Pneumatech AD-750 User manual

PNEUMATECH
AD 750, AD 1000, AD 1250
Instruction book

PNEUMATECH
AD 750, AD 1000, AD 1250
Instruction book
Original instructions
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and drawings.
This instruction book is valid for CE as well as non-CE labelled machines. It meets the
requirements for instructions specified by the applicable European directives as identified in the
Declaration of Conformity.
2017 - 06
No. 9828 0931 61
www.pneumatech.com

Instruction book
49828 0931 61
Table of contents
1 Safety precautions ..........................................................................................................6
1.1 SAFETY ICONS............................................................................................................................... 6
1.2 GENERAL SAFETY PRECAUTIONS .................................................................................................... 6
1.3 SAFETY PRECAUTIONS DURING INSTALLATION ................................................................................. 7
1.4 SAFETY PRECAUTIONS DURING OPERATION..................................................................................... 8
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR ................................................................ 9
2 General description.......................................................................................................10
2.1 INTRODUCTION............................................................................................................................ 10
2.2 AIR SYSTEM ................................................................................................................................ 13
2.3 REFRIGERATION SYSTEM ............................................................................................................. 14
2.4 AUTOMATIC REGULATION SYSTEM................................................................................................. 15
2.5 ELECTRICAL SYSTEM ................................................................................................................... 16
3 Installation .....................................................................................................................17
3.1 DIMENSION DRAWINGS................................................................................................................. 17
3.2 INSTALLATION PROPOSAL............................................................................................................. 18
3.3 ELECTRIC CABLE SIZE AND SETTING OF MOTOR CIRCUIT BREAKER .................................................. 22
3.4 PICTOGRAPHS............................................................................................................................. 23
4 Operating instructions..................................................................................................25
4.1 CONTROL PANEL ......................................................................................................................... 25
4.2 STARTING ................................................................................................................................... 31
4.3 DURING OPERATION..................................................................................................................... 32
4.4 STOPPING................................................................................................................................... 32
4.5 PRESSURE DISCHARGE PROCEDURE............................................................................................. 34
4.6 DISMANTLING.............................................................................................................................. 34
5 Maintenance...................................................................................................................35

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5.1 MAINTENANCE INSTRUCTIONS ...................................................................................................... 35
5.2 DISPOSAL OF USED MATERIAL....................................................................................................... 36
6 Settings..........................................................................................................................37
6.1 DEVICE SETTINGS........................................................................................................................ 37
7 Problem solving ............................................................................................................38
7.1 PROBLEM SOLVING ...................................................................................................................... 38
8 Technical data ...............................................................................................................41
8.1 REFERENCE CONDITIONS AND LIMITATIONS ................................................................................... 41
8.2 AIR DRYER DATA.......................................................................................................................... 42

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69828 0931 61
1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 General safety precautions
1. The operator must employ safe working practices and observe all related work safety requirements and
regulations.
2. If any of the following statements does not comply with the applicable legislation, the stricter of the two
shall apply.
3. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel. The personnel should apply safe working practices by use of personal protection
equipment, appropriate tools and defined procedures.
4. The machine is not considered capable of producing air of breathing quality. For air of breathing quality, the
compressed air must be adequately purified according to the applicable legislation and standards.
5. Before any maintenance, repair work, adjustment or any other non-routine checks:
•Stop the machine.
•Press the emergency stop button.
•Switch off the voltage.
•Depressurize the machine.
•Lock Out - Tag Out (LOTO):
Open the power isolating switch and lock it with a personal lock.
Tag the power isolating switch with the name of the service technician.
•On units powered by a frequency converter, wait 10 minutes before starting any electrical
repair.
•Never rely on indicator lamps or electrical door locks before maintenance work, always
disconnect and check with measuring device.
If the machine is equipped with an automatic restart after voltage failure function
and if this function is active, be aware that the machine will restart automatically
when the power is restored if it was running when the power was interrupted!
6. Never play with compressed air. Do not apply the air to your skin or direct an air stream at people. Never
use the air to clean dirt from your clothes. When using the air to clean equipment, do so with extreme
caution and wear eye protection.
7. The owner is responsible for maintaining the unit in safe operating condition. Parts and accessories shall
be replaced if unsuitable for safe operation.
8. It is not allowed to walk or stand on the unit or on its components.

