and safe operation
of the plant. Strictly adhere to all applicable internal work instructions.
• The plant must be regularly inspected for visible damage.
• Faults and defects that might impair its safety must be eliminated without delay. In the event of malfunction,
follow the instructions in “8. Troubleshooting and repair”. Should you be unable to resolve the problem, contact
the manufacturer.
• The plant, including its control system, must only be operated by suitably trained and instructed personnel.
DANGER Manual pressure relief during operation
Manual pressure relief during plant operation might result in serious injury and/or damage to
property.
• Never open the manual pressure relief ball valves while the plant is in operation.
WARNING Blow-o󰀨 noises during pressure release
When compressed gas is released, it expands, which can be result in a loud noise.
• Therefore always wear hearing protection!
1.3.2. Risk of injury from electric energy
DANGER Electric power
Incorrect connection or damaged components can cause serious or even fatal injury.
• All work on electrical connections and devices must be performed by authorised specialist
technicians and according to DIN VDE regulations (or equivalent national regulations) and
the instructions of the utility company.
• If work needs to be performed on powered parts, a second person must be deployed to
shut down the main switch, should it be required.
• Cordon o󰀨 the working area and set up warning signs.
• Use only insulated tools.
• The electrical equipment of the plant must be tested regularly.
• Use only original fuses of the correct rating.

EN Installation and operating manual
DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS 9
1.3.3. Risks from adsorbents
The adsorbents (desiccants) are contained in the adsorbers (see “2.4. Parts and components”).
The adsorbent has been chosen with reference to the processing system and drying task. Use only adsorbents
supplied by the plant manufacturer.
Adsorbents are chemicals that need to be handled with the necessary care (DIN safety data sheet). The
adsorbents used in your plant are not subject to the labelling requirements according to the German Hazardous
Substances Ordinance. All adsorbents must be stored in a room that is only accessible to trained and instructed
personnel.
WARNING Health risk from adsorbents
Risk of injury to eyes and injury from ingestion
• In the case of contact with the eyes, rinse thoroughly with plenty of water. Always consult
a doctor.
• After ingestion, immediately consult a doctor.
• Spilled adsorbent must be removed without causing airborne dust.
• When removing or adding adsorbent to the absorption dryer, wear a dust mask
(recommended protection class: P2 or FFP2) and safety goggles.
NOTE Handling of adsorbents in the event of a re
There are no restrictions regarding extinguishing agents. The adsorbent might however react
with water or foam.

Installation and operating manual EN
10 DRYPOINT®AC 410 – 495 | DRYPOINT®AC 410 – 495 MS
1.3.4. Safety instructions for maintenance work
All persons involved in the installation, start-up, operation or maintenance of the plant must have read and fully
understood the installation and operating instructions, and in particular the safety instructions. If you have any
queries, please contact the manufacturer.
The manufacturer shall not be liable for damage caused by incorrect installation, assembly or start-up of the plant.
The plant operator shall be solely responsible for such damage.
The responsibilities for maintenance work must be clearly assigned. Before carrying out any maintenance work,
inform the operating personnel.
All prescribed conguration, maintenance and inspection tasks must be carried out by customer service technicians
of the manufacturer and according to the schedule.
Strictly adhere to all instructions regarding the maintenance of the plant.
DANGER Maintenance work during plant operation
Carrying out maintenance work while the plant is in operation poses an increased risk to
persons.
• For certain maintenance tasks, the plant must be completely shut down, de-energized
and depressurised.
• Shut down the plant, following the relevant instructions.
• Depressurise the plant.
• Disconnect it from the electric power supply, secure it against inadvertent switching on
and attach a warning sign
• to the main switch.
• If guards need to be removed, let the plant cool down before carrying out any further
work. Before restarting the plant, mount and secure the guards and insulation.
DANGER Improper replacement of components
Incorrect replacement of components can cause serious or even fatal injury.
• We strongly recommend having damaged or wearing parts replaced by a customer
service technician of the manufacturer.
• After completion of the maintenance work, perform a leakage test.
• To replace large assemblies, use lifting gear and secure the parts properly before moving
them! Use only lifting gear lashing equipment that is in proper working order and has the
necessary load capacity!
DANGER Assembly work above head height
Assembly work above head height can cause serious or even fatal injury.
• For all such work, use safety-approved ladders and work platforms!
• Never use machine parts as climbing aids! Risk of injury from fall!
• For all maintenance work above a height of 1.80 m, wear fall arrest equipment!
NOTE Use of unsuitable or damaged components
The use of unsuitable or damaged components can cause malfunction of the plant.
• If you detect any serious damage to the pressure devices, shut them down and remove
them immediately!
• Replace damaged components with new ones.
• Replace wearing parts according to the prescribed schedule in the devices and spare
parts list or in chapter “7.2. Maintenance schedule”. This list is an integral part of these
installation and operating instructions.
• Use only original spare and accessory parts supplied by the manufacturer. Third-party
components might not meet the necessary stress and safety standards.