CompAir A TX Series User manual

Adsorption dryer
A190-930TX
Operating Instructions
Revision 03—2006/EN

Declaration of Conformity
COMPAIR Drucklufttechnik GmbH
Argenthaler Straße 11
55469 Simmern / Hunsrück
Germany
hereby declares with sole responsibility, that the products
compressed air adsorption dryer
series A190TX–A930TX
assembly type: assembly acc. to Art. 3 No. 2.2,
which this declaration refers to, conform to Directive 97/23/EC and were
subjected to a conformity assessment according to Annex III Modules B + D (for
assembly assessment).
For the assembly, the EC type approval certificate SIG 0271665/2 by Lloyd’s
Register Quality Assurance GmbH, Hamburg, is available.
The quality assurance system is monitored by the service provider stated below
Lloyd’s Register Quality Assurance GmbH (identification number 0525)
Mönckebergstraße 27, D - 20095 Hamburg.
The assembly consists of pressure appliances according to the classification list
(attached to the technical documentation provided by the manufacturer).
The following standards / technical specifications were used:
harmonized standards: DIN EN 292-1, DIN EN 292-2, DIN EN 1050,
DIN EN 50081, DIN EN 50082, DIN EN 60204
The following other EC directives were used:
98/37/EC
89/336/EEC
73/23/EEC
Signature
Stefan Pilath
Quality Manager

Machine passport
Type designation A____TX
Order no.
Project no.
Serial no.
Vessel no.
Vessel no.
Year of manufacture 2009
Issue date of these operating instructions 2009-02 EN
It is the responsibility of the owner,
to enter for the first time any appliance data not stated above,
to keep these appliance data up to date.
The above-stated appliance data provide for a clear identification of the dryer and
its components, and significantly facilitate any service measures.
Further important data on the dryer such as the details on the permissible
operating pressure and the electrical connection are found on the type plate (for
position of the type plate see page 9).

A190-930TX_EN_03_2009-02-06
Table of contents
General information ............................................................................................6
Manufacturer's details ..............................................................................................................6
Details on the dryer ..................................................................................................................7
About these operating instructions...........................................................................................8
For your own safety ............................................................................................9
Signs, instruction plates and danger zones at the dryer ..........................................................9
Intended use of the dryer .......................................................................................................11
General safety notes ..............................................................................................................11
Safety notes on specific operating phases.............................................................................12
Technical product description......................................................................... 15
Summary drawing ..................................................................................................................15
Function description ...............................................................................................................16
Available options ....................................................................................................................18
Transportation, installation and storage.........................................................21
Information on transportation packaging ................................................................................ 21
What to do in the case of transport damage occurring?......................................................... 21
Transporting and installing the dryer ...................................................................................... 22
Anchoring the dryer ................................................................................................................24
Storing the dryer.....................................................................................................................24
Installation..........................................................................................................26
Preconditions for installation ..................................................................................................26
Connect piping ....................................................................................................................... 26
Installing the electrical connection.......................................................................................... 27
Start-up............................................................................................................... 30
Requirements for initial start-up ............................................................................................. 30
Setting times of the operating phases .................................................................................... 31
Overview of operating and control elements .......................................................................... 31
Emergency shutdown.............................................................................................................34
Start up dryer..........................................................................................................................34
Changing cycle mode (optional).............................................................................................36
Monitoring dryer operation...............................................................................38
With dewpoint-sensing control (optional) ............................................................................... 38
Shutdown and restart dryer..............................................................................39
Emergency shutdown.............................................................................................................39

A190-930TX_EN_03_2009-02-06
Depressurising and shutting down the dryer ..........................................................................39
If work is to be carried out on the electrical system................................................................40
Restart ....................................................................................................................................40
Maintenance and repair of the dryer................................................................42
Notes on maintenance............................................................................................................42
Regular maintenance intervals ...............................................................................................43
Instructions for use of the dongle............................................................................................44
Daily maintenance tasks.........................................................................................................44
Weekly maintenance tasks.....................................................................................................45
Monthly maintenance tasks ....................................................................................................45
Maintenance work to be completed every 12 months ............................................................46
Maintenance work to be completed every 24 months ............................................................48
Maintenance work to be completed every 48 months ............................................................50
Identify and eliminate faults .............................................................................54
Summary of faults...................................................................................................................54
Index ...................................................................................................................58
Annex with technical documentation..............................................................61
Technical data ........................................................................................................................62
Replacement and wear parts list ............................................................................................63
Logic control diagram .............................................................................................................64
Flow diagram ..........................................................................................................................66
Dimensional drawings.............................................................................................................67

