ZANDER Multitronic Instruction sheet

Control system
MULTITRONIC
Retrofit Kit
Installation Guidelines
ADDENDUM - TO BE USED ONLY IN CONJUNCTION
WITH MULTITRONIC SUMMARY OPERATING
MANUAL!
Issue 06-2004/EN

Declaration of Conformity
ZANDER Aufbereitungstechnik GmbH & CO KG
Im Teelbruch 118
D–45219 Essen Kettwig
hereby declares with sole responsibility, that the products
Control systems for heatless regenerated adsorption dryers
Retrofit Kit (Plus) Multitronic
to which this declaration applies, conform to the specification of Directive
89/336/EEC including appendices, as shown in tests and as a result of
compliance with harmonised standards:
The following harmonised standards were used:
DIN EN 55011, DIN EN 61000, DIN EN 60204
The following other EC directives were used:
73/23/EC
Date: 01. April 2003
Signature
Dr. Walter Steudle
Managing Director

Multitronic-Retrofit Kit_00_2004-06-16
Table of contents
Declaration of Conformity......................................................................................2
General information................................................................................................2
Manufacturer's details................................................................................................................. 2
Scope of delivery ........................................................................................................................ 3
Warranty notes............................................................................................................................ 3
About these installation guidelines.............................................................................................4
For your own safety................................................................................................5
General safety notes................................................................................................................... 5
Safety notes on specific operating phases................................................................................. 6
Technical product description ..............................................................................7
Transportation and storage ...................................................................................8
Information on transportation packaging.................................................................................... 8
What to do in the case of transport damage occurring?............................................................ 8
Storing the control system .......................................................................................................... 8
Installation................................................................................................................9
Preparation ................................................................................................................................. 9
Connecting cables and mounting the switch box..................................................................... 10
Mounting the sensor cell and connecting the sensor (optional) .............................................. 10
Internal connections and switches ........................................................................................... 11
Installing the electrical connection............................................................................................13
Additional information..........................................................................................14

Manufacturer's details
2Multitronic-Retrofit Kit_01_2004-06-16
General information
Manufacturer's details
Name and address
Zander Aufbereitungstechnik GmbH & Co. KG
Im Teelbruch 118 Postfach 185524
45219 Essen 45205 Essen
Telephone ++49 (0)2054/934-0
Fax ++49 (0)2054/934-164
Internet: www.zander.de
E-Mail: [e-mail]
Service and orders
Service and replacement part order
Telephone ++49 (0)2054/934-180
Fax ++49 (0)2054/934-117
You can also use these telephone numbers to order consumables such as
drying agents etc. as well as replacement parts. When ordering replacement
parts, always state the type and build no. of the dryer. Both are shown on the
type plate of the dryer.
Enquiries and other orders
Telephone ++49 (0)2054/934-134
Fax ++49 (0)2054/934-139

General information
Multitronic-Retrofit Kit_01_2004-06-16 3
Scope of delivery
The Multitronic Retrofit Kit consists of the following components:
Control unit in switch box
Wiring harness, customised, with cable glands
4 self-adhesive dots
or:
Multitronic Retrofit Kit Plus
Control unit in switch box
Wiring harness, customised, with cable glands
4 self-adhesive dots
ZHM 100 dewpoint sensor, in protective packaging
Sensor cell for sensor, complete
Connecting cable for sensor
Associated documents:
Summary operating instructions Multitronic
Installation guidelines Multitronic (present)
Type plate
Warranty notes
In the following cases, the warranty shall be void:
If the control system is used without prior approval and confirmation in writing
by the manufacturer for purposes other than those specified in these
installation guidelines or contractually agreed.
If the control system is transported or stored incorrectly.
If the control system is installed incorrectly.
If the control system is repaired or maintained incorrectly.
If the control system is operated by personnel that does not have the
requisite qualifications.
If modifications are carried out on the control system, the manufacturer did
not approve that.
The manufacturer shall not be held liable for possible consequential damage to
the controlled devices, caused by improper installation or operation of the control
system.

