NANO D1 Series Manual

MAINTENANCE & SERVICE MANUAL
D1 SERIES
HEATLESS COMPRESSED AIR DRYER
www.n-psi.co.uk

Page 2
Document issued created checked revision
17-100-0115 08/06/2015 NMc 1
17-100-0115 13/08/2018 CK 2

Page 3
CONTENTS
TITLE PAGE(S)
1General Informaon 4
1.1 Document introducon 4
1.2 Support & Manufacturing details 4
1.3 General Safety 5
1.4 Warranty guidelines 5
1.5 Packaging 5
2 Service Intervals 6
3 Product Assembly 7
4 Recommended Tools 8
5 Dryer Shutdown Procedure 8
6 Maintenance Guidelines 8
7 Service ‘A’ Outlet manifold service 9
Service ‘A’ Desiccant cartridge replacement 10
Service ‘A’ Inlet manifold service 11-12
8 Service ‘B’ Exhaust valve replacement 13-14
9 Service ‘C’ Outlet valve replacement 15-16
10 Reseng dryer control 17
11 Manifold ghtening sequences 18
12 Dryer start up procedure 19
13 System layout 19
13.1 Typical installaon Hydra -D1 Series (WD1D) 19
14 Process & Instrumentaon diagram - WD1D-8DA-N1A~1G 20
15 Other dryer checks & non-serviceable items 21
16 Troubleshoong 22
17 Service record & notes 23-24

Page 4
©2015 nano puricaon soluons limited
Product: D1 Series - Heatless Compressed Air Dryer
Models: NDL -010, 020, 030, 040, 050 (Including ES Model)
Doc no: 17-100-0115
Issue: 002
1. GENERAL INFORMATION
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 wring from
nano-puricaon soluons limited. It may not be distributed through the internet or computer bullen board
systems without prior consent from nano-puricaon soluons limited.
1.1 Document Introducon
This manual provides factory prescribed installaon and maintenance procedures for a nano-puricaon soluons
D1 Series compressed air dryer. The procedures illustrated in this document are only to be performed by fully
trained competent authorised personnel. For further informaon regarding the procedures outlined in this
document
contact nano-puricaon soluons before proceeding.
Read this document carefully before aempng to install or operate the dryer. This document should be
permanently available at the dryer installaon site and be kept in an easily accessible place alongside the dryer.
1.2 Support and Manufacturers Details
NOTES: highlight important secons of informaon where parcular care and aenon should be paid.
CAUTIONS: indicate any situaon or operaon that may result in potenal damage to the product,
injury to the user, or render the product unsafe.
Annotaons:
nano-puricaon soluons limited
Dukesway, Team Valley Trading Estate,
Gateshead, Tyne and Wear,
United Kingdom, NE11 0PZ
Telephone: [phone]
Internet: www.n-psi.co.uk
E-mail: [email protected]o.uk

Page 5
1.4 Warranty Guidelines
All products are supplied with a 2 year manufacturer’s warranty from the date of purchase, when purchased with
or without an ES (Energy Saving) system when installed and maintained in accordance with the manufacturers
guidelines. Only genuine service parts should be used and no modicaons made. For further informaon please
contact nano-puricaon soluons limited.
1.5 Packaging
All dryers are securely packaged in a bespoke moulded packing system. The dryer module will be secured in a
horizontal posion using two specically moulded support cushions.
The support packing box permits limited longitudinal stacking; however the central secon of the
packing box should not be considered load bearing.
Damage to Packaging
• Check immediately to establish whether damage has occurred to the external packaging and if the damage
extends to the product inside.
• If there is damage to a product, contact the relevant supplier immediately.
In no circumstances must a damaged product be used in operaon. Using damaged products can lead
to irreparable funconal faults or cause serious physical harm.
1.3 General Safety
For your own safety, when carrying out maintenance work on the dryer, all relevant naonal safety regulaons must be
complied with relang 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 convenonal training.
NOTE: highlight important secons of informaon where parcular care and aenon should be paid.
CAUTIONS: indicate any situaon or operaon that may result in potenal damage to the product,
injury to the user, or render the product unsafe.

