OMEGA AIR A-DRY Series User manual

Installation and operating
manual
Please read the following instructions carefully before installing the product. Trouble free
and safe operating of the product can only be guaranteed if recommendations and
conditions stated in this manual are respected.
201
9
0
417
-DRY adsorption dryer series

2

3
Index
1 GENERAL INFORMATION ............................................................................................................................... 5
1.1 D EVICE INFORM TION ........................................................................................................................................ 5
1.2 S UPPLIER INFORM TION ..................................................................................................................................... 5
1.3 B SICS ............................................................................................................................................................ 6
1.4 DSORPTION D RYERS ......................................................................................................................................... 6
1.5 DSORPTION .................................................................................................................................................... 6
1.6 PPROPRI TE USE .............................................................................................................................................. 7
2 SAFETY INSTRUCTIONS .................................................................................................................................. 8
3 TECHNICAL DATA ......................................................................................................................................... 11
3.1 C OMPONENTS ................................................................................................................................................. 11
3.2 P HYSIC L CH R CTERISTICS ............................................................................................................................... 12
3.3 P RESSURE E QUIPMENT D IRECTIVE PED 2014/68/EU (F LUID GROUP 2) ................................................................... 14
3.4 E LECTRIC L CH R CTERISTICS ............................................................................................................................ 14
4 DESCRIPTION OF OPERATION ...................................................................................................................... 15
5 CONTROLLER ............................................................................................................................................... 17
5.1 O PER TION .................................................................................................................................................... 20
5.2 T EST C YCLE .................................................................................................................................................... 22
5.3 D EW P OINT S ENSOR ........................................................................................................................................ 22
5.4 D EW P OINT S ENSOR S ETTING ............................................................................................................................ 23
5.5 S WITCH P OINT ................................................................................................................................................ 24
5.6 S ET S WITCH P OINT .......................................................................................................................................... 24
5.7 D EW P OINT L RM ......................................................................................................................................... 25
5.8 S ET L RM .................................................................................................................................................... 25
5.9 T IMER DR IN .................................................................................................................................................. 26
5.10 T IMER D R IN S ETTING .................................................................................................................................... 27
5.11 I NPUT / O UTPUT ............................................................................................................................................ 28
5.12 S ET ST NDBY ................................................................................................................................................ 28
5.13 S T TISTICS ................................................................................................................................................... 29
EFFICIENCY CONSIDERATIONS ..................................................................................................................... 30
7 TRANSPORTATION ...................................................................................................................................... 31
8 STORAGE ..................................................................................................................................................... 32
9 INSTALLATION ............................................................................................................................................. 33
9.1 I NITI L INSPECTION .......................................................................................................................................... 33
9.2 G ENER L I NST LL TION R EQUIREMENTS .............................................................................................................. 33
9.3 I NST LL TION L YOUT ...................................................................................................................................... 34
9.4 I NST LL TION ................................................................................................................................................. 36
10 COMMISSIONING ...................................................................................................................................... 39
10.1 P RESSURIS TION ........................................................................................................................................... 39
10.2 O PENING O UTLET V LVE ................................................................................................................................ 39
10.3 S T RT - UP .................................................................................................................................................... 40
11 DECOMMISSIONING .................................................................................................................................. 40
12 ADDITIONAL EQUIPMENT .......................................................................................................................... 41
13 MAINTENANCE .......................................................................................................................................... 42
13.1 R EPL CEMENT OF THE MOLECUL R SIEVE ........................................................................................................... 45
13.2 R EPL CEMENT OF THE CONTROL V LVES ............................................................................................................ 47
13.3 R EPL CEMENT OF THE NON - RETURN V LVES ....................................................................................................... 49
13.4 R EPL CEMENT OF THE PURGE EXH UST SILENCERS ............................................................................................... 51

