NANO D-Series Manual

D-Series1
HEATLESS COMPRESSED AIR DRYER
MAINTENANCE & SERVICE MANUAL
www.n-psi.com
NDL-060
NDL-070
NDL-080
NDL-090
NDL-100
NDL-110
NDL-120
NDL-130

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
eHeatless Desiccant Air Dry r: D-Series1 (060-130) Service Manual
Models: NDL-060, 070, 080, 090, 100, 110, 120, 130 (Including ES Model)
Document number: n-psi-D1(060-130)-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 made. For further information please contact us at
support.n-psi.com.

Page 3
nano-purification solutions
11330 Vanstory Blvd
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-060 – NDL-120)
5.1 Service A Instructions – Cartridge Replacement (NDL-130 only)
6. Service B Instructions – Inlet Control & Exhaust Valve Replacement (NDL-060 - NDL-090)
6.1 Service B Instructions – Inlet Valve Replacement (NDL-100 - NDL-130)
6.2 Service B Instructions – Inlet Control & Exhaust Valves Replacement (NDL-100 TO NDL-130)
6.3 Service B Instructions - Outlet Valve Replacement (NDL-060 TO NDL-130)
7. Service C Instructions – ES Models Only
8. Re-setting the Dryer Controller
9. Manifold Tightening Sequences
10. Dryer Start-up Procedure
11. Other Dryer Checks & Non-serviceable Items
12. Troubleshooting
13. Service Record & Notes
MANUFACTURERS DETAILS
CONTENTS
Page(s)
4
5-6
7
7
8
9
10-11
12-13
14-15
16
17-18
19
20
21
22
23
24-25

Page 4
The following table details the recommended service intervals for this product and the service kits to be used.
1. SERVICE INTERVALS
Additional For ES Models Only
Recommended Service Intervals
Required Service Kits
Dryer
Model Service A Service B Service C
Service
Type
B
AP P P P PP
P
PP PP PP PP PP
C
1
Year
2
Years
3
Years
4
Years
5
Years
6
Years
7
Years
8
Years
9
Years
11
Years
10
Years
12
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)
NDL-070
NDL-060
NDL-080
NDL-090
NDL-100
NDL-110
NDL-120
NDL-130
NDK-060
NDK-070
NDK-080
NDK-090
NDK-100
NDK-110
NDK-120
NDK-130
NDK-060 + NVK-090 NSK-130
NDK-070 + NVK-090 NSK-130
NDK-080 + NVK-090 NSK-130
NDK-090 + NVK-090 NSK-130
NDK-100 + NVK-130 NSK-130
NDK-110 + NVK-130 NSK-130
NDK-120 + NVK-130 NSK-130
NDK-130 + NVK-130 NSK-130
P P
12 Years
(72,000 Hrs)
PP

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2. PRODUCT ASSEMBLY
TOP COVER
INLET/OUTLET
(TOP) MANIFOLD
ASSEMBLY
DESICCANT
CARTRIDGES
DRYER
CONTROLLER
DRYER
SHROUD
DRYER
COLUMN
BOTTOM
MANIFOLD
ASSEMBLY
DRYER LEGS
SILENCER
BOX
MODELS NDL-060 TO NDL-090
EXHAUST VALVE
INLET VALVE

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2.1 PRODUCT ASSEMBLY
MODELS NDL-100 TO NDL-130
TOP COVER
OUTLET (TOP)
MANIFOLD
ASSEMBLY
DESICCANT
CARTRIDGES
DRYER
CONTROLLER
DRYER
COLUMN
INLET (BOTTOM)
MANIFOLD
ASSEMBLY
DRYER LEGS
SILENCER
BOX
DRYER
SHROUD
EXHAUST VALVE
VALVE
BLOCK
INLET
BLOCK