Page 6
The following table details the recommended service intervals for this product and the service kits to be used.
2. SERVICE INTERVALS
SERVICE
TYPE
RECOMMENDED SERVICE INTERVALS
2 Years
(12000 Hrs)
4 Years
(24000 Hrs)
6 Years
(36000 Hrs)
8 Years
(48000 Hrs)
10 Years
(60000 Hrs)
12 Years
(72000 Hrs)
AP P P P P P
BPPP
DRYER
MODEL
REQUIRED SERVICE KITS
Service A Service B Service C
NDL-010 NDK-010 NDK-010 & NVK-050
NDL-020 NDK-020 NDK-020 & NVK-050
NDL-030 NDK-030 NDK-030 & NVK-050
NDL-040 NDK-040 NDK-040 & NVK-050
NDL-050 NDK-050 NDK-050 & NVK-050
ALL ES NSK-130
SERVICE
TYPE
ADDITIONAL FOR ES MODELS ONLY
ANNUALLY
CP

Page 7
3. PRODUCT ASSEMBLY MODELS: NDL-010, 020, 030, 040, 050
TOP COVER
OUTLET (TOP)
MANIFOLD
ASSEMBLY
DESICCANT
CARTRIDGES
DRYER
CONTROLLER
DRYER
SHROUD
DRYER
COLUMN
INLET (BOTTOM)
MANIFOLD
ASSEMBLY
DRYER
LEGS
EXHAUST
VALVES
SILENCER
ASSEMBLY
CONTROLLER
COVER
(BOTTOM)
CONTROLLER
COVER (TOP)
VALVE
BLOCK
DRYER
LEGS

Page 8
2. RECOMMENDED TOOLS
The following tools will be required to service the dryer:
5. DRYER SHUT DOWN PROCEDURE
Before performing any maintenance or service operaons on this product, ensure the product is isolat-
ed from the compressed air supply and fully depressurised. Also ensure the product is switched o and
isolated from the mains power.
PROCEDURES
The dryer might sll be pressurised! In order to depressurise the dryer; ensure the dryer is isolated from the com-
pressed air source:
o Close the inlet and outlet valves (refer to Page 19. System layout)
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.
TERMINAL SCREW DRIVER
ALLEN KEY 3mm
ALLEN KEY 4mm
ALLEN KEY 6mm
ALLEN KEY 8mm
TORQUE WRENCH (8-60NM)
TORQUE SOCKET 6mm/10mm
20mm PIN SPANNER
VALVE EXTRACTION TOOL
INTERNAL CIRCLIP PLIERS
MAGNET (for re-seng controller)
PETROLEUM JELLY (VASOLINE)
6. MAINTENANCE GUIDELINES
• Maintenance operaons only to be conducted when the system has been shut down and fully
depressurised.
• All connecons must be undone with care, paying parcular aenon to the areas that become
pressurised.
• Do not modify or adjust the control sengs.
• Only cered nano-puricaon soluons approved replacement parts to be used.
Always check all connecons for leakage and secure seang before operaon.
Ensure all loose parts removed during maintenance are reed correctly before operaon.

Page 9
7. SERVICE ‘A’ INSTRUCTIONS
(Every 12,000 hrs or 24 months)
1. Ensure the dryer is shut down and fully
depressurised before aempng any maintenance
work. (See page 7-8)
2. Remove the 4x M5 dome head screws to
release the top cover and li from assembly.
3. Remove the 2x M6 long cap head screws and
washers as shown from the outlet (top) manifold
assembly.
4. Remove the 4x M4 cap head screws and
washers from the purge block and remove it from
the outlet (top) manifold assembly.
5. Remove and discard the 3x O rings sat on the
underside of the purge block.
(refer to gure 4. page 11.)
6. Insert the new O rings from the service kit
provided and replace into the grooves on the
underside of the purge block.
(refer to gure 4. page 11.)
7. Remove the 8x M6 short cap head screws to
remove the outlet (top) manifold from the dryer
column.
8. Remove the gasket seal from the underside of
the outlet (top) manifold.
MODELS: NDL-010, 020, 030, 040, 050
OUTLET MANIFOLD SERVICE
NDK-010, 020, 030, 040, 050
Figure 1.
2x M6 LONG CAP
HEAD SCREWS
PURGE BLOCK
3x O RINGS
GASKET SEAL
CARTRIDGE HANDLE
NITRILE BALL
8mm PUSH IN
FITTING
4x M4 CAP HEAD
SCREWS
8x M6 SHORT CAP
HEAD SCREWS
OUTLET (TOP)
4x M5 DOME HEAD
SCREWS
(refer to gure.1)