4
13.5 R EPL CEMENT OF THE NOZZLES ........................................................................................................................ 52
14 TROUBLESHOOTING .................................................................................................................................. 53
14.1 C ONTROLLER ................................................................................................................................................ 53
14.2 C ONTROL V LVES .......................................................................................................................................... 53
14.3 L E K GE ...................................................................................................................................................... 54
14.3.1 A leak between the block and the tower .......................................................................................... 54
14.3.2 A leak between the valve and the block ........................................................................................... 55
14.4 H IGH PRESSURE DROP ..................................................................................................................................... 57
14.4.1 Inadequately dimensioned compressor and dryer ............................................................................ 57
14.4.2 he downstream system is oversized ............................................................................................... 57
14.4.3 Oil in the adsorption dryer ................................................................................................................ 58
14.4.4 Dryer connected to the system in the opposite way ......................................................................... 58
14.4.5 Solenoid control valves malfunction ................................................................................................. 58
14.4.6 Clogged pre-filter and/or after-filter ................................................................................................ 59
14.4.7 Increased purge flow on one tower .................................................................................................. 59
14.5 H IGH OUTLET DEW - POINT ............................................................................................................................... 59
14.5.1 Underdiemnsioned adsorption dryer ............................................................................................... 60
14.5.2 Liquid water in the towers ................................................................................................................ 60
14.5.3 Oil in the towers ................................................................................................................................ 60
14.5.4 ower fails to depressurise ............................................................................................................... 61
15 WARRANTY EXCLUSION ............................................................................................................................. 2
1 MAINTENANCE RECORD ............................................................................................................................ 3

5
1 General information
1.1 Device information
Please fill in the fields accordingly. Correct information enables proper and efficient
maintenance of the device, selection of spare parts and technical support.
1.2 Supplier information
dsorption dryer model:
Serial number:
Year of production:
Commissioning date:
Type of towers:
Left tower serial number:
Right tower serial number:
Name:
ddress:
Telephone/Fax:
e-mail:

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1.3 Basics
Compressed air contains contaminants such as water, oil and particulates which must be
removed or reduced to the acceptable level based on specific application requirements.
Standard ISO8573-1 specifies air purity/quality classes for these contaminants. Humidity (water
vapour content) is expressed in the terms of Pressure Dew Point (PDP) where Dew point is the
temperature at which air is 100% saturated with moisture. When the temperature of the air
reduces to or below the dew point, condensation will occur. Reduction of water content down to
pressure dew point +3°C is usually achieved with refrigerant dryers while for lower pressure dew
points adsorption (also called desiccant) dryers are typically used.
1.4 Adsorption Dryers
Typical applications for the adsorption dryers are outdoor installations where the risk of freezing
occurs and applications with high quality requirements in terms of air dryness (PDP < +3°C) such
as the process air in process industry (food and beverage, pharmaceutical, electronic, chemical,
…).
The most common adsorption dryers are heatless regeneration adsorption dryers due to their
simplicity, reliability and relatively low investment costs.
1.5 Adsorption
dsorption is a process where specific molecules adhere to the surface of a highly porous solid
(adsorbent/desiccant) by electrostatic and molecular forces. The adsorbent is normally formed
in sphere form beads. Process of adsorption takes place while air flows through column filled
with the beads. Rate of adsorption depends on several factors (type of adsorbent, relative
humidity, inlet temperature, contact time, face velocity) and therefore adsorption process is
usually set/optimized for every individual application.

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1.6 Appropriate use
DRY series desiccant dryers are intended for highly efficient preparation of top
quality dry compressed air. This appliance must be used only for the purpose for
which it was specifically designed. ll other uses are to be considered incorrect.
Specifically:
•Desiccant dryer can only be used for “GROUP 2” fluids (PED 2014/68/EU).
•Desiccant dryer can not be used for explosive, toxic, flammable, corrosive and
“GROUP 1” fluids (PED 2014/68/EU).
Warning: internal corrosion can seriously reduce the safety of installation: check it during
maintenance.
The manufacturer will under no circumstances be responsible for any damage resulting from
improper, incorrect or unreasonable use.
Use genuine spare parts only. ny damage or malfunction caused by the use of non-genuine
parts is not covered by Warranty or Product Liability.

