Operator manual

Instruction manual
Heatless desiccant air dryers
with Elektronikon and purge control

CD 80 - CD 100 - CD 150
CD 185 - CD 230 - CD 300

ATLAS COPCO
www.atlascopco.com
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

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INSTRUCTION MANUAL

Congratulations on the purchase of your CD 80, CD 100, CD 150, CD

185, CD 250, CD 280 or CD 300 air dryer. It is a solid, safe and
reliable machine, built according to the latest technology. Follow the
instructions in this booklet and we guarantee you years of troublefree
operation. Please read the following instructions carefully before
starting to use your machine.

While every effort has been made to ensure that the information in this
manual is correct, Atlas Copco does not assume responsibility for
possible errors. Atlas Copco reserves the right to make changes
without prior notice.

The drawings of the instruction manual can be found on the fold-out

pages at the back of this manual.

CONTENTS

Safety precautions ..................................................................... 4 Operating instructions ............................................................ 14

Initial start up .............................................................................14
Leading particulars .................................................................... 6
Start up ......................................................................................14
General description ..................................................................... 6
During operation ........................................................................15
Main functions ............................................................................. 6
Stopping.....................................................................................15
Control panel ............................................................................... 6
Display......................................................................................... 7 Maintenance ............................................................................. 15
Calling up other menus ............................................................... 7 General recommendations and precautions..............................15
Function of control programs....................................................... 7 Maintenance activities ...............................................................15
Counters menu............................................................................ 7
Troubleshooting....................................................................... 16
Test menu.................................................................................... 7
Modify params menu................................................................... 8 Technical specifications.......................................................... 16
Modifying parameters.................................................................. 8 Usage of the correction factors..................................................18
Modifying service plans ............................................................... 8 Usage of the correction factors..................................................18
Programming Clock function ....................................................... 8 Usage of the correction factors..................................................18
To modify a command ................................................................. 9 Dryer dataplate ..........................................................................18
Configuration menu ................................................................... 11
Service menu ............................................................................ 11
Saved data menu ...................................................................... 12
Protections ................................................................................ 12

Operation...................................................................................13
Description ................................................................................ 13
Pneumatic diagram ................................................................... 13

Installation.................................................................................14
Positioning................................................................................. 14
Piping ........................................................................................ 14
Electrical wiring ......................................................................... 14

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SAFETY PRECAUTIONS
! To be read attentively and acted accordingly before lifting,
operating, performing maintenance or repairing the air dryer.
Introduction
The policy of Atlas Copco is to provide the users of their equipment with
safe, reliable and efficient products. Factors taken into account are among
others:
– the intended and predictable future use of the products, and the
environments in which they are expected to operate,
– applicable rules, codes and regulations,
– the expected useful product life, assuming proper service and
maintenance.
Before handling any product, take time to read the relevant instruction
book. Besides giving detailed operating instructions, it also gives specific
information about safety, preventive maintenance, etc.
These precautions are general and some statements will therefore not
always apply to a particular unit.
When handling, operating, overhauling and/or performing maintenance or
repair on Atlas Copco equipment, the mechanics are expected to use safe
engineering practices and to observe all relevant local safety requirements
and ordinances. The following list is a reminder of special safety directives
and precautions mainly applicable to Atlas Copco equipment.
This brochure applies to machinery processing or consuming air or
inert gas. Processing of any other gas requires additional safety
precautions typical to the application and are not included herein.
All responsibility for any damage or injury resulting from neglecting
these precautions or by non-observance of ordinary caution and due
care required in handling, operating, maintenance or repair, also if
not expressly mentioned in this brochure or the instruction book(s),
is disclaimed by Atlas Copco.
If any statement does not comply with local legislation, the stricter of
the two shall be applied. Statements in this brochure should not be
interpreted as suggestions, recommendations or inducements that it
should be used in violation of any applicable laws or regulations.
Also refer to the safety precautions of the compressor and of the
equipment which is used or which is part of the installation.
General safety precautions
1 The owner is responsible for maintaining the air dryer in a safe
operating condition. Parts and accessories must be replaced if missing
or unsuitable for safe operation.
2 Maintenance, overhaul and repair work shall only be carried out by
adequately trained personnel; if required, under supervision of
someone qualified for the job.
3 Maintenance work, other than routine attention, shall only be
undertaken when the machine is standing still.
4 Before dismantling any pressurized component, the dryer or the
equipment shall be effectively isolated from all sources of pressure and
be completely vented to atmosphere. In addition, a warning sign
bearing a legend such as “work in progress; do not open” shall be
attached to each of the isolating valves.
5 Normal ratings (pressures, etc. ) shall be durably marked.
6 Never operate a machine or equipment beyond its rated limits
(pressure, etc.).
7 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.
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8 Pressure gauges shall be checked regularly with regard to their
accuracy. They shall be replaced whenever outside acceptable
tolerances.
9 Parts shall only be replaced by genuine Atlas Copco replacement parts.
10 Never use flammable solvents or carbon tetrachloride for cleaning
parts. Take safety precautions against toxic vapours when cleaning
parts in or with cleaning products.
11 Observe scrupulous cleanliness during maintenance and repair. Keep
away dirt by covering the parts and exposed openings with clean cloth,
paper or tape.
12 When performing any operation involving heat, flames or sparks on a
machine, the surrounding components shall first be screened with non-
flammable material.
Safety during use and operation
1 To lift an air dryer, all loose or pivoting parts shall first be securely
fastened.
2 Lifting acceleration and retardation shall be kept within safe limits.
3 No external force may be exerted on the air valves, e.g. by pulling on
hoses or by installing auxiliary equipment directly to a valve.
4 Close the compressor air outlet valve before connecting or
disconnecting a hose. Ascertain that a hose is fully depressurized
before disconnecting it.
5 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.
6 Never play with compressed air. Never apply it to your skin or direct an
air stream at people. Never use it to clean dirt from your clothes. When
using it to clean down equipment, do so with extreme caution and use
eye protection.
7 Wear ear protectors when environmental noise can reach or exceed 90
dB(A). Beware of long-time exposure to noise.
8 Periodically check that:
– all safety equipment is in good working order,
– all hoses, cables, wiring and/or pipes 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,
– air outlet valves and manifold, hoses, couplings, etc. are in good
repair, free of wear or abuse.
9 Execute each vessel of pressure relief valve when dryer outlet valves
are installed.
10 When the air is foreseen to be used as breathing air, provide adequate
filters at the outlet of the dryer.
Safety during maintenance and repair
Maintenance and repair work shall only be carried out by adequately
trained personnel; if required, under supervision of someone qualified for
the job.
1 Use only the correct tools for maintenance and repair work.
2 Before removing any pressurized component, effectively isolate the
dryer from all sources of pressure and relieve the entire system of
pressure. Do not rely on non-return valves (check valves) to isolate
pressure systems.
3 Never weld on, or in any way modify, pressure vessels.
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4 Special service tools are available for specific jobs and should be used
when recommended. The use of these tools will save time and prevent
damage to parts.
5 When jobs on desiccant are executed, always wear dust masks.

