NANO D-Series Manual

D-Series¹
HEATLESS COMPRESSED AIR DRYER
MAINTENANCE & SERVICE MANUAL
www.n-psi.com
NDL-010
NDL-020
NDL-030
NDL-040
NDL-050

Page 2
Copyright
This manual is copyrighted, all rights reserved. It may not, in whole or in part, be copied, photocopied,
reproduced, translated, or reduced to any electronic medium or machine readable form without prior consent
in writing from nano-purification solutions. It may not be distributed through the internet or computer bulletin
board systems without prior consent from nano-purification solutions.
GENERAL INFORMATION
©2012 nano-purification solutions
Heatless Desiccant Air Dryer: D-Series1 (010-050) Service Manual
Models: NDL-010, 020, 030, 040, 050 (Including ES Option)
Document number: n-psi-D1(010-050)-OM-US-01
Issue: 001
Document Introduction
This manual provides manufacturers prescribed procedures for the maintenance and service procedures for a
nano-purification solutions compressed air dryer. The procedures illustrated in this document are only to be
performed by authorised personnel. For further information regarding the procedures outlined in this document
contact nano-purification solutions before proceeding. Read this document carefully before attempting to
service the dryer.
General Safety
For your own safety, when carrying out maintenance work on the dryer, all relevant national safety regulations
must be complied with relating to pressurised and electrical systems. Only authorised, competent and trained
personnel should maintain the dryer, this user guide is intended solely for such personnel and is to be used
only as a reference, it should not be used to replace conventional training.
NOTES: highlight important sections of information where particular care and attention should
be paid.
CAUTIONS: indicate any situation or operation that may result in potential damage to the
product, injury to the user, or render the product unsafe.
Warranty guidelines
All dryers are supplied with a 5 year manufacturer’s warranty from the date of purchase. The dryer should be
installed, operated and maintained in accordance with the manufacturer’s guidelines. Only genuine service
parts should be used and no modifications should be made. For further information please contact us at
[email protected].

Page 3
nano-purification solutions
11330 Vanstory Drive
Huntersville, NC 28078
Telephone: [phone]
Internet: www.n-psi.com
E-mail: [email protected]
Title
1. Service Intervals
2. Product Assembly
3. Recommended Tools
4. Dryer Shutdown Procedure
5. Service A Instructions – Cartridge Replacement (NDL-010 – NDL-050)
5. Service A Instructions - Replacing O-rings, Nitrile Ball and Gasket Seal.
8. Service B Instructions – Exhaust Valve Replacement
9. Service C Instructions – ES Models Only
10. Re-setting the Dryer Controller
11. Manifold Tightening Sequences
12. Dryer Start-up Procedure
13. Other Dryer Checks & Non-Serviceable Items
14. Troubleshooting
15. Service Record & Notes
MANUFACTURERS DETAILS
CONTENTS
Page(s)
4
5
6
6
7
8-10
11-12
13-14
15
16
17
18
19
20-21

Page 4
The following table details the recommended service intervals for this product and the service kits to be used.
1. SERVICE INTERVALS
Required Service Kits
Dryer
Model Service A Service B Service C
NDL-020
NDL-010
NDL-030
NDL-040
NDL-050
NDK-010
NDK-020
NDK-030
NDK-040
NDK-050
NDK-010 + NVK-050 NSK-130
NDK-020 + NVK-050 NSK-130
NDK-030 + NVK-050 NSK-130
NDK-040 + NVK-050 NSK-130
NDK-050 + NVK-050 NSK-130
Additional For ES Models Only
Recommended Service Intervals
Service
Type
B
AP P P P PP
P
PP PP PP PP PP
C
1
Year
2
Years
3
Years
2 Years
(12,000 Hrs)
4 Years
(24,000 Hrs)
6 Years
(36,000 Hrs)
8 Years
(48,000 Hrs)
10 Years
(60,000 Hrs)
P
12 Years
(72,000 Hrs)
PP
4
Years
5
Years
6
Years
7
Years
8
Years
9
Years
10
Years
11
Years
12
Years