8
2 Safety instructions
Improper handling of compressed air systems/equipment and electric
installations/equipment may result in a serious injury or death
Improper handling (transportation, installation, use/operation, maintenance) of
DRY series dryer may result in serious injury or death. s a result of improper
handling damage or reduced performance can occur.
The relevant safety at work and accident prevention regulations, plus operating
instructions, shall apply for operating the adsorption dryer. The adsorption dryer
has been designed in accordance with the generally recognized rules of
engineering. It complies with the requirements of directive 2014/68/EU concerning
pressure equipment.
Ensure that installation complies with local laws for operation and routine testing
of pressure equipment at the place of installation.
Operator/user of the adsorption dryer should make himself familiar with the
function, installation and start-up of the unit.
ll the safety information is always intended to ensure your personal safety. If you are not
experienced in such systems please contact your local representative or manufacturer of the
dryer for help.

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•Before any kind of work on the dryer make sure that it is depressurized (in addition
to dryer this also refers to the nearest upstream and downstream part of the
installation) and disconnected from power supply.
•Do not exceed maximum operating pressure or operating temperature range (see the
technical data in this manual or the data sheet).
•The permissible working temperatures and pressures for the adsorption dryer add-on
parts are given under Technical data for those add-ons. Maximum temperature and
pressure for assembled system is the lowest of any individual part.
•It is necessary to ensure that the adsorption dryer is equipped with the
corresponding safety and test devices to prevent the permissible operating
parameters from being exceeded.
•Ensure that the adsorption dryer is not subject to vibrations that could cause fatigue
fractures.
•dsorption dryer is not to be subjected to mechanical stresses.
•The medium used may not have any corrosive components that could attack the
materials of the adsorption dryer in a way that is not permitted. Do not use the
adsorption dryer in hazardous areas with potentially explosive atmospheres.
•ll installation and maintenance work on the adsorption dryer may only be carried
out by trained and experienced specialists.
•Make sure that the 4 nuts on the top of the dryer are tightly screwed after any
installation or maintenance work.
•It is forbidden to carry out any kind of work on the adsorption dryer, including
welding and constructional changes, etc.
•Depressurize the system before carrying out the installation work.
•Wear respiratory protective equipment when working with the molecular sieve.
Molecular sieve is a crumbling material that is producing fine dust which can cause
respiratory complications if inhaled in sufficient quantities.
•Ensure that the molecular sieve does not come into contact with the liquid water.
Unused molecular sieve in liquid water produces thermal energy that can cause the
water to boil and can inflict serious burns.
•t manipulation with adsorbent some amount of adsorbent can stay on the floor. In
case of adsorbent on the floor be extremely careful and immediately clean the floor
to prevent injuries due to the fall on the slippery surface.
•Ensure that the adsorption dryer is installed as specified and without any stresses.

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•Use the original spare parts only.
•Use the device for the intended purpose only.
•Centre of gravity is positioned relatively high meaning there is a risk of tilting the
dryer, which can cause serious injury or even death.
•For transportation please check and follow local regulations for lifting and
transporting heavy objects.
•Do not climb on the dryer.
•Do not use water to extinguish fire on the dryer or surrounding objects.
•Wear proper personal safety equipment (earplugs, earmuffs, safety goggles, safety
helmet, safety gloves, safety shoes etc.).

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3 Technical data
3.1 Components
Note: The adsorption dryer displayed on the pictures of this
manual is -DRY 6 from -DRY series adsorption dryer.
Part
1 Control valves
2 Consoles
3 Tower 1
4 Tower 2
5 Controller
Pressure indicator
7 Inlet
8 Outlet
3
4
2
8
7
2
1
6
5

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3.2 P ysical c aracteristics
MODEL CONNECTIONS
FLOW CAPACITY DIMENSIONS [mm] WEIGHT
[inch] [Nm
3
/h] [scfm] Height Width* Depth [kg]
DRY ⅜” 6 3,7 520 395 130 11,5
DRY 12 ⅜” 12 7,7 715 395 130 14,2
DRY 24 ⅜” 24 14,9 1105 395 130 19,3
DRY 3 ⅜” 36 22,4 1500 395 130 24,4
DRY 0 ¾” 60 37,3 1105 475 160 45,0
DRY 75 ¾” 75 46,7 1300 475 160 53,0
DRY 105 ¾” 105 65,3 1700 475 160 70,0
DRY 150 1” 150 93,3 1440 570 240 170,5
DRY 200 1” 200 124,4 1655 570 240 182,2
Flow capacity at 7 bar(g), 20°C
* Width with filters
Operating temperature 1,5 - 45 °C 35 - 113 °F
Operating pressure 4 - 16 bar(a) 58 - 232 psi

