DACZ 25-160: Operating Instructions Adsorption Dryer

Operating Instructions
Adsorption Dryer
DACZ 25-160
Issue 09-2003/EN
Declaration of Conformity
Boge Kompressoren
Otto Boge GmbH & Co. KG
Lechtermannshof 26
D-33507 Bielefeld
hereby declares with sole responsibility, that the products
compressed air adsorption dryer
series DACZ 25 to 160
assembly type: assembly acc. to Art. 3 No. 2.2,

which this declaration refers to, conform to Directive 97/23/EC and were
subjected to a conformity assessment according to Annex III Modules B + D (for
assembly assessment).
For the assembly, the EC type approval certificate SIG 0271665/2 by Lloyd’s
Register Quality Assurance GmbH, Hamburg, is available.
The quality assurance system is monitored by the service provider stated below
Lloyd’s Register Quality Assurance GmbH (identification number 0525)
Mönckebergstraße 27, D - 20095 Hamburg.
The assembly consists of pressure appliances according to the classification list

(attached to the technical documentation provided by the manufacturer).
The following standards / technical specifications were used:

harmonized standards: DIN EN 292-1, DIN EN 292-2, DIN EN 1050,
DIN EN 50081, DIN EN 50082, DIN EN 60204
The following other EC directives were used:
98/37/EC
89/336/EEC
73/23/EEC
Signature
Stefan Pilath
Quality Manager
Machine passport
Type designation DACZ
Order no.
Project no.
Build no.
Vessel no.
Vessel no.
Year of manufacture 2003
Issue date of these operating instructions 2003-09 EN
It is the responsibility of the owner,

to enter for the first time any appliance data not stated above,
to keep these appliance data up to date.
The above-stated appliance data provide for a clear identification of the dryer and
its components, and significantly facilitate any service measures.
Further important data on the dryer such as the details on the permissible
operating pressure and the electrical connection are found on the type plate (for
position of the type plate see page 11).
Table of contents
General information ............................................................................................... 8
Manufacturer's details ................................................................................................................ 8
Details on the dryer .................................................................................................................... 9
About these operating instructions........................................................................................... 10
For your own safety ............................................................................................. 11

Signs, instruction plates and danger zones at the dryer.......................................................... 11
Intended use of the dryer ......................................................................................................... 13
General safety notes ................................................................................................................ 13
Safety notes on specific operating phases .............................................................................. 14
Technical product description ........................................................................... 17

Summary drawing..................................................................................................................... 17
Function description ................................................................................................................. 18
Available options....................................................................................................................... 20
Transportation, installation and storage........................................................... 23

Information on transportation packaging.................................................................................. 23
What to do in the case of transport damage occurring?.......................................................... 23
Transporting and installing the dryer........................................................................................ 24
Installing and anchoring............................................................................................................ 25
Storing the dryer ....................................................................................................................... 26
Installation............................................................................................................. 28
Preconditions for installation .................................................................................................... 28
Connect piping.......................................................................................................................... 28
Installing the electrical connection ........................................................................................... 29
Start-up .................................................................................................................. 32
Requirements for initial start-up ............................................................................................... 32
Setting times of the operating phases...................................................................................... 33
Overview of operating and control elements............................................................................ 33
Emergency shutdown............................................................................................................... 36
Start up dryer ............................................................................................................................ 36
Changing cycle mode (optional)............................................................................................... 39
Monitoring dryer operation................................................................................. 41

With dewpoint-sensing control (optional) ................................................................................. 41
Shutdown and restart dryer ................................................................................ 42

Mains power failure .................................................................................................................. 42
DACZ25-160_00_2003-09-12
Emergency shutdown ............................................................................................................... 43
Depressurising and shutting down the dryer............................................................................ 43
If work is to be carried out on the electrical system ................................................................. 43
Restart....................................................................................................................................... 44
Maintenance and repair of the dryer ..................................................................46

Notes on maintenance.............................................................................................................. 46
Regular maintenance intervals................................................................................................. 47
Daily maintenance tasks........................................................................................................... 48
Weekly maintenance tasks....................................................................................................... 49
Monthly maintenance tasks...................................................................................................... 49
Maintenance work to be completed every 12 months ............................................................. 50
Identify and eliminate faults ................................................................................62

Summary of faults..................................................................................................................... 62
Index........................................................................................................................65
Annex with technical documentation.................................................................68

Technical data........................................................................................................................... 69
Replacement and wear parts list .............................................................................................. 71
Logic control diagram ............................................................................................................... 75
Flow diagram ............................................................................................................................ 77
Dimensional drawing ................................................................................................................ 78
DACZ25-160_00_2003-09-12
Manufacturer's details
General information
Manufacturer's details
Name and address
Boge Kompressoren
Postfach 10 07 13 Lechtermannshof 26
D-33507 Bielefeld D-33739 Bielefeld
Fon: 0 52 06/ 601-0
Fax: 0 52 06/ 601-200
Mail: [email protected]
Net: www.boge.de
Service and spare part order
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 serial no. of the dryer. Both are shown on the
type plate attached to the control cabinet of the dryer.
8 DACZ25-160_00_2003-09-12
General information
Details on the dryer
Standard equipment
Dryer, comprising
2 vessels, filled with desiccant
1 vessel, filled with purifying agent
1 upstream filter
1 downstream filter
Piping and muffler
Control system
Associated documents
Operating instructions (present)
Technical documentation (see annex)
Circuit diagrams (see separate document)
Warranty notes
In the following cases, the warranty shall be void:
If aggressive media in the compressed air and in the environment cause
corrosion damage and functional faults on the dryer.
If the dryer is used without prior approval and confirmation in writing by the
manufacturer for purposes other than those specified in these operating
instructions or contractually agreed.
If preset parameters (e. g. on the control system etc.) are changed without
prior approval and confirmation in writing by the manufacturer.
If the dryer is transported or stored incorrectly.
If the dryer is sited and installed incorrectly.
If the dryer is repaired or maintained incorrectly.
If the dryer is operated by personnel that does not have the requisite
qualifications.
If modifications are carried out on the dryer, the manufacturer did not
approve that.
In the event of non-compliance the manufacturer will not accept any liability for
any consequential damage whatsoever.
DACZ25-160_00_2003-09-12 9
About these operating instructions
About these operating instructions

These operating instructions contain basic information on the safe useof the
dryer.
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 with 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 operating instructions

These operating instructions are intended for all persons working on and using
the dryer. We assume that all such persons are specialist personnel, e.g. fitters
or electricians.
Operating instructions: handling

These operating instructions must be continuously available at the site where the
dryer is used. We recommend to prepare a copy and to keep the same in a safe
and freely accessible place next to the dryer. Keep the original document in a
safe place.
10 DACZ25-160_00_2003-09-12
For your own safety
For your own safety

The dryer 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 dryer is used, if
it is operated by non-qualified personnel,
not used within its intended design specifications,
is repaired or maintained incorrectly.
Note:
For your own safety and to prevent machine damage, please note the
information and safety notes in these operating instructions when
working with the dryer.
Signs, instruction plates and danger zones at the dryer
Signs and instructions
Type plate of the Type plate of the

upstream filter downstream filter
Vessel plate
Type plate of the dryer
Front view
DACZ25-160_00_2003-09-12 11
Signs, instruction plates and danger zones at the dryer
Please note the above plates and instructions attached to the dryer. Ensure that
they are not removed and are always readable.
Hazard areas on the dryer
Hazard caused by electrical voltage
Hazard caused by overpressure
Hazard caused by sudden air ejection during

expansion
Symbol in
operating
Hazard area instructions
Warning against hazardous electrical voltage

Different parts of the dryer carry electrical current. These parts may be
connected, opened, and maintained by authorized specialist personnel only.
Warning against overpressure

The entire dryer is under pressure. Before commencing any work, the plant
must be depressurised.
Warning against sudden air ejection
When the vessels are depressurised, air flows suddenly out of the sound
absorber:
This causes a sudden loud cracking noise.
Due to particles carried in the air flow, there is a very considerable risk of
eye injury.
When working on the dryer, always wear eye and ear protection equipment.
Skid risk
When emptying and filling the vessels with drying agent, there is a risk of
skidding caused by spilt drying agent.
12 DACZ25-160_00_2003-09-12
For your own safety
Intended use of the dryer

The dryer is exclusively intended for drying and purifying compressed air.
Depending on the defined input conditions, it dries and purifies compressed air
for industrial use.
The dryer is designed for compressed air, which is free from aggressive water,
oil, and solid matter constituents.
As standard, the dryer is intended to be sited within a building and protected
against the weather. When it is sited in the open air (option), the instructions on
page 20 must be complied with.
The dryer may be operated only in accordance with the data on the type plate
and in accordance with the contractual conditions.
Suspected misuse
The dryer must not be used as a climbing aid! Pipes, valves, and similar fittings
have not been designed for such loads. They could fracture, tear off, or become
damaged in another way.
General safety notes
For your own safety, when carrying out any work on the dryer comply with
all applicable national safety regulations!
Personnel qualification
Only authorized and qualified specialist personnel may be tasked with the work
on the dryer described in these operating instructions.
Conversions and modifications

Without prior approval by the manufacturer, no conversions and modifications
must be made to the dryer! Any non-approved modifications may restrict the
operational safety of the dryer and cause damage to property or personal injury.
Handling of drying and purifying agents

The drying and purifying agents used do not pose any risk to health. However,
when filling and emptying the vessels with drying and purifying agents, increased
dust generation may occur . Please comply with the following instructions:
When handling drying or purifying agents, alway wear a dust mask and eye
protection!
If a spillage occurs, any spilt drying agent must be taken up immediately.
There is a risk of skidding!
DACZ25-160_00_2003-09-12 13
Safety notes on specific operating phases
Transportation and siting

Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
Carefully secure the dryer during transportation.
Start-up
Warning against sudden air ejection!

During expansion the pressure is released suddenly through the muffler:
A loud cracking noise occurs which can injure your hearing.
Particles carried in the air can injure your eyes or skin.
Always wear eye and ear protection, therefore, when you are in the vicinity
of the dryer!
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.
Carry out all prescribed tests and checks.

The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
Before start-up, ensure that no tools or other foreign parts have been left
lying in a part of the dryer where they might pose a hazard to the dryer being
started up.
Emergency shutdown
In any emergency, proceed as described in the section Depressurising and
shutting down the dryer on page 43.
Monitor operation

Particles carried in the air flow act like bullets and can injure your
eyes or skin.
of the dryer!
14 DACZ25-160_00_2003-09-12
For your own safety
Only operate the dryer within the permissible limits (see type plate). By
operating the dryer in conditions that go beyond the defined values, the dryer
is subjected to loads for which it has not been designed. This may cause
functional defects.
Loud noise generation!