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2. PRODUCT ASSEMBLY
TOP COVER
OUTLET (TOP)
MANIFOLD
ASSEMBLY
DESICCANT
CARTRIDGES
DRYER
CONTROLLER
DRYER
SHROUD
DRYER
COLUMN
INLET (BOTTOM)
MANIFOLD
ASSEMBLY
DRYER LEGS
MODELS NDL-010 TO NDL-050
EXHAUST
VALVES
SILENCER
ASSEMBLY
CONTROLLER
COVER
(BOTTOM)
CONTROLLER
COVER (TOP)
VALVE
BLOCK

Page 6
3. RECOMMENDED TOOLS
The following tools will be required to service the dryer:
SOCKETS: 5.5mm, 7mm and 17mm
ALLEN KEY SOCKETS: 3mm, 5mm and 8mm
SCREWDRIVER
TORQUE WRENCH (0-10NM)
ALLEN KEY 4mm
SPANNER 17mm
SPANNER 19mm
4. DRYER SHUT DOWN PROCEDURE
Before performing any maintenance or service operations on this product, ensure the product
is isolated from the compressed air supply and fully de-pressurised. Also ensure the product is
switched off and/or isolated from the mains electrical power.
PROCEDURES
• Closetheinletandoutletvalves.
The dryer might still be pressurised! In order to de-pressurise the dryer; ensure the dryer is isolated from the
compressed air source:
o Cycle the dryer twice to ensure the dryer exhausts and is completely depressurised.
o When fully depressurised the ‘clicking’ of the exhaust valves will be heard but no air
exhausted.
• Whenthedryerisfullydepressurised,isolatefromthepowersupply.

Page 7
5. SERVICE ‘A’ INSTRUCTIONS:
REPLACING DESICCANT CARTRIDGES NDL-010 to NDL-050
(Every 12,000 hrs or 24 months)
Please refer to figure 1
1. Ensure the dryer is shut down and fully
depressurised before attempting any maintenance
work. (See page 6)
1. Remove the 4x M5 dome head screws to release
the top cover and lift from assembly.
2. Remove the 2x M6 cap head screws as shown
from the outlet (top) manifold.
3. Remove the 8x M6 cap head screws to remove
the outlet (top) manifold from the dryer column.
4. Remove the gasket seal.
5. Remove the 2x cartridges using the handle to
withdraw them from the column.
6. Check and clean the outlet (top) manifold and
dryer column as required paying particular attention
to the gasket sealing areas.
7. Remove the new cartridges and gasket seal
from the service kit provided.
8. Insert the new gasket seal into the gasket
groove on the underside of the outlet (top) manifold
ensuring it is fully retained.
9. Insert the 2x new desiccant cartridges and rotate
until they sit correctly into place . Then press down
until they stop and the cartridge is below the top
surface of the dryer column (See Figure’s 2 & 4).
10. Replace the outlet (top) manifold and secure
with the 10x M6 cap head screws tightening to a
torque setting of 5Nm. Refer to the page 16 and
follow the correct tightening sequence.
11. The seal between the dryer column and outlet
(top) manifold should be checked for leaks prior to
fitting the top cover and operating the dryer.
12. Replace the dryer top cover and secure with
the 4x M5 screws. These screws should be hand
tightened or tightened at a torque setting of less
than 1Nm. Insert desiccant cartridge and rotate until it
sits correctly within the dryer column then
push downwards until you hear a click.
Figure 2.
Figure 1.
2x M6 CAP
HEAD SCREWS
8 X M6 CAP
HEAD SCREWS
OUTLET
MANIFOLD
GASKET
SEAL
DESICCANT
CARTRIDGE
4x M5 DOME
HEAD SCREWS
TOP
COVER

Page 8
5.1 SERVICE ‘A’ INSTRUCTIONS
REPLACING O RINGS AND NITRILE BALL WITHIN THE OUTLET
MANIFOLD
(Every 12,000 hrs or 24 months)
2x M6 x 50 CAP HEAD
SCREWS
PURGE BLOCK
3x O RINGS
GASKET SEAL
NITRILE BALL
8mm PUSH IN FITTING
4x M4 CAP HEAD
SCREWS
8x M6 x 25 CAP
HEAD SCREWS
Please refer to figure 4.
1. Ensure the dryer is shut down and
fully depressurised before attempting any
maintenance work. (See page 6)
2. Remove the 4x M5 dome head screws to
release the top cover and lift from assembly.
3. Remove the 2x M6 x 50 and the 8x M6 x
25 cap head screws as shown from the outlet
(top) manifold to release it from the assembly.
4. Remove the 4x M4 cap head screws and
washers to remove the purge block from the
outlet (top) manifold.
5. Remove and discard the 3x O rings sat on
the underside of the purge block.
(See Figure 3.)
6. Insert the new O rings from the service kit
provided and replace into the grooves on the
underside of the purge block. (See Figure 3.)
7. Remove and discard the nitrile ball from the
outlet manifold.
8. Replace the nitrile ball from the service kit,
into the 3 way valve orifice.
9. Sit the purge block back on top of the
outlet manifold and replace the 4x M4 cap
head screws at torque setting of 3Nm.
10. Sit the manifold assembly back on top of
the dryer column and replace the 2x M6 x 50
and 8x M6 x 25 cap head screws at a torque
setting of 5Nm.
NOTE: Refer to the page 16 and follow the
correct tightening sequences.
OUTLET (TOP)
MANIFOLD
Figure 3. Figure 4.
4x M5 DOME HEAD
SCREWS