Page 7
3. RECOMMENDED TOOLS
The following tools will be required to service the dryer:
TERMINAL SCREW DRIVER
ALLEN KEY 3mm
ALLEN KEY 4mm
ALLEN KEY 6mm
ALLEN KEY 8mm
TORQUE WRENCH (8-60NM)
TORQUE SOCKET 6mm
TORQUE SOCKET 8mm
20mm PIN SPANNER
BEARING PULLER
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 depressurised. Also ensure the product is
switched off and/or isolated from the mains power.
PROCEDURES
• Closetheinletandoutletvalves.
The dryer might still be pressurised! In order to depressurise 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 8
5. SERVICE ‘A’ INSTRUCTIONS
REPLACING DESICCANT CARTRIDGES NDL-060 to NDL-120
(Every 12,000 hrs or 24 months)
Please refer to figure 1
1. Ensure the dryer is shutdown and
fully depressurised before attempting any
maintenance work. (See page 7)
2. Remove the 4x M5 screws as shown to
remove the dryer top cover.
3. Remove the 8x M12 cap head screws and
8x washers to remove the top manifold from
the dryer column.
4. Discard the gasket seal.
5. Lift the wire handle and remove the
cartridge from the dryer column.
(See figure 2).
6. Check and clean the top manifold and dryer
column as required, paying particular attention
to the gasket sealing faces.
7. Remove the new cartridges and gasket
seal from the service kit provided.
8. Insert 2x new desiccant cartridges and
press them down until they stop and the
cartridge is below the top surface of the dryer
column.
9. Insert the new gasket seal placing it into the
gasket groove in the top manifold ensuring it
is fully retained.
10. Ensure both handles are folded flat.
11. Replace the top manifold and secure with
the 8x M12 cap head screws tightening to a
torque setting of 80Nm.
NOTE: Refer to the page 20 and follow the
correct tightening sequence.
12. The seal between the dryer column and
top manifold should be checked for leaks prior
to fitting the top cover and operating the dryer
13. Replace the dryer top cover and secure
with the 4x M5 screws. These screws should
be hand tightened only or tightened to a
torque setting of less than 1Nm.
If service A is complete reset the dryer, refer
to page 19.
Care must be taken when removing the
desiccant cartridges not to damage the top face
of the dryer column. This is a sealing face!
(Sealing face shown as the shaded area)
Figure 2.
Figure 1.
GASKET SEAL
TOP MANIFOLD
8x M12 CAP
HEAD SCREWS
TOP COVER
DESICCANT CARTRIDGES
4x M5 SCREWS

Page 9
5.1 SERVICE ‘A’ INSTRUCTIONS
REPLACING DESICCANT CARTRIDGES (NDL-130 ONLY)
(Every 12,000 hrs or 24 months)
Figure 3
Please refer to Service ‘A’ instructions on page
8 of this service guide.
NOTE: NDL-130 dryer has 2x cartridges per
side. (See Figure 3)
DRYER CARTRIDGE
(UPPER)
DRYER CARTRIDGE
(LOWER)
CARTRIDGE JOINING
RINGS
REPLACING DESICCANT CARTRIDGES
1. Lift handle and remove the upper cartridges
from the dryer and discard them.
NOTE: Ensure the upper cartridges have
disconnected from the cartridge joining rings
and the lower cartridges before attempting to lift
from the dryer.
2. Remove the lower cartridges from the dryer
and discard.
3. Identify upper and lower cartridges from the
service kit.
4. Insert joining ring into the head of the lower
cartridge.
5. Insert lower cartridges separatey into dryer.
6. Insert upper cartridges separately into dryer.
7. See page 8 for reassembling top manifold.

Page 10
6. SERVICE ‘B’ INSTRUCTIONS
REPLACING INLET CONTROL AND EXHAUST VALVES (NDL-060 TO NDL-90)
(Every 24,000 hrs or 4 Years)
Figure 1.
Figure 3.
2. Detach each of the solenoid
plugs from the solenoids by
removing the 4x plug screws and
releasing the plugs.
(See Figure 1)
SOLENOID
PLUG
PLUG
SCREW
3. Remove the solenoid coils
by unclipping and sliding the
coils from the valve stems.
(See Figure’s 2 & 3)
Figure 2.
RETAINING
CLIP
SOLENOIDS
COILS
VALVE
STEM
1. Ensure the dryer is shutdown
and fully depressurised before
attempting any maintenance work.
(See page 7)