During expansion the pressure is released suddenly through the
expansion valve. A loud cracking noise may occur.
Always wear ear protection, therefore, when you are next to the dryer
during operation.
The more powerful the dryer is, the more noise may be generated during
operation. Temporarily, the actual noise emission may even exceed
95 dB(A). Therefore, the operator must provide suitable protective equipment
(e. g. ear protection).
Check the dryer regularly for externally visible damage and defects. Any
changes, even in its operating behaviour, must be reported immediately to
the competent office or person.
In the event of an emergency or if a safety-relevant disruption occurs (e.g.
escaping compressed air, defective component), the dryer must be shut
down immediately as described in the section Depressurising and shutting
down the dryer on page 43). The unit may only be restarted after all defects
have been eliminated.
Maintenance of the dryer and fault removal

Carry out maintenance work only when the plant has been shut down and
depressurised!
The factory settings on the control board in the switchbox must not be
changed on any account without prior approval by the manufacturer.
Bolt connections must be undone with care! Note ram pressure values!
Otherwise emerging media may cause personal injury.
Never carry out any welding on a vessel or change the same in any other
way!
Never use pipes and fittings as steps or holding points! The components
might fracture, or the distortions which occur may cause internal damage on
the dryer. There is a risk of injury by slipping off the components,
components breaking off, and expanding compressed air!
Never leave tools, loose parts or cloths in, at or on the dryer.
Following maintenance work always test all flange and bolt connections for
leak tightness and secure seating.
DACZ25-160_00_2003-09-12 15
Only use replacement parts that are suitable for the relevant function and
meet the technical requirements stipulated by the manufacturer. This is
always the case, if you use original replacement parts only.
Disassembly and disposal

Dispose all parts of the dryer, the drying and purifying agents and all other
operating materials in an environmentally safe way and in accordance with all
current statutory regulations. The waste code numbers of the drying and
purifying agents can be obtained from the manufacturer (for manufacturer's
address see page 8).
16 DACZ25-160_00_2003-09-12
Technical product description

Summary drawing
Views
Check valve block (V5–V6)
Vessel pressure gauge
On/Off-Switch
Control cabinet
Power supply connector
Vessel
Discharge point
Front view
Muffler
Compressed air inlet
Upstream filter
Compressed air outlet
Downstream filter
Rear view
Solenoid valve block (V1-V4)
DACZ25-160_00_2003-09-12 17
Function description
Function description
The dryer dries and purifies the compressed air supplied by the compressor and
makes it available for industrial use.
The air is thereby dried alternately in one of the drying agent vessels. The dried
air is subsequently purified in the third vessel, whereby oil residue and other
contaminants are removed.
Before the compressed air is fed into the dryer, it flows through upstream filters
where dust, dirt, oil and water droplets are removed. Thus, the installed upstream
filter is also used for extending the service life of the drying agent.
The installed downstream filters clean the compressed air from drying agent
abrasions, before it is fed into the compressed air system.
The two vessels contain an extremely porous drying agent by means of which
humidity is removed from the compressed air and stored just as in a sponge. The
stored humidity is then removed again from the drying agent and re-introduced
into the ambient environment.
To this end, the two vessels alternate between different operating modes. Whilst
in one vessel, compressed air is de-humidified (adsorption), in the other vessel
the humid drying agent is prepared for another charge (regeneration). These two
states, which run in parallel during compressed air preparation, are described
below.
Adsorption
Via a compressor, humid
compressed air is supplied to the
upstream filter. From here, the
compressed air flows upwards
through the absorption vessel,
which is pressurised. In so doing,
the drying agent dehumidifies the
air. The dried compressed air is
supplied to the pipe network via
the purifying vessel and the
downstream filter.
Adsorption in the left drying agent vessel.
Regeneration (running in parallel to the adsorption)

At the same time the other vessel is prepared for a renewed take-up of humidity.
This process is called regeneration.
The regeneration is subdivided into three phases: expansion, dehumidification,
and pressure build-up.
18 DACZ25-160_00_2003-09-12
With the dewpoint-sensing control option, the regeneration phase is followed by a

standby phase.
Expansion phase
During the expansion phase, the
pressure in the regenerating
vessel is released via the muffler
down to ambient pressure within
just a few seconds. The outflow of
the compressed air becomes
noticeable due to a sudden
powerful flow noise at the muffler.
Dehumidification phase
Prior to being released into the
purifying vessel, dried com-
pressed air is bled by means of
an orifice plate. This separate
regeneration air flow is fed
through the depressurised vessel.
Regeneration in in the right drying agent vessel
The humidity stored in the drying agent is taken up by the air flow and expelled
into atmosphere via the muffler.
Pressure build-up phase

After dehumidification the
pressure in the regenerated
vessel is built up to operating
pressure, so that the switchover
from regeneration to adsorption
can take place at operating
pressure level.
Pressure build-up in the right drying agent vessel
DACZ25-160_00_2003-09-12 19
Available options
Standby phase (only with the dewpoint-sensing control option)

When in standby phase, the fully regenerated vessel is ready for absorption
operation. The system is switched to this vessel, as soon as the measured
dewpoint at the compressed air outlet has reached the set dewpoint value for
switchover.
Switchover
When the drying agent in the adsorbing vessel has taken up a sufficient level of
humidity, then the switchover between the vessels will be effected between the
vessels. Following switchover, the above-described process is repeated, with the
adsorption and regeneration now taking place in the respective different vessel.
Available options
The following options are available for the dryer:
Start-up device
Outside installation
Auxiliary heater
Bypass line
Signalling contacts of control system
Regeneration gas return line for compressor synchronisation
Dewpoint-sensing control
Pneumatic control
Paint compatible design
Start-up device
A start-up device basically consists of a pressure holding device, which is located
at the rear of the dryer. The pressure holding device ensures that pressure can
build up in the dryer and adsorption take place.
It is always required when an empty compressed air reservoir or an empty
compressed air system must be filled downstream of the dryer (e.g. following
weekend shutdowns and when the pressure in the compressed air system can
frequently drop below the stated operating pressure).
The start-up device cannot be combined with the regeneration gas return line
option.
Outside installation
As standard, the dryer is not suitable for outside installation, as its function and
service life is influenced by the following factors:
Environmental humidity due to rain (or other deposit)
Corrosion caused by environmental humidity or a salt-containing environment
Freezing of valves, cocks, flaps, and other components at low temperatures
Therefore, a planned outside installation must always be discussed in advance
with the manufacturer to allow specific technical design measures to be provided
for the installation location.
20 DACZ25-160_00_2003-09-12
Auxiliary heater
For installation sites with temperatures under +1 ºC, the wet side of the dryer
must be equipped with an auxiliary heater to prevent valves, cocks, flaps, and
other components from freezing up.
Bypass line
The bypass line is a "detour line", which allows the compressed air system to
continue operating even whilst maintenance of the dryer is in progress. However,
during this time the air is not dried but flows through the bypass line past the
dryer and through to the actual loads.
Filters in the bypass line are meaningful so that the actual loads are largely
protected against dirt, water, and oil droplets even whilst maintenance is in
progress.
Signalling contacts of the control system

The control system is equipped with a digital input for the synchronised operation
with a compressor. This feature allows for synchronised and thus efficient dryer
operation with discontinuous compressor operation.
The control system can also be equipped with an optional operation signalling
contact with which the dryer operation can be monitored from an external device.
Dryers with the optional dewpoint-sensing control are equipped with such a
contact as standard. It is used for the transmission of operating signals and for
the output of dewpoint alarms.
Regeneration gas return for compressor synchronisation

Compressor synchronisation helps reduce energy costs, as the dryer can be
operated independently of the compressor.
When the compressor is switched off, the regeneration gas return ensures that
regeneration is continued, as soon as a certain compressed air volume is
reached behind the dryer.
The regeneration gas return must be adjusted to suit the installed compressed air
system. Prior to installation, please consult the manufacturer.
The regeneration gas return option cannot be combined with the optional start-up
device.
Dewpoint-sensing control
With a dewpoint-sensing control system, you can operate the dryer in fixed or
variable cycles. In the fixed cycle, switchover is effected after a fixed time period
(usually after 5 minutes). In the variable cycle, the switchover is effected in
relation to the dew point reached and the charging of the drying agent . The
adsorption time in the variable cycle amounts to 60 minutes maximum.
Pneumatic control
A pneumatic control system can be used wherever an alternative to the electronic
control system is required, such as e.g. in explosion hazard areas.
DACZ25-160_00_2003-09-12 21
Available options
Paint compatible design

Paint shop plants impose particularly stringent requirements with regard to the
cleanliness of the compressed air, as already the minutest contaminations can
reduce the quality of the paint finish. Even minute quantities of oil and grease
containing foreign materials or solvents — above all silicones — are sufficient to
cause pits, discolorations, swellings, and other contaminations in the paint finish.
Dryers in a paint compatible design comprise seals and filters that are absolutely
free of grease and silicon and thus ensure a high quality of the compressed air
used for painting.
22 DACZ25-160_00_2003-09-12
Transportation, installation and storage
Danger due to incorrect transportation!

The dryer must be transported by authorized and qualified specialist
personnel only. During transportation all applicable national regulations
for accident prevention must be complied with. Otherwise there is a risk of
personal injury.
Only use suitable and technically perfect lifting gear with a sufficient carrying
capacity.
During transportation the dryer must be carefully secured against falling over.
The manufacturer will not be liable for any damage caused by incorrect storage
or incorrect transportation. Please note therefore the following instructions as well
as the storage instructions on page 26.
Information on transportation packaging

Depending on the type of transportation, the dryer is delivered in different types
of packaging:
All transportation types: the apertures of the dryer are closed off by means of
plugs.
In addition, when transportation is effected by air: the dryer is packaged in a
wooden box.
In addition, when transportation is effected by ship: the dryer is packaged in a
film material and in a wooden box.
If the packaging is undamaged

► The undamaged packaging should be removed only at the final installation
site, as it offers protection against any weather influences.
What to do in the case of transport damage occurring?

► Check whether only the packaging or the dryer 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 8.
Warning!
A damaged dryer must not be taken into operation! Damaged components
may lead to functional faults and possibly cause further damage.
DACZ25-160_00_2003-09-12 23
Transporting and installing the dryer
Transporting and installing the dryer
Requirements for the installation site

The conditions at the installation site have a large influence on the functional
capability of the dryer and the service life of the drying and purifying agent. In
order to ensure a mode of operation, which is as continuous as possible, and low
maintenance, the installation site must meet the following requirements:
The installation site must be located within a building - protected against the
weather. For outside installation (option) the instructions on page 20 must be
complied with.
The ambient temperature must not drop below +1 °C. If necessary, an
auxiliary heater is to be provided (for information on the auxiliary heater, see
page 21).
When selecting the installation site, it should be taken into account that the
noise emission of the dryer can exceed 95 dB(A) temporarily (for further
information on the noise emission, see also page 15).
The installation area must be level and firm. It must have the necessary
carrying capacity for the weight of the dryer. The weight of the dryer is
specified in the technical data section of the annex.
The dryer should be installed with
sufficient spacing at the top, sides,
and rear, in order to be able to
carry out maintenance work and
change the drying and purifying
agent without any hindrances (see
figure).
Necessary spacing at the top and sides = min. 1

m
If in doubt, the installation site must be inspected by specialists. If you have any
queries in this regard, please contact the manufacturer (for details see page 8).
Transportation using lifting or forklift trucks
Warning against damage to property!