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LEADING PARTICULARS

General description Control panel

The CD air dryers are built to remove moisture from compressed air The control panel of the Elektronikon II regulator is shown in figure 2:
for industrial purposes. All units are designed for indoor use. 1 .... Stop button
An overview of the main parts of the dryer units is given in figure 1A . Push button to stop the dryer. LED (8) goes out.
1 .....Tower A 10... Pressure dewpoint sensor 2 .... Start button
2 .....Tower B 11 ... Air inlet Push button to start the dryer. LED (8) lights up indicating that the
3 .....3-way valve 12... Air outlet regulator is operative (in automatic operation).

4 .....Non-return valves 13... Pneumatic actuator 3 .... Display

Indicates messages concerning the dryer operating condition, a
5 .....Solenoid valves 14... Pressure transmitters service need or a fault.
6 .....Elektronikon® controller 15... Pneumatic valves 4 .... Scroll keys
7 .....Silencers 16... Control air valve Keys to scroll through the display.
8 .....Cubicle 17... Purge line 5 .... Tabulator key
9 .....Display Key to select the parameter indicated by a horizontal arrow. Only
the parameters followed by an arrow pointing to the right are
accessible for modifying.
Main functions 6 .... Voltage on LED
Indicates that the voltage is switched on.
Automatic control of the dryer 7 .... General alarm LED
Is alight if a warning, service warning or shut-down warning
The regulator maintains the pressure dewpoint between
condition exists or if a sensor is out of order.
programmable limits automatically by defining the switching time. A
Blinks in case of an emergency stop.
number of programmable settings, are taken into account.
8 .... Automatic operation LED
! A number of time-based automatic start/stop commands Indicates that the regulator is automatically controlling the dryer.
may be programmed (See page 8). Take into account that a 9 .... Function keys
start command will be executed (if programmed and Keys to control and program the dryer.
activated), even after manually stopping the dryer. 10 .. Pictograph - Alarm
11... Pictograph - Automatic operation
Protecting the dryer
12 .. Pictograph - Voltage on
Shut-down warning
If the dryer inlet temperature exceeds a programmed value, this will
Function keys
be indicated to warn the operator.
Service warning The keys are used:
A number of service operations are grouped in plans (called Service – To call up or to program settings.
plans A, B and C). Each Service plan has a programmed time interval. – To reset service message or an emergency stop.
If a time interval is exceeded, a message will appear on display to
– To have access to all data collected by the regulator.
warn the operator to carry out the service actions belonging to that
plan. The functions of the keys vary depending on the displayed menu. The
actual function is abbreviated and indicated on the bottom line of the
Warning display just above the relevant key. The most common abbreviations
A warning message also appears if: are listed below.
– The pressure dewpoint exceeds a programmed value.
Abbreviation Designation Function
– The pressure status in the dryer vessels is not correct.
Add Add To add dryer start/stop commands (day/hour)
Automatic restart after voltage failure Back Back To return to a previously shown option or menu
For dryers leaving the factory, this function is made inactive. If
Canc Cancel To cancel a programmed setting when
desired, the function can be activated. Consult Atlas Copco.
programming parameters
Del Delete To delete dryer start/stop commands
Help Help To find the Atlas Copco internet address
Lim Limits To show limits for a programmable setting
Main Main To return from a menu to the main screen
Menu Menu Starting from the main screen: to have access to
submenus
Menu Menu Starting from a submenu, to return to the previous
menu

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Abbreviation Designation Function Program/ Description

Mod Modify To modify programmable settings Function
Saved data Calling up the saved data: last shut-down, last emergency stop
Prog Program To program modified settings
data
Rset Reset To reset a timer or message
Rtrn Return To return to a previously shown menu
Xtra Extra To find the module configuration of the regulator Counters menu

Display Function
To allow the operator to call up the:
Normally, the display shows the operation status of the dryer, the
pressure in the vessels and the abbreviations of function keys F1, F2 – running hours
and F3. The main screen looks as follows: – regulator (module) hours (the hours the module has been under
tension)
Vessel A B
bar 7.0 0.5 Procedure

Regenerating B ~ 1. Starting from the Main screen:

Menu Unld – press the key "Menu" (F1)

– press the ~ key until the option "Counters" is followed by a
F1 F2 F3
horizontal arrow
Main screen
– press the tabulator key to activate the menu

Calling up other menus 2. By pressing the ~ key, the above-mentioned data can be found.

