Compressed Air Alliance DEW 1 Series User manual

www.compressedairalliance.com 1
User Manual
Dew Point Sensor -
W Series
Model: DEW

Dew Point Sensors –W Series User Manual v1
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Table of Contents
Notices...........................................................................................................................................3
Warnings .......................................................................................................................................3
About Dew Point Sensors............................................................................................................5
Specifications –W Series .............................................................................................................6
Dew Point Sensor Pack................................................................................................................7
Installation Overview ...................................................................................................................8
Installation ....................................................................................................................................9
Using the Display........................................................................................................................16
Commuication Settings .............................................................................................................22
Warranty......................................................................................................................................23
Calibration...................................................................................................................................23
Trouble Shooting........................................................................................................................24
Commissioning Report ..............................................................................................................27

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Notices
Please read this manual in full and
carefully observe the notes and
instructions before and during
installation, operation and
maintenance. The manufacturer cannot
be held liable for any damage which
occurs as a result of noncompliance
with this manual.
Do not tamper with device. Should
the device be tampered with in any
manner other than a procedure which
is described and specified in this
manual, the warranty is cancelled and
the manufacturer is exempt from
liability.
The product is designed exclusively
for the described application. Use of
this product in conditions not specified
in this manual or, contrary to the
instructions provided by the
manufacturer, is considered improper
handling of the product and will void
your warranty. The manufacturer will
not be held liable for any damages
resulting from improper use of the
product.
This manual should be read carefully by
relevant personnel and the end user.
This manual should be kept with the
product and be made available as
needed. Once you install or use the
product, you accept that you have
read, understood and complied with
this manual.
Compressed Air Alliance endeavours to
make the content of this manual
correct, but is not responsible for
omissions or errors and the
consequences caused. In case of any
doubts or questions regarding this
manual or the product, please contact
Compressed Air Alliance.
Warnings
Ignoring the warnings can lead to
serious injury and/or cause damage!
When handling, operating or carrying
out maintenance on this product,
personnel must employ safe working
practices and observe all local health &
safety requirements and regulations.
Improper operation or maintenance of
this product could be dangerous and
result in an accident causing damage to
machinery or injury or death.
The manufacturer cannot anticipate
every possible circumstance which may
represent a potential hazard. The
warnings in this manual cover the most
common potential hazards and are
therefore not all-inclusive. If the user
employs an operating procedure, an
item of equipment or a method of
working which is not specifically
recommended by the manufacturer
they must ensure that the product will
not be damaged or made unsafe and
that there is no risk to persons or
property.
NEVER CHANGE ORIGINAL
COMPONENTS WITH ALTERNATIVES.

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Compressed Air
Safety
Any contact with quickly escaping air
or bursting parts of the compressed
air system can lead to serious injuries
or even death.
•Do not exceed the maximum
permitted pressure.
•Only use pressure rated
installation materials and parts.
•Avoid getting hit by escaping air
or bursting parts.
•The system must be pressure-
less during maintenance work.
Electrical Safety
Any contact with energised parts of
the product, may lead to an electrical
shock which can lead to serious
injuries or even death. The user shall
take all measures necessary to
protect against electrical shock.
Consider all regulations for electrical
installations.
The system must be disconnected
from any power supply during
maintenance work.
Any electrical work on the system is
only allowed by authorised qualified
personal.
Storage and transportation
•Make sure that the
transportation temperature of
the sensor is between
-10°C to 60°C (14°F to 140°F).
•Please make sure that the
storage temperature of the
sensor is between -10°C to 50°C
(14°F to 122°F) and the humidity
is <90%, no condensation. Avoid
direct UV and solar radiation
during storage.
Cleaning
If you need to clean the product it is
recommended to use a clean, dry
cloth. For stubborn marks, use
distilled water or isopropyl alcohol
only.
Please note: contamination on the
sensor tip will affect calibration and
accuracy of the sensor. Removal of
the contamination may not fix the
issue.
Disposal
Electronic devices are recyclable
material and do not belong in the
household waste. The product,
accessories and its packing material
must be disposed according to local
statutory requirements.