Manufacturer's details
6 A190-930TX_EN_03_ 2009-02-06
General information
Manufacturer's details
Name and address
COMPAIR Drucklufttechnik GmbH
Argenthaler Straße 11
55469 Simmern / Hunsrück
Germany
Telephone: [phone]
Telefax: [phone]
Internet: www.compair.com
Service and spare part order
You can also use these telephone numbers to order consumables such as
drying agents etc. as well as replacement parts. When ordering replacement
parts, always state the type and serial no. of the dryer. Both are shown on the
type plate attached to the control cabinet of the dryer.

General information
A190-930TX_EN_03_ 2009-02-06 7
Details on the dryer
Standard equipment
Dryer, comprising
2 vessels, filled with desiccant
Piping and muffler
Control system
Associated documents
Operating instructions (present)
Technical documentation (see annex)
Circuit diagrams (see separate document)
Warranty notes
In the following cases, the warranty shall be void:
If aggressive media in the compressed air and in the environment cause
corrosion damage and functional faults on the dryer.
If the dryer is used without prior approval and confirmation in writing by the
manufacturer for purposes other than those specified in these operating
instructions or contractually agreed.
If preset parameters (e. g. on the control system etc.) are changed without
prior approval and confirmation in writing by the manufacturer.
If the dryer is transported or stored incorrectly.
If the dryer is sited and installed incorrectly.
If the dryer is repaired or maintained incorrectly.
If the dryer is operated by personnel that does not have the requisite
qualifications.
If modifications are carried out on the dryer, the manufacturer did not
approve that.
In the event of non-compliance the manufacturer will not accept any liability for
any consequential damage whatsoever.

About these operating instructions
8 A190-930TX_EN_03_ 2009-02-06
About these operating instructions
These operating instructions contain basic information on the safe useof the
dryer.
Characters and symbols used
►Work steps that you have to carry out in the sequence stated are marked by
black triangles.
Lists are marked by a small box.
Note:
These notes provide you with hints and information on the safe and
efficient handling of machines and devices.
Warning!
These safety notes warn against damage to property and help you to
avoid such damage.
Danger!
These danger notes with a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid serious or
life-threatening situations for yourself and/or third parties.
Target group of these operating instructions
These operating instructions are intended for all persons working on and using
the dryer. We assume that all such persons are specialist personnel, e.g. fitters
or electricians.
Operating instructions: handling
These operating instructions must be continuously available at the site where the
dryer is used. We recommend to prepare a copy and to keep the same in a safe
and freely accessible place next to the dryer. Keep the original document in a
safe place.

For your own safety
A190-930TX_EN_03_ 2009-02-06 9
For your own safety
The dryer has been built in accordance with the state of the art and the
recognized technical safety regulations. Nevertheless, there is a risk of personal
injury and damage to property when the dryer is used, if
it is operated by non-qualified personnel,
not used within its intended design specifications,
is repaired or maintained incorrectly.
Note:
For your own safety and to prevent machine damage, please note the
information and safety notes in these operating instructions when
working with the dryer.
Signs, instruction plates and danger zones at the dryer
Signs and instructions
Vessel plate Vessel plate
Type plate of the dryer
Front view
Please note the above plates and instructions attached to the dryer. Ensure that
they are not removed and are always readable.

Signs, instruction plates and danger zones at the dryer
10 A190-930TX_EN_03_ 2009-02-06
Hazard areas on the dryer
Hazard caused by electrical voltage
Hazard caused by overpressure
Hazard caused by sudden air ejection during
expansion
Hazard area
Symbol in
operating
instructions
Warning against hazardous electrical voltage
Different parts of the dryer carry electrical current. These parts may be
connected, opened, and maintained by authorized specialist personnel only.
Warning against overpressure
The entire dryer is under pressure. Before commencing any work, the plant
must be depressurised.
Warning against sudden air ejection
When the vessels are depressurised, air flows suddenly out of the sound
absorber:
This causes a sudden loud cracking noise.
Due to particles carried in the air flow, there is a very considerable risk of
eye injury.
When working on the dryer, always wear eye and ear protection equipment.
Skid risk
When emptying and filling the vessels with drying agent, there is a risk of
skidding caused by spilt drying agent.

