DRYPOINT XCp Series [PDF 2 MB]
Contents
1. 1 Outlet Poppet Check Valve 40642 0 0 1 Outlet Poppet Check Valve 400213 2 Outlet Poppet Check Valve 420093 0 0 2 Outlet Poppet Check Valve 4020816 ojo Pressure Relief Safety Valve i Pressure Relief Safety Valve 4026666 9441041 J X Pressure Relief Safety Valve 4026667 X Pressure Relief Safety Valve 4026668 AE AE AE A 1 Pressure Relief Safety Valve 4026669 9 90 Purge Flow Control Valve X Purge Flow Control Valve 40764 o Y Purge Flow Control Valve 4020765 opor j 1 Purge Flow Control Valve 4020766 AE AAA Electronic Controller BEKOTOUCH Controller PLC 4026721 4 4 0 o jojo jojojo ojo BEKOTOUCH Display Screen 4026720 09 0 0 O o jojo jojojojo Solenoid Valve Assembly Complete MAC Solenoid Valve Assembly 4024046 4 0 0 40 4 4 9 Tower Pressure Gauge 24 0 160 psig Pressure Gauge am S 1 1 1 S 1 1 1 5 auge Clamp ass o TL jo O o jo o 6 6 6 FRL Combo Package FRL Combo Package LY 20 130 psig Filter Regulator Combo 4026419 e 0 O jeje ojo jo o jojo Pilot Air Filter Element 0 Pilot Air Filter Element Replacement Filter Element for FRL Combo onrequest2. Pressure Dewpoint Dryer Model Alarm Alert DRYPOINT XC Series Heatless Regenerated Dryers OM10001 Rev D 19 Here the controller provides the system information along with an animation of the drying process based on the operating sequence it is on Each step is detailed below along with a screen shot of the process Startup System Start Up 70 sec The controller is evaluating its system parameters to determine the correct step on which to start The system retains its sequence history so in the case of a power interruption the controller will restart on its last step At start up both the exhaust solenoid valves are closed and the compressed air passes through both drying towers Step 1 Vessel B De pressurizing first 5 10 seconds of Regeneration Vessel Ais in the process of drying system air while vessel B s purge exhaust valve is open thus depressurizing the vessel as the start to the regeneration process Step 2 Vessel B Regenerating 240 sec While vessel A remains in process of drying the system air vessel B is using purge air from vessel A s outlet to regenerate the desiccant Step 3 Vessel B Re Pressurize 60 sec Vessel A continues the process of drying system air while vessel B s purge exhaust valve closes thus allowing the vessel to re pressurize 1 1 1970 PLEASE WAIT FOR START UP 3 SEC R H 5 0 1 1 1970 VESSEL B DEPRESSURIZING 85 SEC R H 5 0 Hr o 1 1 1
3. TO TOTO Brass Cone Silencer Brass Cone Silencer Replacement Brass Cone Silencer 49648 e e e ej e e e e ejeoj o On Off Switch RepacementOn OffSwth 40672 jejejejejeje jojo jo o 0 EMS Sensor Replacement EMS Sensor JP orequest 0 0 9 o jojo jo jo o o Replacement Resistor o AP orequest 0 0 9 TOTO TOTO o po a Pressure Switch Pressure Switch Replacement Pressure switch Tones 6 Jo O 6 TOTO TOTO O TOTO Tube Fitting Package T Tube Fitting Package Replacement Tube Fitting Package Jonrequet O TOTO TOTO O EXA Speed Control Replacement Speed Control m 6 o o e Jo ojo Jo jojojo Seene O Screen for EMS Replacement ScreenforeMS Lareet 0 0 O TO TOTO O TOTO Replacement Tower Screen onrequest 9 94 jo E jojojo NOTE When inquiring about any other part always indicate the data listed on the identification plate 35 12 DISMANTLING OF THE DRYER If the dryer is to be dismantled and disposed of then it must be split into groups of materials of construction Pat Mater Electric cables Copper PVC Electric Parts PVC Copper Bronze Silicon We recommend complying with the safety rules and regulations for the disposal of each type of material The adsorption material and the filter cartridge will contain droplets of lubrication oil Do not dispose of these materials in the environment All local Governmental
