Pneumatech PH 55 User manual

Pneumatech
Heatless adsorption air dryers
PH 55, PH 75, PH 95, PH 120, PH 140, PH 190, PH 230, PH 275,
PH 350, PH 420, PH 550
Instruction book

Pneumatech
Heatless adsorption air dryers
PH 55, PH 75, PH 95, PH 120, PH 140, PH 190, PH 230,
PH 275, PH 350, PH 420, PH 550
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.
2021 - 08
No. 2920 7111 23
www.pneumatech.com

Table of contents
1 Safety precautions..........................................................................................................5
1.1 SAFETY ICONS................................................................................................................................... 5
1.2 SAFETY PRECAUTIONS, GENERAL...........................................................................................................5
1.3 SAFETY PRECAUTIONS DURING INSTALLATION...........................................................................................6
1.4 SAFETY PRECAUTIONS DURING OPERATION.............................................................................................. 7
1.5 SAFETY PRECAUTIONS DURING MAINTENANCE OR REPAIR........................................................................... 8
1.6 DISMANTLING AND DISPOSAL.................................................................................................................9
2 General description......................................................................................................11
2.1 GENERAL DESCRIPTION..................................................................................................................... 11
2.2 OPERATION.....................................................................................................................................12
3 Electric diagram............................................................................................................15
4 DC1 controller...............................................................................................................16
4.1 CONTROL PANEL.............................................................................................................................. 16
4.2 MAIN SCREEN..................................................................................................................................17
4.3 SELECTION MENU............................................................................................................................ 18
4.4 ALARM SCREEN................................................................................................................................19
4.5 EDITING PARAMETERS....................................................................................................................... 20
5 Graphic controller.........................................................................................................23
5.1 GENERAL .......................................................................................................................................23
5.2 CONTROL PANEL.............................................................................................................................. 24
5.3 ICONS USED.................................................................................................................................... 25
5.4 MAIN SCREEN..................................................................................................................................28
5.5 CALLING UP MENUS.......................................................................................................................... 32
5.6 INPUTS MENU...................................................................................................................................33
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5.7 OUTPUTS MENU............................................................................................................................... 34
5.8 COUNTERS......................................................................................................................................35
5.9 EVENT HISTORY MENU.......................................................................................................................37
5.10 TEST MENU..................................................................................................................................... 38
5.11 SERVICE MENU................................................................................................................................ 39
5.12 PROTECTIONS MENU......................................................................................................................... 43
5.13 WEEK TIMER MENU...........................................................................................................................44
5.14 INFO MENU......................................................................................................................................54
5.15 MODIFYING SETTINGS........................................................................................................................54
5.16 EXTRA MENU...................................................................................................................................60
5.17 WEB SERVER.................................................................................................................................. 62
5.18 PROGRAMMABLE SETTINGS.................................................................................................................71
6 Installation.....................................................................................................................72
6.1 DIMENSION DRAWINGS.......................................................................................................................72
6.2 INSTALLATION PROPOSAL................................................................................................................... 72
7 Electrical connections..................................................................................................76
8 Operating instructions................................................................................................. 77
9 Maintenance..................................................................................................................79
9.1 MAINTENANCE................................................................................................................................. 79
9.2 NOZZLE REPLACEMENT......................................................................................................................80
10 Problem solving............................................................................................................81
11 Technical data...............................................................................................................82
11.1 REFERENCE CONDITIONS................................................................................................................... 82
11.2 LIMITATIONS FOR OPERATION..............................................................................................................82
11.3 DRYER DATA................................................................................................................................... 82
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12 Instructions for use...................................................................................................... 86
13 Guidelines for inspection.............................................................................................87
14 Pressure Equipment Directives...................................................................................88
15 Declaration of conformity............................................................................................ 89
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4 2920 7111 23

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
humidity in 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. Arrange the air intake so that loose clothing worn by people cannot be sucked in.
7. Ensure that all piping is free to expand under heat and that it is not in contact with or close to
flammable materials.
8. No external force may be exerted on the air outlet valve. The connected pipe must be free of
strain.
9. 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.
10. Air-cooled machines must be installed in such a way that an adequate flow of cooling air is
available and that the exhausted cooling air does not recirculate to the inlet.
11. 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.
12. 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.
13. 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.
14. 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.
15. For water-cooled machines, the cooling water system installed outside the machine has to
be protected by a safety device with set pressure according to the maximum cooling water
inlet pressure.
16. 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.
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17. 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. This is done in case the safety valve of the dryer is out of
order or blocked.