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About Dew Point Sensors
When it comes to monitoring
compressed air and gas systems,
nothing offers a better payback than
a dew point sensor. Once you have
moisture in your system, everything
becomes a problem. If you have ever
had this occur, you'll know the
problem occurred days before you
discovered it and it took even longer
to dry out after the issue was fixed.
Most people don't think of dew point
sensors as providing efficiency, but
wet compressed air or gases will do
irreparable damage to components,
create reliability issues throughout
your entire plant and allow bacteria,
rust and corrosion to build up in your
system. Moisture issues are
extremely difficult to rectify and
component failures will go on for
years.
If you have a system running a
desiccant dryer or with a specified
purity requirement, then you are
already aware that dew point is a
critical component of your system
and therefore should be monitored
continuously.
Indicators on refrigerant dryers
don’t measure dew point
The indicator on your refrigerant
dryer is exactly that, an indicator, it is
not measuring the dew point
entering your plant. It is only
measuring the temperature of the
refrigerant gas. Any number of issues
before and after your dryer can lead
to the dew point deteriorating and
will not be shown on the dryer
indicator.
Compared to your compressed air or
gas system, dew point sensors are
cheap, easy to install and have low
maintenance requirements. They are
the most cost effective sensor
purchase you are ever likely to make.
Benefits of monitoring dew point
•Improve system reliability
•Reduce product contamination
risks
•Reduce system maintenance
•Reduce operating and energy
costs
•Reduce the risk of rust and
corrosion build up
•Improve dryer reliability
•Improve filter life and
performance
•Reduce the risk of bacteria,
fungus and yeast build up
•Alerts you to changes in dryer
performance before moisture
appears in your plant
•Easy to install and low
maintenance
•Suitable for temporary or
permanent installations.

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Specifications –W Series
DEWx1xxxx
DEWx2xxxx
DEWx3xxxx
Technology
Polymer
Alumin-Oxide
Quartz
Dryer Type
Refrigerant, Desiccant or Membrane dryers up to 4 Mpa
(600psi)
Gases
Air, Argon, Carbon Dioxide, Carbon Monoxide, Helium,
Hydrogen, Nitrogen, Oxygen
Accuracy
Dew Point: ±3°C
Temperature: ±0.5°C
Pressure: ±0.3% FS (at 23°C)
The accuracy of the sensor is affected by on-site conditions.
Contaminants such as oil, high humidity or other impurities can
affect the calibration and accuracy of the sensor.
Minimum gas flow
> 1 L/min
Measurement Ranges
Dew Point
Measurement
-60°C to +60°C
-76°F to 140°F
-80°C to +20°C
-112°F to +68°F
-110°C to +0°C
-166°F to +32°F
Gas Relative
Humidity
0 to 95% RH
Pressure
Measurement
0 to 40 bar or
0 to 16 bar if using the integrated pressure sensor
Gas Temperature
Measurement
-40°C to +100°C
-40°F to +212°F
Outputs
Output
No output –stand alone unit only.
Power
Power Supply
Standard wall socket, 110-240vAC
Other Information

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DEWx1xxxx
DEWx2xxxx
DEWx3xxxx
Options
Integrated pressure sensor
Display
11cm (4.3”) LCD colour touch screen
Ambient
Temperature
-30°C to +70°C
-22°F to +158°F
Dimensions
320 mm L x 158 mm W X 95 mm D
12.6” L x 6.2” W x 3.7” D
Casing
Plastic
Installation Type
Permanent or temporary installation
Calibration
Frequency
Every 2 years provided the sensor is not exposed to relative
humidity above 85%
Dew Point Sensor Pack
Each dew point sensor comes with:
✓Wall mount dew point sensor
✓6 mm PTFE tube with nitto fitting. Tube length: 1.5 meters (5 foot) long
oA longer tube can be provided upon request, but it will slow the sensor’s
response time.

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Installation Overview
Step 1 –Attach dew point monitor to a suitable location.
•The dew point monitor must be installed on a solid, vertical surface (eg a
wall or post), near a power supply.
Step 2 –Create a connection point on the pipe, eg a ball valve, nozzle or nipple.
•The dew point monitor must be connected to dry side of system (ie after a
dryer or in gases with relative humidity below 80%).
•Do NOT create a connection point on the bottom of a pipe or in a location
that allows moisture to gather in the dew point monitor.
Step 3 –Connect dew point monitor to the pipe.
Step 4 –Connect power to the dew point monitor and turn on power.
Step 5 –Set alarm.
Step 6 –Fill out the Commissioning Report (last page of this manual)
Tools and Equipment needed for installation
(not included with Dew Point Sensor Pack)
Ball Valve
(optional)
Screw Driver
Drill
Thread Tape /
Sealant
Screws
Nitto coupling
(optional)

