Pneumatech PH 230 HE User manual

PNEUMATECH
PH 230 HE, PH 320 HE, PH 390 HE, PH 530 HE, PH 635 HE
Instruction book

PNEUMATECH
PH 230 HE, PH 320 HE, PH 390 HE, PH 530 HE,
PH 635 HE
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.
2016 - 08
No. 2920 1891 00
www.pneumatech.com

Table of contents
1 Safety precautions..........................................................................................................4
1.1 SAFETY ICONS................................................................................................................................... 4
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................4
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................5
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 6
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 6
2 General description........................................................................................................8
2.1 GENERAL DESCRIPTION....................................................................................................................... 8
2.2 OPERATION.....................................................................................................................................10
3 Electrical diagram.........................................................................................................13
4 Controller.......................................................................................................................14
4.1 CONTROL PANEL.............................................................................................................................. 14
4.2 DIGITAL OUTPUT CONTACTS................................................................................................................15
4.3 ICONS USED.................................................................................................................................... 17
4.4 MAIN SCREEN..................................................................................................................................20
4.5 CONTROLLER MENU STRUCTURE..........................................................................................................23
4.6 TEST MENU..................................................................................................................................... 27
4.7 MODIFYING SETTINGS........................................................................................................................28
4.8 WEB SERVER.................................................................................................................................. 34
4.9 PROGRAMMABLE SETTINGS.................................................................................................................42
5 Installation.....................................................................................................................43
5.1 DIMENSION DRAWINGS.......................................................................................................................43
5.2 INSTALLATION PROPOSAL................................................................................................................... 48
5.3 ELECTRICAL CONNECTIONS.................................................................................................................49
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6 Operating instructions................................................................................................. 51
7 Maintenance..................................................................................................................54
7.1 MAINTENANCE................................................................................................................................. 54
7.2 DISPOSAL OF USED MATERIAL............................................................................................................. 55
8 Problem solving............................................................................................................56
9 Technical data...............................................................................................................57
9.1 REFERENCE CONDITIONS................................................................................................................... 57
9.2 LIMITATIONS FOR OPERATION..............................................................................................................57
9.3 SPECIFIC DATA................................................................................................................................ 57
10 Instructions for Use......................................................................................................60
11 Guidelines for inspection.............................................................................................61
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2920 1891 00 3

1 Safety precautions
1.1 Safety icons
Explanation
Danger to life
Warning
Important note
1.2 Safety precautions, general
General precautions
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.
1. The dryers are designed for normal indoor use.
2. The operator must employ safe working practices and observe all related work safety requirements
and regulations.
3. If any of the following statements does not comply with the applicable legislation, the stricter of the
two shall apply.
4. Installation, operation, maintenance and repair work must only be performed by authorized, trained,
specialized personnel.
5. The dryer is not considered capable of producing air of breathing quality. To obtain air of breathing
quality, the compressed air must be adequately purified according to the applicable legislation and
standards.
6. Before any maintenance, repair work, adjustment or any other non-routine checks, stop the dryer,
press the emergency stop button, switch off the voltage and depressurize the dryer. In addition, the
power isolating switch must be opened and locked. For plug versions, remove the plug from the wall
socket and secure it.
7. 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.
8. The owner is responsible for maintaining the dryer in safe operating condition. Parts and accessories
shall be replaced if unsuitable for safe operation.
9. It is not allowed to walk or stand on the dryer or its components.
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1.3 Safety precautions during installation
Precautions during installation
1. The dryer must only be lifted using suitable equipment and 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. Place the dryer where the ambient air is as cool and clean as possible. If necessary, install a suction
duct. Never obstruct the air inlet. Care must be taken to minimize the entry of moisture at the inlet air.
3. Any blanking flanges, plugs, caps or desiccant bags must be removed before connecting the pipes.
4. 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.
5. The aspirated air must be free of flammable fumes, vapors and particles, e.g. paint solvents, that can
lead to internal fire or explosion.
6. Ensure that all piping 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 starting 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 equipment.
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. Piping or other parts with a temperature in excess of 80˚C (176˚F) and which may be accidentally
touched by personnel during normal operation must be guarded or insulated. Other high-temperature
piping must be clearly marked.
13. If no safety valve is present in the air net close to the desiccant dryer (e.g. safety valve of
compressor), full flow safety valves must be installed on the dryer vessels.
14. If the maximum pressure of the compressor is higher than the design pressure of the dryer, a full flow
safety valve must be installed between the compressor and the dryer in order to blow off the excessive
pressure in case the safety valve of the dryer should be out of order or blocked.
Also consult following safety precautions: Safety precautions during operation and Safety
precautions during maintenance or repair.
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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2920 1891 00 5

