EKOM AD500 User manual

AD500 - 2250
User manual
Návod na použitie

DRYER
SUŠIČ
AD500-2250
EKOM spol. s r. o.
Priemyselná 5031/18
SK-921 01 Piešťany
Slovak Republic
tel.: [phone]
fax: [phone]
www.ekom.sk
email: eko[email protected]k
DATE OF LAST REVISION
DÁTUM POSLEDNEJ REVÍZIE
01/2020
NP_AD500-2250-1_01_2020
112000401-000

CONTENTS.................................................................................................. 5
OBSAH ........................................................................................................46

CONTENTS
01/2020 -5- NP_AD500-2250-1_01_2020
CONTENTS
GENERAL INFORMATION............................................................................................................6
1. CONFORMITY WITH THE REQUIREMENTS OF THE EUROPEAN UNION...................6
2. SYMBOLS........................................................................................................................6
3. DEVICE USE ...................................................................................................................7
4. GENERAL SAFETY INSTRUCTIONS..............................................................................8
5. STORAGE AND TRANSPORT ........................................................................................9
PRODUCT DESCRIPTION ..........................................................................................................10
6. VARIANTS.....................................................................................................................10
7. ACCESSORIES.............................................................................................................10
8. PRODUCT FUNCTION..................................................................................................11
TECHNICAL DATA......................................................................................................................17
9. MAXIMUM AIRFLOW CORRECTION AT THE DRYER INLET......................................18
10. OUTLET AIR PURITY....................................................................................................18
INSTALLATION...........................................................................................................................19
11. INSTALLATION CONDITIONS ......................................................................................19
12. DRYER ASSEMBLY ......................................................................................................19
13. PNEUMATIC CONNECTION.........................................................................................20
14. ELECTRICAL CONNECTION........................................................................................21
15. COMMISSIONING .........................................................................................................22
16. ETHERNET CONNECTION...........................................................................................22
17. PNEUMATIC AND ELECTRICAL DIAGRAMS...............................................................25
OPERATION................................................................................................................................28
18. SWITCHING ON THE DRYER.......................................................................................29
19. SWITCHING OFF THE DRYER.....................................................................................29
20. DISPLAY SCREEN........................................................................................................29
PRODUCT MAINTENANCE ........................................................................................................33
21. PRODUCT MAINTENANCE...........................................................................................33
22. LONG-TERM SHUTDOWN............................................................................................43
23. DISPOSAL OF DEVICE.................................................................................................43
TROUBLESHOOTING.................................................................................................................44
24. REPAIR SERVICE.........................................................................................................45
ANNEX ........................................................................................................................................88
25. INSTALLATION RECORD .............................................................................................88

GENERAL INFORMATION
NP_AD500-2250-1_01_2020 -6- 01/2020
GENERAL INFORMATION
Read the User manual carefully and keep it before use of the product. The User manual provides
information on correct use –installation, operation and maintenance of the product.
The User manual corresponds with the design of the product and condition according to the
applicable safetyand technical standards at the time of printing. The manufacturer reserves allrights
concerning the protection for the stated connections, procedures and names.
Slovak version is original of the User manual. The User manual has been translated in accordance
with the best available knowledge. The Slovak version is to be used in the event of any uncertainties.
1. CONFORMITY WITH THE REQUIREMENTS OF THE EUROPEAN UNION
This product conforms to the requirements of the European Union 2006/42/EC, 2014/29/EU,
2014/35/EU, 2014/30/EU, 2011/65/EU and is safe if used in compliance with the intended use and
if all safety instructions are followed.
User manual is in compliance with requirements of Directive 2006/42/EC.
2. SYMBOLS
The following symbols and marks are used in the User manual, on the device and its packaging:
General warning
Warning –risk of electric shock
Warning - compressor is controlled automatically
Warning –hot surface
General caution
Read User Manual
Refer to instruction manual
CE –marking
Serial number
Protecting earthing
Fuse
Compressed air inlet

GENERAL INFORMATION
01/2020 -7- NP_AD500-2250-1_01_2020
Compressed air outlet
Label for the power cord, equipment fuses and main switch
Control wire input
Package handling label –fragile
Package handling label –this side up
Package handling label –keep dry
Package handling label –temperature limits
Package handling label –limited stacking
Package label –recyclable material
Manufacturer
3. DEVICE USE
3.1. Intended use
The dryer is designed exclusively for cooling, drying and filtration of oil-free compressed air for
industrial use in applications where specific compressed air parameters and properties arerequired.
The dryer is exclusively intended for treatment of air without content of oil and explosive or
chemically unstable substances.
The dryer is intended for operation in clean and dry rooms.
3.2. Incorrect use
Contamination risk.
Air from the dryer without additional treatment is not suitable for breathing and
direct contact with food.
Explosion risk.
The product is not intended for operation in rooms with explosion risk.
The dryer must not be connected to oil-lubricated compressors without an upstream oil separator
installed.
The dryer must not be used for treatment of aggressive gases.
The dryer must not be operated in rooms with the presence of flammable vapours.
The dryer must not be operated in other conditions than mentioned in the technical data.