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Installation
WARNING! Incorrect installation can damage the dew point monitor or
cause it to work incorrectly.
Notes
•Before installing the product, make sure it is rated for your system (refer
to the “Specifications” section).
oUse of the product outside specified ranges or operating parameters can
lead to malfunctions and may damage the product or system.
•The dew point monitor must be disconnected from any power supply
during installation and maintenance work.
•The dew point monitor must be installed on a solid, vertical surface (eg a wall or
post).
•Do not use this product in explosive areas.
•Do not use this product outdoors. The dew point monitor is only suitable for
indoor applications.
•Always use the correct tools (eg screw driver, spanner / wrench) to install the
product.
•Only use pressure rated materials and parts when installing and maintaining
the product.
•Do not disassemble the product.
•Please observe local and national regulations before/during installation and
operation.
•The product must be installed properly and calibrated regularly, otherwise it
may lead to inaccurate measurement values.
•Response times: The dew point sensor may take up to 24 hours to stablise.
Once stablised, response times will be a few seconds or less.

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Step 1 –Attach dew point monitor to suitable location
The dew point monitor must be installed on a solid, vertical surface (eg a wall or
post). Make sure the dew point monitor is installed near a power socket.
The dew point monitor must be connected to dry gas (gas humidity should be less
than 80% relative humidity (RH)).
There are 4 mounting holes on the back of the dew point monitor. You access these
inside the cabinet.
•Drill 4 holes to match dimensions shown below.
oHorizontal spacing: 146 mm (5.7”)
oVertical spacing: 226 mm (8.9”)
•Remove caps from each corner of the front panel.
•Unscrew front panel and open.
•Attach dew point monitor to a solid, vertical surface
using screws.
oFix firmly to prevent loosening or shaking
•Close and secure / screw front panel. Insert caps in
each corner.
226 mm (8.9”)
(Vertical)
146 mm (5.7”)
(Horizontal)
Back of Dew
Point Monitor
Mounting
hole
Remove caps and
unscrew front panel
Mounting holes
Dew Point Sensor

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Correct Installation
Incorrect Installation
Do NOT install the dew point monitor before a dryer or in gases with a relative
humidity above 80%.
Do NOT install the dew point monitor below the connection point, as shown below.
Do NOT let condensate reach the tip of the sensor.
Dry Side
Wet Side
Dryer
Compressor
Filter
Filter
Sensor in wet gas
Sensor below
connection point
Dry Side
Wet Side
Dryer
Compressor
Filter
Filter
Sensor in dry gas

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Step 2 –Create a connection point on the pipe
You need a connection point on the pipe, eg a ball valve or a nozzle or nipple.
The dew point monitor must be connected to dry side of system (after a dryer or in
gases with relative humidity below 80%).
Do NOT create a connection point on the bottom of a pipe or in a location that
allows moisture to gather in the dew point monitor.
Use of a ball valve is optional - You do not need to use a valve to install the sensor.
However, using a valve will make removing the sensor easier (eg when you need to
remove the sensor for calibration).
If installing a ball valve, you can use a hot tap drill and clamp to create a connection
point on pressurized or unpressurized pipes. See the Compressed Air Alliance
website for information on hot tap drills and clamps.
Ball Valve
Welded nipple on pipe
OR

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Step 3 –Connect dew point monitor to pipe
•Inset the PTFE tube into the 6 mm push fitting on the dew point monitor.
•Insert the other end of the PTFE tube (with the nitto fitting) into the connection
point (eg valve, nipple or nozzle).
oThe nitto fitting can be removed and the tube connected to a nipple using a
push fitting or other connector, if required.
oUse thread tap or sealant, where required.
•Open the valve.
•Check for leaks at the PTFE tube connection points.
6mm PTFE Tube
Dew Point Monitor
Nitto fitting can be
removed, if needed
Ball Valve
(optional)