For your own safety
A190-930TX_EN_03_ 2009-02-06 11
Intended use of the dryer
The dryer is exclusively intended for drying compressed air. Depending on
defined input conditions, it dries compressed air for industrial use.
The dryer is designed for compressed air, which is free from aggressive water,
oil, and solid matter constituents.
As standard, the dryer is intended to be sited within a building and protected
against the weather. When it is sited in the open air (option), the instructions on
page 18 must be complied with.
The dryer may be operated only in accordance with the data on the type plate
and in accordance with the contractual conditions.
Suspected misuse
The dryer must not be misused as a climbing aid! Pipes, valves, and similar
fittings have not been designed for such loads. They could fracture, tear off, or
become damaged in another way.
General safety notes
For your own safety, when carrying out any work on the dryer comply with
all applicable national safety regulations!
Personnel qualification
Only authorized and qualified specialist personnel may be tasked with the work
on the dryer described in these operating instructions.
Conversions and modifications
Without prior approval by the manufacturer, no conversions and modifications
must be made to the dryer! Any non-approved modifications may restrict the
operational safety of the dryer and cause damage to property or personal injury.
Handling drying agents
The drying agents are perfectly safe when in an unused condition. However,
when filling and emptying the vessels with drying agents, increased dust
generation may occur. Please comply with the following instructions:
When filling drying agents into the vessels, wear a dust mask and eye
protection!
If a spillage occurs, any spilt drying agent must be taken up immediately.
There is a risk of skidding!

Safety notes on specific operating phases
12 A190-930TX_EN_03_ 2009-02-06
Safety notes on specific operating phases
Transportation and siting
Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
Carefully secure the dryer during transportation.
Start-up
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
A loud expansion noise is caused which may damage your hearing.
Particles carried in the air can injure your eyes or skin.
Always wear eye and ear protection, therefore, when you are in the
vicinity of the dryer!
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
Carry out all prescribed tests and checks.
The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
Before start-up, ensure that no tools or other foreign parts have been left
lying in a part of the dryer where they might pose a hazard to the dryer being
started up.
Emergency shutdown
In any emergency, proceed as described in the section on page 39.
Monitor operation
Warning against sudden air ejection!
During expansion the pressure is released suddenly through the muffler:
A loud cracking noise occurs which can injure your hearing.
Particles carried in the air flow act like bullets and can injure your
eyes or skin.
Always wear eye and ear protection, therefore, when you are in the
vicinity of the dryer!

For your own safety
A190-930TX_EN_03_ 2009-02-06 13
Only operate the dryer within the permissible limits (see type plate). By
operating the dryer in conditions that go beyond the defined values, the dryer
is subjected to loads for which it has not been designed. This may cause
functional defects.
The more powerful the dryer is, the more noise may be generated during
operation. Therefore, the operator must provide suitable protective
equipment (e. g. ear protection).
Check the dryer regularly for externally visible damage and defects. Any
changes, even in its operating behaviour, must be reported immediately to
the competent office or person.
In the event of an emergency or if a safety-relevant disruption occurs (e.g.
escaping compressed air, defective component), the dryer must be shut
down immediately as described in the section on page 39).The unit may
only be restarted after all defects have been eliminated.
Maintenance of the dryer and fault removal
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
Carry out maintenance work only when the plant has been shut down and
depressurised!
The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
Bolt connections must be undone with care! Note ram pressure values!
Otherwise emerging media may cause personal injury.
Never carry out any welding on a vessel or change the same in any other
way!
Never use pipes and fittings as steps or holding points! The components
might fracture, or the distortions which occur may cause internal damage on
the dryer. There is a risk of injury by slipping off the components,
components breaking off, and expanding compressed air!
Never leave tools, loose parts or cloths in, at or on the dryer.
Following maintenance work always test all flange and bolt connections for
leak tightness and secure seating.
Only use replacement parts that are suitable for the relevant function and
meet the technical requirements stipulated by the manufacturer. This is
always the case, if you use original replacement parts only.