Starting from the Main display: Test menu

– Use the ~ key for a quick look at the actual dryer status
– Press the key Menu (F1). The option "Status data" will be Function
followed by a horizontal arrow:
To carry out a display test, i.e. to check whether the display and LEDs
– Press the tabulator key to select this menu. are still intact.
– Use the ~ key to scroll until the desired submenu is followed
by a horizontal arrow and then press the tabulator key to Procedure
select this menu. 1. Starting from the Main screen:
For detailed instructions, consult the User manual for Elektronikon – press the key "Menu" (F1)
regulator.
– press the ~ key until the option "Test" is followed by a
horizontal arrow
Function of control programs
– press the tabulator key to activate the menu
2. The option "Display test" will be followed by a horizontal arrow.
Program/ Description
Function 3. After pressing the tabulator key, the regulator will generate a
series of patterns on the display which enable the operator to
Main Shows in short the operation status of the dryer.
check that each pixel still functions normally; at the same time the
It is the gateway to all functions.
LEDs are lit.
Status data - Protections
- Service
- Expansion Mods
Measured data Calling up:
- actually measured data
- status of some inputs
Counters Calling up the:
- running hours
- regulator (module) hours
Test Allows a display test.
Modify params Modifying the settings for:
- parameters
- protections
- service plans
- clock functions
- configuration (time, date, display language, …)
Service Calling up service plans and resetting the timers.

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Modify params menu Programming Clock function

To program time-based start/stop commands for the dryer.

Function
The menu allows the operator to program: Programming start/stop commands
– Parameters. In this example, the dryer will be programmed as follows:
– Protection settings. – On Monday at 06:15 starting
– Service plan settings. – On Saturday at 18:00 stopping
– Clock settings. 1. Starting from the Main screen:
– Configuration settings. – press the key "Menu" (F1)
– press the ~ key until the option "Modify params" is followed by
Modifying parameters a horizontal arrow
– press the tabulator key to activate the menu
Function 2. Use the ~ key to scroll until the option "Clock function" is followed
To modify a number of parameters. by a horizontal arrow. Press the tabulator key, following screen
appears:
Procedure
Clock Function
1. Starting from the Main screen:
– press the key "Menu" (F1) Not activated }
– press the ~ key until the option "Modify params" is followed by
a horizontal arrow Menu Mod Del
– press the tabulator key to activate the menu F1 F2 F3
2. The first option ("Parameters") will be followed by a horizontal
arrow. 3. Press the tabulator key, following screen appears:
3. Press the tabulator key: the first item ("PDP level") and its setting
will appear.
Monday }
Tuesday
4. Use the ~ key to scroll until the parameter to be modified is
followed by a horizontal arrow. Wednesday ~
Menu Mod Del
Modifying service plans F1 F2 F3

Function 4. Use the | or ~ key until the day on which a command must be
To modify the hour intervals for the Service plans. programmed is followed by a right pointing arrow. Press the
tabulator key, following screen appears:
Service plans
The service operations to be carried out are grouped in plans, called --:-- ----------- }
Service plan A, B or C. When reaching an interval, a message will --:-- -----------
appear on the screen indicating which Service plans are to be carried
out. --:-- ----------- ~
Menu Mod Del
! Always consult Atlas Copco in case any timer setting should
be changed. The intervals must not exceed the periods F1 F2 F3
below and must coincide logically.
5. Press the key "Mod" (F2). The first two dashes will flash. Use the
| or ~ key to enter "06". Press the tabulator key to jump to the
following two dashes. Use the | or ~ key to enter "15". Press the
tabulator key to jump to the row of dashes. Use the | or ~ key to
enter the command Start. Press the key "Prog" to program the
command: 06:15 Start
6. Programming the command to stop on Saturday at 18:00 is
carried out in a similar way as described above.

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To activate/deactivate the timer To modify a command

1. Starting from the Main screen:
Suppose the command to stop the dryer on Saturday 18:00 is to be
– press the key "Menu" (F1) modified: stopping at 17 o'clock instead of 18 o'clock:
– press the ~ key until the option "Modify params" is followed by 1. Starting from the Main screen:
a horizontal arrow
– press the key "Menu" (F1)
– press the tabulator key to activate the menu
– press the ~ key until the option "Modify params" is followed by
2. Use the ~ key to scroll until the option "Clock function" is followed a horizontal arrow
by a horizontal arrow. Press the tabulator key, following screen
– press the tabulator key to activate the menu
appears:
2. Use the ~ key to scroll until the option "Clock function" is followed
Clock Function by a horizontal arrow. Press the tabulator key, following screen
Not activated } appears:

Clock Function
Menu Mod Del Not activated }
F1 F2 F3
Menu Mod Del
3. Press the key "Mod", "Not activated" starts blinking.
F1 F2 F3
4. Press the ~ key, "Not activated" changes into "Activated".
5. Press the key "Prog". 3. Press the tabulator key, following screen appears:

Important: Monday }
1. It is necessary to program the start/stop commands in successive Tuesday
order timewise, e.g.: Wednesday ~
– 07.30 start Menu Mod Del
– 17.00 stop
F1 F2 F3
– etc.
2. Make sure that the clock function is activated (indicated as 4. Scroll through the display until "Saturday" is followed by a
"Activated"). If not, the programmed start/stop commands will not horizontal arrow. Press the tabulator key. If necessary, scroll
be executed. through the dryer start/stop commands until the command to be
modified is followed by the horizontal arrow on the screen. Press
the key "Mod", the first two digits of the command start blinking.
Modify as required using the scroll keys, i.e. in the example
above change "18" into "17" using the | key.
5. If necessary, press the tabulator key to go to the next field to be
modified, the minutes indication and the start/stop indication.
6. Press the key "Prog" to program the new command or the key
"Canc" to quit without reprogramming.