4. Compressor off Faulty inlet valve Faulty signal Faulty Outlet valve Pneumatic High dew point Overloaded No power Flow control valve No pilot control air Exhaust Silencers Purge Exhaust Valve Purge line Purge Valve Inlet Valve Purge Valve Exhaust Silencers Desiccant Purge Exhaust Valve Low Pressure High Flow High Temperature y 0 GY A JA JA JA yO UU Y A JA UY A JA JA A AAA JJ The troubleshooting and the eventual checks must be performed by qualified personnel only The technician that services the machine must wear hearing and eye protection while servicing the dryer Each employee must select a proper personal protection device PPD hearing protector such as earmuffs ear canal caps or earplugs in order to prevent permanent hearing damage or loss SUGGESTED ACTION Check power and electric Check the operation of inlet and purge exhaust valves Ensure Control pilot air is delivering at 80 psi Ensure DIN connectors are properly attached to solenoid valves See controller troubleshooting Check if compressor Sync is commanding dryer off The inlet valves are blocked open and clean The controller continuously supplies solenoid valve PVA and or PVB check the electric wiring and if necessary replace Outlet Check valve s stuck open serviceable only by qualified technician Ensure tube routing matches diagram Ensure operation sequence and purge setting Check capacity versus operati
5. SETTINGS under the Energy Management option To enable this refer to the SETTINGS section of the manual 8 4 Controller Settings SETTINGS BEKOTOUCH 1 1 1970 SETTINGS HRFHAIIHTY CEPITEXH DEVV POINT COMATOL MEAT Ad ARAS DIUWPOSNT Al SE Leef Within the SETTINGS function of the controller the system can be configured based on several characteristics that will affect the operation of dryer Humidity Control Dewpoint Demand Optional Cycle Type Selection Time Cycle Selection Humidity control and humidity alarm are displayed on the main SETTINGS screen HUMIDITY CONTROL These values come set from the factory and should only be adjusted if calibration is needs HUMIDTY ALARM 20 096 Dewpoint demand is a feature that will only be displayed on the main SETTINGS screen DEWPOINT CONRTOL if the function is activated The factory setting for dewpoint control and dewpoint alarm is 45F an 40F respectively DEWPOINT ALARM To adjust any of these values use the touch screen on the controller to select and re entering a new value via the Touch Input Panel To pick between the two options for Cycle Type Selection simply use the controller touch screen and tap the Cycle Type Selection button to toggle between Time Control and Energy Management System The active selection will be displayed DRYPOINT XC Series Heatless Regenerated Dryers OM10001 Rev D 22 To pick between the two options for Cycle Ti
6. Synchronization Standard The controller has the capability to synchronize the dryer with compressor when the compressor switches ON and OFF Hence it prevents a situation where the dryer continues to operate and use purge air from the compressed air network though there is no supply of compressed air In case the voltage 120V AC Input drops at the input the purge exhaust valves are immediately closed After the compressor signal comes back online the drying cycle is continued from the same point meaning that the last open valve also opens again Note two exceptions This is not valid if the remaining regeneration time is less than 30 seconds in which case it immediately switches over to the other drying column which means the other valve is opened Ifthe compressor is switched off for more than 24 hours then the device is completely restarted 16 8 0 CONTROLLER INFORMATION AND OPERATION 8 1 Display Overview The interface between the dryer and the operator is the control panel shown below BEKOTOUCH Home Button Alarm History Settings Histogram The operation of the dryer is controlled and monitored constantly by the advanced system controller This is a multi function device Itdisplays the operating status through the display panel Itcan be used to select from a fixed time interval or use energy management Chart the relative humidity and dewpoint optional of the system Provides and reco