Safety notes on specific operating phases
14 A190-930TX_EN_03_ 2009-02-06
Disassembly and disposal
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
Dispose all parts of the dryer, the drying agent, and all other operating
materials in an environmentally safe way and in accordance with all current
statutory regulations. The waste code numbers of the drying agents can be
obtained from the manufacturer (for the manufacturer's address see page 6).

Technical product description
A190-930TX_EN_03_ 2009-02-06 15
Technical product description
Summary drawing
Regeneration gas orifice
Filling point Pressure gauge (PI)
On/off-switch Vessel
Power supply Control box
Filter for control gas Solenoid valve block (Y1-Y4)
Drain point
Front view
Check valve V3 Check valve V2
Compressed air outlet Eyebolt
Compressed air inlet Expansion valve V4
Expansion valve V5
Main inlet valve V1 Muffler
Rear view

Function description
16 A190-930TX_EN_03_ 2009-02-06
Function description
The dryer dries the compressed air supplied by the compressor and makes it
available for industrial use.
If so, installed up- and downstream filters purify the compressed air, feeded to
resp. dissipated from the dryer.
The two vessels contain an extremely porous drying agent by means of which
humidity is removed from the compressed air and stored just as in a sponge. The
stored humidity is then removed again from the drying agent and re-introduced
into the ambient environment.
To this end, the two vessels alternate between different operating modes. Whilst
in one vessel, compressed air is de-humidified (adsorption), in the other vessel
the humid drying agent is prepared for another charge (regeneration). These two
states, which run in parallel during compressed air preparation, are described
below.
Adsorption
Via a compressor, humid compressed air is
supplied to the compressed air inlet of the dryer.
From here, the compressed air flows upwards
through the absorption vessel, which is
pressurised. In so doing, the drying agent
dehumidifies the air. The dry compressed air is
supplied to the pipe network via the compressed
air outlet of the dryer.
Here, adsorption is shown in the
left vessel.
Regeneration (running in parallel to the adsorption)
At the same time the other vessel is prepared for a renewed take-up of humidity.
This process is called regeneration.
The regeneration is subdivided into three phases: expansion, dehumidification,
and pressure build-up.
With the dewpoint-sensing control option, the regeneration phase is followed by a
standby phase.

Technical product description
A190-930TX_EN_03_ 2009-02-06 17
Expansion phase
During the expansion phase the pressure in the
right vessel is released via the muffler down to
ambient pressure within just a few seconds. The
outflow of the compressed air becomes
noticeable due to a sudden powerful flow noise at
the muffler.
Dehumidification phase
Prior to being released into the pipe network,
dried compressed air is bled by means of an
orifice plate. This separate regeneration air flow
is fed through the depressurised vessel. The
humidity stored in the drying agent is taken up by
the air flow and expelled into atmosphere via the
muffler.
Here, regeneration is shown in the
right vessel.
Pressure build-up phase
After dehumidification the pressure in the
regenerated hollow section vessel is built up to
operating pressure, so that the switchover from
regeneration to adsorption can take place at
operating pressure level.
Pressure build-up
Standby phase (only with the dewpoint-sensing control option)
When in standby phase, the fully regenerated vessel is ready for absorption
operation. The system is switched to this vessel, as soon as the measured
dewpoint at the compressed air outlet has reached the set dewpoint value for
switchover.
Switchover
When the drying agent in the adsorbing vessel has taken up a sufficient level of
humidity, then the switchover between the vessels will be effected between the
vessels. Following switchover, the above-described process is repeated, with the
adsorption and regeneration now taking place in the respective different vessel.