About these installation guidelines
4Multitronic-Retrofit Kit_01_2004-06-16
About these installation guidelines
These installation guidelines contain basic information on the safe use of the
control system.
Characters and symbols used
►Work steps that you have to carry out in the sequence stated are marked by
black triangles.
Lists are marked by a small box.
Note:
These notes provide you w ith hints and information on the safe and
efficient handling of machines and devices.
Warning!
These safety notes warn against damage to property and help you to avoid
such damage.
Danger!
These danger notes with a grey background warn against personal injury
and/or danger to life and limb; danger notes help you to avoid serious or
life-threatening situations for yourself and/or third parties.
Target group of these installation guidelines
These instructions have been specifically drawn up for persons involved in the
installation, configuration and maintenance of the control system. We assume
that these persons are
trained technical staff, e.g. electricians, who
have already carefully read and fully understood the summary operating
instructions of the summary operating manual of the Multitronic control
system.
Installation guidelines: handling
These installation guidelines must be continuously available at the site where the
control system is used. We recommend to prepare a copy and to keep the same
in a safe and freely accessible place next to the control system. Keep the
original document in a safe place.

For your own safety
Multitronic-Retrofit Kit_01_2004-06-16 5
For your own safety
The control system has been built in accordance with the state of the art and the
recognized technical safety regulations. Nevertheless, there is a risk of personal
injury and damage to property when the control system is used, if
it is operated by non-qualified personnel,
not used within its intended design specifications,
is repaired or maintained incorrectly.
General safety notes
For your own safety, when carrying out any work on the dryer comply with
all applicable national safety regulations!
Intended use of the control system
The Multitronic control system is designed as a retrofit or replacement kit for cold
regeneration adsorption dryers for compressed air that are equipped with
electrically operated input and blow-off valves. The control system is customised
to suit dryers of the specified series (or the specified model); it may only be used
in devices that feature the agreed
supply voltage
valve types, and
control cycles.
Suspected misuse
Never use the Multitronic control system in conjunction with
heat regeneration dryers,
dryers equipped with extras, e.g. blower or heat exchanger.
If in doubt, contact the manufacturer, who will advise you on the retrofitting
options.
Personnel qualification
Danger! Risk of electrocution!
All w ork at electrical components must be carried out by authorised and
suitably qualified technical personnel!
All persons involved in work on the Multitronic control system and persons
operating the system must first read the summary operating manual and these
installation instructions.

Safety notes on specific operating phases
6Multitronic-Retrofit Kit_01_2004-06-16
Installation and modifications
The control system may only be modified
if the respective modification is described in this installation manual,
or
if the manufacturer has given his explicit consent in writing; these rules apply
also accordingly to work in connection with installation.
Safety notes on specific operating phases
General safety measured to be taken during operation
Warning against electrical voltage
Only qualified specialist personnel may carry out work on the electrical
system!
Safety during installation and decommissioning
Risk of injury due to voltage-carrying parts!
The electrical supply cable and external power lines are live even after the
dryer is switched off and, in the event of body contact, may cause serious
injury! Before carrying out any work on the electrical system, the electrical
supply cable and all external power lines must be made voltage-free!

Technical product description
Multitronic-Retrofit Kit_01_2004-06-16 7
Technical product description
The Multitronic Retrofit Kit is a complete control unit designed for installation
(retrofitting or replacement) and use in most compressed air adsorption dryer
models with cold regeneration. It is suitable for dryers with 1 or 2 blow-off valves
(3-valve or 4-valve models) as well as for dryers equipped with an additional
pressure build-up valve (5-valve models). Whether the dryer is controlled directly
or by means of pilot valve is thus not relevant.
The control system is factory-configured to suit the dryer type, whereby the
necessary relays are installed and the cycle times, supply voltage and signal
contacts are adjusted.
The Multitronic Retrofit Kit is a compact assembly whose components are not
available as separate spare parts.
The Multitronic Retrofit Kit Plus consists of the standard kit and additional
components for the measuring of the dewpoint.
For more information, please refer to the included summary operating manual of
the Multitronic system.