7. flow of the dryer We recommend the dryer be installed with a 0 01 micron CLEARPOINT coalescing pre filter at the inlet and a 1 micron CLEARPOINT particulate post filter at the outlet It is recommended to install both 5 micron and 1 micron filters upstream of the dryer in order to maintain the operational lifespan of the inlet filter 2 4 Mounted Filters with Bypass Mounted Filters with Bypass is an optional setup for DRYPOINT XC The three valve system bypass allows for the flow of air to be uniterupted while servicing or completing preventative maintinance such as Exchange pre and post filters Services exhaust sllencers Change desiccant 3 TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION 3 1 Technical Data by Model Size oom moder sie 080 100 120 160 200 250 300 a00 500 eso 800 owe sm 80 100 120 160 200 250 300 400 500 eso sno COI 1 m s s s s s 70 70 79 75 75 75 oec m fan 20 al a7 20 s sse 9 Rex Alumina Temperature Temperature Temperature Temperature Maximum Inlet Air Temperature Dryer ratings adhere to the following inlet conditions per ISO 7183 Table 2 Option A2 Inlet Compressed Air Temperature 100 F 38 C Inlet Compressed Air Pressure 100 psig 7 bar Maximum Ambient Air Temperature 100 F 38 C Inlet Compressed Air Relative Humidity 100 Saturated SCFM is defined as the flow rate of free air in cubic feet per minute measured at 1
8. process by which water vapor is removed from the compressed air being dried All desiccant material types are adversely affected by oil aerosols dirt rust scale and liquid water If contaminated the desiccant material will lose its adsorption proprieties Moreover during operation the desiccant releases solid particles as fine powder that are particularly abrasive and can be extremely damaging to downstream components and users For this reason it is highly recommended that the dryer is equipped with two high efficiency CLEARPOINT filters 0 01 micron filtration grade coalescing pre filter with differential pressure gauge and either a float drain or BEKOMAT 1 0 micron filtration grade particulate post filter differential gauge optional and with a manual drain 3 4 Flow Diagram 4 E em ex d is L Sg NA Y Number Name Number nome a Outlet Check Valves 6 PurgeControlVave 3 5 Cycle Operation AUT COF POP Sch Er MEM A E The cycle time is factory set for operation at i 100 psig inlet air pressure and 100 F inlet air temperature 10 minutes for 40 F 40 C IVA Inlet Valve Vessel A IVB Inlet Valve Vessel B 500 5 5 min PVA Purge Valve Vessel A TOS 305 TOs 3085 PVB Purge Valve Vessel B Pressurization Sequence After proper pressurization of the unit the dryer the operator may begin the start up During the start up phase both solenoid val
9. regenerating tower reads O psig while the drying tower reads full line pressure ANNUALY Replace the pre and post filter elements Replace the exhaust silencers Replace the pre filter float drain or BEKOMAT service unit Check if the solenoid valves are working properly Check if all screws of the electrical wiring are securely tightened Verify operation of the dryer EVERY 2 YEARS In addition to the scheduled annual maintenance Install inlet and purge exhaust valve service kit Verify operation of the dryer EVERY 3 YEARS In addition to the scheduled annual maintenance Replace the desiccant adsorption material in both towers The estimated average lifespan of the adsorption material is 3 5 years when using 10 minute cycle times or 3 000 operating hours per year In all cases the lifetime of desiccant material is heavily dependent on the quality and temperature of the inlet air and ensuring that scheduled maintenance is consistently carried out Verify operation of the dryer 27 9 2 Maintenance and Service Intervals Preventative maintenance of the pre and post filter element and desiccant material is required The controller monitors the dryers operating hours and will activate the maintenance alarms when certain values are reached initial Alarm Every 4 000 hours Every 800 hours Every 12 000 hours Every 1 500 hours NOTE The maintenance alarms reminders do not change the operation of the controller i