GENERAL INFORMATION
NP_AD500-2250-1_01_2020 -8- 01/2020
Any other use of the product beyond the intended use is considered as incorrect use. The
manufacturer is not responsible for any damages or injuries as a result of incorrect use or
disobedience to instructions stated in this User manual. All risks shall be solely borne by the user /
operator.
4. GENERAL SAFETY INSTRUCTIONS
The product is designed and manufactured so that any risks connected with its use are minimized
and the product is safe for the user and surrounding when used according to the intended use and
the instructions stated below are followed.
4.1. Required qualification if the personnel
Each user must be trained by the manufacturer or an organization authorized by the
manufacturer or instructed on the device operation by other trained user.
Installation, new settings, changes, extensions and repairs of the product may be performed by
the manufacturer or an organization authorized by the manufacturer (hereinafter qualified
technician).
- Otherwise the manufacturer is not responsible for safety, reliability and correct function of
the product.
4.2. General instructions
When operating the dryer, all acts and local regulations valid in the place of use must be
observed. The operator and user are responsible for following the applicable regulations.
Before every use, the user must check, if the device is functioning correctly and safely. Before
building the dryer in other devices, the supplier must assess, if the supplied air and construction
of the device comply with the requirements of the specified intended use. Taking this into
account, follow the product technical data. Assessment of conformity shall be performed by the
manufacturer –supplier of the final product.
4.3. Protection from dangerous voltage and pressure
The device can be connected only to a properly mounted socket with protective earthing.
Before connecting the product,check if mains voltage andmains frequency statedon the product
are in compliance with the values of the mains.
Before putting the product into operation, check eventual damages to connected pneumatic
hoses and electrical cables. Replace damaged pneumatic hoses and electrical cables
immediately.
Immediately disconnect the product from the mains (pull out the mains plug) in hazardous
situations or technical malfunctions.
Relief valve settings must not be changed and it must not be used to depressurize the device.
4.4. Original spare parts and accessories
Safety of operating staff and failure-free operation of the product are guaranteed only when
original spare parts are used. Only accessories and spare parts stated in the technical
documentation or explicitly approved by the manufacturer may be used.
The warranty does not apply to damages arising from use of accessories and spare parts other
than prescribed or recommended by the manufacturer and the manufacturer is not responsible
for them.

GENERAL INFORMATION
01/2020 -9- NP_AD500-2250-1_01_2020
5. STORAGE AND TRANSPORT
The manufacturer ships the device in a transport packaging. This protects the device from damage
during transport.
Risk of damage to pneumatic parts.
The dryer may only be transported depressurized. Prior to transport, vent air
pressure from the chambers and drain off condensate from the condensate
separator.
Original packaging must be kept for eventual return of the device. If possible,
always use the original device packaging for optimal protection of the product. If
it is necessary to return the product within the guarantee period, the
manufacturer does not guarantee for damages caused by incorrect packaging of
the product.
Protect the device from high humidity, dirt and extreme temperatures during transport
and storage. Do not store together with volatile chemical substances.
If it is not possible to keep the original packaging, dispose of the packaging in an
environmentally friendly way. Transport cardboard can be recycled with old paper.
It is not permitted to store and transport the device outside the defined
conditions.
5.1. Ambient conditions
Products can be stored in rooms and means of transport that are free from any traces of volatile
chemical substances under the following climatic conditions:
Temperature
from –25°C o +55°C, in 24h to +70°C
Relative humidity
max. 90% (non-condensing)