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MATERIALS
Consoles Steel
Control blocks luminium
Tower tubes luminium
Panels Steel
Control valve seats luminium
Non-return valve luminium, Steel, P (polyamide)
Sealing NBR
dsorption material Silica gel
Corrosion protection nodized
Outside protection Powder paint coated (Epoxy-polyester base)
Lubricant Shell cassida grease RLS 2
End-caps P 6
Controller Housing BS
CORRECTION FACTORS
To calculate the correct flow capacity of a given device based on actual operating conditions,
multiply the nominal flow capacity by the appropriate correction factor(s).
   

 

   
Example: Corrected flow capacity for nominal flow capacity of 36 Nm
3
/h at operating
pressure of 6 bar(g) and inlet temperature of 40 °C would be:
   0,88  0, 97  36 

⁄ 30,73 

⁄
CORRECTION FACTOR – OPERATING PRESSURE
[bar] 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
[psi] 29 44 59 73 88 103 118 132 147 162 176 191 206 220 235
C
OP
0,38 0,5 0,6 0,75 0,88 1 1,13 1,25 1,38 1,5 1,63 1,75 1,88 2 2,1
CORRECTION FACTOR – INLET TEMPERATURE
[°C] 25 30 35 40 45 50
C
IT
1,00 1,00 1,00 0,97 0,87 0,80

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3.3 Pressure Equipment Directive PED 2014/68/EU
(Fluid group 2)
Technical datasheet is available. For additional technical specification contact the
manufacturer.
3.4 Electrical c aracteristics
DRY 6/12/24/36/60/75/105/150/200 Category I, Module
Supply voltage 230 V ± 10 % 110 V ± 10 %
Supply frequency 50 Hz
Power consumption <40 W for DRY 6 to DRY 105
<70 W for DRY 150 to DRY 200
Stand-by contact 24 VDC
Protection class -
housing IP 65
Digital output Type of contact Voltage free NO or NC
Maximum switching voltage 250 Vac or 30 Vdc
Maximum switching current 3
Dielectric strength of contacts to PE 4 kV
Digital input Voltage across free contacts 3,3 V
Current through contact 40 µ
Negative contact is grounded
nalog input Type 4…20 m
Supply voltage 24 V
Input resistance 100 Ω
Short circuit protected
Maximum input voltage 3 V
Negative contact is grounded

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4 Description of operation
dsorption dryer is intended for removal of vapour from the inlet compressed air in order to
reach a desired dew point at the outlet.
During normal operation of the adsorption dryer the non-dried compressed air enters the
adsorption dryer through the inlet and passes through the appropriate inlet control valve
into a tower where the process of adsorption is in progress. In the tower the air passes the
molecular sieve which removes the water vapour content through the process of adsorption.
fter leaving the tower the dried compressed air leaves the adsorption dryer through the
outlet.
If a process of regeneration is underway in the second tower then part of the dried air is lead
through a nozzle into the tower where the regeneration is in progress. There the air that has
been dried and heated through the process of adsorption expands after leaving the nozzle
and passes the molecular sieve. Through the process of desorption the water vapour content
gets released from the molecular sieve and is carried by the air through the appropriate
release control valve after which it is discharged from the system.
fter a set time the adsorption in the first tower is stopped and the control valves are run
through a sequence that pressurises both towers and starts the adsorption in second tower
and regeneration in the first tower.
Time of regeneration is constant and does not change. The dried air used for regeneration is
released which means that while the regeneration is in progress the adsorption dryer
operates at a lower efficiency. In most operating conditions the adsorption process can run
for a longer time than the time that is needed to regenerate the tower. Consequently
although times of regeneration and adsorption can be equal, in most operating conditions it
is more economical that the adsorption time is longer since such operation can greatly
increase the efficiency of the adsorption dryer.
DRY adsorption dryers have a factory pre-set adsorption time adjusted to the operating
conditions specified by the costumer to ensure the optimal operation. *
If the compressed air station shuts down, a stand-by signal is received or the adsorption
dryer gets disconnected from the power supply both adsorption dryer inlet control valves
open while both release control valves are closed so the air can flow from inlet through the
towers to the outlet. fter the start signal is received or power returns the adsorption dryer
continues where it has stopped.
* For more information contact your supplier.