The dryer is delivered lying on its side on a transportation pallet. At the top
it is protected by a carton. Top and sides have not been designed for
mechanical loads.
Therefore do not place any load onto the top face. Do not stack.
Therefore, always transport the dryer on a lifting or forklift truck.
24 DACZ25-160_00_2003-09-12
► Secure the dryer on the lifting

or forklift truck against sliding
movements.
► Transport the dryer to its
installation site.
Dryer on transportation pallet
Installing and anchoring
Installing by crane
► Remove the packaging of the dryer.
► Attach suitable lifting gear to the transport
lugs of the vessels (see figure).
Transportation on pressure vessel
DACZ25-160_00_2003-09-12 25
Storing the dryer
► Place dryer in an upright position, and

position the same at its installation site
(see figure).
Positioning by crane
Anchoring the dryer

The upright stand profiles of the dryer are provided with four pre-drilled
anchorage bores.
► Use suitable attachment material to anchor
the dryer to the floor (see figure).
► In the case of vibrating floors: place the dryer
on suitable vibration dampers.
Bores at the foot of the dryer
Storing the dryer

If the dryer is to be stored for an extended period of time, the storage location
must meet the following conditions:
The dryer must not be stored in the open air.
The storage room must be dry.
The storage room must be free from dust or the dryer must be covered by a
protective sheet.
The storage room must have an ambient temperature of at least +1 °C.
26 DACZ25-160_00_2003-09-12
In order to store the dryer proceed as follows:

► Take dryer out of operation as described on page 43.
► Ensure that the compressed air inlet valve installed by the owner, and the
installed compressed air outlet valve installed by the owner, are both closed,
and that the dryer is depressurised.
► Disconnect dryer from the compressed air system.
► Disconnect the dryer from the electrical power supply and all external lines.
► Use film material or similar to close the compressed air inlet apertures and
compressed air outlet apertures on the dryer in order to protect them against
contamination.
► If possible cover dryer with a protective sheet.
The dryer can now be stored for long periods.
Note:
If you wish to take the dryer back into service after an extended period
of storage, please proceed as described for its first commissioning
and start-up (see page 37).
Store drying and purifying agents

► Do not store drying and purifying agents in the open air.
► Protect drying and purifying agents against humidity.
DACZ25-160_00_2003-09-12 27
Preconditions for installation
Installation
Only authorized and qualified specialist personnel may carry out work on
pipes and electrical systems.
As soon as the dryer has been set up at its installation location, you can install
the compressed air infeed and outlet lines make the electrical connections.
Preconditions for installation

For a correct installation the following preconditions must be met on the part of
the owner.
Connections and lines for the infeed and outfeed of compressed air must be
provided.
A compressed air inlet valve as well as a compressed air outlet valve must
be installed by the owner, so that the dryer can be installed and maintained in
a depressurised condition (see also the installation example on page 29).
All pipes, couplings, and connections must have the correct diameter and
match the operating pressure.
Hazard caused by exceeding the limit values!

A safety device must be provided in order to protect against the maximum
permissible operating pressure from being exceeded.
The data required to meet these preconditions are contained in the technical
documentation attached in the annex.
Warning!
If the above preconditions are not complied with, a safe operation of the
dryer cannot be assured. Also, the functionality of the dryer may be
detrimentally affected.
Connect piping
In order to ensure that the dryer operates optimally, the dryer must be assembled
into the compressed air system free of all stresses.
► Ensure before connection that all infeed and outfeed compressed air lines
and valves are clean and undamaged.
► Check the bolt connections and retighten if necessary, as they could have
worked loose during transportation.
► Remove plugs on the pressure inlet and outlet.
28 DACZ25-160_00_2003-09-12
Installation
All piping must be free from any stress and tension whatever!
Pipes subject to stress may burst due to the load placed on them during
operation. This may cause damage to property and personal injury.
► Use steel pipes to connect the dryer to the compressed air system.
The following figure shows an installation example.
Compressed air system Item Component

1 Entry, humid air
2 Compressed air inlet
valve, owner end
3 Upstream filter
4 Dryer
5 Downstream filter
6 Compressed air outlet
valve, owner end
7 Outlet, dry air
8 Bypass line (option)
9 Valve in bypass line
(option)
10 Bypass filter (option)
11 Valve, outlet bypass
filter (option)
Example of an installation with bypass line
► The connection lines for the upstream filter (3) are to be installed at a slight
incline in the direction of the upstream filter.
► One shutdown valve each (2, 6) is to be installed at the compressed air inlet
and outlet ends of the dryer.
► If you fit a bypass line (8) with additional shutdown valve:
Fit the line such that, when carrying out maintenance work on the dryer, the
line system can continue to be supplied with compressed air.
Installing the electrical connection
Warning against electrical voltage

Only qualified specialist personnel may carry out work on the electrical
system!
DACZ25-160_00_2003-09-12 29
Installing the electrical connection
Installing the supply cable

The components of the dryer have been connected to the control cabinet at the
factory. You only need to connect the control cabinet to the electrical supply
cable.
The switchbox is provided with a connector where electrical power must be
connected.
► Ensure that the cross-section of the electrical supply cable corresponds to
the power rating of the dryer and the electrical voltage provided by the
customer.
► Make the electrical supply cable to the dryer voltage-free.
► Secure the electrical supply cable to the dryer against switch-on.
► Undo bolt (1) on the connector and
withdraw connector with seal from the
switchbox.
► Use a suitable tool to remove the
terminal block from the connection
box.
► Undo the PG union and pull the cable
through the aperture (3). The
exposed phase ends should not be
longer than 35 mm max.
► Now make the cable connection as Connect electrical cable to device

follows: adapter
— Earth to terminal PE
— L1 to terminal 1
— N to terminal 2
Terminal 3 is not used.
► Fit terminal block into the connector and use bolt to remount the connector
with seal on the switchbox.
► In all phases the dryer must be protected against short circuits by means of
fuses.
► In order to relief cable strain, re-tighten the PG union.
Connecting the external signalling lines
For compressor synchronisation

The control system is equipped with a digital input that ensures that the dryer can
only be operated while the compressor is on.
If the compressor is switched off, the regeneration process started in one of the
chambers is however completed. Subsequently, the respective expansion valve
is automatically closed. In standby mode, the control system remains switched
on, and the economy cycle LED is on. The dryer is now ready for the next
switching procedure, which takes place as soon as the compressor is switched
on again.
30 DACZ25-160_00_2003-09-12
Installation
To install the external line, proceed as follows:

► Connect the signalling line to the potential-free busbar connection of the
compressor to terminals 1 and 2 on the control board (see circuit diagram).
For operation monitoring system (optional)

Operators have the option to connect the dryer to a fault signalling system,
connecting the respective line to a potential-free operation signalling contact.
With this option, the following statuses and events can for example be
transmitted to a remote control room:
Dryer on (contact made)
Power supply disconnected (no contact)
Dewpoint alarm (only with dewpoint-sensing control option, no contact)
To install the external lines, proceed as follows:
► Connect the lines of the fault signalling system to relay R5 (see circuit
diagram).
Check bolt connections

Before the initial start-up:
► Check all unions and bolt connections as well as the terminals in the control
cabinet for secure seating; re-tighten if necessary.
DACZ25-160_00_2003-09-12 31
Requirements for initial start-up
Start-up
Warning!
The dryer must be taken into operation by trained personnel only!
Untrained personnel does not have the required knowledge. Such
personnel might cause serious faults.
Note:
You can order the initial commissioning and start-up from the
manufacturer and have your personnel trained by the manufacturer.
For telephone number, see page 8.
Carry out all prescribed tests and checks.

Before start-up, ensure that no tools or other foreign parts have been left
lying in a part of the dryer where they might pose a hazard to the dryer being
started up.
Requirements for initial start-up

For the first start-up the following preconditions must have been met:
The pipe system is free from
— scales
— thread abrasions
— welding beads and
— other contaminations.
All shutdown valves
— of the compressed air inlet and outlet valves installed by the owner
— in the bypass line (if available)
are closed.
The dryer is correctly sited and installed.
Checks before start-up

Ensure that
all pipe, cable and bolt connections on the dryer have been retightened,
no pipes chafe against body edges,
all mountings are perfectly secure,
the electrical connections are in safe contact and in good condition,
owner-end and pressurised parts such as safety valves or other devices are
not blocked up by dirt or paint,
all compressed air system parts which are pressurised (valves, hoses etc.)
are free from wear symptoms and defects.
32 DACZ25-160_00_2003-09-12
Start-up
Setting times of the operating phases

In its standard version the dryer is delivered with a time-dependent control
system. The phase sequence occurs in a fixed cycle.
With the optional dewpoint-sensing control, the dryer can also be operated at
variable cycles (depending on the dewpoint).
The following table provides information on the duration of the individual phases.
Phase duration Fixed cycle Variable cycle
Adsorption 5 min 60 min, maximum
Regeneration, total 5 min 5 min
− of which: expansion time ~ 0.2 min ~ 0.2 min
− of which: dehumidification time ~4 min ~4 min
− of which: pressure build-up ~1 min ~1 min

Standby — ~ 55 min, maximum
Overview of operating and control elements
ON/OFF switch
The ON/OFF switch (2) is located to the side of the control cabinet and above the
mains plug (1, see figure):
If it is set to 0, the power supply is disconnected and the dryer is switched off.
The main and expansion valves are normally closed. This ensures that the
main flow direction is blocked when the dryer is switched off.
If the switch is set to I, the dryer is switched
on and begins to operate in fixed cycle mode
(i.e. time-controlled).
If the switch is set to position II, the dryer is
switched on and begins to operate
— with compressor synchronisation
— in variable cycle mode (i.e. dew-point-
controlled).
Position II is only relevant for operation with
the optional regeneration gas return system
for compressor synchronisation and/or
dewpoint-sensing control.
Control cabinet with ON/OFF switch
DACZ25-160_00_2003-09-12 33
Overview of operating and control elements
Display panel
The display panel at the
switchbox is equipped
with LEDs (light emitting
diodes) and a digital
display, indicating the
operating status of the
dryer:
Display panel at the switchbox
LED Power (1)

LED is on when dryer is switched on.
Flow diagram (2)
The current operating phases of the dryer are indicated by means of 4 LEDs:
Vessel B1: Vessel B2:
Regeneration 1 Regeneration 2
Adsorption 1 Adsorption 2
Depending on the operating phase, the following LEDs might be on

simultaneously:
Adsorption B1 and regeneration B2 or
regeneration B1 and adsorption B2.
34 DACZ25-160_00_2003-09-12
Start-up
Digital display (3)

The digital display shows the individual programme steps and the respective
remaining time. For details regarding the sequence of the individual processing
steps and their duration, please refer to the logic control diagram, page 75.
Display Explanation
2 215 Default display: The figure to the left indicates the current
processing step; the figure to the right shows the remaining
time in seconds.
In this example, step 2 is being completed, whereby there are
215 seconds remaining.
SEr. After 8000 operating hours, "SEr." (service) is displayed for
periods of 1 minute, alternating with the default display.
Notify the service personnel of the manufacturer, as a routine
service is now due.
– 25 With the dewpoint-sensing control option, the display shows the
currently measured dewpoint instead of the default data. The
range of display is -100 °C to +20 °C.
If the measured dewpoint exceeds the preset alarm limit (5 °C
above the switchover value), the displayed dewpoint value is
flashing.
With the optional dewpoint-sensing control, the following error messages might
be displayed:
Display Cause
+20 Upper measuring range limit exceeded
999 Dewpoint sensor defective
sens Dewpoint sensor not powered
or Cable defective or disconnected
–999 Sensor defective
LED Economy cycle (4)

This LED is only relevant in units that are equipped with the optional
regeneration gas return for compressor synchronisation and/or dewpoint-
sensing control. The LED is on, if the dryer is switched on but does not need
regeneration air (standby phase):
with compressor synchronisation: if the compressor is switched off and/or
if the dryer is set to variable cycle mode (dewpoint-controlled operation).