10. the customer some means of energy savings Under partial load conditions there are no adjustment to the target humidity needed 7 2 Dewpoint Demand Optional Dewpoint demand comes as optional programmable function on the DRYPOINT XCp line of dryers in order to provide the unit with an additional energy management function and real time dewpoint monitoring The dewpoint monitoring is done through a METPOINT DPM dewpoint polymer sensor located at the outlet of the dryer Dewpoint control is the target dew point of the dryer the factory setting and recommendation is 45F Below this value the controller program will work alongside humidity control to provide energy saving with the dryer The dewpoint alarm is the setting at which the controller will go into alarm if the value goes above that number the factory setting and recommendation is 40F Above this value the high dewpoint minor alarm will trigger Dewpoint demand differs from humidity control in that dew point demand monitors the outlet performance while humidity control monitors the humidity mid vessel While dewpoint demand is a more accurate measurement and measure the dewpoint of air leaving the dryer when an unacceptably high dewpoint is detected it is traditionally late to react Humidity control compensates for this with a fast reaction time in the vessel The conjunction of the two control features provides the customer an accurate and fast way to provide energy savings with the
11. the same for multiple models so do not be concerned if the tower is not entirely full 6 Desiccant that has been contaminated with oil or other substances may require different disposal methods and procedures than desiccant that is being replaced due to aging Consult the appropriate MSDS and follow all applicable laws and regulations regarding disposal 9 5 Inlet and Exhaust Valve Repair 1 Isolate and shut down the dryer see page 14 2 Make certain that there are no pockets of pressure contained by the various valves 3 Openthe bleed valve on the bottom of the control air filter housing 4 Loosen the one touch pneumatic fitting no tools required that attaches the control air tubing to the valve body Carefully move the tubing aside and out of the way We suggest 5 Disassemble the valve for cleaning or repair Service kits are available for all valves see page 30 6 Reassemble the valve and ensure that all O rings gaskets and components have reassembled or replaced accordingly 29 10 TROUBLESHOOTING GUIDE O SYSTEM TROUBLE Dryer stopped All the inlet air is discharged through the silencers t Liquid comes out of the silencers t Depressurization e Repressurization High Humidity or High Dewpoint SS YU YYY y y 0 UY A JA 27 A JA JA A JA JA A FY POSSIBLE CAUSE No power Valve problem No pilot control air Solenoid valves Controller
12. your unit and ensure the correct power supply is connected Do not energize the circuit at this time 4 4 Verify that proper short circuit protection has been provided following all applicable codes and regulations Verify that all the steps of in the previous chapters relating to installation have been observed Verify that the connection to the compressed air system is correct Verify that the condensate drain pipe is properly fastened and connected to a collection system or container Remove any packaging and other material that might obstruct the area around the dryer Before starting the dryer your compressor should be running your compressed air system pressurized and the dryer bypassed and not yet pressurized E O ONDU With the dryer bypassed and in isolation see page 14 SLOWLY open the inlet isolation valve allowing compressed air into the dryer It is critical that the dryer be pressurized slowly to prevent fluidization of the desiccant bed Keep the outlet isolation valve closed at this time SLOWLY open the outlet isolation valve All valves are now in their open positions and compressed air is flowing through both towers and downstream Close the dryer bypass valve The bypass valve must be bubble tight to prevent any moisture from contaminating the dry air outlet from the dryer Plug in the dryer and energize the electrical circuit the dryer is now ON Verify that the controller is on Check all piping for compresse