PRODUCT DESCRIPTION
NP_AD500-2250-1_01_2020 -10- 01/2020
PRODUCT DESCRIPTION
6. VARIANTS
The individual variants of the dryer are marked as follows:
ADE F-G/H (e.g. AD1500 S-40/8b),
The E, F, G and H codes are specified in the following table of available dryer variants.
Dryer variants
AD –Dryer line designation
E–Nominal flow at 7 Bar(g)
500
500 l/min (30 m3/h)
750
750 l/min (45 m3/h)
1000
1000 l/min (60 m3/h)
1500
1500 l/min (90 m3/h)
2250
2250 l/min (135 m3/h)
F–Dryer version
S
Standard version
C
Version with dew point sensor and
purge control
G–Pressure dew point at 7 / 9 Bar(g)
20
Pressure dew point -20°C
40
Pressure dew point -40°C
H–Working pressure
8b
6 - 8 Bar(g)
10b
8 - 10 Bar(g)
AD500-1000
AD1500
AD2250
7. ACCESSORIES
Accessories are not included in a standard order, they must be ordered separately.
Filters set
Dryer can be equipped with outlet compressed air filter set as required. The filter assemblies for the
individual dryer variants are specified below.

PRODUCT DESCRIPTION
01/2020 -11- NP_AD500-2250-1_01_2020
Name
Filter
specification
Dryer
Article number
FILTER KIT FS 49AHb)
AC/HC/0,01um
AD-500-1250 E,S
447000001-179
FILTER KIT FS 50AHb)
AC/HC/0,01um
AD-1500-2250 E,S
447000001-180
FILTER KIT FS 51AHb)
AC/HC/0,01um
AD-500-1250 C
447000001-169
FILTER KIT FS 52AHb)
AC/HC/0,01um
AD-1500-2250 C
447000001-170
FILTER KIT FS 49S a)
0,01um
AD-500-1250 E,S
447000001-171
FILTER KIT FS 50Sa)
0,01um
AD-1500-2250 E,S
447000001-172
FILTER KIT FS 51Sa)
0,01um
AD-500-1250 C
447000001-173
FILTER KIT FS 52Sa)
0,01um
AD-1500-2250 C
447000001-174
FILTER KIT FS 49Fa)
1um
AD-500-1250 C
447000001-175
FILTER KIT FS 50Fa)
1um
AD-1500-2250 C
447000001-176
FILTER KIT FS 51Fa)
1um
AD-500-1250 E,S
447000001-177
FILTER KIT FS 52Fa)
1um
AD-1500-2250 E,S
447000001-178
a) Accessory “Filter kit FS 49S-FS 52S” and “Filter kit FS 49F-FS 52F” filter assemblies contain a bracket and
a 1 or 0,01 µm particulate filter
b) The accessory “Filter kit FS 49AH-FS 52AH” filter assembly contains a bracket and a 0,01 µm particulate
filter with an AC (activated carbon) filter and HC (catalytic) filter.
8. PRODUCT FUNCTION
8.1. Design and principle of operation
Dryer design
The AD model line of dryers consists of adsorption dryers based on the PSA (“Pressure Swing
Adsorption”) method. Fig. 1. The dryer is composed of a compressed air cooler with fans (1),
condensate separator (13), inlet valve module (2), two chambers with replaceable cartridges filled
with adsorbent (3), outlet module (4) and control unit (5).
The inlet valve module is fitted with inlet (8 and 9) and regeneration (purge) (6 and 7) normally-
closed (NC) solenoid valves, which are used for cyclic chamber switching. Silencers (11) are
installed on the regeneration valves outlets. An outlet logic valve and purge orifices are installed in
the outlet module. The outlet module contains a dew point sensor in the “C” dryer versions.
Compressed air enters the equipment through the inlet (12) at the bottom of the cooler. The
compressed air outlet (17) is located in the output module.
The switch, power cord connector and control signal connector (e.g. from the compressor) are
placed from below at the front of the dryer. The RJ-45 Ethernet connector is located in the rear.
Principle of operation
Inlet air flows through the cooler and condensate separator into the valve module, where it is
directed into the active chamber with adsorbent, where the air is dried. The air then passes through
the built-in filters (see Fig. 1), outlet module and outlet filters (if the dryer is equipped accordingly)
to the outlet. A portion of the dry air (purge air) is directed into the second, regenerated chamber
from the outlet module through the purge orifices. The purge air with moisture removed from the
adsorbent is then released through the silencer. The chambers switch their functions cyclically.
Risk of high temperatures.
Placing air flow impediments upstream or downstream of the cooler is prohibited.
The temperature of internal and external parts of the equipment may rise to
hazardous levels.