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Step 4 –Connect dew point monitor to power and turn on
WARNING! Incorrect wiring can damage the sensor or cause it to work
incorrectly.
Notes:
•Only connect the dew point monitor to a standard wall socket, 110-240vAC.
High voltages will damage the product.
•Consider all local and national safety requirements and regulations for electrical
installations.
•Any electrical work on the system is only allowed by authorised and qualified
personal.
•Do not tamper with the wiring inside the dew point monitor. Modifying the
wiring will void your warranty and could damage the sensor.
Plug in the Dew Point Monitor and turn the power point on.
oThere is no on/off switch on the dew point monitor.
Power indicator
Green / Red light
Green = normal operation
Red = alarm triggered

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Step 5 –Set alarm
You can set the alarm via the touch screen display. Only one (1) alarm can be set.
When the alarm triggers, the light will go red and a sound will be heard.
•Press “Sensor Setting”on the menu at the bottom of the screen.
•Press “Alarm” on the menu on the left hand side of the screen.
•Adjust alarm settings.
oChannel –Select which measurement channel (dew point, temperature or
relative humidity) you want to set the alarm.
oType (Upper / Lower) –Select if the alarm to trigger when it goes above or
below the threshold value.
oHystersis - Set the Hystersis value.
▪For example, if you set the alarm to trigger when it reaches an upper
value of 25 and the Hystersis is 1, the alarm will automatically turn off
when the reading drops to 24.
oThreshold - Enter the alarm set point (ie the point you want the alarm to
trigger).
1
2
3

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Using the Display
The touch screen display has three (3) main menus (along the bottom of the screen)
–‘Value’, ‘Sensor Setting’and ‘Menu’.
•Value (or home screen) shows you the current dew point, temperature and
relative humidity values.
•Sensor Setting allows you to set the alarm and view the modbus settings of the
dew point sesnor.
•Menu allows you to change the brightness of the screen, set the date and time,
view the device information (serial number, hardware version and software
version) and update the modbus settings of the display to match the modbus
settings of the dew point sensor.
Value Screen
The Value screen (or home screen) shows you the current dew point, temperature
and relative humidity values.
Date and Time
Menu options
Measurement Values
Home screen
(Value)

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Sensor Setting
RS485
View the modbus settings for the dew
point sensor. You can not edit this
screen.
Notes:
•You can not change the dew point
sensor’s modbus settings using
the display.
•If you need to change the modbus
settings of the dew point sensor,
you must use the CAA Service
Software. Contact Compressed Air
Alliance for more information.
•If you change the modbus settings
of the dew point sensor, you will
need to update the modbus
settings of the display (go to
‘Menu > Communication’ to
change the modbus settings of
the display).
Which Modbus screen do I
use?
The dew point monitor has two
screens with Modbus information.
Sensor Setting > RS485 (this
screen) = Modbus setting of the
dew point sensor.
Menu > Communication =
Modbus setting of the touch
screen display
In order for the touch screen
display to work, the modbus
settings of the display (Menu >
Communication) must match the
modbus settings of the sensor
(Sensor Setting > RS485)

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Alarm
Set the alarm. You can only set one (1)
alarm.
If you don’t want to use the alarm, set
the threshold to well outside your dew
point range.
Set the alarm:
•Select which channel you want to
set the alarm for - dew point,
temperature or relative humidity.
•Set the alarm to trigger when it
reaches an upper or lower limit.
•Set the Hystersis value.
oFor example, if you set the
alarm to trigger when it
reaches an upper value of 25
and the Hystersis is 1, the
alarm will automatically turn
off when the reading drops to
24.
•Set the alarm value / threshold.
Dew Point
Compressed Air Alliance does not
recommend you change the dew point
settings.
This screen is password protected.

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Menu Screen
The menu screen has two options:
•Communication settings for the
touch screen display
•System which allows to change
the brightness of the screen,
change the date / time and view
the device information.
To return to the previous screen, click
on the back arrow ( <) on the top left
of the screen.
System > Screen
Change the screen brightness by
sliding the bar.
Click on the back arrow ( <) at the top
left of screen to return to the previous
page.
Click the back arrow ( <) to
return to the previous screen

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System > Date
Change the date and time of the dew
point monitor.
•Click on the field to update
•Enter new value
•Click “Enter”
Click on the back arrow ( <) at the top
left of screen to return to the previous
page.
Note:
•If you loose power to the dew
point monitor or you turn the
power off, the date / time will
reset to midnight on 1 January
2000.
System > Device Info
View the:
•Product’s serial number
•Hardware version
•Software version.
Click on the back arrow ( <) at the top
left of screen to return to the previous
page.