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9. If compressed air is used in the food industry and more specifically for direct food contact, Pneumatech
recommends, for optimal safety, the use of certified Class 0 compressors in combination with appropriate
filtration depending on the application. Please contact your Pneumatech Customer Center for advice on
specific filtration.
1.3 Safety precautions during installation
All responsibility for any damage or injury resulting from neglecting these precautions,
or non observance of the normal caution and
care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during installation
1. The machine must only be lifted using suitable equipment in accordance with the applicable safety
regulations. Loose or pivoting parts must be securely fastened before lifting. It is strictly forbidden to dwell
or stay in the risk zone under a lifted load. Lifting acceleration and deceleration must be kept within safe
limits. Wear a safety helmet when working in the area of overhead or lifting equipment.
2. The unit is designed for indoor use.
3. Place the machine where the ambient air is as cool and clean as possible.
4. Any blanking flanges, plugs, caps and desiccant bags must be removed before connecting the pipes.
5. Air hoses must be of correct size and suitable for the working pressure. Never use frayed, damaged or
worn hoses. Distribution pipes and connections must be of the correct size and suitable for the working
pressure.
6. Ensure that the discharge pipe from the dryer to the air net is free to expand under heat and that it is not
in contact with or close to flammable materials.
7. No external force may be exerted on the air outlet valve; the connected pipe must be free of strain.
8. If remote control is installed, the machine must bear a clear sign stating: DANGER: This machine is
remotely controlled and may start without warning.
The operator has to make sure that the machine is stopped and that the isolating switch is open and
locked before any maintenance or repair. As a further safeguard, persons switching on remotely
controlled machines shall take adequate precautions to ensure that there is no one checking or working
on the machine. To this end, a suitable notice shall be affixed to the start equipment.
9. The electrical connections must correspond to the applicable codes. The machines must be earthed and
protected against short circuits by fuses in all phases. A lockable power isolating switch must be installed
near the dryer.
10. On machines with automatic start-stop system or if the automatic restart function after voltage failure is
activated, a sign stating "This machine may start without warning" must be affixed near the instrument
panel.
11. Never remove or tamper with the safety devices, guards or insulation fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure must
be protected by a pressure-relieving device or devices as required.
12. Pipework or other parts with a temperature in excess of 80°C (176°F) and which may be accidentally
touched by personnel in normal operation must be guarded or insulated. Other high-temperature
pipework must be clearly marked.
13. If the ground is not level or can be subject to variable inclination, consult the manufacturer.
Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance.
These precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and
cover several machine types and equipment; hence
some statements may not apply to your machine.

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89828 0931 61
1.4 Safety precautions during operation
All responsibility for any damage or injury resulting from neglecting these precautions,
or non observance of the
normal caution and care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during operation
1. Never touch any piping or components of the machine during operation.
2. Use only the correct type and size of hose end fittings and connections. When blowing through a hose or
air line, ensure that the open end is held securely. A free end will whip and may cause injury. Make sure
that a hose is fully depressurized before disconnecting it.
3. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
4. Never operate the machine when there is a possibility of taking in flammable or toxic fumes, vapors or
particles.
5. Never operate the machine below or in excess of its limit ratings.
6. Keep all bodywork doors shut during operation. The doors may be opened for short periods only, e.g. to
carry out routine checks. Wear ear protectors when opening a door.
7. People staying in environments or rooms where the sound pressure level reaches or exceeds 80 dB(A)
shall wear ear protectors.
8. Periodically check that:
•All guards are in place and securely fastened
•All hoses and/or pipes inside the machine are in good condition, secure and not rubbing
•There are no leaks
•All fasteners are tight
•All electrical leads are secure and in good order
•Safety valves and other pressure relief devices are not obstructed by dirt or paint
•Air outlet valve and air net, i.e. pipes, couplings, manifolds, valves, hoses, etc. are in good
repair, free of wear or abuse
9. If warm cooling air from dryer is used in air heating systems, e.g. to warm up a workroom, take
precautions against air pollution and possible contamination of the breathing air.
10. Do not remove any of, or tamper with, the sound-damping material.
11. Never remove or tamper with the safety devices, guards or insulations fitted on the machine. Every
pressure vessel or auxiliary installed outside the machine to contain air above atmospheric pressure shall
be protected by a pressure relieving device or devices as required.
Also consult following safety precautions: Safetyprecautions duringinstallationand
Safety precautions during maintenance.
These
precautions apply to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine typ
es and equipment; hence
some statements may not apply to your machine.

