CD Desiccant Dryers for High Quality Air Applications

1.

Quality Air Seminar 2002
CD DESICCANT DRYERS
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
For High Quality Air Applications

2. Range & Sizes

Quality Air Seminar 2002
Range & Sizes
Chapter
A Broad & Deep Range From 2-280 l/s
Range & Sizes
• Smallest - CD 2 = 2 l/s or 4.24 cfm
Working principles
• Largest - CD 280 = 280 l/s or 593 cfm
Build-up & Function
• Units available with different PDP’s, options and control systems
Improvements
• All variants available in both 11 bar (159 psi) and 16 bar (232 psi) versions
Service
• All variants available 50/60 Hz and 230/110V
Trouble shooting
• Various pressure approvals available - CE, ASME, DIR, SQL, UDT
Pages
Complete CD Dryer Range
Oil Free Compressor Range
FAD for standard ZT1 units at 8.6 bar (at 50 Hz)
CD 2-60
ZT
CD 65-280
ZT22
ZT30
ZT37
Variable speed
CompressorsZT37
2-90
kW (2.7-125 HP)
- VSD
2
44 65
l/s
254
280

3. Desiccant Technology

Quality Air Seminar 2002
CD7-60 Working principal
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Working
CD7-65 Working
CD65-280 Working
ICD65-280 Working
The CD Desiccant type air dryers utilize
chemicals beads, called desiccant, to adsorb water
vapour from compressed air. The desiccant
provides an average -40°C pressure dew point
performance.
The CD dryers are configured with two pressure
vessels, filled with desiccant, switching valves to
direct the compressed air flow and controls for
proper switching of the dryer vessels. The
desiccant material is a solid adsorbent which
removes water vapour by physical forces which
attract water vapour to the surface of the material.
Solid adsorbent materials are highly porous on a
microscopic scale which provides a large surface
area for adsorption. Adsorption is an exothermic
process and as the drying takes place heat is
released and is stored in the desiccant bed and
later used in the regeneration process.

4. Desiccant Adsorption Principle

Quality Air Seminar 2002
CD7-60 Working principal
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Working
CD7-65 Working
CD65-280 Working
ICD65-280 Working
The basic operation of a the CD dryer consists
of one drying cycle and one regeneration
cycle, which is continuously repeated.
For example, a 4 minute cycle consists of a 2
minute drying cycle and a 2 minute
regeneration cycle. During the drying cycle,
compressed air, at full pressure, flows through
one desiccant vessel. As the air flows through
the desiccant bed, microscopic pores on the
surface of the desiccant beads "strips" the
water vapor and lubricant molecules from the
air, thereby reducing the relative humidity of
the air. The relative humidity of the dried air is
equivalent to a pressure dew point of -40°C or
lower.

5. The Adsorption Process

Quality Air Seminar 2002
CD7-60 Build up & Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
Purge nozzle

6. The Adsorption Process

Quality Air Seminar 2002
CD65-280 Working
principal
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Working
CD7-65 Working
CD65-280 Working
ICD65-280 Working
CD65-280CDAnimation.exe

7. The Purge Process

Quality Air Seminar 2002
CD65-280 Working
principal
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Working
CD7-65 Working
CD65-280 Working
ICD65-280 Working
CD65-280ICDAnimation.exe

8. The Purge Process

Quality Air Seminar 2002
CD65-280 Build up & Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up

9. CD7-60 Working principal

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
Range & Sizes
Dew
Transmitter
Working principles
Build-up & Function
Improvements
Nozzle
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
Non Return
valve

10. CD7-60 Working principal

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Cleaning of sensor only with Aceton
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up

11. CD7-60 Build up & Function

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
Range & Sizes
Working principles
Program/Function
Description
Main screen
Shows in short the operation status of the dryer.
It is the gateway to all functions.
Build-up & Function
Improvements
Service
Trouble shooting
Status data
Pages
CD7-65 Build up
CD65-280 Build up
Measured data
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
Counters
Protections : Shutdow / Warings / Start Failure
Service
Expansion Mod
Calling up:
actually measured data
status of some inputs
Calling up the:
running hours
regulator (module) hours

12. CD65-280 Working principal

Quality Air Seminar 2002
CD65-280 Build up & Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
Vessel “A” under pressure
Vessel “B” regenerating
Warning : sensor error

13. CD65-280 Working principal

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
Range & Sizes
Warnings
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
Dewpoint Failure
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
No dewpoint

14. CD65-280 Build up & Function

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
Service

15. CD65-280 Build up & Function

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up

16. CD65-280 Build up & Function

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up

17. CD65-280 Build up & Function

Quality Air Seminar 2002
CD65-280 Build up & Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up