On both vessels, pressure gauges are fitted which show the operating
overpressure. The operating overpressure indicates the operating phase of the
relevant vessel:
DACZ25-160_00_2003-09-12 35
Emergency shutdown
During adsorption the pressure gauge should indicate the nominal operating
overpressure.
During regeneration the indication of the pressure gauge on the regenerating
vessel
— should decrease in the expansion phase from operating overpressure to
0 bar overpressure,
— indicate an overpressure of 0 bar in the dehumidification phase.
With an increasing duration of operation, a higher overpressure can be indicated
during regeneration. This overpressure during regeneration is also designated as
dam pressure.
The dam pressure should not exceed 0.3 bar, otherwise read the instructions
on page 48.
During the pressure build-up phase the indication on the pressure gauge
should again rise to operating overpressure level.
Differential pressure gauge

On each of the upstream and downstream filters, a differential pressure gauge is
installed. The differential pressure between the filter inlet and outlet ends is used
as an indicator for the degree of filter element contamination. The indication
should be within the green range up to 0.35 bar maximum, otherwise read the
instructions on page 50.
Emergency shutdown
In the event of an emergency, shut down the dryer as described in chapter
Depressurising and shutting down the dryer, page 43.
Start up dryer

eyes or skin.
of the dryer!

36 DACZ25-160_00_2003-09-12
Start-up
The more powerful the dryer is, the more noise may be generated during
operation. Temporarily, the actual noise emission may even exceed
95 dB(A). Therefore, the operator must provide suitable protective equipment
(e. g. ear protection).
Only operate the dryer within the permissible limits. By operating the dryer in
conditions for which it has not been designed, functional faults may be
caused.
Check the dryer regularly for externally visible damage and defects. Any
changes, even in its operating behaviour, must be reported immediately to
the competent office or person.
escaping compressed air, defective component), the dryer must be shut
down immediately as described in the section Depressurising and shutting
down the dryer on page 43). The unit may only be restarted after all defects
have been eliminated.
Open compressed air supply and switch on dryer

For start-up, please proceed in the sequence shown here.
► Ensure that the compressed air inlet and outlet valves installed by the owner
are closed (see installation example on page 29).
► Ensure that the compressed air system upstream of the dryer is pressurised.
If necessary, pressurise (switch on compressor).
Slowly open compressed air inlet valve!

Avoid sudden pressure build-up in any circumstance! If pressure builds up
too fast, this may cause damage to the dryer. Therefore, the compressed
air inlet valve must always be opened quite slowly!
► Slowly open the compressed air inlet valve, installed by the owner, upstream
of the dryer.
► Switch on dryer: to this end, set the ON/OFF
switch to I.
ON/OFF switch
If the dryer is taken into operation for the first time, or after a change of drying
agent, the following intermediate step is meaningful. In the case of a restart
situation, the following intermediate step can be skipped.
Operating the dryer for the first time (or after a change of drying agent) separately
Depending on the transportation and storage conditions, the drying agent in the
vessels can already be loaded with humidity from the environment. At each first
start-up it makes sense therefore to operate the dryer from some time separately
from the compressed air system. This causes the drying agent in each vessel to
be regenerated repeatedly and thus to be prepared optimally for the take-up of
humidity.
DACZ25-160_00_2003-09-12 37
Start up dryer
Note:
Depending on the pressure dew point to be achieved, we recommend
to operate the dryer at first start-up without compressed air
consumption:
for at least 4 hours at a pressure dew point of –25 to –40 °C or
for approx. 3 to 5 days at a pressure dew point of –70 °C.
If you wish to take the dryer into operation in accordance with our
recommendation, proceed as follows:
► Ensure that the compressed air outlet valve installed by the owner is closed.
► Keep the compressed air outlet valve closed for the time period
recommended above.
Then the dryer can be taken into service in the compressed air system as
described in the following section:
Operate dryer immediately in the compressed air system

► Ensure that the compressed air system downstream of the dryer is
pressurised or that a start-up device (option, see page 20) was installed into
the compressed air system directly downstream of the dryer.
The importance of this increases with the size of the compressed air system
downstream of the dryer. Smaller compressed air systems can be
pressurised also by means of compressed air fed through the dryer.
Slowly open compressed air outlet valve!

Avoid a sudden drop in pressure in any circumstance! If pressure drops
too fast, this may cause damage to the dryer. Therefore, the compressed
air outlet valve must always be opened quite slowly!
► Slowly open the compressed air outlet valve installed by the owner. Observe
the vessel pressure gauge of the pressurised vessel. The pressure should
not drop below the operating pressure (if poss.). If necessary, keep the
compressed air outlet valve in a slightly open position until the compressed
air system downstream of the dryer has filled up completely; only then should
the valve be opened fully.
The dryer has then be taken into operation within the compressed air system.
In the event of a fault

escaping compressed air, defective component), the dryer must be shut down
immediately as described in the section Depressurising and shutting down the
dryer on page 43).
Then proceed as follows:
Remedy fault
► Look up possible cause of the fault, and how to remedy the same, in the
table on page 63.
► Remedy fault.
38 DACZ25-160_00_2003-09-12
Start-up
► Repeat the start-up procedure.
Changing cycle mode (optional)
When can I change cycle mode?

If the dryer has been successfully commissioned and is equipped with one of the
following options:
regeneration gas return for compressor synchronisation or
dewpoint-sensing control
it can be set to economy cycle mode.
When should I change cycle mode?

Cycle changes should be made during the pressure build-up phase and prior to
switchover; during this phase, the pressure in both vessels is just below operating
pressure so that a fast pressure build-up is prevented when the vessels are
switched.
During this period, only the adsorption LED is on in the diagram, and the digital
display shows step 4 or step 9 for the duration of 1 minute (see logic control
diagram; not displayed with dewpoint sensing).
Which cycle modes can I choose?

If the dryer is connected to a compressor synchronisation system and is
equipped with the dewpoint-sensing control option, these two optional devices
can only started together. The compressor synchronisation has thereby
precedence over the dewpoint-sensing control.
With regeneration gas return for compressor synchronisation (optional)

If compressor synchronisation is enabled, the dryer can only be operated in
conjunction with the compressor. As soon as the compressor is switched off, the
dryer is automatically set to standby mode.
The installed regeneration gas return ensures however that a regeneration cycle
started in one of the vessels is completed. Subsequently, the respective
expansion valve is closed. In standby mode, the control system remains on, and
the dryer is ready for the next switchover, which is made as soon as the
compressor is switched on.
With dewpoint-sensing control (optional)

Dryers equipped with dewpoint-sensing control operated in variable cycle mode,
based on the measured dewpoint of the dried air at the compressed air outlet. As
soon as a certain dewpoint is reached, as the drying agent in the absorbing
vessel is saturated, the vessels are switched.
The dewpoint at which a switchover is made is preset at the factory.
DACZ25-160_00_2003-09-12 39
Changing cycle mode (optional)
How do I change cycle mode?

► Wait until the dryer has reached the pressure build-up phase (phase prior to
switchover).
One LED for Adsorption B1/B2 is on in the flow diagram.
► Set the ON/OFF switch to position II.
The programme continues the cycle. ON/OFF switch
40 DACZ25-160_00_2003-09-12
Monitoring dryer operation
Monitoring dryer operation

The dryer operates fully automatically. However, you should carry out the regular
checks described in the Chapter Maintenance and repair of the dryer.

eyes or skin.
of the dryer!
Display of dewpoint
If the dryer is equipped with a dewpoint-sensing control system, the digital display
at the front of the switchbox shows the currently measured dewpoint. The range
of display is –100 °C to +20 °C.
If the set dewpoint is exceeded, the system automatically completes a switchover
between the vessels. The dewpoint at which a switchover is made is preset at the
factory.
► After commissioning or extensive maintenance work, check the dewpoint
display at the dryer.
Under certain circumstances, the desired dewpoint is only reached after
prolonged operation.
Error messages
If the measured dewpoint exceeds the preset alarm limit (5 °C above the
switchover value), the displayed dewpoint value is flashing. In addition, an error
message can be issued through the potential-free busbar.
Error codes and their causes:
Display Cause
+20 Upper measuring range limit exceeded
999 Dewpoint sensor defective
sens Dewpoint sensor not powered
or Cable defective
–999 Sensor defective
For instructions on how to eliminate faults, see chapter Identify and eliminate
faults
DACZ25-160_00_2003-09-12 41
Mains power failure
Shutdown and restart dryer

In the following cases, the dryer must be fully shut down and depressurised:
In the event of an emergency or malfunction
For maintenance work
For dismantling
Risk of injury from escaping compressed air!

as long as the unit is pressurised! Suddenly escaping compressed air
might cause serious injuries.
Prior to any work, release all pressure from the unit.
Mains power failure

In the event of a power failure, follow the instructions below:
In the event of a power failure, or when the dryer is switched off with the ON/OFF
switch
all main valves are closed
all expansion valves are closed
As a result
the pressure at the inlet side of the dryer is increased, while the compressor
is on (until the compressor is automatically switched off by the control
system),
the pressure in the vessel (without start-up device) is reduced, as the
compressed air outlet valve is open, while compressed air is taken in from
the pipeline system,
no compressed air is fed to the downstream compressed air system.
Note:
If the unit is equipped with a compressor synchronisation system, first
switch off the compressor and then wait until the dryer has reached
the standby phase before switching it off with the ON/OFF switch.
This ensures that the regeneration cycle is completed, and that the
pressure in both vessels is at the same level.
Note:
As soon as the dryer is switched on again, the programme continues
the cycle from the point at which it has been stopped.
42 DACZ25-160_00_2003-09-12
Emergency shutdown
In any emergency proceed as described in the next section.
Depressurising and shutting down the dryer

In order to make the dryer safe, follow the instructions in the next three sections:
Disconnect dryer from compressed air system

► Close the compressed air outlet valve (provided by operator).
► Close the compressed air inlet valve (provided by operator).
► If installed: Open bypass line.
Depressurise dryer
► Leave the dryer on until the expansion phase in both vessels has been
completed.
During the expansion phase, the vessels are completely depressurised.
► Check the pressure in the dryer at both vessel pressure gauges. The
pressure gauges should show value "0".
Disconnect voltage supply

► Switch off the dryer by setting the ON/OFF
switch to position 0.
ON/OFF switch
If work is to be carried out on the electrical system

► Depressurise and shut down the dryer, following the instructions in the above
chapter.
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!
► Make the electrical supply cable to the dryer voltage-free.