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To add a command Adding a command between two existing commands

Adding a command at the end of an existing list 1. The regulator does not allow to enter a new command which is
situated timewise before the last command in the list.
1. Starting from the Main screen:
– press the key "Menu" (F1) 2. Scroll through the display until the command before which the
new command must be entered is followed by the horizontal
– press the ~ key until the option "Modify params" is followed by arrow and press the key "Mod". Change this command to the
a horizontal arrow new command and press the "Prog". Press the ~ key, add the
– press the tabulator key to activate the menu last command of the list and press the key "Prog".
2. Use the ~ key to scroll until the option "Clock function" is followed
To delete commands
by a horizontal arrow. Press the tabulator key, following screen
appears: 1. Starting from the Main screen:
– press the key "Menu" (F1)
Clock Function
– press the ~ key until the option "Modify params" is followed by
Not activated } a horizontal arrow
– press the tabulator key to activate the menu
Menu Mod Del 2. Use the ~ key to scroll until the option "Clock function" is followed
F1 F2 F3 by a horizontal arrow. Press the tabulator key, following screen
appears:

Suppose the command to stop the dryer at 18:00 must be added Clock Function
to the list of Monday: Not activated }
– 06:15 start
3. Press the tabulator key, following screen appears: Menu Mod Del
Monday } F1 F2 F3
Tuesday
Wednesday ~ Deleting all commands
Press the key "Del" (F3) in the screen above. A question to confirm
Menu Mod Del
the deleting operation will appear.
F1 F2 F3

Deleting all commands related to a specific day

4. Scroll through the display until "Monday" is followed by a
Scroll through the display until the desired day is followed by a
horizontal arrow. Press the tabulator key. Scroll through the dryer horizontal arrow. Press the key "Del" (F3). A question to confirm the
start/stop commands until the first empty command line is
deleting operation will appear.
indicated by the horizontal arrow on the screen.
5. Press the key "Mod", the first two digits of the command start
Deleting a specific start/stop command
blinking. Enter "18:00 stop" using the scroll keys | or ~ to modify
a field and the tabulator key to jump from one field to another. Scroll through the display until the desired start or stop command line
is followed by a horizontal arrow. Press the key "Del" (F3). A question
6. Press the key "Prog" to program the new command or the key to confirm the deleting operation will appear.
"Canc" to quit without reprogramming.

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Configuration menu Service menu

Function Function
To reprogram a number of parameters. – To reset the service plans which are carried out.
– To check for both the next service plans to be carried out and to
Procedure
find which service plans were carried out previously.
1. Starting from the Main screen:
– press the key "Menu" (F1) Service plans
– See Maintenance activities to find which service actions are
– press the ~ key until the option "Modify params" is followed by
related to these plans.
a horizontal arrow
When the service plan interval is reached, a message will appear on
– press the tabulator key to activate the menu
the screen.
2. Use the ~ key to scroll until the option "Configuration" is followed
by a horizontal arrow. Example

3. Press the tabulator key: The first option shown is "Time". If Programmed service plan intervals ex-factory
another option is desired, scroll through the display (using | or ~
keys) and select it using the tabulator key. Service plans Intervals

4. In case of option "Time", the second line on the screen indicates Service plan A Every 4.000 running hours
the actual setting, e.g. 14:30. Service plan B Every 8.000 running hours or yearly
5. If it is desired to modify the time, press the key "Mod". If not, Service plan C Every 40.0000 running hours
press the key "Menu" to return to the submenu.
6. After pressing the key "Mod", the first field will blink. Modify the Resulting service actions to be carried out
hours using the | or ~ keys. Then press the tabulator key to go
to the next field (i.e. 30). The setting of this field can now be Service actions according to At
modified with the | or ~ keys. Service plan A, B and C 40.000 running hours
7. The bottom line of the display will show two options: … ….
– "Prog" to program the new setting
– "Canc" to cancel the new setting
Procedure
8. Proceed in a similar way for the other parameters to be modified.
1. Starting from the Main screen:
– press the key "Menu" (F1)
– press the ~ key until the option "Service" is followed by a
horizontal arrow
– press the tabulator key to activate the menu
2. A screen similar to the one below appears:

Service Timer
Running Hours }
hrs 3971 ~
Menu
F1 F2 F3
Service menu
The screen shows that the total compressor running time is
3971 hrs.

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3. Press the tabulator key: Saved data menu

Next Timer
Function
Level ABC
To call up some dryer data saved by the regulator. These data are:
hrs 4000 ~
– Last emergency stop data
Back Rset
F1 F2 F3 Procedure

Service menu 1. Starting from the Main screen:

The screen shows that the next service plans to be carried out – press the key "Menu" (F1)
are plans A, B and C and that these plans are to be carried out – press the ~ key until the option "Saved data" is followed by a
each 4000 running hours. horizontal arrow
4. Press the ~ key to find which service plans were carried out – press the tabulator key to activate the menu
previously: 2. The list of last emergency stop cases is shown.
Previous Timer | 3. Scroll through the items to select the desired emergency stop
item.
Level AB
hrs 2008 4. Press the tabulator key to find the date, time and other data
reflecting the status of the compressor at the last shut-down
occurred.
F1 F2 F3
Service menu Protections
The screen shows that service plans A and B were carried out at
2008 running hours. Protection Minimum Nominal Maximum
5. Stop the dryer, switch off the voltage and carry out the service Dryer inlet pressure for 11 bar units 3.5 bar 7 bar 11 bar
operations related to plans A, B and C.
Dryer inlet pressure for 16 bar units 10.5 bar 12.5 bar 16 bar
6. Switch on the voltage and scroll to the service screen. Press the Dryer inlet temperature 1 °C 35 °C 45 °C
"Rset" button (F3) to reset the timer. Confirm the question for
resetting. Dryer regenerating pressure 0 bar 0,7 bar 1 bar
Pressure dewpoint -45 °C -40 °C -20 °C
Notes
– The "Rset" button only appears when the next Timer level is
almost reached (from 400 running hours before elapsing of the
service plan interval).
– After pressing the | key, the Life time hours are shown (i.e. the
number of hours elapsed since initial programming ex-factory).
This counter is not taken into account.

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OPERATION Pneumatic diagram

Figure 3A shows the pneumatic diagram:

Description A .... Tower A PA ..Pneumatic actuator
AF .. Air filter PR ..Pressure regulator
The construction of the air dryer is simple, reliable and easy to
service. The dryer has two towers containing the adsorbing material or B .... Tower B .......(only for 16 bar units)
desiccant. This desiccant is a very porous grain material which can CA . Control air valve PV ..Pneumatic valve
adsorb large amounts of water vapour. IV ... 3-way valve S.....Silencer
The operation cycle of the dryers is repetitive and is controlled by a N .... Nozzle SV ..Solenoid valve
factory-set timer and a PDP-sensor. While the desiccant in the first
NV . Non-return valve TV ..Pneumatic valve
tower dries the compressed air, the desiccant in the second tower is
P1 .. Pressure transmitter 1
being regenerated and vice versa. Regeneration of the desiccant is
achieved by means of purge air from the drying tower. P2 .. Pressure transmitter 2
The compressed air entering the dryer is led to one of the towers by
means of the inlet valve which is controlled by the pneumatic actuator.
As the air flows upwards through the tower, the desiccant adsorbs the
water vapours and the compressed air is dried. Once the top of the
tower is reached, the air leaves the dryer via the non-return valve
A small portion of the dried air does not leave the dryer immediately
via the non-return valve but is expanded to atmospheric pressure and
flows downwards through the other tower, regenerating the desiccant.
This regenerating air is finally released via the exhaust valve and the
silencer.
A second small portion of the dried air flows via the control air valve,
an air filter and the pressure regulator (only for the 16 bar units) to the
solenoid valves which are controlled by the Elektronikon® and to the
PDP-sensor The air leaving the solenoid valves (when energized) is
used to control the pneumatic actuator and the pneumatic valves.
After a certain period, the cycle will restart. The fully regenerated
tower will now dry the air whereas the other tower will be regenerated.
The PDP-sensor measures the pressure dewpoint of the air wich is
leaving the drying tower. When the PDP temperature is below the set
point then the drying tower will keep on drying until the PDP
temperature exceeds the set point. Then the regenerated tower will
start drying the compressed air and the other tower will be
regenerated.

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INSTALLATION OPERATING INSTRUCTIONS

! In your own safety interest, always observe all relevant

Positioning
It is important to keep the following in mind when installing the dryer:
– Place the dryer at a location where the temperature never
exceeds the limits.
– Provide enough space (approximately 80 cm) around the dryer
for maintenance operations.
– Place the dryer as level as possible and fix it firmly to the
concrete.
– When the compressor has NO built-in water separator, a water
separator has to be installed before the CD dryer, in order to
prevent free water from entering the dryer.
Piping
! When installing the piping, make sure that all pipes are
clean.
To ensure correct operation of the dryer, it has to be fitted properly into
the compressed air system consisting of a compressor, the dryer and
an application.
The recommended installation, as shown in figure 4, can only be used
in case the particular application allows to bypass the dryer.
AR .......Air receiver
BV .......Bypass valves
Together with the external inlet valve and the external outlet
valve, the bypass valves allow the dryer and the filters to be
serviced while non-dried air flows through the bypass system.
D .........Dryer
EIV ......External inlet valve
To cut off the air supply towards the dryer.
EOV ....External outlet valve
To cut off the air supply towards the air consumer.
If installed, provide each vessel with pressure relief valves.
WSD....Water separator (optional)
To prevent free water from entering the dryer. The water
separator must always be installed in case of 'Standard Pack
Units'.
! Never overload the dryer as it will damage the desiccant. It
may be recommended to install the air dryer upstream of the
air receiver to prevent overload (e.g. after extending the dry
air system). Consult Atlas Copco if in doubt.
safety instructions.
! Some of the components mentioned in the operating
instructions were not mentioned before in this manual, e.g.
external inlet valve and external outlet valve. Refer to the
chapter “Installation – Piping” for more detailed information.
Initial start up
To start up the dryer for the first time or after a long period of standstill,
proceed as follows:
1. If installed, open the bypass valves of the dryer.
2. Close the air supply towards the PDP-sensor and unplug the
PDP-sensor.
3. Cut off the air supply from the compressor towards the dryer by
closing the external inlet valve.
4. If installed, close the external outlet valve.
5. Start the compressor and wait for pressure.
6. Slowly open the external inlet valve.
7. Check the connections of the dryer for air leaks and repair if
necessary.
8. Switch on the voltage to the dryer.
9. Switch the dryer on by pushing button I on the Elektronikon.
10. Let the dryer operate for several hours with the external outlet
valve closed.
11. Gradually open the external outlet valve.
12. As required, close the bypass valves of the dryer.
13. Press the stop button 0 and switch off the voltage to the dryer.
14. Plug the PDP-sensor.
15. Open the air supply towards the PDP-sensor.
! If the application allows air that is not dried optimally, the
valve towards the air consumer may be opened even when
the PDP temperature is too high. In this case, it will take
more time for the desiccant to dry completely.
Start up