Page 11
VALVE
DIAPHRAGM
EXHAUST
VALVE
M5 SOCKET
HEAD SCREWS
6. SERVICE ‘B’ INSTRUCTIONS
REPLACING INLET CONTROL AND EXHAUST VALVES (NDL-060 TO NDL-090)
(Every 24,000 hrs or 4 Years)
Figure 4.
4. Remove the 16x M5 socket head screws and the 16x spring washers and discard them. Remove and
discard the exhaust valve bodies from the bottom manifold. (See Figure 4)
5. Remove and discard the 4x diaphragms from the bottom manifold. (See Figure 4)
6. Replace the 4x diaphragms and 4x exhaust valves from the service kit and replace the 16x M5 socket head
screws and spring washers from the service kit and tighten to a torque setting of 6Nm. (See Figure 4)
NOTE: Refer to the page 20 and follow the correct tightening sequence.
7. Reattach the 4x solenoid coils and 4x solenoid plugs. (See Figure 1)
When service B is complete reset the dryer, refer to page 18.
BOTTOM
MANIFOLD

Page 12
6.1 SERVICE ‘B’ INSTRUCTIONS
REPLACING INLET VALVES NDL-100 TO NDL-130 ONLY
(Every 24,000 hrs or 4 Years)
Figure 2.
VALVE BLOCK
3. Remove the 6x M8 socket
head cap screws and 6x washers
from the inlet block to release
both the valve block and inlet
block from the bottom manifold
and from each other.
(See Figure 2)
INLET BLOCK
1. Ensure the dryer is shut down
and fully depressurised before
attempting any maintenance
work. (See page 7)
Figure 1.
6x M8 HEAD
CAP SCREWS
2. Remove the screws and
release the solenoid plugs from
the inlet control valves.
(See Figure 1)
INLET CONTROL
VALVES
SOLENOID
PLUG
SCREW
BOTTOM
MANIFOLD
2x O RINGS
4. Remove and discard the 2x
O rings from the inlet block and
replace them from the service kit.
(See Figure 2)

Page 13
Figure 3.
INLET VALVES
FLOW DIRECTION
ARROW
7. Insert the new inlet valves into the valve block ensuring the flow direction arrow is pointing as shown and
the valve ridge details cover the spill port. (See Figures 4 & 5)
Figure 4.
5. Remove the inlet valves from the valve block by pushing them out. (See Figure 3).
6. Discard the old inlet valves.
Figure 5.
SPILL PORT
VALVE RIDGE
DETAILS
8. Replace the 6x M8 socket head cap screws and 6x washers and tighten at a torque setting of 20Nm.
(See Figure 2)
6.1 SERVICE ‘B’ INSTRUCTIONS
REPLACING INLET VALVES NDL-100 TO NDL-130 ONLY
(Every 24,000 hrs or 4 Years)
NOTE: The spill ports are
1.5mmØ holes within the
valve block.
9. Reattach the solenoid plugs and the screw to complete the assembly. (See Figure 1)
When service A is complete reset the dryer, refer to page 18.

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6.2 SERVICE ‘B’ INSTRUCTIONS
REPLACING INLET CONTROL AND EXHAUST VALVES (NDL-100 TO NDL-130)
(Every 24,000 hrs or 4 Years)
Figure 1.
VALVE
GASKET
INLET
CONTROL
VALVE
SCREWS
1. Remove the 6x fixing screws and 6x washers to release the inlet control valves from the valve block.
(See Figure 1)
2. Discard the valve gaskets and inlet control valves and replace from the service pack.
3. Replace the 6x fixing screws and 6x washers.
4. Replace the solenoid plug and screw (See Figure 1 on page 12)
When service B is complete reset the dryer, refer to page 18.

Page 15
(Every 24,000 hrs or 4 Years)
6.2 SERVICE ‘B’ INSTRUCTIONS
REPLACING INLET CONTROL AND EXHAUST VALVES (NDL-100 TO NDL-130)
Figure 1.
O RING
SILENCER BOX
VALVE DIAPHRAGM
EXHAUST VALVE
Figure 2.
SILENCER
FIXING
NUT
M5 SOCKET HEAD
SCREWS
1. Ensure the dryer is shutdown
and fully depressurised before
attempting any maintenance work.
(See page 7)
2. Unscrew the silencer fixing nut
using a 20mm pin spanner and
remove the O ring to release the
silencer box from the assembly.
(See Figure 1)
3. Remove the 8x M5 socket head
screws and the 8x spring washers
and remove the exhaust valve
bodies and diaphragms from the
inlet (bottom) manifold.
(See Figure 2)
4. Replace the 2x diaphragms and
2x exhaust valves from the service
kit.
5.Replace the 8x M5 socket head
screws and spring washers and
tighten at a torque setting of 6Nm.
Reattach the 2x solenoid valves
and 2x plugs. (See Figure 2)
NOTE: Refer to the page 20
and follow the correct tightening
sequence.