Information on transportation packaging
8Multitronic-Retrofit Kit_01_2004-06-16
Transportation and storage
The manufacturer will not be liable for any damage caused by incorrect storage
or incorrect transportation. Please note therefore the following instructions.
Information on transportation packaging
The control system is supplied in a sturdy cardboard box.
If the packaging is undamaged
►Leave the system in the undamaged packaging until all preparations for the
installation are completed.
What to do in the case of transport damage occurring?
►Check whether only the packaging or the control system itself were
damaged.
►If any damage is found, please contact the manufacturer immediately to file a
damage report. The telephone number is found on page 2.
Warning!
A damaged control system must not be taken into operation! Damaged
components may lead to functional faults and possibly cause further
damage.
Storing the control system
If the control system is to be stored for an extended period of time, the storage
location must meet the following conditions:
Store device in dry room and protect it against dust.
Ensure that the ambient temperature is between +1 °C and +50 °C.

Installation
Multitronic-Retrofit Kit_01_2004-06-16 9
Installation
Only authorized and qualified specialist personnel may carry out work on
electrical systems.
Hazard due to a sudden release of pressure!
Never remove any parts of the dryer, or manipulate the same in any way,
for as long as the plant is still pressurised! A sudden escape of pressure
may cause serious injuries.
Before carrying out any work on the dryer, first depressurise the plant.
Preparation
Inspection of delivered goods
►Inspect delivery for completeness.
►Check the details regarding the power supply with the data on the original
type plate of the dryer to be retrofitted and ensure that the specifications are
matc hi ng.
Preparing the dryer
►Release all pressure from the unit and disconnect it from the power supply.
►Secure against inadvertent switching on.
►Preparing mounting area. If necessary, dismantle existing control system and
remove cables.
►Clean mounting surface and ensure that it is free from dust and grease; use
only solvent-free detergents.
►Optional for Retrofit Kit Plus: For the installation of the sensor cell at the
compessed air outlet, you must mount a suitable branch fitting (T-piece) after
the dust filter. In large units, it is generally possible to install an additional
outlet line in the existing control air pipe.
Define the place at which you wish to mount the sensor cell; the cell's power
supply line should be from the side, while the sensor cell and the sensor are
mounted vertically.
►Position the self-adhesive dots (not reusable) to mark the mounting position
of the switch box.
►Remove the type plate and mark it as invalid.
►Attach the new supplied type plate; add missing data using a water-proof felt
pen.

Connecting cables and mounting the switch box
10 Multitronic-Retrofit Kit_01_2004-06-16
Connecting cables and mounting the switch box
For an overview of the general layout of the circuit board, please refer to the
diagram on page 11. To mount the switch box and wiring harness, proceed as
follows:
►Check whether the selected position of the switch box and the cable
connections to the valves are suitable by holding the box against the unit.
The maximum cable length is 1300 mm. Mount conduits, if necessary.
►Connect wiring harness to the solenoid valves of the dryer.
►Insert harness through the centre metric cable gland at the base of the switch
box.
►Connect the cables for the individual solenoid valves to the respective
terminal bar.
—In 3-valve models with normally closed main valves:
Y1-Y2 to terminal bar X1-X2;
bridge terminal bars X3 and X4, then connect Y3 to X3.
—In 4-valve models with normally closed main valves:
Y1-Y4 to terminal bar X1-X4.
—In 4-valve models with normally open main valves:
Y1 to X2, Y2 to X1; Y3 to X3 and Y4 to X4.
—In 5-valve models with normally closed main valves:
Y1-Y5 to X1-X5.
For detailed instructions regarding correct wiring, please refer to page 12 ff.
►Attach the switch box in the correct position, using the four self-adhesive
dots.
Mounting the sensor cell and connecting the sensor (optional)
Installation of dewpoint sensing system (optional)
To enable dewpoint measuring (optional), the sensor cell (3) must be mounted on
the outlet side of the dryer to the outlet line (4):
►Secure the sensor cell at a suitable place (i.e. near the compressed air
outlet) and in a vertical position, using the two threaded 6.5-mm bores (3a).

