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.
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-DRY adsorption dryer series

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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

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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

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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.

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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.).