Available options
18 A190-930TX_EN_03_ 2009-02-06
Available options
The following options are available for the dryer:
Start-up device
Outside installation
Auxiliary heater
Bypass line
Signalling contacts of control system
Compressor synchronisation
Dewpoint-sensing control
Pneumatic control
Paint compatible design
Pre- and after-filter
Condensate drain systems for pre- and after-filter
Start-up device
A start-up device basically consists of a pressure holding device, which is located
at the rear of the dryer. The pressure holding device ensures that pressure can
build up in the dryer and adsorption take place.
It is always required when an empty compressed air reservoir or an empty
compressed air system must be filled downstream of the dryer (e.g. following
weekend shutdowns and when the pressure in the compressed air system can
frequently drop below the stated operating pressure).
Outside installation
As standard, the dryer is not suitable for outside installation, as its function and
service life is influenced by the following factors:
Environmental humidity due to rain (or other deposit)
Corrosion caused by environmental humidity or a salt-containing environment
Freezing of valves, cocks, flaps, and other components at low temperatures
Therefore, a planned outside installation must always be discussed in advance
with the manufacturer to allow specific technical design measures to be provided
for the installation location.
Auxiliary heater
For installation sites with temperatures under +1 ºC, the wet side of the dryer
must be equipped with an auxiliary heater to prevent valves, cocks, flaps, and
other components from freezing up.
Bypass line
The bypass line is a "detour line", which allows the compressed air system to
continue operating even whilst maintenance of the dryer is in progress. However,
during this time the air is not dried but flows through the bypass line past the
dryer and through to the actual loads.

Technical product description
A190-930TX_EN_03_ 2009-02-06 19
Filters in the bypass line are meaningful so that the actual loads are largely
protected against dirt, water, and oil droplets even whilst maintenance is in
progress.
Signalling contacts of the control system
The control system is equipped with a digital input for the synchronised operation
with a compressor. This feature allows for synchronised and thus efficient dryer
operation with discontinuous compressor operation.
The control system can also be equipped with an optional operation signalling
contact with which the dryer operation can be monitored from an external device.
Dryers with the optional dewpoint-sensing control are equipped with such a
contact as standard. It is used for the transmission of operating signals and for
the output of dewpoint alarms.
Compressor synchronisation
Compressor synchronisation helps reduce energy costs, as the dryer can be
operated independently of the compressor.
When the compressor is switched off, the regeneration gas return ensures that
regeneration is continued, as soon as a certain compressed air volume is
reached behind the dryer. The regeneration process must be continued and
ended so that the drying agent does not become unusable prematurely.
The compressor synchronisation controller is a higher-level controller than the
pressure dew point controller (see below). When both options are in place, the
compressor synchronisation controller is treated as the prime controller.
Dewpoint-sensing control
With a dewpoint-sensing control system, you can operate the dryer in fixed or
variable cycles. In the fixed cycle, switchover is effected after a fixed time period
(usually after 5 minutes). In the variable cycle, the switchover is effected in
relation to the dew point reached and the charging of the drying agent . The
adsorption time in the variable cycle amounts to 60 minutes maximum.
Pneumatic control
A pneumatic control system can be used wherever an alternative to the electronic
control system is required, such as e.g. in explosion hazard areas.
Paint compatible design
Paint shop plants impose particularly stringent requirements with regard to the
cleanliness of the compressed air, as already the minutest contaminations can
reduce the quality of the paint finish. Even minute quantities of oil and grease
containing foreign materials or solvents — above all silicones — are sufficient to
cause pits, discolorations, swellings, and other contaminations in the paint finish.
Dryers in a paint compatible design comprise seals and filters that are absolutely
free of grease and silicon and thus ensure a high quality of the compressed air
used for painting.

Available options
20 A190-930TX_EN_03_ 2009-02-06
Preliminary and afterfilter
The installation of suitable preliminary filters is recommended for these reasons:
Removal of dirt or oil particles contained in the compressed air to prevent
contamination of the desiccant.
Elimination of large water droplets and thus prevention of unnecessary use of
desiccant.
Extension of service life of desiccant.
Preliminary filters should be installed as close to the dryer as possible. The pipe
feeding the air to the preliminary filter should be at a slight slope.
It is recommended to install an afterfilter behind the dryer to prevent
contamination of the dried compressed air with desiccant particles.
Condensate drain systems for preliminary and afterfilter
Condensate drain systems are installed to drain water that has collected in the
preliminary or afterfilter from the filter. There are two distinct types of condensate
drain system, namely level-controlled systems and time-controlled systems.