If the dryer has not been used for more than 3 months, refer to the
Concerning the piping, following checks should be carried out: chapter “Initial start up”. In all other cases proceed as follows:
– plugs and pipes must be removed before connecting the pipes,
1. Cut off the air supply from the compressor towards the dryer by
– make sure that all pipes, filters, valves, etc. are clean and are closing the external inlet valve.
installed correctly with or without bypass system,
2. Cut off the air supply towards the PDP-sensor.
– make sure that no external force is exerted on the piping.
3. If installed, close the external outlet valve between the dryer unit
Electrical wiring and the dry air consumer.
4. Slowly open the external inlet valve.
The electrical wiring must comply with the local regulations. The air
dryer must be earthed and protected by fuses against short-circuiting. 5. Switch the dryer on.
6. Gradually open the air outlet valve.
! Before switching on the main power supply, check the
voltage requirements in the technical specifications or on 7. As required, close the bypass valves of the dryer.
the dryer’s data plate. 8. Open the air supply towards the PDP-sensor.

2920 7012 00 14
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

! Close the external inlet valve in case the compressor needs MAINTENANCE
to be restarted. The air speed in the start-up phase of the
compressor may damage the desiccant.
General recommendations and precautions
During operation
The dryer does not need any specific maintenance. Nevertheless,
At regular intervals, check the PDP temperature. If the PDP before carrying out any maintenance or corrective activity, read the
temperature is too high let the dryer regenerate (by closing the outlet following recommendations and safety precautions and act
valve). accordingly:
– Check that the dryer is switched off.
Stopping – Disconnect pressure sources and vent the internal pressure of
the system before dismantling any pressurized component.
To stop the dryer proceed as follows:
– Use original Atlas Copco spare parts only.
1. If installed and if necessary, open the bypass valves of the dryer – Check the correct operating after maintenance.
so that the application will still receive compressed air.
2. Close the external inlet valve between the compressor and the ! Filters and valves installed between the compressor, the
dryer and the external outlet valve between the dryer and the dry dryer and the air consumer may need other maintenance
air consumer. activities than those mentioned below (e.g. draining the
filters and replacing the filter elements). Refer to the
3. Let the dryer run for a period without consumption, to appropriate manual for more information.
depressurize the vessels.
4. Switch the dryer off . Maintenance activities

! If the dryer is stopped for a longer period, close the inlet and
outlet valve to avoid moisture from entering the dryer. Daily
– Check PDP temperature.

Service plan A, at least once a year

– Replace the silencers.
– Replace the filter elements DD/PD.
– Exchange the dewpoint sensor: certificate is only one year valid.
For updating, contact Atlas Copco customer center.

Twice a year
– Check for damaged wiring or loose connections.
– Check for air leaks.

Service plan B
– Replace the desiccant. In normal working conditions, the lifetime
of the desiccant is approximately 5 years. It is recommended to
have the desiccant replaced by an Atlas Copco service
technician.
– Replace the silencers.
– Replace the filter elements DD/PD.
– Exchange the dewpoint sensor: certificate is only one year valid.
For updating, contact Atlas Copco customer center.

2920 7012 00 15
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

TROUBLESHOOTING

Symptom Possible cause Corrective action

The PDP temperature is too high
The dryer produces a lot of noise
Insufficient air leaves the dryer
The drain is not working correctly.
The air flow through the dryer is too high.
The outlet pressure is too low.
The inlet temperature is too high.
Check the silencer and its fixation to the unit.
Too much purge air escapes.
Check the drain valve of the filter.
Check for correct application.
Check whether the compressor provides enough air for the
application.
Check the compressor aftercooler.
Replace the silencer if necessary or correct its fixation.
Check the condition of the solenoid valve and replace it if
necessary. Also check the pneumatic valves and the 3-way valve.

TECHNICAL SPECIFICATIONS

Specifications of CD 80 up to CD 300

APPLICABLE FOR 11 BAR AND 16 BAR UNITS CD 80 CD 100 CD 150 CD 185 CD 250 CD 300
Nominal conditions
Compressed air inlet temperature 35 °C 35 °C 35 °C 35 °C 35 °C 35 °C
Outlet pressure dewpoint -40 °C -40 °C -40 °C -40 °C -40 °C -40 °C
Outlet pressure dewpoint with “-70 °C” option -70 °C -70 °C -70 °C -70 °C -70 °C -70 °C
Humidity 100 % 100 % 100 % 100 % 100 % 100 %

Limit values
Maximum ambient temperature 40 °C 40 °C 40 °C 40 °C 40 °C 40 °C
Minimum ambient temperature 1 °C 1 °C 1 °C 1 °C 1 °C 1 °C
Maximum compressed air inlet temperature 50 °C 50 °C 50 °C 50 °C 50 °C 50 °C
Minimum compressed air inlet temperature 1 °C 1 °C 1 °C 1 °C 1 °C 1 °C