► Secure the electrical supply cable to the dryer against switch-on.
DACZ25-160_00_2003-09-12 43
Restart
Restart
Depending on the fittings installed by the operator and the actual pressure
conditions, the unit might have to be restarted at operating pressure. The
following general rules apply:
When switched off, the dryer is blocked in the main flow direction.
The pressure in the vessel drops (provided that the compressed air outlet
valve provided by the operator is opened), if
— compressed air can escape to the compressed air system,
— the dewpoint-sensing control is implemented.
If compressed air system and dryer have remained at operating pressure

► Ensure that the compressed air inlet valve (provided by the operator) is open.
► Set ON/OFF switch to I. The programme
continues the cycle from the point at which it
was interrupted.
ON/OFF switch
Slowly open compressed air outlet valve!

Avoid a sudden drop in pressure in any circumstance! If pressure drops too
fast, this may cause damage to the dryer. Therefore, the compressed air
outlet valve must always be opened quite slowly!
► Slowly open the compressed air outlet valve installed by the owner. Observe
the vessel pressure gauge of the pressurised vessel. The pressure should
not drop below the operating pressure (if poss.). If necessary, keep the
compressed air outlet valve in a slightly open position until the compressed
air system downstream of the dryer has filled up completely; only then should
the valve be opened fully.
► If available, block off bypass line.
The dryer is now in operation again and operates fully automatically.
If compressed air system and dryer have not remained at operating pressure
► If disconnected, reconnect the voltage supply of the dryer.
► Pressurise and switch on the dryer as described in the section Open
compressed air supply and switch on dryer on page 37.
The dryer is now in operation again and operates fully automatically.
After the purifying agent has been replaced

The newly filled purifying agent contains minute dust particles that can block the
downstream filters. We therefore recommend to complete the following steps
before you restart the dryer, in order to protect your equipment:
► Remove the housing base and the filter element from the downstream filter.
44 DACZ25-160_00_2003-09-12
Wear eye protection and dust mask due to increased dust generation!
If the dryer is operated without downstream filter, there is a risk of
increased dust generation.
In order to avoid any eye irritations, wear protective goggles!
In order to avoid any dust inhalation, wear dust mask!
Restart the dryer:

► Switch on the dryer and pressurise as described in section Open
compressed air supply and switch on dryer, page 37.
The compressed outlet valve must be closed and the downstream filter housing
must be open:
► Operate the dryer for approx. thirty minutes, blowing the dust particles off
from the downstream filter.
Shut down the dryer:
► Close the compressed air inlet valve installed by the owner.
► Switch off the dryer by setting the ON/OFF switch to position 0.
Reassemble the downstream filter and restart the drier:
► Assemble and mount the downstream filter as described on page 50.
► Switch on the dryer and pressurise as described in section Open
compressed air supply and switch on dryer, page 37.
► Check that the vessel and the downstream filter are leak tight.
DACZ25-160_00_2003-09-12 45
Notes on maintenance
Maintenance and repair of the dryer

In order to allow maintenance work on the dryer to be carried out efficiently and
without danger for maintenance personnel, you should comply with the following
instructions.
Notes on maintenance
Warning!
Maintenance tasks may be carried out only by authorized and qualified
specialist personnel, and only with the plant in a switched off and
depressurised condition.
Note:
In order to ensure perfect maintenance and reliable operation we
recommend that you conclude a maintenance contract (For telephone
number, see page 8).
When exchange or replacement parts are ordered, always state the
dryer type and the build no. of the dryer. These data are found on the
type plate attached to the control cabinet door.
Carry out all maintenance work only when the plant has been shut down and
depressurised!
Bolt connections must be undone with care! Note ram pressure values!
Otherwise emerging media may cause personal injury.
Do not modify the factory settings of the control system in any way without
prior consultation with the manufacturer.
Never carry out welding work on a vessel or modify the same in any way!
Following maintenance work, always check all flange and bolt connections
for leakage and secure seating.
Never use pipes and fittings as steps or holding points! The components
might fracture, or the distortions which occur may cause internal damage on
the dryer. There is a risk of injury by slipping off the components,
components breaking off, and expanding compressed air!
Never leave tools, loose parts or cloths in, at or on the dryer.
Only use replacement parts that are suitable for the relevant function and
meet the technical requirements stipulated by the manufacturer. This is
always the case, if you use original replacement parts only.
46 DACZ25-160_00_2003-09-12
Regular maintenance intervals
Note:
If a vessel has been depressurised, e.g. after completion of the
expansion phase, and the pressure remains above 0 bar, the vessel is
pressurised by what is known as ram pressure. This might be due to
blockage at the muffler(s),
contamination of the dust sieves,
spent drying and purifying agent.
To prevent such malfunctions, regularly service the dryer as described
below.
The table provides an overview of the maintenance work to be carried out. The
individual tasks are described in the following pages.
Maintenance interval
12 months
24 months
48 months
see page
monthly
weekly
daily
Component Maintenance task to be carried
Complete dryer Carry out visual and function checks. ▲ 48
Vessel pressure gauge Check dam pressure. For a dam pressure

exceeding 0.3 bar:
– Check muffler. ▲ 48
– Check dust sieve.
– Check drying agent.
Upstream and Check differential pressure on the upstream
downstream filters and downstream filters. In the event of the
▲ 49
differential pressure exceeding 0.35 bar, renew
filter element.
Replace all filter elements after 1 year of

z 50
operation.
Upstream filter Check function of the condensate trap, clean if

▲ z 49
necessary.
Muffler Clean muffler, resp. renew filter element. z 50
Dew point sensor (with Must be calibrated.

optional dew point z 51
sensing-control
Purifying agent Renew. z 52
Check valves Renew. z 54
Solenoid valves Renew valve bodies. z 55
Renew pilot valves and solenoids. z 57
Dust sieves, drying agent Renew. z 58
Codes: ▲ Check. z Renew.
DACZ25-160_00_2003-09-12 47
Daily maintenance tasks
When carrying out any maintenance work, comply with the following safety
instructions:
Danger!
There is a very considerable risk of personal injury, when carrying out
work on the activated and pressurised dryer.
Before commencing any maintenance tasks always shut down the dryer as
described on page 43, Depressurising and shutting down the dryer!
Warning against electrical voltage!

Only qualified specialist personnel may carry out work on the electrical
system!
Daily maintenance tasks
Carry out visual and function check on the complete dryer

► Check dryer for external damage or unusual noise generation.
► Duly eliminate any defects found.
If message SEr. is displayed, a routine service must be completed:
► Contact the service department of the manufacturer.
Clean dryer
► Remove any loose dust by means of a dry cloth, and, if required, also by
means of a moist and well wrung cloth.
► Clean the surfaces with a moist well wrung cloth.
Check dam pressure

If, following depressurisation of a vessel, e.g. after the expansion phase, the
overpressure has not decreased to 0 bar, then there is a residual pressure,
designated as dam pressure, in the vessel.
► Check for dam pressure: if the dryer functions correctly, the respective
pressure gauge indicates 0 bar. Then there is no dam pressure.
If the dam pressure is greater than 0.3 bar:
► Depressurise the dryer and shut it down (see page 43).
Dam pressure can be caused by:
a blocked muffler,
a blocked dust sieve or
drying and purifying agent which is too old.
The respective necessary maintenance measures are described in the following
sections.
48 DACZ25-160_00_2003-09-12
Weekly maintenance tasks
Check differential pressure on the filters

► Check the differential pressure on the pressure gauge of the filter.
The differential pressure should be 0.35 bar max. If the differential pressure
exceeds 0.35 bar, we recommend that you replace the filter element (see
page 50). The filter elements must be replaced in any case every year.
Monthly maintenance tasks
Check the function of the condensate trap on the upstream filter

A level-controlled condensate trap is installed at the upstream filter. The
condensate trap drains the condensate automatically whenever a predefined fill
level is reached. This trap prevents that the humidity separated from the filter
ingresses into the dryer and has a detrimental effect on the drying agent.
Check the condensate trap as follows:
► If a permanent flow noise can be heard when
the discharge valve is closed, this indicates a
leakage. The condensate trap is poss.
contaminated or defective.
► Turn knurled screw (see fig., item 1) on the
housing bottom to the right. The condensate
trap opens.
If the condensate trap
operates correctly, some condensate or even
just compressed air will emerge.
is defective, an unusual amount of condensate
emerges, or neither condensate nor
compressed air emerge.
If no compressed air or an unusually large amount of condensate, or no water
condensate at all, emerge, you have to remove the condensate trap, clean and if
necessary, replace the same. To this end, proceed as follows:
► Unscrew the bottom section of the filter housing; remove the condensate
trap, clean or fit new condensate trap.
► Refit bottom section of the filter housing: first screw on very tightly then
unscrew by a quarter turn.
► Restart dryer (see page 44).
► Recheck function of the condensate trap.
DACZ25-160_00_2003-09-12 49
Maintenance work to be completed every 12 months
Renew filter elements on the filters

The filter elements must be replaced every 12 months.
► Depressurise dryer and take out of service (see page 43).
► Remove the bottom section of the
filter housing (see figure).
► Replace filter element.
► Refit bottom section of the filter
housing: first screw on very tightly,
and then unscrew by a quarter turn.
► Dispose of used filter element in
accordance with the applicable
regulations.
► Restart dryer (see page 44). Check
the all filters for leaks.
Open filter
Check mufflers
The dryer is either equipped with a standard muffler or a fine filter muffler. If the
respective muffler becomes blocked, a dam pressure is generated which in
extreme cases may cause the muffler to burst.
Hazard caused by blocked muffler!

Blocked mufflers can cause a dangerous overpressure to build up which
may cause the mufflers to burst. Flying fragments may cause personal
injury and damage to property.
Therefore, mufflers must be checked at least once a year and cleaned or
renewed if they are contaminated.