18. When unit is not permanently secured to the floor in the vertical position or mounted
vertically, access to electrical equipment is feasible through the unit base. In this case,
additional barriers must be provided during installation. Tag with "Warning: High Voltage"
symbol
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.
1.4 Safety precautions during operation
Precautions during operation
1. Always be careful when touching any piping or components of the dryer during operation.
On dryers using heat to regenerate the desiccant, some parts will become very hot.
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 closed during operation. Bodywork should be opened for short periods
only, e.g. to carry out routine checks. Wear ear protectors when removing a panel.
7. People staying in environments or rooms where the sound pressure level reaches or
exceeds 90 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 condition, free of wear or abuse
9. 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.
10. Do not remove any of, or tamper with, the sound dampening 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
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atmospheric pressure shall be protected by a pressure relieving device or devices as
required.
12. 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.
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. No inspection covers shall be opened before
enough cooling time has elapsed. This is done 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 operation.
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.
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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 with 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.
1.6 Dismantling and disposal
Dismantling
Once the end of life of the machine is reached, please follow next steps:
1. Stop the machine.
2. Check all safety precautions mentioned in the previous chapters to secure safe handling
(e.g. LOTO, cool-down, depressurize, discharge, ...).
3. Separate the harmful from the safe components (e.g. drain oil from oil containing parts).
4. Refer to the disposal topic mentioned below.
Disposal of electrical and electronic appliances (WEEE)
This equipment falls under the provisions of the European Directive 2012/19/EU on waste
electrical and electronic appliances (WEEE) and may not be disposed as unsorted waste.
The equipment is labelled in accordance with the European Directive 2012/19/EU with the
crossed-out wheelie bin symbol.
At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate
collection.
For more information check with your local waste authority, customer center or distributor.
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Disposal of other used material
Used filters or any other used material (e.g. filter bags, filter media, desiccant, lubricants,
cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe
manner, and in line with the local recommendations and environmental legislation.
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2 General description
2.1 General description
Introduction
The air dryers described in this book are heatless adsorption dryers, designed to remove
humidity from compressed air for industrial applications.
PH dryers are available in a version to reach a pressure dew point down to -20 °C (-4 °F) or down
to -40 ˚C (-40 ˚F) and are equipped with a DC1 electronic controller. A pressure dew point (PDP)
sensor is available as option.
The dryers are designed for indoor use and at altitudes up to 2000 m (6560 ft).
PH 230 with DC1 controller — General view
Main parts
An overview of the main parts of the dryer is given in the image below:
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PH 230 – Main parts
Reference Description Reference Description
1 DC1 controller 4 Silencer
2 Right tower 5 Air outlet
3 Left tower
2.2 Operation
General
With its simple construction, the air dryer is both reliable and easy to service. A dryer module
basically consists of two towers, containing the adsorption material or desiccant. The desiccant is
a very porous grain material, able to adsorb large amounts of water vapor.
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Flow diagram
Reference Designation Reference Designation
AIR INLET Air inlet V4 Regeneration valve
AIR OUTLET Air outlet V5 Left check valve
A Left desiccant tower V6 Right check valve
B Right desiccant tower M1 Blow off silencer
V1 Left 3–2 valve M2 Regeneration silencer
V2 Right 3–2 valve N1 Nozzle
V3 Blow off valve
Depending on dryer size, the dryer may consist of a single dryer module (see flow diagram) or a
combination of several dryer modules in parallel.
Operation principle
The operation cycle of the dryer is repetitive and is controlled by a factory set timer in the
controller or by the pressure dew point (PDP) sensor, which is optionally available. While the
desiccant in one 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.
The compressed air entering the dryer is led to one of the towers by means of one of the two 3–2
valves. The position of the 3–2 valves is controlled by the solenoid valves. As the air flows
upwards through the tower, the desiccant adsorbs the water vapor and the compressed air is
dried. The dried air leaves the dryer via the outlet check valve.
A small portion of the dried air passes a nozzle, expands to atmospheric pressure and flows
downwards through the other tower, regenerating (drying) the desiccant. A nozzle for operation of
the dryer at 7 bar is installed as standard. Alternative nozzles for use at different operating
pressures may be delivered with the units. Contact your supplier. The regeneration air is released
via the corresponding solenoid valve and the silencer. The solenoid valves are controlled by the
timer.
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After a preset period (or when triggered by the PDP sensor) the function of the towers is
reversed. The fully regenerated tower will now dry the air, while the desiccant in the other tower
will be regenerated.
By default, the regeneration timer will restart from the beginning of the cycle in case of a power
failure during operation or in case the dryer was switched off.