Installation
Multitronic-Retrofit Kit_01_2004-06-16 11
►Connect the sensor cell to the outlet end of the partial flow to be analysed:
Connect the components with the 1/8“ threaded bore (3b), the quick-fit
couplings and the 4-6mm connecting hose.
►Mount the sensor: remove the protective caps (5, 6)_ and screw sensor (2)
into the cell.
►Connect the sensor to the signal cable. Place seal onto the sealing face;
connect coupler socket (1) and secure it by tightening the screw.
The coupler socket and the signal cable are factory-wired. For details of the
wiring of the signal cable and the circuit board, see page 13.
Internal connections and switches
The following diagram shows the general layout of the circuit board including
connections.
General wiring diagram of the 4-valve model [5-valve model only available without alarm contact]
Switch S1

Internal connections and switches
12 Multitronic-Retrofit Kit_01_2004-06-16
Risk of injury from live parts!
After connection to the power mains, the terminal bars, electrical supply
cables and external lines are live and may cause serious injury if
touched!
Therefore, first connect all wires of the valve control system and
complete all necessary modifications and settings to the unit; only then
connect the system to the power supply line.
Prior to carrying out any work at electrical components, disconnect the
power supply line and any additional external supply cables!
Valve control connections
In 3-valve models with normally closed main valves
►Connect solenoid valves Y1–Y2 to terminal bars X1–X2.
►Bridge terminal bars X3 and X4.
►Connect solenoid valve Y3 to X3.
In 4-valve models with normally closed main valves
►Connect solenoid valves Y1–Y4 to terminal bars X1–X4.
In 4-valve models with normally open main valves
During the processing of breathing air, the main valves of the dryer are normally
open, i.e. air can circulate.
►Connect solenoid valve Y1 to X2 and valve Y2 to X1; connect blow-off valve
Y3 to X3 and valve Y4 to X4.
In 5-valve models
The pressure build-up valve Y5 is wired via X5.
►Connect solenoid valves Y1–Y5 to terminal bars X1–X5.
Connection of synchronised compressor operation – X8
Terminal bar X8 with terminals 1 and 2 is used as the input contact.
►Connect the signal line of potential-free busbar of the compressor.
For operation without compressor synchronisation, bridge terminals 1 and 2.

Installation
Multitronic-Retrofit Kit_01_2004-06-16 13
Connection of optional operating alarm – X5
The board is equipped with an optional terminal bar X5 for the alarm (not
available in 5-valve models). This ensures that the contact at X5 is opened in the
event of an alarm or power failure.
Connection of optional dewpoint sensor unit – X8, X5 and S2
Terminal bar X8 provides the input terminals for the dewpoint sensing system.
►Connect the signal cable of the sensor to terminals 4 (brown), 5 (white) and 6
(green) on terminal bar X8.
►If you wish to connect an external dewpoint sensing system with a 4-20 mA
output, use only terminals 5 (4-20 mA) and 6 (PE/GND) of bar X8.
►If you wish to connect the alarm contact of an external dewpoint sensor to
control the Multitronic, it must be designed as a potential-free normally closed
contact and connected to terminals 3 and 4 on bar X8. In this case, DIP
switch S2 must be set to position OFF to ensure that the display does not
show a sensor error (“SENS”).
The terminal bar X5 is designed as a potential-free alarm contact for the output of
an auto-resetting dewpoint alarm (not available in 5-valve models or in
conjunction with an external digital input port).
By default, the dewpoint alarm is set to a value of +5 °C above the respective
nominal switc hi ng value for dewpoint sensor contro l.
►If the current dewpoint measured via the 4-20 mA input is to be shown the
Multitronic display, set DIP switch S2 to position ON.
Resetting system
Switch S3 is used as the reset key. It enables operators to reset the currently run
programme.
In order to prevent sudden changes in pressure when the system switches
between the vessels, only certain steps of the programme procedure are reset
(see logical diagram in the Multitronic summary operating manual).
Display and configuration of the nominal dewpoint value
The display board located in the cover of the switch box is equipped with a
plus/minus key labelled “Dewpoint +/-“.
To view the preset nominal value, press the key once (ensure that the control
system is on).
To adjust the nominal value, press key again; the value is adjusted in steps
of 1 degree.
The default value is –40 °C. If the measured dewpoint reaches this value, the
system switches vessels.
Installing the electrical connection
For instructions on how to connect the unit to the power supply system, please
refer to the Multitronic summary operating manual.

Installing the electrical connection
14 Multitronic-Retrofit Kit_01_2004-06-16
Additional information
Note:
For additional information regarding commissioning, operation and
decommissioning of the control system, please refer to the enclosed
summary operating manual of the Multitronic system and the
operating instructions of your dryer.