Specific data
Pressure drop through dryer 0.1 bar 0.15 bar 0.16 bar 0.2 bar 0.14 bar 0.19 bar
Pressure drop through dryer with “-70 °C” option 0.07 bar 0.1 bar 0.11 bar 0.14 bar 0.09 bar 0.13 bar
In- and outlet connection 1 1/2 “ 1 1/2 “ 1 1/2 “ 1 1/2 “ 2“ 2“
Desiccant type Activated aluminium Al2O3
Desiccant type with “-70 °C” option Molucular sieves
Total amount of desiccant 112 kg 140 kg 170 kg 200 kg 260 kg 300 kg
Recommende filter size PD/DD/DDp
PD/DD/DDp 120 PD/DD/DDp 150 PD/DD/DDp 175 PD/DD/DDp 280 PD/DD/DDp 280
120
Power consumption 10 W 10 W 10 W 10 W 10 W 10 W
Dimensions (LxWxH) 728x950x1695 728x950x1695 848x1089x1731 848x1089x1731 960x1106x1816 1116x11173x1854
Mass 320 kg 340 kg 415 kg 445 kg 600 kg 650 kg

2920 7012 00 16
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

APPLICABLE FOR 11 BAR UNITS ONLY CD 80 CD 100 CD 150 CD 185 CD 250 CD 300
Nominal conditions
Compressed air inlet pressure (e) 7 bar 7 bar 7 bar 7 bar 7 bar 7 bar

Limit values
Maximum compressed air inlet
11 bar 11 bar 11 bar 11 bar 11 bar 11 bar
pressure (e)
Minimum compressed air inlet
4 bar 4 bar 4 bar 4 bar 4 bar 4 bar
pressure (e)

Specific data
Nominal capacity at dryer inlet 80 l/s 100 l/s 150 l/s 185 l/s 250 l/s 300 l/s
Nominal capacity at dryer inlet with “-70 °C” option 64 l/s 80 l/s 120 l/s 148 l/s 200 l/s 240 l/s
Purge air consumption
18 % 18 % 18 % 18 % 18 % 18 %
(average during 1/2 cycle)
Purge air consumption with “-70 °C” option
23 % 23 % 23 % 23 % 23 % 23 %
(average during 1/2 cycle)
Time of a half cycle 180 s 180 s 180 s 180 s 180 s 180 s
Purge time 145 s 145 s 145 s 145 s 145 s 145 s

Correction factors for inlet flow

Inlet pressure (bar) 4 5 6 7 8 9 10 11
Correction factor Kp 0.47 0.68 0.84 1 1.1 1.2 1.3 1.38
Inlet temperature (°C) 20 25 30 35 40 45
Correction factor Kt 1 1 1 1 0.84 0.71

APPLICABLE FOR 16 BAR UNITS ONLY CD 80 CD 100 CD 150 CD 185 CD 250 CD 300
Nominal conditions
Compressed air inlet pressure (e) 12.5 bar 12.5 bar 12.5 bar 12.5 bar 12.5 bar 12.5 bar

Limit values
Maximum compressed air inlet
16 bar 16 bar 16 bar 16 bar 16 bar 16 bar
pressure (e)
Minimum compressed air inlet
11 bar 11 bar 11 bar 11 bar 11 bar 11 bar
pressure (e)

Specific data
Nominal capacity at dryer inlet 96 l/s 120 l/s 180 l/s 220 l/s 300 l/s 360 l/s
Purge air consumption
11 % 11 % 11 % 11 % 11 % 11 %
(average during 1/2 cycle)
Time of a half cycle 250 s 250 s 250 s 250 s 250 s 250 s
Purge time 195 s 195 s 195 s 195 s 195 s 195 s

Correction factors for inlet flow

Inlet pressure (bar) 11 12.5 13 14 15 16
Correction factor Kp 0.89 1 1.04 1.11 1.19 1.24
Inlet temperature (°C) 20 25 30 35 40 45
Correction factor Kt 1 1 1 1 0.84 0.71

2920 7012 00 17
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

Usage of the correction factors

When the actual inlet pressure or inlet temperature differs from its nominal value, multiply the nominal capacity with the corresponding correction
factor to obtain the correct capacity.

Dryer dataplate

The dryer dataplate is shown in figure 5:

1.......Dryer type 3.......Maximum pressure 5.......CE mark
2.......Dryer serial number 4.......Year of construction

2920 7012 00 18
 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Customer's Installation

1
1X5 1X5 1X5
L 1 1 1

2920 7012 00
N
PE

S0
4

1
1
1
MAX. FUSE a MAX. FUSE a

emergency stop
remote START/Pr. STOP
DP DD filter 2067
DP PD filter 2068
DP DDP filter 2069
IEC : Class gL/gG CSA : HRC Form II
1X6 1X6 1X6 1X6 1X6 1X6
1 3
22 22 22 22 22 22
A F0 2 4
A S3 11 S1' S4' PDS11 PDS12 PDS13
UL : Class K5 DP DP DP
12

A
1X6
1X0 10
1X6 1X6 1X6 1X6 1X6 1X6 1X6
L N 2X10:9 2X10:6 11 12 13 14 16 17 18

2
1
DOOR

T1

5
1X3 K01 K02 2X9 1 2 3 4 5 6 7 8 9 10 11 12 13
PE AUXILIARY CONTACTS
24 Vac

7
DI01
DI02
DI03
DI04
DI05
DI06
DI07
DI08
DI09
DI010
250VAC 10A AC11
2X10 2X12

Supply
Q1 Q2
2X10:8 2X10:5 NO NO Manual operation
1 2 1 2 C K01 E1 Mk IV B
K07 C
24V