18. CD65-280 Build up & Function

Quality Air Seminar 2002
CD65-280 Build up & Function
Chapter
Range & Sizes
Working principles
Build-up & Function
Symptom
The PDP temperature is too high
Improvements
Possible cause
Corrective action
The dryer has not had the time to
regenerate completely.
Close the valve installed between the dryer
and the application (if permitted) and have
the desiccant regenerated.
The drain is not working correctly
Service
The air flow through the dryer is too
high.
Check for correct application.
The outlet pressure is too low.
Check whether the compressor provides
enough air for the application.
The inlet temperature is too high.
Check the compressor after cooler.
Check the silencer and its fixation to
the unit.
Replace the silencer if necessary or
correct its fixation.
Too much purge air escapes.
Check the condition of the solenoid valve
and replace it if necessary. Also check the
pneumatic valves and the 3 -way valve.
Trouble shooting
Pages
CD7-65 Build up
CD65-280 Build up
Dryer produce a lot of noise
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
Insufficient air leaves the dryer
Check the drain valve of the filter.

19. CD65-280 Build up & Function

Quality Air Seminar 2002
CD65-280 Build up
& Function
Chapter
What Happens In Hot Ambients
Range & Sizes
Decrease Inlet Pressure (but nothing else)
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
The capacity of
a dryer is based
on the actual
flow at inlet,
not FAD.
Therefore the
lower the inlet
pressure the
less FAD can be
processed
The purge nozzle
allows a fixed actual
flow, regardless of
pressure. This means
that as pressure
decreases the amount
of purge available,
once expanded to
atmospheric
pressure, is less.
CD7-65 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
CD65-280 Build up
What Does This Mean…...
If the FAD inlet flow is not decreased, the actual volume of air going through the
dryer will increase. Therefore the speed of the air through the dryer also
increases above the nominal speed which damages the desiccant. As there is
more actual air flow through the dryer, the desiccant bed becomes “extra” wet.
A lower pressure are dryer inlet also reduces the amount of purge air available,
with the result that not even a normally wet bed can be regenerated. An extra
wet bed will cause the dew point to crash even quicker. The dryer must be derated to account for this reduction in purge air.

20. CD65-280 Build up & Function

Quality Air Seminar 2002
CD7-60 Improvements
Chapter
Range & Sizes
Working principles
Build-up & Function
O-ring rolled in piston inlet-outlet valve
Starting from serial number AIQ 556 570
And 1x AIQ 510 874
Improvements
Service
Trouble shooting
New : Nickel plated
Pages
Old : Steel
Material of nipples change into Brass nickel plated
Between Solenoid valve and inlet base
CD7-17 :0603 5105 03 replaced by 0603 4100 17
CD24-60: 0603 4104 03 replaced by 9740 2021 44

21. CD65-280 Build up & Function

Quality Air Seminar 2002
CD7-60 Service tools
Chapter
Range & Sizes
CD24-60 for plug 1617 6181 00 (old) and 1617 6225 00 (new)
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-60
CD-60
CD7-60
CD65-280
CD7-17 for plug 1617 6180 00

22. CD65-280 Build up & Function

Quality Air Seminar 2002
CD7-60 Service tools
Chapter
Range & Sizes
Valve seat CD7-60
To protected valve seat tool
2903 0014 01 is for CD7-17
2903 0043 00 is for CD7-17
2903 0014 02 is for CD24-60
2903 0044 00 is for CD24-60
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-60
CD-60
CD7-60
CD65-280

23. CD65-280 Build up & Function

Quality Air Seminar 2002
CD7-60 Service Kits
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
CD7-60 Tools
CD-60 Tools
CD7-60 Kits
CD65-280 Kits
Service kits

24. CD65-280 Build up & Function

CD65-280 ServiceQuality
Kits Air Seminar 2002
Service kits
Chapter
Range & Sizes
CD65-80-100
4000Hrs
2901 1000 00
CD65-80-100
40000Hrs
2901 1001 00
Build-up & Function
CD140
4000Hrs
2901 1002 00
Improvements
CD140
40000Hrs
2901 1003 00
Service
CD170
4000Hrs
2901 1004 00
Trouble shooting
CD170
40000Hrs
2901 1005 00
CD230-280
4000Hrs
2901 0995 00
CD7-60
CD230-280
40000Hrs
2901 0996 00
CD-60
Kit 4000Hrs consist of Silencer 1617 6164 03 2x + Filter elements
DD/PD.
Working principles
Pages
CD7-60
CD65-280
Kit8000Hrs consist of kit 4000Hrs + Recalibration dew point sensor ECB
AII0120
Kit 40000Hrs consist of 4000Hrs kit + Dessicant
CD2 till 6 there are no kits available
Download of software can be found were you find the MKIV software