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1.5 Safety precautions during maintenance or repair
All responsibility for any damage or injury resulting from neglecting these precautions,
or non observance of the normal caution a
nd care required for installation, operation,
maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
Precautions during maintenance or repair
1. Always use the correct safety equipment (such as safety glasses, gloves, safety shoes, etc.).
2. Use only the correct tools for maintenance and repair work.
3. Use only genuine spare parts.
4. All maintenance work shall only be undertaken when the machine has cooled down.
5. A warning sign bearing a legend such as "Work in progress; do not start" shall be attached to the starting
equipment.
6. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there
is no one checking or working on the machine. To this end, a suitable notice shall be affixed to the remote
start equipment.
7. Close the dryer air outlet valve before connecting or disconnecting a pipe.
8. Before removing any pressurized component, effectively isolate the machine from all sources of pressure
and relieve the entire system of pressure.
9. Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety precautions against
toxic vapours of cleaning liquids.
10. Never use damaging contaminants. (e.g. dust, fibres, fine sand) for cleaning parts.
11. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the parts
and exposed openings with a clean cloth, paper or tape.
12. Never weld on, or in any way modify, pressure vessels.
13. Whenever there is an indication or any suspicion that an internal part of a machine is overheated, the
machine shall be stopped but no inspection covers shall be opened before sufficient cooling time has
elapsed; this to avoid the risk of spontaneous ignition of the oil vapour when air is admitted.
14. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
15. Make sure that no tools, loose parts or rags are left in or on the machine.
16. All regulating and safety devices shall be maintained with due care to ensure that they function properly.
They may not be put out of action.
17. Before clearing the machine for use after maintenance or overhaul, check that operating pressures,
temperatures and time settings are correct. Check that all control and shut-down devices are fitted and
that they function correctly.
18. Protect the motor, air filter, electrical and regulating components, etc. to prevent moisture from entering
them, e.g. when steam cleaning.
19. Make sure that all sound-damping material and vibration dampers, e.g. damping material on the bodywork,
is in good condition. If damaged, replace it by genuine material from the manufacturer to prevent the
sound pressure level from increasing.
20. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
21. The following safety precautions are stressed when handling refrigerant:
•Never inhale refrigerant vapours. Check that the working area is adequately ventilated; if
required, use breathing protection.
•Always wear special gloves. In case of refrigerant contact with the skin, rinse the skin with
water. If liquid refrigerant contacts the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all refrigerant is flushed away; then
seek medical first aid.
Also consult following safety precautions: Safetyprecautions duringinstallationand
Safety precautions during operation.
These precautions apply
to machinery processing or consuming air or inert gas.
Processing of any other gas requires additional safety precautions typical to the
application which are not included herein.
Some precautions are general and cover several machine types and equipment;
hence
some statements may not apply to your machine.

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10 9828 0931 61
2 General description
2.1 Introduction
General view
AD 750 up to AD 1250
Introduction
The AD air dryers remove moisture from compressed air by cooling the air near to the freezing point.
This causes water to condense. The condensate is automatically drained. The air is warmed up before
leaving the dryer.