PRODUCT DESCRIPTION
NP_AD500-2250-1_01_2020 -12- 01/2020
8.2. AD500-2250 S
“S” versions represent the standard dryer version without pressure dew point sensor and purge
control. The control unit in the “S” dryer versions performs the following tasks:
evaluation of the control signal from the compressor;
chamber switching - controlling the inlet and regeneration solenoid valves;
counting RUN hours when the dryer is active;
counting STANDBY hours;
monitoring service intervals and indicating upcoming service;
counting the cycles of solenoid valves (note: the Inlet_A inlet valve is monitored);
displaying information according to the user interface specifications (see Chapter 20).
8.3. AD500-2250 C
“C” dryer versions are equipped with a pressure dew point sensor and support purge control. The
control unit in the “C” dryer versions performs the following functions above and beyond the “S”
versions:
monitoring and evaluation of pressure dew point (PDP) values;
indication of a high dew point level;
purge control - pause chamber regeneration (“ECONOMY” mode);
counting ECONOMY mode hours.
8.4. Operating modes
“RUN” mode
The dryer is in “RUN” mode when the control signal from the compressor is active. The cooling fans
are running and the valves cyclically switch the chambers based on the diagram specified below. T
represents the chamber switching period, while dT is the phase of pressure equalisation in the
chambers before switching.

PRODUCT DESCRIPTION
01/2020 -13- NP_AD500-2250-1_01_2020
Valve switching diagram –“RUN” mode
"STANDBY” mode
The dryer is in “STANDBY” mode when the control signal from the compressor is inactive. The
cooling fans are off and chamber switching is deactivated.
"ECONOMY” mode (only “C” version)
“ECONOMY” mode is only available in dryers equipped with a dew point sensor.
The dryer switches into “ECONOMY” mode if the dew point over a defined period of time is lower
than the set point (varies according to dryer configuration). Chamber regeneration is paused, the
inlet valves continue to switch chambers cyclically based on the following schedule.
As the dew point rises and approaches the set point, "ECONOMY” mode is deactivated and the
dryer switches to “RUN” mode.
The duration of “ECONOMY” mode is limited. After a defined period, the dryer shortly switches into
standard “RUN” mode and then continues in “ECONOMY” mode.

PRODUCT DESCRIPTION
NP_AD500-2250-1_01_2020 -14- 01/2020
Valve switching diagram –“ECONOMY” mode

PRODUCT DESCRIPTION
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Fig. 1: Dryers AD500 –AD1000
Description to Fig. 1 - Fig. 2 - Fig. 3
1 Cooling module
2 Inlet valve module
3 Dryer chamber
4 Outlet module
5 Control unit
6 Regeneration solenoid valve
7 Regeneration solenoid valve
8 Inlet solenoid valve
9 Inlet solenoid valve
10 Pressure relief valve
11 Noise silencer
12 Compressed air inlet
13 Condensate separator
14 Pressure gauge
15 Timer
16 Dryer pan
17 Air outlet

PRODUCT DESCRIPTION
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Fig. 2: Dryer AD1500
Fig. 3: Dryer AD2250

TECHNICAL DATA
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TECHNICAL DATA
Dryers are designed to operate in dry, ventilated and dust-free indoor rooms with the following
climatic conditions:
Temperature
from +5°C to +40°C
Relative humidity
max. 95%
AD500
AD750
AD1000
AD1500
AD2250
Dryer version
S
C
S
C
S
C
S
C
S
C
Control unit
●
●
●
●
●
●
●
●
●
●
Dew point sensor
-
●
-
●
-
●
-
●
-
●
Nominal inlet
flow at 7 Bar(g)
l/min
500
750
1000
1500
2250
Voltage
V
230
Frequency
Hz
50 / 60
Max. current
A
0.3
0.3
0.3
0.4
0.5
Pressure dew
point (PDP)
°C
-20
-40
-70a)
Working
pressure
Bar(g)
6 –8
8 –10
Maximum
pressure
Bar(g)
10
Minimal pressure
Bar(g)
3
Noise level at
7 Bar(g) (LpA)
dB(A)
Operating mode
%
S1-100
S1-100
S1-100
S1-100
S1-100
Regeneration
loss at 71)/92)
Bar(g)b)
%
PDP -20°C: 15%1) / 12,5%2)
PDP -40°C: 20%1) / 17,5%2)
Air purity class
(ISO 8573-
1:2010)
up to 1.3.13)
up to 1.2.14)
Dimensions (net)
w x d x h
mm
530x350x965
530x350x1310
530x350x1460
Net weight
kg
46c)
58c)
64c)
1) Valid for versions with a working pressure of 6 –8 Bar(g)
2) Valid for versions with a working pressure of 8 –10 Bar(g)
3) Valid for versions with PDP -20°C
4) Valid for versions with PDP -40°C
a) Please contact the manufacturer if dew point -70°C is required
b) Regeneration losses are indicative only and correspond to a working pressure of 7 Bar(g) (for 6 –8 Bar(g)
versions) and 9 Bar(g) (for 8 –10 Bar(g) versions). The values represent total losses, including the
chamber depressurization at the start of the regeneration process.
c) Weight value is only informative and applies only to a product without any accessories