Particles carried in the air flow can injure your eyes or skin.
of the dryer!
The correct procedures for all muffler versions are described below.
Clean or renew standard mufflers

50 DACZ25-160_00_2003-09-12
► Unscrew muffler as shown in the

opposite figure.
► Check for contamination:
— Blow out with compressed air
for cleaning
— or renew muffler, if necessary.
► Screw on the muffler using a
wrench on the hexagon muffler
collar.
Undo muffler
Replace the element in the fine filter muffler

► Undo knurled screw on the lid cap
and remove cap.
► Unscrew old filter element. Arrows
on the element bottom mark the
direction of rotation.
► Insert new filter element and screw
on tightly. Renew muffler element
► Re-engage lid cap at the top section of the housing and fix in position by
means of the knurled screw.
Recalibration of dewpoint sensor (optional)

In order to ensure accurate dew-
point measuring, we recommend
recalibrating the dewpoint sensor
at least every 12 months. The
recalibration must be carried out
by the manufacturer. This period
depends however on the actual
application and might thus be
extended accordingly.
Dewpoint sensor (1)
Warning!
The dew point sensor is a sensitive measuring device. It can be damaged if
subjected to forceful vibrations or shocks. Therefore, please handle the
dew point sensor with great care at all times.
DACZ25-160_00_2003-09-12 51
For calibration, the pressure dewpoint sensor must be dismantled. In order to

limit the impact on the dryer operation to a minimum, we recommend that you
contact the manufacturer well in advance (for contact details, see page 8) and
order a new dewpoint sensor. Upon receipt of your old pressure dewpoint sensor,
we will issue a credit note.
After receipt of the new pressure dewpoint sensor, replace the sensor as follows:
► Hold the box of the dewpoint sensor ready.
► Release pressure from dryer and shut down the unit (see page 43).
Installing / dismantling pressure dewpoint sensor
► Loosen the screw at the adapter (1) and disconnect signal cable with the
adapter and seal.
► Remove dewpoint sensor from the sensor cell (3) by turning the nut (2).
► Take the new dewpoint sensor (2) from the box, remove the protective caps
(4, 5) and screw it into the sensor chamber (3).
► Place seal onto sealing face; connect adapter (1) and secure it by tightening
the screw.
► If no other maintenance work is to be carried out: Restart the dryer (see
page 44).
Note:
For posting, the dewpoint sensor must be equipped with protective
caps and placed in a solid box.
► Place the protective caps (4, 5) onto the old dewpoint sensor and pack it
properly in the box.
► Send the old dewpoint sensor to the manufacturer.
Replace purifying agent

The active surface of the purifying agent can be reduced by oil residue and other
contaminants. The purifying agent must therefore be replaced once every
12 months. When replacing the purifying agent, please observe the following
safety instructions:
52 DACZ25-160_00_2003-09-12
When emptying/filling purifying agent, increased dust generation might
occur.
In order to avoid eye irritations, wear protective goggles!
Remove used purifying agent

► Place suitable collection vessel underneath the drain point of the purifying
vessel.
► Use a suitable tool to unscrew the plug.
► Drain purifying agent into the collection
vessel.
► Use an industrial vacuum cleaner to hoover
up carefully the residues of the purifying
agent via the drain plug aperture. In this way,
you also clean the sieve bottom at the same
time from any possible contamination or
deposits.
► Apply a non-locking thread seal to the plug Unscrew plug

and screw in tightly. Check the thread seal
and renew if necessary.
Caution!
The spent purifying agent might be contaminated with hazardous substances.
Dispose of it in an environmentally safe manner, taking into account possible
contamination. The waste code number of the purifying agent can be obtained
from the manufacturer (see page 8).
► Dispose of the used purifying agent in accordance with all applicable

regulations.
Fill with new purifying agent
Risk of falls!
The dryer must not be misused as a climbing aid! The components have
not been designed for such loads and could fracture.
Only use approved climbing aids when filling the vessels.
DACZ25-160_00_2003-09-12 53
► Remove used purifying agent (see above section) and ensure that the
discharge point is closed.
► Disassemble check valve
block with mountings as well
as dust sieves as described
on page 58.
Disassemble upper pipe bridge
► Refill the vessel with new purifying agent. Use a funnel, if necessary. Ensure
that the agent is filled into the vessel with a high bulk density.
► Subsequently refit dust sieves and check valve block with mountings as
described on page 58.
► Restart dryer as described on page 44, After the purifying agent has been
replaced. Check that the connection is leak tight.
Replacing check valves

Check valves are wear parts and should be replaced every 12 months,
regardless of whether there is visible damage or not.
To replace the check valves, you must dismantle the check valve block. To do
this, proceed as follows:
► Loosen the nuts connecting the
upper pipe bridge to the vessels.
► Remove the upper pipe bridge.
Dismantling the upper pipe bridge
Replace the check valves (3) as shown in the diagram below:
54 DACZ25-160_00_2003-09-12
Check valve block
► Remove the screws (1) from the threaded blocks (2, 5).
► Push check valves (3) from the housing (4).
► Mount the new check valves (3). Please note:
The arrows (6) on the housing (4) and the check valves (3) must point
towards the compressed air outlet (as shown above).
► Close the housing (4) and tighten the screws at the threaded blocks (2, 5).
Remount the upper pipe bridge:
► Secure the elbow of the upper pipe bridge by tightening the nuts.
► If no other maintenance work is to be carried out: Restart dryer (see page
44). Check connection for tightness.
Replacing solenoid valve bodies

Solenoid valves are wear parts and should be replaced every 12 months,
regardless of whether there is visible damage or not.
To replace the valve bodies, you must first dismantle the lower pipe bridge. To do
this, proceed as follows:
► Pull the coupling plugs with seal (item 1 in diagram below) from the
solenoids.
► Loosen the nuts connecting the lower pipe bridge to the vessels.
► Loosen the nuts between the upstream filter and the compressed air system.
DACZ25-160_00_2003-09-12 55
► Remove the lower pipe bridge.

Replace the solenoid valve bodies as shown in the diagram below:
Rear view of solenoid valve block

Foreground: main valves V1-V2; background: expansion valves V3-V4
► Remove the screws (2) from the threaded blocks (3, 4).
► Push the valve bodies (5) from the housing (6).
► If necessary, clean the inside of housing (6) with a liquid metal detergent.
► Lubricate the sleeves of the new valve bodies (5) slightly (e.g. with Vaseline)
to ensure that they can be easily pushed into the housing.
► Insert the new valve bodies (5) into the housing (6). Please note:
— The arrows (7) on the housing (6) and the valve bodies (5) must point in
the direction as shown in the above diagram.
— The cross ribs (7) on the valve body sleeves must face upwards in order
to cater for the connection to the control air.
► Close the housing (6) and tighten the screws at the threaded blocks (3, 4).
Remount the lower pipe bridge:
► Secure the elbow of the lower pipe bridge by tightening the nuts.
► Tighten the nut between the upstream filter and the compressed air inlet
pipe.
► Place the coupling plugs with seals (1) onto the solenoids.
► If no other maintenance work is to be carried out: Restart dryer (see page
44). Check connection for tightness.
56 DACZ25-160_00_2003-09-12
Replacing pilot valves and solenoids in solenoid valves

Pilot valves and solenoids are wear parts and should be replaced every
24 months, regardless of whether there is visible damage or not.
Rear view of solenoid valve block:

replacing pilot valves and solenoids
To replace the pilot valves and solenoids, proceed as follows:

► Pull the coupling plugs with seals (1) from the solenoids.
► Loosen the nuts (2) at the solenoids (3) and remove the solenoids.
► Loosen the screws (4) at the pilot valves.
► Remove pilot valves, insert new pilot valves and secure them with the
screws (4) to the housing.
► Insert new solenoids (3) and secure them with the nuts (2).
► Place coupling plugs with seals (1) onto the solenoids.
► If no other maintenance work is to be carried out: Restart dryer (see
page 44). Check solenoid valves for proper functioning.
DACZ25-160_00_2003-09-12 57

To complete the following maintenance tasks, you must dismantle the pipe
bridges and the vessels. We therefore recommend that you carry out these tasks
together.
Note:
In accordance with national regulations, a pressure vessel inspection
may be prescribed to be carried out at regular intervals by an
independent supervisory office.
For an inspection of the pressure vessels, the drying agent must be
removed as described as follows.
When inspecting the pressure vessels, it is recommended to check the
condition of all fittings such as e.g. sieve bottoms and dust sieves,
including gaskets. If necessary, these fittings must be cleaned or
renewed.
In the event of comprehensive maintenance or repair tasks, contact
the manufacturer (see page 8).
Replace dust sieve

Between vessels and upper pipe bridge, dust sieves are fitted which retain the
drying and purifying agent dust. If these dust sieves become blocked, a dam
pressure is generated which can cause compressed air fluctuations in the
compressed air system.
For disassembling the dust sieves, the entire check valve block complete with all
mounted elbow pipes must be removed first.
Risk of falls!
Only use approved climbing aids when disassembling the check valve
block.
58 DACZ25-160_00_2003-09-12
► Unscrew the union nuts from the

elbow pipes.
► Withdraw check valve block
complete with all mountings.
► Remove teflon tape and use a
groove wrench (or alternatively a
500 g/750 g hammer head) to
unscrew the dust sieves.
► Use compressed air or wire brush
to clean dust sieves or renew if nec.
► Screw in dust sieves and re-seal
with new teflon tape.
Removal of dust sieve
► Refit complete check valve block, tighten union nuts.

► Restart dryer (see page 44). Check that the connection is leak tight.
Renew drying agent

The service life of the drying agent is usually approx. 3 to 5 years. However, in
favourable installation conditions, the change of drying agent may be carried out
at a substantially later date (for notes on the installation site, see also page 24).
The change interval depends very significantly from the degree of contamination
in the compressed air (or the quality of the compressed air upstream filters). Oil,
dust, and dirt particles cover the drying agent surface and reduce its effective
surface, in part quite irreversibly.
If in doubt, have a sample of your drying agent assessed by specialists. Send a
sample of approx. 200 g to the manufacturer (for address, see page 8).
Comply with the following safety notes when changing the drying agent:
When emptying the drying agent, increased dust generation may occur.
In order to avoid any eye irritations, wear protective goggles!
Risk of skidding!
If drying agent has been spilt on the floor, there is a risk of skidding
caused by the drying agent beads. Therefore, spilt drying agent must
always be taken up immediately.
DACZ25-160_00_2003-09-12 59
Remove used drying agent

► Place suitable collection vessel underneath the drain point.
► Use a suitable tool to unscrew the plug.
► Drain drying agent into the collection vessel.
► Use an industrial vacuum cleaner to hoover
up carefully the residues of the drying agent
via the drain plug aperture. In this way, you
also clean the sieve bottom at the same time
from any possible contamination or deposits.
► Apply a non-locking thread seal to the plug
and screw in tightly. Check the thread seal
and renew if necessary.
Unscrew plug
► Repeat the process on the second vessel.
Warning!
If the dryer is not used within specifications, the drying agent can be contami-
nated with pollutants. Always take this into account for the environmentally
safe disposal of the drying agent. The waste code numbers of the drying agent
can be obtained from the manufacturer (see page 8).
► Dispose of the used drying agent in accordance with all applicable

regulations.
Fill with new drying agent
Risk of falls!
Only use approved climbing aids when filling the vessels.
► Remove used drying agent (see

above section) and ensure that the
discharge point is closed.
► Disassemble check valve block with
mountings as well as dust sieves as
► Fill the several drying agents in as
separate layers (according to the
technical data in the appendix).
If necessary, use a funnel. Take
special note of the next step:
► Provide for a high bulk density in Remove check valve block

the vessel.
60 DACZ25-160_00_2003-09-12
Note:
To achieve an optimum bulk density, we recommend using a
"snowstorm" filling pipe available from the manufacturer.
► Otherwise use a rubber hammer to tap regularly against the vessel wall
during filling or use a rod to distribute and compact the drying agent through
the vessel opening.
► Repeat the process on the second vessel.
► Subsequently refit dust sieves and check valve block with mountings as
► Restart dryer (see page 44). Check that the connection is leak tight.
DACZ25-160_00_2003-09-12 61
Summary of faults
Identify and eliminate faults