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Safety devices
Safety devices
Reference Name
1 Fan protection grid
2 Grounding
3 Safety pressure switch

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12 9828 0931 61
Danger Zones
Risks present on the whole machine.
Refer to images added on the next page for the location of danger zone.
Danger Zones
Reference Danger signal Description of danger signal
1 Dangerous electric voltage
2 Air not fit for breathing
3 High pressure
4 Fan rotating (not shown in image)
5 Hot parts

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2.2 Air system
Air flow diagram
Text on figure:
(1) Air inlet
(2) Air outlet
(3) Condensate drain
Reference Name
1 Refrigerant compressor
2 Condenser
3 Motor and fan
4 Evaporator
5 Condensate separator
6 Impurity trap
7 Expansion capillary tube
8 Refrigerant filter
9 Hot gas by-pass valve
10 Air/air heat exchanger
11 Digital controller
12 Fan control switch
13 High pressure shut-down switch
14 Liquid separator
15 Automatic condensate drain
Description
Compressed air enters heat exchanger (10) and is pre-cooled by the outgoing, cold, dried air. Water in
the incoming compressed air starts to condense. The air then flows through heat exchanger/evaporator
(4) where the refrigerant evaporates causing the air to be cooled further to close to the evaporating
temperature of the refrigerant. This results in further condensation. The cold air then flows through
separator (5) where all the condensate is separated from the air. The condensate is automatically
drained.

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14 9828 0931 61
The cold, dried air flows through heat exchanger (10) where it is warmed up by the incoming air to
approx. 10˚C (18˚F) below the incoming air temperature.
Condensation in the air net cannot occur unless the air is cooled below the pressure dewpoint indicated
by the digital controller (11).
2.3 Refrigeration system
Refrigerant flow diagram
Text on figure:
(1) Air inlet
(2) Air outlet
(3) Condensate drain
Reference Name
1 Refrigerant compressor
2 Condenser
3 Motor and fan
4 Evaporator
5 Condensate separator
6 Impurity trap
7 Expansion capillary tube
8 Refrigerant filter
9 Hot gas by-pass valve
10 Air/air heat exchanger
11 Digital controller
12 Fan control switch
13 High pressure shut-down switch
14 Liquid separator
15 Automatic condensate drain

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Description
Compressor (1) delivers hot, high-pressure refrigerant gas which flows through condenser (2) where
most of the refrigerant condenses.
The liquid flows through liquid refrigerant dryer/filter (8) to capillary tube (7). The refrigerant leaves the
capillary tube at evaporating pressure.
The refrigerant enters evaporator (4) where it withdraws heat from the compressed air by further
evaporation at constant pressure. The heated refrigerant leaves the evaporator and is sucked in by the
compressor (1).
2.4 Automatic regulation system
Air flow diagram
Text on figure:
(1) Air inlet
(2) Air outlet
(3) Condensate drain
Reference Name
1 Refrigerant compressor
2 Condenser
3 Motor and fan
4 Evaporator
5 Condensate separator
6 Impurity trap
7 Expansion capillary tube
8 Refrigerant filter
9 Hot gas by-pass valve
10 Air/air heat exchanger
11 Digital controller
12 Fan control switch
13 High pressure shut-down switch
14 Liquid separator
15 Automatic condensate drain

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16 9828 0931 61
Description
The condenser pressure must be kept constant to obtain stable operation. Fan control switch (12)
therefore stops and starts the cooling fan (3).
If, under partial or no load, the evaporator pressure drops below a certain level, the hot gas by- pass
valve (9) opens and hot, high-pressure gas is fed to the evaporator circuit to prevent the evaporator
pressure from dropping any further.
2.5 Electrical system
Description
The fan control switch starts the fan motor as soon as the condenser pressure reaches the upper set
point of the switch and will stop the fan motor when the condenser pressure decreases to its lower set
point.
The high pressure shut-down switch stops the compressor motor when the pressure in the refrigerant
circuit reaches the upper setpoint of the switch.
The low pressure shut-down switch stops the compressor motor when the pressure in the refrigerant
circuit drops below the setpoint of the switch.