L1L2
3 4 3 4 NC NC Automatic operation
NO NO

8
1X5 1X5 C K02 K08 C
20 21 NC NC General warning
NO NO

6
C K03 K09 C

20
21
1 2 3 4 5 6 7 8 9
NC NC General shutdown

10 9 8 7 6 5 4 3 2 1
b 2X11

NO
C K04
NC
NO
2X3
Y1

9
A1 Y2 A1 C K05
U1 NC

3
1X6

1
A2 NO
3 A2
C K06

4
2
Gnd
Temp01
Gnd
Temp02
Gnd
Temp03
Gnd
V+
P01
Gnd
V+
P02
1X6 2X2

9 8 7 6 5 4 3 2 1
NC 2X5
4 1 2 3 4 5 6 7 8 9 10 11 12 1 9
1 9

Gnd 4X3
I01

2
1X5 1X5 1X5 Gnd AIE2
2 2 2 I02
Gnd
I03
Gnd
8 7 6 5 4 3 2 1 4X5

I04

4X4
gnd
gnd/V+ sign 1 9

L
1
1
1
2
2
2
3
4

N
11
10
14

12
13
16
17
18

20
21
22
22
22
1X0 1X5 1X6

Legend:

SO : Main switch: customers installation

FO : Main fuses : customers installation
Q1 : Main circuit breaker
Q2 : Circuit breaker control circuit Marking of connectors 2X5 to 2X12 Pressure transducer
T1 : Transformer for control voltage pin configuration
1
2
3
4
5
6
7

E1 : Elektronikon analog input module gnd V+

S1' : Remote START/STOP

S3 : Emergency stop 1 2 1 2 3 1 2 3 sign gnd V+
1 2 1 2 3 1 2 3 sign gnd V+
T01 : Inlet temperature sensor sign
P01 : Pressure sensor tower A P P
Pt 1000
P02 : Pressure sensor tower B
Y1 : Solenoid valve 1 Y1 Y2 T01 P01 P02 PDP01
Y2 : Solenoid valve 2
PDP01 : pressure dewpoint sensor
U1 : Supply 24V/DC
1X0 : terminal strip (supply)
1X3 : terminal strip (earth)
1X5 : terminal strip (24V/AC)
1X6 : terminal strip (24V/DC)

NOTES:

a Maximum fuse with regards to shortcircuit protection of starter.

Cable section may impose a fuse a smaller size.
b For correct transfo connections: see on trafo.
9827 1207 00
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19
2920 7012 00
5

The dryer unit (1) must be installed on a level floor suitable for taking
the weight of the dryer. There must be a free space of 800mm around
the dryer.

7 On both inlet filters a drain tube must be installed. The drainpipes to

the drain collector must not dip into the water. For draining of pure
condensate water, install an oil/water separator (Consult Atlas Copco).

The inlet filter type DD (2) for general-purpose filtration (particle

1 removal down to 1micron with a maximum oil carry-over of 0.5 ppm).
4
A high efficiency PD-filter (3) installed downstream the DD- filter (particle
removal down to 0.01 micron and max. oil carry - over of 0.01 ppm).

An outlet dust filter type DDp (4) (particle removal down to 1micron)
installed downstream the dryer.
Should oil vapour and odours be indesirable, a QD carbon filter should
be installed downsteam the DDp filter.

It is recommended to install by-pass pipes over each filter together

with ball valves in order to isolate the filters during service
operations, without distrubing the compressed air delivery.

It is recommended to install pressure relief valves on each vessel of

Fig. 4

the dryer when there are ball valves installed at the inlet and the
outlet of the dryer to isolate the dryers from the air net.

The installation sequence is Compressor (5) -vessel (6) -dryer.

Minimum free area to be reserved For the dryer there is no extra ventilation needed.
for the dryer installation.
2 3
Waterseparator (7) : High efficiency waterseparator removes 90%
8 in the compressor air when by-passing the dryer. If the WSD is not
mounted in the compressor, a WSD need to be added in the installation
1000 downstream the vessel.

800
The drainpipes (8) to the drain collector must not dip into the water.
For draining of pure condensate water, install an oil/water separator.
Consult Atlas Copco.

Notes

- All pipes should be installed stress-free to the

compressor unit.
- For more information concerning air nets,
1000
cooling systems, etc. refer to the compressor

800
installation manual.
9827 1492 00
CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

20
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

1A

1 2 3

4
5
4

9 8 11 10 7 12 6

2920 7012 00 21
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300

1 Product type

2 Serial number

3 Max. work pressure(e) bar

4 Year of manufacture 20

MADE BY ATLAS COPCO n.v.

WILRIJK - BELGIUM

5
1617 5664 00
0038

3A

NV NV

N
P1 P2

CA

AF

A B
PR

SV
SV

PA

IV
PV
PV

TV TV S

80 cm
CD ..

80 cm

2920 7012 00 22
 CD 80 – CD 100 – CD 150 – CD 185 – CD 250 – CD 300
1 bar = 14.504 psi
1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 lmp gal (UK)
1 l = 0.035 cu.ft
2920 7012 00
1 m = 3.281 ft
1 mm = 0.039 in
1 m³/min = 35.315 cfm
1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
t°F = 32 + (1.8 x t°C)
t°C = (t°F - 32)/1.8
23
 What sets Atlas Copco apart as a company is our
conviction that we can only excel in what we do if we
provide the best possible know-how and technology to
really help our customers produce, grow and succeed.
There is a unique way of achieving that - we simply
call it the Atlas Copco way. It builds on interaction, on
long-term relationships and involvement in the
customers' process, needs and objectives. It means
having the flexibility to adapt to the diverse demands
of the people we cater for.
It's the commitment to our customers' business
that drives our effort towards increasing their
productivity through better solutions. It starts with fully
supporting existing products and continuously doing
things better, but it goes much further, creating
advances in technology through innovation. Not for
the sake of technology, but for the sake of our
customer's bottom line and peace-of-mind.
That is how Atlas Copco will strive to remain the
first choice, to succeed in attracting new business and
to maintain our position as the industry leader.
No. 2920 7012 00 / DC 2006.12