TECHNICAL DATA
NP_AD500-2250-1_01_2020 -18- 01/2020
9. MAXIMUM DRYER INLET AIRFLOW CORRECTION
The nominal inlet flow specified in the table with technical specifications corresponds to the following
operating conditions:
Working pressure
7 Bar(g)
Inlet air temperature
100°C
Moisture content in inlet air
Absolute moisture content 27.5 g/m3at 0 Bar(g)
This corresponds to a compressor drawing in air
with a temperature of 30°C and relative humidity
of 90% at normal atmospheric pressure
Ambient temperature
30°C
At other operating conditions, maximum dryer airflow (Qm) is calculated using the nominal flow
shown above in the technical specifications (Qn) and a combination of correction factors k1, k2, k3
using the formula:
Qm= k1 xk2 xk3 x Qn
Correction factor k1–effect of working pressure
6 –8 Bar(g)
Working pressure
(Bar(g))
3
4
5
6
7
8
9
10
k1
0,51
0,63
0,75
0,88
1,00
1,12
1,25
1,37
8 –10 Bar(g)
Working pressure
(Bar(g))
3
4
5
6
7
8
9
10
k1
0,40
0,50
0,60
0,70
0,80
0,90
1,00
1,10
Correction factor k2–effect of inlet air temperature
Temperature (°C)
80
90
100
110
120
k2
1,12
1,05
1,00
0,91
0,85
Correction factor k3–effect of ambient air / cooling air temperature
Temperature (°C)
20
25
30
35
40
k3
1,24
1,11
1,00
0,83
0,71
Provided calculation is informative. Please consult the manufacturer regarding specific application
and conditions.
10. OUTLET AIR PURITY
Based on the accessory filtration that is used (Chapter 7), the following outlet air purity levels can
be achieved (expressed as A.B.C purity classes, where A is the purity class for the particulate, B is
water vapour content and C is oil content pursuant to ISO 8573-1:2010).
Filter set
Pressure dew point
FS 49-52 F
FS 49-52 S
FS 49-52 AH
-20°C
3.3.1
1.3.1
1.3.1
-40°C
3.2.1
1.2.1
1.2.1

INSTALLATION
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INSTALLATION
Risk of incorrect installation.
Only a qualified technician may perform installation and commissioning of the
compressor. His obligation is to train the operating personnel on the use and
maintenance of the device. He shall confirm installation and training of operators
by an entry into the installation record (see annex / Príloha).
11. INSTALLATION CONDITIONS
The device may only be installed and operated in dry, well-ventilated and dust-free rooms with
conditions stated in technical data.
Risk of damage to the device.
The equipment may not be operated in outdoor environment or in humid or wet
rooms.
Risk of explosion.
Do not use the equipment in the presence of explosive gases, dust or
combustible liquids.
The dryer must be installed in such a way, that it is accessible at all times for operation and
maintenance and label on the device is accessible.
The dryer must stand on a flat, sufficiently stable base (be aware of the compressor weight, see
technical data).
12. DRYER ASSEMBLY
Unpack the dryer from the packaging.
Put the dryer at the place of operation (Fig. 4).
12.1. Manipulation
At least two persons are needed to manipulate the equipment.
Integrated handles are installed on the lower brackets on the product. Each person must grasp the
equipment with one hand on a handle and the other behind the dryer chamber when moving the
equipment.

INSTALLATION
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Fig. 4: Manipulation with the equipment
13. PNEUMATIC CONNECTION
13.1. Compressed air inlet
Connect compressed air source to the
dryer inlet (1) (Fig. 5).
A G 3/4” connection is installed.
Fig. 5: Compressed air inlet
13.2. Compressed air outlet
Connect the dryer outlet (1) to the
compressed air distribution system (Fig. 6).
A G 3/4” connection is installed.
Fig. 6: Compressed air outlet