13. 4 7 psia 1 013 bar at 68 F 20 C temperature with 0 relative humidity 0 WVP 3 2 Correction Factors Operating Pressure and Inlet Air Temperature s90 95 F 100 1os F 110 215 120 6opsiG 089 076 O65 059 049 osa 038 085 073 066 oss 049 042 sopsig 100 096 082 074 062 055 048 sopsig 106 105 090 081 068 060 052 100PSIG 110 110 100 090 076 067 058 i30PSIG 124 1 24 124 112 094 083 072 How to size the dryer capacity for actual conditions How to select the dryer for actual conditions ADJUSTED CAPACITY ADJUSTED CAPACITY Standard Flow Rate x Correction Factor System Flow Rate Correction Factor Example Example Dryer Model DRYPOINT XCp 250 System Flow Rate 300 scfm Standard Flow Rate 250 scfm Operating Conditions 130 psig 100 F Operating Conditions 110 psig 110 F ADJUSTED CAPACITY 300 scfm 1 24 242 scfm ADJUSTED CAPACITY 250 scfm x 0 87 218 scfm Select Dryer Model DRYPOINT XCp 250 3 3 General Function The DRYPOINT X heatless desiccant dyer series are fitted with two pressure vessels positioned parallel to one another and filled with adsorption material activated alumina as standard While the compressed air is dried in one tower the saturated desiccant is regenerated in the second A minimal portion of the treated air is used for the regeneration process and expelled along wit
14. 970 STEP 2 YESSEL B REGENERATION 15 SEC 1 1 1970 YESSEL B RE PRESSURIZING 43 SEC DRYPOINT XC Series Heatless Regenerated Dryers OM10001 Rev D 12 14 59 AM DRYER STATUS OPERATION TIME 35 HOURS ENERGY SAVINGS 5 3 HOURS DRYPOINT XCp 400 5 19 27 AM DRYER STATUS OPERATION TIME 35 HOURS ENERGY SA INGS 3 3 HOURS DRYPOINT XCp 400 12 18 43 AM DRYER STATUS OPERATION TIME 35 HOURS ENERGY SAYINGS 5 3 HOURS DRYPOINT Cp 400 12 19 15 AM DRYER STATUS OPERATION TIME 35 HOURS ENERGY SAYINGS 5 3 HOURS LA DRYPOINTE Cp 400 20 Savings Extended Drying 30 min max In extended drying vessel A will continue drying for an extended period of time up to 30 min maximum or until the moisture control sensor is triggered At that point extended drying is terminated and the next step will start Here energy savings is calculated in hours and totaled on the screen Step 4 Vessel A De Pressurization This starts the process of drying using the other vessel Vessel Bis in the process of drying system air while vessel A s purge exhaust valve is open thus depressurizing the vessel as the start to the regeneration process Step 5 Vessel A Regenerating 240 sec While vessel B remains in process of drying the system air vessel A is using purge air from vessel B s outlet to regenerate the desiccant Step 6 Vessel A Re Pressurize 60 sec Ves
15. EN Installation and Operation Manual Heatless Regenerated Dryer DRYPOINT XC Premium Series READ MANUAL FIRST BEFORE INSTALLATION AND OPERATION SAFETY AND SYSTEM PRECAUTIONS ist Ust ee a a E ENEE 3 1 Definition or the Safety SymbOls ege 3 1 2 Operation k WarDIDBS apa a Ra blade dines ias 3 2 INSPECTION AND INSTALLATION eenegen utin eva Nec bean TS O os geg 4 Sch Incoming Inspection and Transportation ardor dana 4 2 2 De signapd se oT me DIVER ee desi da utes Lut ee Lco icone Ech 4 2 3 EOCALOM anauinStala Cio Samsara insana ano alada ee 4 2 4 Mounted Filters WIEN BY BASS um ui eo si ERR E t pO OR UI RENTES eut ita ST NET DEE 6 3 TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION 7 3L Technical Data erte EE KE 7 AEG Te dee e ara ed DRE Ada 8 Sm erri rei MD m T E 8 IA FOW RE e Ti ats cons qe itum avem des ex ted acd Md MEM tn cM AS O T da 9 SS ee hallo DEE 10 4 PURGE VALVE ADJUSTMENT EE 11 SEM podus P A 12 Duk MentcaconNP On WO Staup cias a 12 BZ Start Up Nee e EE 13 5 EECHER ge NEE 14 6 ISOLATION AND SHUT DOWN PROCEDURES usas asia aaa asas singe be usa ul ace a 14 7 STANDARD AND OPTIONAL FEATURES cuca iii A AA AA AI AA id 15 Z BE T L e Ee Ltd e NEE 15 A Leeder eege eds deca o a 15 Tr CVCIS TYPE SECO EE 15 TAE MIME CY CIE SEION a Eege 16 A HE d O9 WIE I EE 16 Eliae OIN gare Ee 16 VIS ARA Djs UR AN M EL TOT DUE T EN 16 8 Compressor SvnehronizdtlOT