Page 10
7. SERVICE ‘A’ INSTRUCTIONS MODELS: NDL-010, 020, 030, 040, 050
DESICCANT CARTRIDGE REPLACEMENT
AND INLET MANIFOLD SERVICE
GASKET SEAL
SOLENOID PLUGS
4x M4 LONG CAP
HEAD SCREWS
4x M4 SHORT CAP
HEAD SCREWS
EXHAUST VALVES
VALVE STEM
2x M6 LONG CAP
HEAD SCREWS
VALVE BLOCK
8x M6 CAP HEAD
SCREWS
NITRILE BALL
INLET
MANIFOLD
8mm ELBOW PUSH
IN FITTING
Figure 2.
9. Remove the 2x cartridges using the
handle to withdraw them from the column.
10. Check and clean the outlet (top)
manifold and dryer column as required
paying parcular aenon to the gasket
sealing areas.
On the underside of the dryer
(refer to gure 2.)
11. Unclip the solenoid plug from the valve
stem. (See gure 2 & 3 on page 13)
12. Remove the 4x M4 long cap head screws
and washers from the valve block only, to
retain the exhaust valves in posion.
13. Remove the 2x M6 long cap head screws
to release the valve block from the inlet
manifold.
14. Remove and discard the 3x O rings on
the underside of the valve block.
15. Insert the new O rings from the
service kit and replace into the grooves on
the underside of the valve block.
(refer to gure 5 on page 12)
16. Remove the 8x M6 cap head screws
from the inlet manifold to release it from
the dryer.
17. Remove and discard the nitrile ball from
the inlet manifold.
18. Replace the nitrile ball from the service
kit and replace into the 3 way valve orice.
(refer to gure 6 on page 12)
19. Remove and discard the gasket seal
from the underside of the inlet manifold.
20. Insert the new gasket seal from the
service kit into the gasket seal grooves on
the underside of the inlet manifold.

Page 11
Insert desiccant cartridge and rotate unl it sits
correctly within the dryer column then push
downwards unl you hear a click.
Figure 3.
Figure 4.
7. SERVICE ‘A’ INSTRUCTIONS MODELS: NDL-010, 020, 030, 040, 050
(Refer to gure 4.)
21. To reassemble, place the valve
block on top of the inlet manifold
ensuring the proles of the screw holes
line up correctly. Ensure the nitrile ball
does not fall out.
22. Insert 4x M4 long cap head screws
through both exhaust valves and
ghten at a torque seng of 3Nm.
Refer to the page 18 and follow the
correct ghtening sequence.
23. Place the manifold assembly back
onto the dryer and insert the 2x M6
long cap head screws through the valve
block ghtening at a torque seng of
5Nm.
24. Insert the 8x M6 cap head screws
into the inlet manifold and ghten
to a torque seng of 5Nm. Refer to
the page 18 and follow the correct
ghtening sequence.
25. Stand dryer upright.
26. To nish the assembly reaach the
solenoid plugs to the exhaust valve.
27. Remove the new cartridges from
the service kit provided.
28. Insert the 2x new desiccant
cartridges and rotate unl they sit
correctly into place . Then press down
unl they stop and the cartridge is
below the top surface of the dryer
column
(refer to gure 3).

Page 12
INLET MANIFOLD SERVICE
7.SERVICE ‘A’ INSTRUCTIONS
(Every 12,000 hrs or 24 months)
NDK-010, 020, 030, 040, 050
MODELS: NDL-010, 020, 030, 040, 050
Figure 5.
Figure 6.
29. Insert the new gasket seal into
the gasket groove on the underside
of the outlet (top) manifold ensuring
it is fully retained.
30. Remove and discard the nitrile
ball from the outlet manifold.
31. Replace the nitrile ball from
the service kit, into the 3 way valve
orice.
32. Sit the purge block back on top
of the outlet manifold and replace
the 4x M4 cap head screws at torque
seng of 3Nm. Refer to page 18 for
the correct ghtening sequence.
33. Replace the outlet (top) manifold
assembly back on top of the dryer
column and secure with the 2x M6
long and 8x M6 short cap head
screws ghtening to a torque
seng of 5Nm. Refer to the page
18 and follow the correct ghtening
sequence.
34. The seal between the dryer
column and outlet (top) manifold
should be checked for leaks prior to
ng the top cover and operang
the dryer.
35. Replace the dryer top cover and
secure with the 4x M5 screws. These
screws should be hand ghtened or
ghtened at a torque seng of less
than 1Nm.
NOTE: Ensure you refer to the page
18 and follow the correct ghtening
sequences.

Page 13
(Every 24,000 hrs or 4 Years)
8. SERVICE ‘B’ INSTRUCTIONS
EXHAUST VALVE REPLACEMENT
MODELS: NDL-010, 020, 030, 040, 050
NDK-010~050 & NVK-050
SOLENOID PLUG
SOLENOID PLUG
SCREWS
VALVE SOLENOID
RETAINING
CLIPS
VALVE SOLENOIDS
1. Ensure the dryer is shut down and
fully depressurised before aempng any
maintenance work. (See page 7-8)
2. Remove the solenoid plugs by
removing the plug screws and pulling the
plug free from the valve solenoid.
(See gure 1)
3. Remove the valve solenoids by
unclipping the retaining clips and sliding
the solenoids down and free from the
valve stems. (See gures 2 & 3)
Figure 1.
Figure 2.
Figure 3.