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17
5 Controller
Y1, Y3 – left and right inlet valve
Y2, Y4 – left and right purge valve
Y6 – drain valve (*)
d.p. – dew point sensor (*)
* depend of the model
dp
2
L
1
Y1
Inlet
Y2
Y4
Y3
Y6
Outlet
drain
4
3
6
5
8
7
10
9
12
11
N
14
13
16
15
18
17
20
19
N
L
dig. in
dew
point
L
N
L
N
L
N
L
N
24Vdc
SENS
Controller
Mains
Left
Column
Right
Column
2A F

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Interface Layout and Menu structure
The controller of dryer comprises a display and keys. They are used to show necessary
information about dryer state. They enable user to set some working parameters. Next to
the display, there are three LED’s, which provide quick information of dryer state.
1 Green Dryer is operational
2 Yellow Digital input is cleared. Dryer is
going to standby according to
settings
3 Red larm is triggered. It may be
dew point alarm or some other
internal alarms.
4 Cancel
5 Decrement
6 Increment
7 Enter
The chart on Figure shows, how to navigate among different menus, which are described in
more detail afterwards. The navigation begins in the operation menu that shows current
state of the dryer. With keys increment/ decrement, the most important parameters are
scanned. By pressing the enter key for two seconds, menus are entered, where dryer’s
settings can be changed.
1
2
3
4
5
6
7
Increment Enter
Decrement Cancel

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◄ADSORBING IDLE >
09:15 00:00
2 sec.
***** TEST CYCLE *****
Press '+' to start!
***** Dew Point **[1]
---°C
Current: 0.0mA
***** Dew Point **[2]
---°C
Switch Point: -40°C
***** Dew Point **[3]
---°C
Alarm: -40°C
**** Timer Drain *[4]
Disabled: 00:00
(Press CANCEL to
test)
**** Input/Output *[5]
Input: 1
Output: 1
Valves: 001000
***** Statistics **[6]
W.Hours: 1234h
Nb.Cycles: 4321
Drain Valve: 123456
2 sec.
***** Dew Point *****
Set Dew Point at
>4mA: -40°C
20mA: 20°C
2 sec.
***** Dew Point *****
Set
>Switch Point: -40°C
Mode: Variable Cycle
2 sec.
***** Dew Point *****
Set
>Alarm: -30°C
Output: Dryer Active
2 sec.
**** Timer Drain ****
Set
>Period OFF: 00:30
P
eriod ON:
--
:
--
2 sec.
**** Input/Output ****
Set Standby Mode:
>Mode: Finish Cycle
2 sec.
Power On: 15
Dryer version
50Hz Soft.ver
1. Operation 2. Test Cycle
3. DP Sensor 4. Dew Point Sensor Setting
5. Switch Point 6. Set Switch Point
7. DP larm 8. Set larm
9. Timer Drain 10. Set Timer
11. Input/ Output 12. Set Stanby
13. Statistics 14. Statistics

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5.1 Operation
The Operation Menu shows a momentary state of dryer. In the following Figure, adsorption
takes place in the left and regeneration in the right column. Below the label dsorbing is
time that remains for adsorption. Similarly, the time below the label Regenerating is time
that remains for regeneration.
fter the regeneration time expires, the right column becomes idle. That is, the purge valve
closes and pressure in the right column builds up slowly.
fter the adsorption period in the left column is over, dryer passes sequence of three states
to switch columns. The sequence is necessary to suppress pressure fluctuations in the outlet.
s the two columns have switched roles, adsorption takes place in the right and
regeneration in the left column. gain, the remaining time for adsorption and regeneration
is show under the respective labels.
◄ADSORBING REGEN.>
12:33 02:30
◄ADSORBING IDLE >
09:15 00:00
◄CHANGE COLUMNS >
00:00 00:01
◄CHANGE COLUMNS ►
00:01 00:00
< READY ►
00:01 00:00