1.4 Safety precautions during operation
Precautions during operation
1. Always be careful when touching any piping or components of the dryer 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. People staying in environments or rooms where the sound pressure level reaches or exceeds 90 dB(A)
shall wear ear protectors.
7. 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
condition, free of wear or abuse
8. If warm cooling air from dryers is used in air heating systems, e.g. to warm up a working area, take
precautions against air pollution and possible contamination of the breathing air.
9. Do not remove any of, or tamper with, the sound dampening material.
10. 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.
11. Yearly inspect the air receiver. Minimum wall thickness as specified in the instruction book must be
respected. Local regulations remain applicable if they are more strict.
Also consult following safety precautions: Safety precautions during installation and Safety
precautions during maintenance or repair.
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.
1.5 Safety precautions during maintenance or repair
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.
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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 starting 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 vapors of cleaning liquids.
10. Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering the
parts and exposed openings with a clean cloth, paper or tape.
11. Never weld on, or in any way modify, pressure vessels.
12. 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 vapor when air is admitted.
13. Never use a light source with open flame for inspecting the interior of a machine, pressure vessel, etc.
14. Make sure that no tools, loose parts or rags are left in or on the machine.
15. 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.
16. 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.
17. Protect the motor, electrical and regulating components, etc. to prevent moisture from entering them,
e.g. when steam-cleaning.
18. 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.
19. Never use caustic solvents which can damage materials of the air net, e.g. polycarbonate bowls.
20. The following safety precautions are stressed when handling desiccant:
• Take precautions not to inhale desiccant dust.
• Check that the working area is adequately ventilated; if required, use breathing protection.
• Do not overfill the dryer when replacing desiccant.
Also consult following safety precautions: Safety precautions during installation and 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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2920 1891 00 7

2 General description
2.1 General description
Introduction
The air dryers described in this book are heatless adsorption dryers, built to remove moisture from
compressed air for industrial purposes. The standard version is intended to reach a pressure dew point
(PDP) of -40 ˚F. There is also a version available for a pressure dew point of -100 ˚F.
All dryers are designed for indoor use.
The dryers described in this book are equipped with a smart controller. A Pressure Dew Point (PDP) sensor
can be installed with a sales kit.
Main parts
A general overview of the main parts of the dryer units is given in below images:
Front view PH 230 HE up to PH 635 HE
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Rear view PH 230 HE up to PH 635 HE
Reference Designation Reference Designation
A Tower A 1 Control panel
B Tower B 2 Purelogic™ controller
IN Dryer inlet 3 Cubicle
OUT Dryer outlet SV Solenoid valves
IV Inlet valve N Nozzle for regeneration air
PA Pneumatic actuator P1 Pressure gauge, tower A
PV Pneumatic valve P2 Pressure gauge, tower B
S Silencer AF Air filter
NV Non-return valve CA Control air valve
PR Pressure regulator (232 psi version) PDP PDP sensor (if installed)
P01 Pressure sensor P02 Pressure sensor
Control panel
The dryer is controlled by a PurelogicTM controller. Consult the dedicated chapter for a complete
description of the controller functions.
Safety valve
If no fire extinguishing system is present close to the dryer, safety valves must be installed on the vessels of
the dryer in order to relieve the overpressure in the vessel because of fire in the neighbourhood of the dryer.
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2920 1891 00 9

Sonic nozzle (available as an option)
Excessively high air velocity (e.g. due to low inlet pressure) may cause the desiccant to "float" in the
vessels. The desiccant beads scrape against each other, creating additional dust. High-speed flow occurs
when a compressor starts against an empty air net or when working at a discharge air pressure that is too
low. A high volume of compressed air output can result in a pressure drop, which in turn increases the
speed.
Therefore, it is recommended to protect the drying medium against excessive volumetric flow through the
desiccant by installing a sonic nozzle.
Refer to the instruction delivered with the sonic nozzle to install and adjust it.
2.2 Operation
The construction of the air dryer is simple, reliable and easy to service. The dryer has two towers,
containing the adsorbing material or desiccant. The desiccant is a very porous grain material which can
adsorb large amounts of water vapor.
The operation cycle of the dryer is repetitive and is controlled by the Purelogic™ controller and a PDP
(Pressure Dew Point) sensor (when installed and activated).
The compressed air entering the dryer is led to one of the towers by means of the inlet valves (IV), which
are controlled by a pneumatic actuator (PA). As the air flows upwards through the tower, the desiccant
adsorbs the water vapor and the compressed air is dried. The dry air leaves the dryer via the outlet,
connected to the top of the tower.
While the desiccant in the first tower dries the compressed air, the desiccant in the second tower is being
regenerated. Regeneration of the desiccant is achieved by means of purge air from the drying tower: a
small portion of the dried air passes a nozzle (N), expands to atmospheric pressure and flows downwards
through the other tower, regenerating the desiccant. The regenerating air is released via the corresponding
exhaust valve (PV) and the silencer (S).
The regeneration time is regulated by a programmed half cycle time. Solenoid valves, controlled by the
controller, energize the pneumatic valves that determine the function of the towers. In case a PDP sensor is
installed and activated, a second small portion of the dried air flows via the control air valve (100), a small
air filter (101) and the pressure regulator (PR - only used on 232 psi versions) to the PDP sensor.
The PDP sensor constantly measures the pressure dew point of the air leaving the drying tower. As long as
the PDP temperature is below the set point (-40 °F or -100 °F), the drying tower will keep on drying, until
the PDP temperature exceeds the set point. On that moment the regenerated tower will start drying the
compressed air and the other tower will start regenerating. As long as the PDP temperature is below the set
point, regeneration of the non-drying tower is stopped after the pre-set time interval of the timer has
elapsed. As a result, reduction of purge air is achieved.
Flow diagram
The figure below shows the pneumatic diagram of the dryer.
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Reference Designation Reference Designation
(1) Sonic nozzle (optional) 107 3/2 spool valve monostable
(2) Outlet PS Pressure switch
(3) Air net 100 Manual valve
(4) Dryer 101 Pilot air filter
(5) Vessel 104 Pressure regulator (only on 232 psi
version)
(6) Compressor 112 Adjustable restriction
(7) Inlet 103 Filter with drain
(8) Controller V11/V12 Outlet valve, vessel A/B
PI Pressure indicator 114 Orifice
OF1 Outlet filter IF1/IF2 Inlet filter
V21/V22 Safety valve PT01/PT02 Pressure vessel A/B
PI01/PI02 Pressure indicator, vessel A/B V3/V4 Regulating valve, vessel A/B
V1/V2 Inlet valve, vessel A/B 109 Silencer
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2920 1891 00 11