The following table provides information on what designatory abbreviations are to
be used for the various components. These designations are also found in the
technical documentation.
Abbreviation Component
PI Pressure gauge
PDI Differential pressure gauge
V1–V2 (Y1–Y2) Main valves (solenoid valves)
V3–V4 (Y3–Y4) Expansion valves (solenoid valves)
V5–V6 Check valves
Summary of faults
There are different fault types. In the case of most electrical faults (e. g. short
circuit, defective fuse etc.) the main valves close. In the case of some process
faults, the dryer will continue to operate for some time. Faults on the dryer
become noticeable e.g. due to unusual noises and dam pressures.
The following table shows who is allowed to remedy a fault: the owner's specialist
personnel or the manufacturer's service engineer.
62 DACZ25-160_00_2003-09-12
Identify and eliminate faults
Table of possible faults
Service engineer
Spec. personnel
Fault Possible cause Remedy
Excessive dam pressure Muffler or filter element of the muffler
Check mufflers or filter elements for
during regeneration is contaminated. contamination, clean if nec., and poss. z z
renew.
Expansion valve V3/V4 does not open Check expansion valve for
z z
correctly. contamination, if nec. clean/renew.
Dust sieves are contaminated. Clean or renew dust sieves. z z
Vessel pressure is too Excessive differential pressure on the Check differential pressure on the
low upstream filter. upstream filter, if. nec. renew filter z
element.
No pressure build up The compressed air system upstream Check whether the compressed air
of the dryer is not pressurised. system upstream of the dryer is z
pressurised. Remove any faults.
Solenoid valve Y1/Y2 does not open Check supply voltage, cable, contacts
z z
correctly. and solenoid; replace, if necessary.
Excessive compressed Leakage. Check condensate trap at the upstream
z z
air consumption filter; clean, if necessary.
Dryer does not switch Solenoid valve Y1/Y2 does not open Check supply voltage, cable, contacts
z z
over correctly. and solenoid; replace, if necessary.
Solenoid valve Y1/Y2 cannot be Check supply voltage.
opened properly Check pilot valves; replace, if
z z
(audible humming sound or valve necessary.
flapping).
Control board defective. Check fuse in supply line and in the
z z
switchbox; replace, if necessary.
Power supply interrupted, cable Reconnect the unit to the power supply.
broken.
z
Compressor might be off. Check compressor synchronisation
circuit.
Error in control programme. Restart programme. z
No expansion Solenoid valve Y3/Y4 cannot be Check supply voltage, cable, contacts
z z
opened. and solenoid; replace, if necessary.
Solenoid valve Y3/Y4 cannot be Check supply voltage.
opened properly Check pilot valves; replace, if
(audible humming sound or valve necessary. Check valve bodies for z z
flapping). contamination; clean or replace, if
necessary.
Dryer is continuously Solenoid valve Y3/Y4 cannot be Check supply voltage.
bled closed properly (audible humming Check solenoid and diaphragm; z z
sound or valve flapping). replace, if necessary.
Main valve V1/V2 does not open. Check main valve, replace if nec. z z
Dryer is excessively bled Solenoid valve Y1/Y2 cannot be Check solenoid and diaphragm;
z z
closed. replace, if necessary.
DACZ25-160_00_2003-09-12 63
Summary of faults
Service engineer
Spec. personnel
Fault Possible cause Remedy
Pressure dew point is not Operating pressure is too low. Increase operating pressure. z
reached
Compressed air volume flow is too Reduce compressed air volume flow z
high.
Compressed air inlet temperature is Reduce compressed air inlet
too high. temperature or pre-connect a z z
compressed air cooler.
Control board is defective. Check control board, if nec. renew. z
Differential pressure on the upstream Check differential pressure on the

filter is too high. upstream filter, if nec. renew filter z
element.
Condensate trap on the upstream Check function of the condensate trap, z z
filter does not work. if nec. clean or renew.
Drying agent is contaminated or too Check upstream filter for contamination, z
old. if nec. renew element.
Check drying agent for contamination, if
z z
nec. renew drying agent.
Regeneration gas too low. Check function of expansion valve
V3/V4 and muffler, if nec. renew muffler
z z
or filter element.
Service technician
Specialised
personnel
Fault code Description of fault Possible cause Remedy

+20 Upper measuring range Drying capacity See instructions for commissioning.
z
limit exceeded exceeded. If the drying agent is wet, replace it.
Error in programme. Restart programme. z
999 Dewpoint sensor Sensor defective or Replace sensor.
defective irreversibly z
contaminated.
sens Sensor not powered, or Sensor, sensor cable Visual inspection; check power
or cable or sensor defective or sensor adapter supply (24 V to terminals 4 and 6). z
–999 defective. Replace defective component(s).
64 DACZ25-160_00_2003-09-12
Index
Index
Date of manufacture ................................................... 4
Dehumidification
A
explanation ........................................................... 19
Abbreviation Design
Components ......................................................... 62 paint compatible ................................................... 22
Address, manufacturer ............................................... 8 Detour line ........................................... see bypass line
Adsorption, explanation............................................ 18 Dew point sensor
air ejection maintenance interval ............................................ 47
hazard .................................................................. 12 Dewpoint-sensing control ......................................... 21
Auxiliary heater......................................................... 21 Differential pressure gauge ...................................... 36
Digital display
B explanation ........................................................... 35
Documentation, technical ......................................... 68
Bolt connections....................................................... 28
Dryer
Build no. ................................................................... 46
maintenance interval ............................................ 47
Bypass line......................................................... 21, 29
drying agent
handling................................................................ 13
C service life ............................................................ 59
Changing cycle mode Drying agent
explanation ........................................................... 39 charging................................................................ 21
Check valves maintenance interval ............................................ 47
maintenance interval ............................................ 47 Drying agents
Components ............................................................. 62 storage ................................................................. 27
Compressed air .................................................. 13, 18 dust generation......................................................... 59
Compressor synchronisation.................................... 21 Dust generation ............................................ 13, 45, 53
option ................................................................... 21 Dust mask................................................................. 13
Compressor synchronisation line Dust sieves
installation ............................................................ 30 maintenance interval ............................................ 47
Condensate trap
E
Connection lines....................................................... 29
Ear protection ..................................................... 15, 37
Connector
electrical voltage, hazard.......................................... 12
electrical ............................................................... 30
Enquiries, telephone number...................................... 8
consumables .............................................................. 8
Example for installation ............................................ 29
Control
Expansion, explanation ............................................ 19
dewpoint-sensing ................................................. 21
Eye protection .......................................................... 13
Control cabinet ......................................................... 17
Control system
pneumatic............................................................. 21 F
signalling contacts................................................ 21 Fabrication no............................................................. 4
Conversions ............................................................. 13 Factory settings ........................................................ 15
Cycle Filter elements
fixed...................................................................... 21 maintenance interval ............................................ 47
variable................................................................. 21 Fixed cycle................................................................ 21
Cycle mode change Flow diagram............................................................ 77
explanation ........................................................... 39 Fluid group ............................................................... 69
D H
Danger notes hazard areas............................................................. 12
Danger! ................................................................ 10 Humidity.................................................................... 69
Danger warning, maintenance ................................. 48
DACZ25-160_00_2003-09-12 65
Operating pressure .................................................. 38
I permissible ............................................................. 4
Installation area........................................................ 24 safety device ........................................................ 28
Installation example ................................................. 29 Operating signalling contact
Installation site, requirements .................................. 24 installation ............................................................ 31
Operation signalling
contact.................................................................. 21
L
Orders, telephone number ......................................... 8
LEDs
Original replacement parts ................................. 16, 46
explanation........................................................... 34
Outside installation................................................... 20
Liability ....................................................................... 9
overpressure, hazard ............................................... 12
lifting gear .......................................................... 14, 23
Limits, permissible.............................................. 15, 37
P
Packaging ................................................................ 23
M
Parameters
Machine damage, prevention................................... 11
preset ..................................................................... 9
Machine passport....................................................... 4
Personnel qualification ............................. 9, 11, 13, 48
Mains voltage........................................................... 69
Power supply
Maintenance
interrupted ............................................................ 42
dam pressure ....................................................... 48
Pressure build-up
differential pressure ............................................. 49
explanation ........................................................... 19
drying agent ......................................................... 59
sudden ................................................................. 37
dust sieve............................................................. 58
pressure vessel .................................................. 15, 46
Muffler .................................................................. 50
Programme
replacement of filter element................................ 50
sequence, steps ................................................... 75
sensor .................................................................. 51
Protection class........................................................ 69
Maintenance contract............................................... 46
purifying agent
Maintenance interval
handling................................................................ 13
condensate trap ................................................... 49
Purifying agent
Maintenance, danger warnings................................ 48
Media
Purifying agents
aggressive.............................................................. 9
storage ................................................................. 27
Misuse...................................................................... 13
Misuse, suspected ................................................... 13
Modifications on the dryer........................................ 13 R
Muffler Regeneration, explanation ....................................... 18
maintenance interval ............................................ 47 Regulations for accident prevention......................... 23
Repairs, telephone number ........................................ 8
Replacement parts ............................................. 16, 46
N
Restart
Noise level ............................................................... 69
pressure conditions .............................................. 44
Notes
safe, efficient handling ......................................... 10
S
Safety notes ............................................................. 11
O
general ................................................................. 13
On/Off switch
operating phases.................................................. 14
explanation........................................................... 33
Warning!............................................................... 10
On/Off-Switch........................................................... 17
Safety valves...................................................... 28, 32
Operating instructions ................................................ 9
Service, telephone number ........................................ 8
safe place............................................................. 10
Shutdown valves ...................................................... 29
safety notes.......................................................... 11
Shutting down .......................................................... 43
target group.......................................................... 10
emergency............................................................ 43
Operating overpressure
Signalling lines
minimum, maximum............................................. 69
external................................................................. 30
66 DACZ25-160_00_2003-09-12
Index
skid risk .................................................................... 12 minimum, maximum ............................................. 69