Page 9
5.2 SERVICE ‘A’ INSTRUCTIONS
REPLACING O RINGS, NITRILE BALL AND GASKET SEAL WITHIN THE
INLET MANIFOLD
(Every 12,000 hrs or 24 months)
Please refer to figure 5.
1. Ensure the dryer is shut down and
fully depressurised before attempting
any maintenance work. (See page 6)
2. Unclip the solenoid plug from the
valve stem.
(See Figure 2 & 3 on page 11)
3. Remove the 8x M4 cap head screws
and washers from the valve block to
release the exhaust valves.
4. Remove the 2x M6 cap head screws
to release the valve block from the inlet
manifold.
5. Remove and discard the 3x O rings
on the underside of the valve block.
6. Insert the new O rings from the
service kit and replace into the grooves
on the underside of the valve block.
(See Figure 6 on page 10)
7. Remove the 8x M6 cap head screws
from the inlet manifold to release it from
the dryer.
8. Remove and discard the nitrile ball
from the inlet manifold.
9. Replace the nitrile ball from the
service kit and replace into the 3 way
valve orifice. (See Figure 7 on page 10)
10. Remove and discard the gasket seal
from the underside of the inlet manifold.
11. Insert the new gasket seal from the
service kit into the gasket seal grooves
on the underside of the inlet manifold.
Figure 5.
GASKET SEAL
SOLENOID PLUGS
4x M4 CAP HEAD
SCREWS
EXHAUST VALVES
2x M6 CAP HEAD
SCREWS
VALVE BLOCK
8x M6 CAP HEAD
SCREWS
NITRILE BALL
INLET MANIFOLD
8mm ELBOW PUSH IN
FITTING

Page 10
5.2 SERVICE ‘A’ INSTRUCTIONS
REPLACING O RINGS, NITRILE BALL AND GASKET SEAL WITHIN THE
INLET MANIFOLD
(Every 12,000 hrs or 24 months)
Figure 6.
Figure 7.
Please refer to figure 4.
12. To reassemble, place the valve
block on top of the inlet manifold
ensuring the profiles of the screw
holes line up correctly.
13. Sit the exhaust valves on top of
the valve block, ensuring the profiles
of the screw holes line up correctly.
14. Insert 4x M4 cap head screws
through both exhaust valves and
tighten at a torque setting of 3Nm.
Refer to the page 16 and follow the
correct tightening sequence.
15. Place the manifold assembly
back onto the dryer and insert the
2x M6 cap head screws through the
valve block tightening at a torque
setting of 5Nm.
16. Insert the 8x M6 cap head
screws into the inlet manifold and
tighten to a torque setting of 5Nm.
Refer to the page 16 and follow the
correct tightening sequence.
17. To finish the assembly reattach
the solenoid plugs to the exhaust
valve.
When service A is complete reset
the dryer, refer to page 15.