25. CD65-280 Build up & Function

Trouble shooting Quality Air Seminar 2002
Chapter
1/ Dew point too high : Electrical Problem
Range & Sizes
1.1 Connected Electrical ?
Working principles
1.2 Check working of the solenoid
Build-up & Function
Improvements
1.3 Mitchell sensor (if available)
1.4 Check Timer card (if available)
Service
Trouble shooting
Pages
Electrical Conn
Solenoid
Mitchell Sensor
Timer Card
Connections Airinlet
2/ Dew point too high : Mechanical Problem
2.1 Check the diameter of the air inlet
2.2 Check air flow over the Mirchell sensor (if available)
2.3 Check all vavles
2.4 Check silencers and connections of the tubes (if available)
2.5 Check all needle valves
2.6 Check the installation on set up

26. CD65-280 Build up & Function

Air Seminar 2002
Trouble shooting Quality
CD7-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Electrical Conn
Solenoid
Mitchell Sensor
Timer Card
Connections Airinlet
Check if the power supply is connected
Check if the power supply is connected
This is for the CD65-280 purge control
This is for the CD65-280 standard and
CD7-60

27. CD65-280 Build up & Function

Air Seminar 2002
Trouble shooting Quality
CD7-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Electrical Conn
Solenoid
Mitchell Sensor
Timer Card
Connections Airinlet
The working of de solenoid can be checked to put a metal piece or srewdriver
on the electrical vale .
The valve is working ( blow off air on the silencer ) if you feel some magnet
with a metal piece. (see figure)
The other valve is not electrical “on”so you don’t feel a magnet

28. CD65-280 Build up & Function

Air Seminar 2002
Trouble shooting Quality
CD65-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Electrical Conn
Solenoid
Mitchell Sensor
Timer Card
Connections Airinlet
Check also the electrical connection , if one of the
wires is grounded you can expect a bad read out

29. CD7-60 Improvements

Air Seminar 2002
Trouble shooting Quality
CD7-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Electrical Conn
Solenoid
Mitchell Sensor
Timer Card
Connections Airinlet
How to check te working of the time card :
Connect with the correct tension , one of the solenoid
connnections have the same tension as the power supply
, the other has no tension , after the fixed time the
tension of the solenoids will switch. This is an example of
220V 50Hz

30. CD7-60 Service tools

Air Seminar 2002
Trouble shooting Quality
CD7-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Electrical Conn
Solenoid
Mitchell Sensor
Timer Card
Connections Airinlet
Check if the the right inoutlet connetion is
foreseen ( for the
correct figures see
instruction book)

31. CD7-60 Service tools

Quality Air Seminar 2002
Trouble shooting CD65-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
There must be a small air flow going over the sensor ,
you can check this with your hand hold under the tube
and you will feel some air flow. ( +/-4a5L/min)
Service
If the is no air flow a bad reading out on the
electronikon can be expected
Trouble shooting
It there is to much air flow you have also to much loss
air ( no warning or indication is seen on the display)
Pages
Flow Sensor
Valves Sensor
Silencers
Needle valves
Installation
The regulation can be set by the needle valve

32. CD7-60 Service Kits

Air Seminar 2002
Trouble shooting Quality
CD65-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Flow Sensor
Valves Sensor
Silencers
Needle valves
Installation
Valves must be open , in case on of them is closed a bad
reading out of the dew point on the electronikon

33. CD65-280 Service Kits

Air Seminar 2002
Trouble shooting Quality
CD7-65
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Flow Sensor
Valves Sensor
Check the right connections of
the tubes ( see intrustion
munual)
Silencers
Needle valves
Installation
Ckeck the silencers on dirt
inside , when the silencers
are blocked a lower dew
point can be the cause)

34. Trouble shooting

Quality Air Seminar 2002
Trouble shooting CD65-280
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Flow Sensor
Valves Sensor
Silencers
Needle valves
Installation
Check the needle valves , a closed needle valve means no switching of the towers
the exhaust valve is blocked.
Regulate the needle valve as follows , turn with screw driver the screw complete
to the right (closed) then 2 turns back to the left , blocked the counter screw and
½ turn to the left
A complete open valve give a full pressure on the exhaust valve and open
immediately the exhaust valve , the regulation is to slow down the open time

35. Trouble shooting CD7-280

Air Seminar 2002
Trouble shooting Quality
CD7-65
Chapter
Range & Sizes
Working principles
Build-up & Function
Improvements
Service
Trouble shooting
Pages
Flow Sensor
Valves Sensor
Silencers
Needle valves
Installation
Check the installation as mentioned in the instruction manual , depending of the
type of CD another installation proposal is required
(WSD, and correct filter installed before the CD , check the set up of the
sequence of the vessel and CD)