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9828 0931 61 17
3 Installation
3.1 Dimension drawings
AD 1000 - 1250 connection details
AD 750 connection details
Dimension drawing

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18 9828 0931 61
Reference Name
(1) Electric cable outlet
(2) Condensate drain outlet
(3) Air inlet
(4) Air outlet
(5) NPT adaptors (2X) (UL version only)
(6) Unit measurement in mm
[x] = [inch]
3.2 Installation proposal
Transport and handling
The machine must be transported as shown in the following figure.
For machine weight, see the section “Air dryer data”.
Unpacking
Cutting the metal strapping is a dangerous operation. D
o not cut pieces in the
environment.
After removing the packing, ensure that no damage has occurred to the machine during transportation.
If you are in doubt, do not use the machine. Call your distributor’s service department or dealer.
The packing material (plastic bags, polystyrene foam, nails, screws, wood, metal strapping, and so on.)
must not be left within the reach of children or left in the environment, as they are a potential source of
danger and pollution. Dispose of these materials in the approved collection centers.

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9828 0931 61 19
Moving
To move the dryer use a forklift truck. Do not use metal cables for lifting.
Move the dryer gently.
Ensure that the operator can see the whole machine from the control panel and check
the presence of any unauthorized persons in the vicinity of the machine.
Compressor room example

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20 9828 0931 61
Text on figure:
Reference Name
(1) Compressor
(2) Air receiver
(3) To the air piping
(4) Dryer
(5) Ventilation proposal
(6) Air flow
(7) Minimum free area to be reserved for the dryer’s installation
(8) Service side
(9) Control panel side
• Air treatment with dryer downstream of the air receiver: this can be used when the
compressor runs constantly and the cooling capacity of the dryer is equal to the air delivery of the
compressor. Under this condition the load of the dryer is constant.
• Air treatment with dryer upstream of the air receiver: this can be used when the air demand
is variable. For short periods the air demand is higher than the air delivery of the compressor;
the air receiver must be large enough to meet the instant air demand.
Reference Description
1 The refrigerant air dryer should be installed on a level floor suitable for taking the
weight of the dryer.
Ensure that there is sufficient space around the machine to allow maintenance.
Keep environmental conditions (temperature and humidity) in the machine room
stable to avoid refrigerant compressor/fan overload and/or reduction of dryer
performance. Similar failures will invalidate the warranty.
2 Ventilation: the inlet grids and ventilation fan should be installed in such way that
any recirculation of cooling air to the dryer is avoided. The maximum air velocity to
the grids has to be limited to 5 m/s. The maximum allowable pressure drop over the
cooling air ducts is 30 Pa. When 30 Pa is exceeded, a ventilation fan is needed at
the outlet of the cooling air ducts.
Ensure appropriate composition of the air within the machine room.
The condensate drain pipes must not dip into the condensate. Do not allow
untreated condensate to enter the draining system.
Ensure canalization system (duct and fan) is designed properly. Incorrectly
designed canalization system will lead to machine warranty being made void.
The operating conditions to be complied with are the following:
•Min. room temperature: +5°C (41°F) (compulsory)
•Max. room temperature: +46°C (114,8°F) (compulsory)
•Min. inlet allowed temperature: +3°C (37,4°F)
•Max. inlet allowed temperature: +60°C (140°F)
•Max. working pressure: 14 bar (203 psi)
3 Power supply cable to be sized and installed by a qualified electrician.
Check that the supply voltage is the same as the value indicated on the machine data
plate.
It is recommended to install an automatic cut-out device (in customer scope)
upstream for the machine against overcurrent, with a differential device.
4 Optionally line filters can be provided. Contact your dealer for more info on the
filtration kind and level desired.