Skidding risk Transport damage .................................................... 23
charging drying agent........................................... 59 transport lugs............................................................ 25
Snowstorm filling pipe Type plate ................................................................ 11
charging drying agent........................................... 61
Solenoid valves
U
Specialist personnel ........................................... 10, 28 Use, intended ........................................................... 13
Standard equipment ................................................... 9 Use, safe .................................................................. 10
Standby phase
with dew point-sensing control ............................. 20 V
Start-up device ......................................................... 20
Variable cycle ........................................................... 21
Start-up, requirements.............................................. 32
Storage room
requirements ........................................................ 26
vibration dampers ..................................................... 26
Supply cable, electrical ............................................ 30
Visual inspection....................................................... 48
Supply lines.............................................................. 28
Voltage
Switching off............................................................. 42
electrical ............................................................... 29
Switchover
explanation ........................................................... 20
symbols, explanation................................................ 12 W
Warranty..................................................................... 9
T Waste code numbers................................................ 16
Target group ............................................................ 10

Temperature, ambient
DACZ25-160_00_2003-09-12 67
Annex with technical documentation
This annex comprises the following information and technical documentation:
Technical data
Replacement and wear parts list
Logic control diagram
Flow diagram
Dimensional drawing
68 DACZ25-160_00_2003-09-12
Technical data
Capacity* Length Height Width Weight

3
Type m /h mm mm mm kg
DACZ 25 145 770 1650 490 155

DACZ 35 200 820 1665 490 186
DACZ 45 255 885 1730 490 262
DACZ 60 360 935 1765 490 324
DACZ 70 400 1140 1815 585 369
DACZ 100 620 1245 1815 585 485
DACZ 125 750 1305 1935 585 629
DACZ 160 950 1465 1950 620 720
* relative to 1 bar (abs.) and 20 °C at 7 bar operating pressure and a feed temperature of 35 °C.
Type DACZ 25–160

Fluid group (acc. to 97/23/EC) 2
max. operating overpressure 16 bar
min. operating overpressure 4 bar
min. ambient temperature ≥ +1 °C
max. ambient temperature ≤ +50 °C
Rel. humidity ≤ 60 %
Noise level : +3 dB (A) relative to free field measurement, 1 m surr. 65 – 95 dB(A)
field
Mains voltage (see type plate)
Protection class IP 54
DACZ25-160_00_2003-09-12 69
Technical data
Filling Drying agent Purifying agent

quantity
B1 B2 B3
Top 87.5 % MS512 87.5 % Activated
100 %
Bottom 12.5 % Ecosorb 12.5 % carbon
appr. in [kg] per vessel
DACZ 25
Top 17.0 17.0
Bottom 2.5 2.5 9.1
DACZ 35
Top 20.0 20.0
Bottom 3.5 3.5 12.0
DACZ 45
Top 28.0 28.0
Bottom 4.0 4.0 15.0
DACZ 60
Top 37.5 37.5
Bottom 5.5 5.5 20.0
DACZ 70
Top 45.5 45.5
Bottom 6.5 6.5 25.0
DACZ 100
Top 64.0 64.0
Bottom 9.0 9.0 35.0
DACZ 125
Top 76.0 76.0
Bottom 10.5 10.5 47.0
DACZ 160
Top 111.0 111.0
Bottom 16.0 16.0 60.0
70 DACZ25-160_00_2003-09-12
Type DACZ
Item Designation 25 35 45 60
1 Vessel
2 Dust sieve 738040008001
3 Drying agent (complete) 938110000207 938110000307 938110000407 938110000507
4 Purifying agent Activated Carbon 675070000001
5 Pressure gauge PI 650200031821
6 Discharge closure 620160003106 620160003108
50 Pipe bridge, top

50 Check valve block V5-V6 633310025300
Check valves (set) 933310025300
52 Closure plug G1/8 616000000601
53.4 Seal G1/8 671200006001
56.1 Closure plug G1/2 615900001001
(for regeneration gas orifice plate)
70 Upstream filter 30 FP 50 FP
70.3 Filter element 30 FP 575078855 —
70.3 Filter element 50 FP — 575078856
70.3.25 O ring 50x3 671000005030
70.4 Threaded rod 701030004001 701030005001
70.5 O ring 104x4 671000010440
70.7 Condensate trap 104100000004
70.9 Differential pressure gauge 104000009001
80 Downstream filter 30 V 50 V
80.3 Filter element 30 V 575051055 —
80.3 Filter element 50 V — 575051056
80.3.25 O ring 50x3 671000005030
80.4 Threaded rod 701030004001 701030005001
80.5 O ring 104x4 671000010440
80.6 O ring 50x3 671000005030 —
80.8 Manual drain 632100000001
100 Pipe bridge, bottom

100 Solenoid valve block V1-V4 633300025300
Valve body set V1-V2 933300025300
Pilot valve set 933300015003
Solenoids (set 230 V) 933300010003
Solenoids (set 115 V) 933300010004
Solenoids (set 24 V DC) 933300010005
Solenoids (set 24 V AC) 933300010006
DACZ25-160_00_2003-09-12 71
Type DACZ
200 Muffler
200 Muffler, complete 799030002501
Fine filter muffler (option) 102910105001
350 Control system

380 Dew point sensor (option) 655000010001
400 Start-up device (Option)

400 Pressure holding device 651800025001
500 Regeneration gas return (Option)

503 Check valve 632500001501
72 DACZ25-160_00_2003-09-12
Type DACZ
1 Vessel
2 Dust sieve 738040014001 738040015001
3 Drying agent (complete) 938110000607 938110000807 938110001157 938110001407
4 Purifying agent Activated Carbon 675070000001
5 Pressure gauge PI 650200031821
6 Discharge closure 620160003109
50 Pipe bridge, top

50 Check valve block V5-V6 633310040300 633310050300
Check valve set 933310040300
52 Closure plug G1/8 616000000601
53.4 Seal G1/8 671200006001
56.1 Closure plug G1/2 615900001501
(for regeneration gas orifice plate)
70 Upstream filter 80 FP 120 FP 160 FP

70.3 Filter element 80 FP 575078857 — —
70.3 Filter element 120 FP — 575078858 —
70.3 Filter element 160 FP — — 575078859
70.3.25 O ring 50x3/76x3 671000005030 671000007630
70.4 Threaded rod 701030006001 701030007001 701030008001
70.5 O ring 104x4/122x5 671000010440 671000012250
70.7 Condensate trap 104100000004 104100000013
80 Downstream filter 80 V 120 V 160 V

80.3 Filter element 80 V 575051057 — —
80.3 Filter element 120 V — 575051058 —
80.3 Filter element 160 V — — 575051059
80.3.25 O ring 50x3/76x3 671000005030 671000007630
80.4 Threaded rod 701030006001 701030007001 701030008001
80.5 O ring 104x4/122x5 671000010440 671000012250
80.8 Manual drain 632100000001 630300001501
100 Pipe bridge, bottom

100 Solenoid valve block V1-V4 633300040300 633300050300
Pilot valve set 933300015003
Solenoids (set 230 V) 933300010003
Solenoids (set 115 V) 933300010004
Solenoids (set 24 V DC) 933300010005
Solenoids (set 24 V AC) 933300010006
DACZ25-160_00_2003-09-12 73
Type DACZ
200 Muffler
200 Muffler, complete 799030004001 799030005001
Fine filter muffler (option) 102910105001
350 Control system

380 Dew point sensor (option) 655000010001
400 Start-up device (Option)

400 Pressure holding device 651800025001
500 Regeneration gas return (Option)

503 Check valve 632500001501
74 DACZ25-160_00_2003-09-12
Adsorption in B1 and regeneration in B2
DACZ25-160_00_2003-09-12 75
Regeneration in B1 and adsorption in B2
76 DACZ25-160_00_2003-09-12
Flow diagram
Pos. Designation Pos. Designation

2 Dust sieve 200 Muffler
50 Check valve block V5–V6 350 Control system
56 Regeneration gas orifice plate
70 Upstream filter * Optional devices:
80 Downstream filter 380 Dewpoint-sensing unit
100 Solenoid valve block V1–V4 400 Start-up device
500 Regeneration gas return line
DACZ25-160_00_2003-09-12 77
Dimensional drawing
Dimensional drawing
78 DACZ25-160_00_2003-09-12
Type DACZ
Dimensions 25 35 45 60 70 100 125 160

A 770 820 885 935 1140 1245 1305 1465
B 1650 1665 1730 1765 1815 1815 1935 1950
C 490 490 490 490 585 585 585 620
H1 890 890 890 890 1000 1000 1000 1000
H2 450 490 525 565 690 770 815 920
L1 705 755 805 855 1060 1165 1225 1385
L2 350 350 350 350 450 450 450 450
L3 400 400 400 400 500 500 500 500
Connection
Input 1“ 1“ 1“ 1“ 1 1/2 “ 1 1/2 “ 1 1/2 “ 2“
Output 1“ 1“ 1“ 1“ 1 1/2 “ 1 1/2 “ 1 1/2 “ 2“
DACZ25-160_00_2003-09-12 79

DACZ 25-160: Operating Instructions Adsorption Dryer

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DACZ 25-160: Operating Instructions Adsorption Dryer

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Operating Instructions

assembly type: assembly acc. to Art. 3 No. 2.2,

The assembly consists of pressure appliances according to the classification list

The following standards / technical specifications were used:

It is the responsibility of the owner,

For your own safety ............................................................................................. 11

Technical product description ........................................................................... 17

Transportation, installation and storage........................................................... 23

Monitoring dryer operation................................................................................. 41

Shutdown and restart dryer ................................................................................ 42

Maintenance and repair of the dryer ..................................................................46

Identify and eliminate faults ................................................................................62

Annex with technical documentation.................................................................68

Name and address

Details on the dryer

About these operating instructions

Characters and symbols used

Target group of these operating instructions

Operating instructions: handling

For your own safety

Signs, instruction plates and danger zones at the dryer

Signs and instructions

Type plate of the Type plate of the

Type plate of the dryer

Hazard areas on the dryer

Hazard caused by electrical voltage

Hazard caused by overpressure

Hazard caused by sudden air ejection during

Warning against hazardous electrical voltage

Warning against overpressure

Intended use of the dryer

General safety notes

Conversions and modifications

Handling of drying and purifying agents

Safety notes on specific operating phases

Transportation and siting

Warning against sudden air ejection!

Hazard due to a sudden release of pressure!

 Carry out all prescribed tests and checks.

Warning against sudden air ejection!

Loud noise generation!

Maintenance of the dryer and fault removal

Disassembly and disposal

Hazard due to a sudden release of pressure!

Technical product description

Vessel pressure gauge

Power supply connector

Compressed air inlet

Compressed air outlet

Solenoid valve block (V1-V4)

Adsorption in the left drying agent vessel.

Regeneration (running in parallel to the adsorption)

With the dewpoint-sensing control option, the regeneration phase is followed by a

Pressure build-up phase

Pressure build-up in the right drying agent vessel

Standby phase (only with the dewpoint-sensing control option)

Signalling contacts of the control system

Regeneration gas return for compressor synchronisation

Paint compatible design

Carry out all prescribed tests and checks.

Carry out all prescribed tests and checks.