Page 16
8x M12 CAP
HEAD SCREWS
TOP
MANIFOLD
(Every 24,000 hrs or 4 Years)
6.3 SERVICE ‘B’ INSTRUCTIONS
REPLACING OUTLET VALVES (NDL-060 TO NDL-130)
Please refer to figure 1
1. Ensure the dryer is shutdown and fully depressurised before attempting any maintenance work.
(See page 7)
2. Remove the 4x M5 screws to remove the dryer top cover.
3. Remove the 8x M12 cap head screws and 8x washers to remove the top manifold from the dryer column.
4. Using a pair of circlip pliers, remove each circlip.
5. Remove the valve seat using a pair of bearing pullers and then remove the valve.
6. Remove the DU bush and replace it from the service kit.
7. Replace the valve and valve seat from the service guide and re-insert the circlip.
8. Place the manifold back on top of the dryer column and insert the 8x M12 cap head screws and 8x washers
and tighten at a torque setting of 80Nm.
NOTE: Refer to the page 20 and follow the correct tightening sequence.
9. Replace the top cover and insert the 4x M5 screws to secure it in place.
CIRCLIP
VALVE SEAT
VALVE
DU BUSH
FITTING
Figure 1.

Page 17
M4
SCREWS
7. SERVICE ‘C’ INSTRUCTIONS
ES MODELS ONLY
(Every 6,000 hrs or 12 months)
Figure 1.
Figure 3.
Figure 4.
2. Remove the 4x M5 screws to remove
the top cover. (See Figure 1)
4. Remove the screw from the sensor
plug and detach it from the dew point
sensor assembly. (See Figure 3 & 4)
SENSOR
PLUG
SCREW
SENSOR
PLUG
CONTROLLER
CHASSIS PLATE
1. Ensure the dryer is shutdown and
fully depressurised before attempting any
maintenance work. (See page 7)
Figure 2.
3. Release the catches located at the top
and bottom of the shroud to open it.
(See Figure’s 1 & 2)

Page 18
Figure 6.
Figure 7.
6. Unscrew the dew point sensor from the sensor block and
replace with the new or re-calibrated sensor. (See Figure 7)
7. SERVICE ‘C’ INSTRUCTIONS
ES MODELS ONLY
(Every 6,000 hrs or 12 months)
7. Reattach the new or re-calibrated dew point sensor and sensor
block assembly to the controller chassis plate using the 2x fixing
screws.
8. Replace the sensor plug and screw to complete the sensor
assembly. (See Figure 3 & 4)
9. Close the shroud and ensure the latches are in position.
10. Replace the top cover and insert the 4x M5 screws. These
screws should be hand tightened only. (See Figure 1)
DEW POINT SENSOR
SENSOR BLOCK
Figure 5.
5. Remove the 2x fixing screws from the controller chassis plate
and release the dew point sensor assembly. (See Figure 5 & 6)
When service C is complete reset the dryer, refer to page 19.

Page 19
8. RESETTING THE DRYER CONTROLLER
Figure 1.
CONTROLLER
RESET AREA
1. Ensure the dryer is on and running, see dryer start up procedure on
page 18.
2. Place a magnet over the controller reset area shown in Figure 1 for
8-10 seconds until the dryer re-sets. (See Figure 1)
3. Once re-set the hours run counter will show ‘00000’.
NOTE: Magnet not included in the service kit.

Page 20
9. MANIFOLD TIGHTENING SEQUENCES
1
2
3
4
5
6 7
8
1
2
3
4
5
6 7
8
Top manifold
Bottom manifold
FOR MODELS NDL-060 TO NDL-130