Page 11
6. SERVICE ‘B’ INSTRUCTIONS
REPLACING EXHAUST VALVES (NDL-010 TO NDL-050)
Figure 2.
Figure 3.
Figure 1.
SOLENOID PLUG
SOLENOID
PLUG SCREWS
VALVE SOLENOID
RETAINING CLIPS
VALVE SOLENOIDS
1. Ensure the dryer is shut down and
fully depressurised before attempting
any maintenance work. (See page 6)
2. Remove the valve solenoid plugs by
removing the plug screws and pulling
the plug free from the solenoid.
(See Figure 1)
3. Remove the valve solenoids by
unclipping the retaining clips and sliding
the solenoids down and free from the
valve stems. (See Figures 2 & 3)
(Every 36,000 hrs or 60 months)

Page 12
6. SERVICE ‘B’ INSTRUCTIONS
REPLACING EXHAUST VALVES (NDL-010 TO NDL-050)
Figure 4.
4. Remove the 8x M4 socket head
screws and the 8x M4 spring
washers and release the exhaust
valve bodies and diaphragms from
the inlet manifold.
(See Figures 4 & 5)
Figure 5.
VALVE
DIAPHRAGM
EXHAUST
VALVE BODY
5. Replace the 2x diaphragms and
2x exhaust valve bodies from the
service kit.
6. Insert the 8x M4 socket head
screws and 8x washers and tighten
to a torque setting of 3Nm.
NOTE: Refer to the page 16 and
follow the correct tightening
sequence.
When service B is complete reset
the dryer, refer to page 15.
M4 SPRING WASHERS
M4 SOCKET
HEAD SCREWS
(Every 36,000 hrs or 60 months)

Page 13
7. SERVICE ‘C’ INSTRUCTIONS
REPLACING OR RE-CALIBRATING THE DEW POINT SENSOR (ES MODELS ONLY)
(Every 6,000 hrs or 12 months)
Figure 4.
Figure 2.
Figure 1.
2. Remove the 4x M5 screws to release
the top cover and lift from assembly.
(See Figure 1)
3. Remove the controller top over by
removing the 4x screws. (See Figure 2)
4. Remove the plug screw and detach the
plug from the sensor (See Figure 3 & 4)
1. Ensure the dryer is shut down and
fully depressurised before attempting any
maintenance work. (See page 6)
Figure 3.
DEW POINT PLUG

Page 14
8. SERVICE ‘C’ INSTRUCTIONS
DEW POINT SENSOR
Figure 5.
Figure 7.
(Every 6,000 hrs or 12 months)
4. Remove the dew point sensor assembly
by sliding the sensor bracket upwards from
the dryer shroud to expose the sensor
block fixing screws. (See Figure 4 & 5)
DEW POINT SENSOR
BRACKET
DEW POINT SENSOR
DEW POINT SENSOR
BLOCK
5. Remove the 2x fixing screws from the
assembly to detach the sensor from the
bracket. (See Figure 5)
6. Unscrew the dew point sensor from the
sensor block and replace it with the new or
re-calibrated sensor. (See Figure 7)
7. Re-attach the dew point sensor to the
sensor bracket using the 2x fixing screws
and replace the dew point sensor
assembly by sliding the bracket back into
the dryer shroud.
8. Replace the dew point sensor plug and
plug screw.
9. Replace the controller cover.
10. Replace the dryer top cover.
DEW POINT SENSOR
BLOCK
2x SCREWS
Figure 6.
REPLACING OR RE-CALIBRATING THE DEW POINT SENSOR (ES MODELS ONLY)
When service C is complete reset the
dryer, refer to page 15.

Page 15
9. RE-SETTING THE DRYER CONTROLLER
Figure 1.
Figure 2. (Top view with cover off)
Re-set Area
2. Remove the 4x M5 to release the top
cover. (See Figure 1)
1. Ensure the dryer is on and running, see
dryer start up procedure on page 17.
3. Place a magnet on the marked area in
Figures 1 & 2 (re-set area) for 8 - 10
seconds until the controller resets.
(See Figure’s 1 & 2 )
4. Once re-set the hours run counter will
show ‘00000’.

Page 16
1
2
3
4
5
6
7
89
10
11
12
13
14
10. MANIFOLD TIGHTENING SEQUENCES
NDL-010 TO NDL-050
3
4
5
6
7
89
10 1
2
11
12
13
14
15
16 17
18
Outlet (top) manifold
Inlet (bottom) manifold

Page 17
10. DRYER START-UP PROCEDURE
Do not allow the dryer to flow air unless powered up, switched on and cycling. Resulting effect
could be cartridge contamination; requiring replacement cartridges.
•Connectallpipework.
- Ensure the inlet operating pressure parameters are between 4-16 barg.
- Ensure the inlet air temperature is between 1.5°C-50°C.
•ConnecttheIECpowersupplyunderneaththedryerusingtheretainingcliptosecureinposition.
•Opentheinletandoutletvalves.
•Turnonthedryerusingtheswitchlocatedunderneaththefrontofdryerbody.
•Thedryerwilldisplayitsstatusandcommencenormaloperation.Whenthedryerispoweredupthedisplay
will show “initialising dryer” for approximately 20 seconds, ensuring the dryer is in equilibrium state before
commencing operation.