The working sequence of the controller is as follows:
Status Left tower Right tower V1 V2 V3 V4
0 Stopped Stopped 0 0 0 0
1 Adsorbing Adsorbing 0 0 0 0
2 Shifting Adsorbing 1 0 0 0
3 Depressurizing Adsorbing 1 0 1 0
4 Regenerating Adsorbing 1 0 1 1
5 Equalizing Adsorbing 1 0 0 0
6 Freeze (compressor
synchronization)
Adsorbing 1 0 0 0
7 Standby Adsorbing 1 0 0 0
8 Adsorbing Adsorbing 0 0 0 0
9 Adsorbing Shifting 0 1 0 0
10 Adsorbing Depressurizing 0 1 1 0
11 Adsorbing Regenerating 0 1 1 1
12 Adsorbing Equalizing 0 1 0 0
13 Adsorbing Freeze (compressor
synchronization)
0 1 0 0
14 Adsorbing Standby 0 1 0 0
When the ON/OFF push-button is pressed during operation, the controller jumps automatically to
status 5 or 12 (equalization phase). After that, the Stop status (0) will be reached. The following
start command will restart the sequence from the state 2 or 9. The same happens when the
power is switched off.
On dryers with a PurelogicTM controller, the functionPDP Extended Cycle can be activated. See
section Modifying Settings. When this function is activated, the regeneration air flow stops when
the PDP is reached.
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3 Electric diagram
The complete electric diagram can be found in the electrical cabinet and in your technical
documentation.
Drawing number Controller type
9827 2939 00 Graphic controller
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4 DC1 controller
4.1 Control panel
1 Display
2 ON/OFF button
3 LEFT button
4 ENTER button
5 RIGHT button
6 Alarm LED
7 Power On LED
Button functions
Press any button to light up the display.
Button Normal
operation
Alarm
status
Selection
menu
Alarms
browser
Parameters
editing
Counters and
service menu
ON/OFF Starts/stops the dryer
LEFT No action No action Moves the
cursor
upwards
cyclically
Displays the
previous alarm
cyclically
— Selects the
parameter
— Decrements
the data value
No action
With the PDP option available, you can press the left or right button to show a graph of the PDP.
RIGHT No action No action Moves the
cursor
downwards
cyclically
Displays the
next alarm
cyclically
— Selects the
parameter
— Increments the
data value
No action
With the PDP option available, you can press the left or right button to show a graph of the PDP.
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Button Normal
operation
Alarm
status
Selection
menu
Alarms
browser
Parameters
editing
Counters and
service menu
ENTER Displays the
selection
menu
Cancels
the
displayed
alarm for
one minute
(alarm
acknowled
gment)
Selects the
pointed menu
and activates
it
— Returns to
the selection
menu
— Cancels the
service alarm, if
pressed for 5 s
— Starts the
parameter editing
— Selects the
numerical data
digits
— Confirms the
modified value
— Pressed for at
least 2 s, returns
to the selection
menu
Returns to the
selection menu
LED functions
LED Color Description
Power
ON
Green The controller is turned on.
Alarm Blinking
red
The controller is in alarm condition.
Fixed red The controller needs technical assistance.
4.2 Main screen
During normal operation the following image is displayed:
• In the upper right area, the current working phase countdown and the measured dew point
are displayed.
When the pressure dew point (PDP) sensor is not enabled, the dew point is not displayed.
When the PDP sensor is enabled but either not connected or defective, no dew point value
is displayed (four dashes substitute the measure).
• In the lower area, the current working phase of each vessel is displayed.
• In the upper left area of the screen, an animated icon is present:
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Icon Description
Rotating arrow
Displayed when the dryer is in its working phases.
Stationary vertical bars
Displayed when the dryer is in the FREEZE status.
Stationary square
Displayed when the dryer is stopped.
The various working phases are:
Phase Text displayed on screen Translation
Stop STOPPED STOPPED
Shifting SHIFTING SHIFTING
Adsorbing ADSORBING ADSORBING
Pressure relief DEPRESS DEPRESS
Regeneration REGENERAT REGENERAT
Pressure equalize EQUALIZE EQUALIZE
Freeze FREEZE FREEZE
Standby STANDBY STANDBY
Blowing off BLOW OFF BLOW OFF
4.3 Selection Menu
When you press ENTER in the normal operation main screen (not during alarm!), you will see the
following selection menu:
Press LEFT or RIGHT to navigate to the required menu item and press ENTER to select.
Selection Translation Description
1 Alarms Alarms Alarms browser
2 Settings Settings Parameters list
3 Counters Counters Counters status
4 Service Service Service status
5 Exit Exit Back to the main display
Select item 5 (Exit) to return to the main screen or wait approximately 30 seconds.
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