Reference Designation Reference Designation
TT01 Inlet temperature PDP01 Pressure Dew Point
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12 2920 1891 00

3 Electrical diagram
The complete electrical diagram is available inside the electric cabinet.
Some generally used symbols are given in below table:
Reference Designation Reference Designation
F1/2/... Fuses T1 Transformer
Y1/Y2 Solenoid valves MT01 PDP sensor
PT01/PT02 Pressure transducer, Tower A/B TT01 Temperature sensor, inlet
E1 Regulator E2 Expansion module IO2
PDS11/12/13 Pressure drop (ΔP) over filter
(optional)
S0 Main switch (customer's
installation)
S1' Remote start/stop switch
(optional)
S3' Remote emergency stop
(optional)
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2920 1891 00 13

4 Controller
4.1 Control panel
Purelogic controller
Reference Designation Function
1 Display Shows the dryer operating condition and a number
of icons to navigate through the menu.
2 Pictogram Automatic operation
3 Pictogram General alarm
4 General alarm LED Blinks when operating in shutdown warning
condition.
5 Pictogram Service
6 Service LED Lights up when service is needed.
7 Automatic operation LED Indicates that the controller runs in automatic mode.
8 Voltage on LED Lights up when supply is switched on. Dryer unit
might start automatically!
9 Pictogram Voltage on
10 Enter key Enter and confirmation key
11 Escape key To navigate to previous screen or to cancel current
action
12 Scroll keys Keys to scroll through the menu
13 Stop button Button to stop the dryer. LED (7) dims.
14 Start button Button to start the dryer. LED (7) lights up, indicating
that the controller is operational.
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4.2 Digital output contacts
Warning
Voltage-free outputs may only be used to control or monitor functional systems. They
should NOT be used to control, switch or interrupt safety related circuits.
Stop the compressor and switch off the supply before connecting external equipment. Check
the Safety precautions.
Connections for external equipment
The controller always comes with expansion module IO2 that has a number of digital output contacts
which can be used to connect external equipment.
Depending on the optional equipment, extra expansion modules are added to the machine configuration
(IO2, IO34).
Expansion Module IO2
The digital output contacts have following specifications:
Relay Connector Maximum load
K01 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K02 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
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Relay Connector Maximum load
K03 3 X 31 15 A / 250 V AC
15 A / 30 V DC
RC* protected
K04 3 X 31 10 A / 250 V AC
10 A / 30 V DC
resistive load
K05 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K06 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K07 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K08 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K09 3 X 30 10 A / 250 V AC
10 A / 30 V DC
resistive load
K10 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K11 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K12 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K13 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K14 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
K15 3 X 32 10 A / 250 V AC
10 A / 30 V DC
resistive load
* = Resistor Capacitor
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4.3 Icons used
Status icons
Name Icon Description
Stopped/Running When the dryer is stopped, the icon stands still.
When the dryer is running, the icon is rotating.
Machine control mode Local start/stop
Remote start/stop
Network control
Automatic restart after voltage
failure
Automatic restart after voltage failure is active
Week timer Week timer is active
Active protection functions Emergency stop
Shutdown
Warning
Service Service required
Main screen Main chart
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2920 1891 00 17

Input icons
Icon Description
Pressure
Temperature
Digital input
Special protection
System icons
Icon Description
Failure expansion module
Network problem
General alarm
Regulation
General settings
Acess key / User password
Menu icons
Icon Description
Inputs
Outputs
Alarms (Warnings, shutdowns)
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