Page 18
11. OTHER DRYER CHECKS & NON-SERVICEABLE
ITEMS
DAILY CHECKS
Visual and functional check of the dryer should be carried out daily:
• Check the dryer for any external damage.
Assess and eliminate any defects found.
• If the red service light appears, the dryer must be serviced.
Contact the service department and request a dryer service kit.
• Remove any loose dust or dirt from the dryer; clean all surfaces that appear to have attracted unwanted
contaminants.
• Check the dewpoint sensor display (where applicable). If the dew point is not achieved, the dewpoint
reading on the display will alternate with “dewpoint alarm” every 5 seconds. The no-volt alarm will also
activate.
Contact the service department and request a product service.
MAINTENANCE GUIDELINES
• Maintenance operations only to be conducted when the system has been shut down and fully
depressurised.
• All connections must be undone with care, paying particular attention to the areas that become
pressurised.
• Do not modify or adjust the control settings.
• Only certified n-psl approved replacement parts to be used.
• Always check all connections for leakage and secure seating.
• Ensure all loose parts are removed or secured to the dryer before operation.

Page 19
12. TROUBLESHOOTING
1. Insufficient inlet pressure
2. Electrical Fault
3. Moist or contaminated desiccant
4. Too high air consumption
5. Excessive inlet air temperature
6. Insufficient purge air
7. Exhaust silencer blocked
1. Inlet pressure min 4 bar. If not adjust inlet pressure
settings.
2. Ensure the power is on and the dryer front panel is
illuminated; check the dryer is cycling correctly.
3. Eliminate the cause of contamination. Replace cartridges
– do not re-use.
4. Ensure the performance of the dryer matches the required
system air consumption.
5. Check against technical specification.
6. Purge incorrectly adjusted. Consult service personnel to
adjust settings (Factory pre-set).
7. Consult service personnel.
Poor dew point
performance
Problem CausedProblem Solution
8. Controller not functioning correctly
9. Insufficient inlet pressure
10. Failure to de-pressurise when
cycling
11. Outlet flow stops
8. Ensure the controller is powered; check the on screen
column status to ensure it is powering the solenoid valves
during normal cyclic operation.
9. Inlet pressure = min 4 barg. If not adjust inlet pressure
settings.
10. Solenoid valve not functioning correctly; if there is power
to the coil, replace valve. A correctly working valve outputs an
audible click when it energises.
11. Check inlet air supply.
Failure of dryer to
cycle
12. Failure to initialise dryer
13. Erratic air flow from exhaust
12. Switch off and restart dryer. Ensure dryer is pressurised
before powering dryer to allow dryer to initialise before
commencing operation.
13. Faulty or damaged valve; service required.
Constant
depressurisation
Opening the inlet valve too quickly
Valve should be opened slowly allowing the pressure to build up gradually.
Inlet/outlet head pipe
Diameter too small.
Pipe work unsupported.
Inlet pipe work from low point in system, allowing bulk water to collect and enter the dryer.
Electrical controller
Incorrect fuse fitted or fuse blown. Check the plug and fuse located on top of the controller back plate inside
the dryer front cover.
Additional Items
Use of non-authorised components.
Untrained / unauthorised maintenance / installation personnel used.
Increase in air consumption without relation to the flow capacity of the dryer.
Purging the dryer with cleaning agents that could damage the components or the desiccant.
Covers removed or loose during operation.
Failure to carry out a service when indicated by the dryer.
Do not allow the dryer to flow air unless powered up, switched on and cycling. Resulting effect could be
cartridge contamination; requiring replacement cartridges.
REFERENCE TO KNOWN ISSUE

Page 20
13. SERVICE RECORD & NOTES
The following table allows the customer to document the service history of the product and
to make notes related to each service.
DRYER SERVICE RECORD
PRODUCT CODE:
............................................................
PRODUCT SERIAL NO.
..........................................................................
SERVICE TYPE
A / B / C DATE SERVICED BY (PRINT/SIGN) NOTES