Page 14
8. SERVICE ‘B’ INSTRUCTIONS
(Every 24,000 hrs or 4 Years)
EXHAUST VALVE REPLACEMENT
MODELS: NDL-010, 020, 030, 040, 050
NDK-010~050 & NVK-050
4. Remove the 8x M4 long and short
socket head screws and the 8x M4
spring washers and release the exhaust
valve bodies and valve diaphragms from
the inlet manifold.
(See gures 4 & 5)
5. Replace the 2x diaphragms and 2x ex-
haust valve bodies from the service kit.
6. Insert the 8x M4 socket head screws
and 8x washers and ghten to a torque
seng of 3Nm.
NOTE: Refer to the page 18 and
follow the correct ghtening
sequence.
When service B is complete reset the
dryer, refer to page 17.
VALVE
DIAPHRAGM
EXHAUST
VALVE BODY
M4 SPRING WASHERS
M4 SHORT SOCKET HEAD
SCREWS
M4 LONG SOCKET
HEAD SCREWS
Figure 5.
Figure 4.

Page 15
DEWPOINT SENSOR REPLACEMENT
MODELS: ES MODELS ONLY
NSK-130
9. SERVICE ‘C’ INSTRUCTIONS
(Every 6,000 hrs or 12 months)
2. Remove the 4x M5 screws to release the top
cover and li from assembly.
(See gure 1)
3. Remove the controller top over by
removing the 4x screws. (See gure 2)
4. Remove the plug screw and detach the plug
from the sensor (See gures 3 & 4)
1. Ensure the dryer is shut down and
fully depressurised before aempng any
maintenance work. (See page 7-8)
Figure 2.
Figure 1.
Figure 4.
Figure 3.

Page 16
9. SERVICE ‘C’ INSTRUCTIONS MODELS: ES MODELS ONLY
NSK-130
DEWPOINT SENSOR REPLACEMENT
DEW POINT SENSOR
5. Remove the dew point sensor assembly by
sliding the sensor bracket upwards from the
dryer shroud to expose the sensor block xing
screws. (See gure 5 & 6)
DEW POINT SENSOR
BRACKET
DEW POINT SENSOR
DEW POINT SENSOR
BLOCK
6. Remove the 2x xing screws from the as-
sembly to detach the sensor from the bracket.
(See gure 5)
7. Unscrew the dew point sensor from the
sensor block and replace it with the new or
re-calibrated sensor. (See gure 7)
8. Re-aach the dew point sensor to the
sensor bracket using the 2x xing screws and
replace the dew point sensor
assembly by sliding the bracket back into the
dryer shroud.
9. Replace the dew point sensor plug and plug
screw.
10. Replace the controller cover.
11. Replace the dryer top cover.
DEW POINT SENSOR
BLOCK
2x SCREWS
Note: When service C is complete reset
the dryer, refer to page 17.
Figure 6.
Figure 7.
Figure 5.

Page 17
10. RESETTING DRYER CONTROLLER
CONTROLLER
RESET AREA
1. Ensure the dryer is on and running, see dryer start up procedure on page 19.
2. Place a magnet over the controller reset area shown in Figure 1 for 8-10 seconds
unl 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.
(magnet used: Eclipse part no. E846)
Figure 1.

Page 18
11. MANIFOLD TIGHTENING SEQUENCE
Outlet (top) manifold
Inlet (boom) manifold
1
2
3
4
5
6
7
8 9
10
11
13 12
14
1
2
3
4
5
6
7
8 9
10
11
12
18 13 15
14 17 16

Page 19
12. DRYER START-UP PROCEDURE
Do not allow the dryer to ow air unless powered up, switched on and cycling.
Resulng eect could be cartridge contaminaon; requiring replacement cartridges.
OUTLE
T
I
NLET
WATER
SEPARATOR
0.1µm OR BETTER
COALESCING FILTER
IMPORTANT: It is essenal that the system into which the dryer is installed is ed
with a pressure liming/relief device. This device should be between the compressor
and the dryer. The device must be set to prevent the maximum working pressure of 16
barg (232 psig) from being exceeded.
13. SYSTEM LAYOUT
13.1. Typical installaon D1 Series
• Connect to mains power.
• Connect all pipe work, ensure inlet & outlet valves closed.
• Ensure the inlet operang pressure parameters are between 6-16 barg (58 - 232 psig).
• Ensure the inlet air temperature is between 1.5°C - 50°C (35°F - 122°F).
• Slowly open the inlet valve.
• Turn on the electrical power to the dryer.
• Slowly open the outlet valve.
• The dryer will display its status and commence normal operaon.
• Soware version number will be displayed on the screen for the rst 5 seconds
INLET VALVE
OUTLET VALVE

Page 20
14. PROCESS & INSTRUMENTATION DIAGRAM
14.1. NDL-010 ~ 050
Water Separator