16. LVE B SOLENOID PURG VALVE A HUETRAL 37 14 GENERAL DESCRIPTION OF PARTS Desiccant An adsorbent used for drying air or gases The proper quantity size and type are necessary Inlet Valve Normally open air operated switching valves used to direct air flow through the towers Exhaust Valve Normally closed air operated switching valves used to exhaust purge air hold air in the on line tower and exhaust air from the tower ready to be regenerated Outlet and Check Valves Valves that allow full flow in one direction and no flow in the opposite direction These valves are used in conjunction with the inlet and exhaust valves to control the desired flow of process air through the dryer Safety Relief Valves Valves on each tower to protect the vessels from overpressure situations The setting is indicated on each valve Purge Exhaust Silencer Installed to reduce exhaust noise during purge and blow down for the protection all personnel and to comply with OSHA standards Silencers are non mechanical but must be maintained Purge Flow Control Valve Valve that allows the adjustment and regulation of purge air flow used for the regeneration process BEKOTOUCH Controller Electronic controller that provides an interface between the operator and dryer provides dryer cycle control operates the electric solenoid valves provides indicator lights and alarm controls All hard wired connections including the powe
17. alves Backpressure silencers or mufflers are clogged install new muffler elements SERVICEABLE ONLY BY QUALIFIED TECHNICIAN 31 t Drain t Pre Filter e Post Filter e Controller Ze Relief Valve Solenoid y A JA JA LLULLU JILL JL AA AA JJJ Application Electrical Contaminated Drain Application Dirty element Electrical Differential pressure gauge Dryer dusting Dirty element Electrical Differential pressure gauge Defective No power supply Loose connection Over pressure Leak Over temperature Electrical Pneumatic Defective y A JA JA VUE AAA JJJ AA AA yoo Overloaded with water check pre filter and upstream bulk water separator Check electrical connections Clean drain and plumbing Install service drain kit or replace entire unit Failure with upstream bulk water separator Contaminated filter replace element Faulty electrical signal Clean check and or replace Ensure proper dryer sequence Contaminated filter replace element Faulty electrical signal Clean check and or replace Replace controller Ensure voltage supply Check connections Check system pressure and correct Replace valve Ensure system temperature or fire has not occurred Ensure connections and signal are adequate Ensure pilot supply is good and valve is clean Replace with new 32 11 MAINTENANCE AND SPARE PARTS We strongly recommend stocking the suggested spare parts to help e
18. best performance recovery 7 3 Cycle Type Selection Standard Cycle Type Selection is another system programmable function on the DRYPOINT XCp dryer line The control has one of two options Time Cycle and Energy Management System Time Cycle control makes the dryer switch at a specific time interval either 5 min or 10 min selected under Time Cycle This selection is used when a defined NEMA cycle is desired Energy Management System allows the system to enter an extended drying cycle maximum of 30 minutes This function can be used where there is variable load demand on the compressed air system throughout the day i e a factory with a constant compressed air demand during first shirt however a much lower demand during second and or third shift The savings in this function is the elimination of unnecessary purge air used in regeneration of the second tower For additional information on the system sequence see Section 7 3 under the sequence step Savings 15 7 4 Time Cycle Selection Standard Time Cycle is a programmable function for the DRYPOINT XCp line of dryers under SETTINGS It has two options 5 Min Cycle and 10 Min Cycle This is the total NEMA cycle of the dryer depending on selection the unit will complete a full drying cycle which consists of both tower drying The 10 Min Cycle is the standard mode and should be selected when a dew point of 40 F is desired The 5 Min Cycle mode should be selected for fast troubleshoot
19. ction Restriction Damaged Seal A JA JA A TUG A JA VUE vd 4 y See purge Inlet Valve troubleshooting Ensure that the controller has correct voltage See controller troubleshooting Replace fouled desiccant Contaminated inlet pre filter replace Contaminated outlet post filter replace Overflow ensure air inlet flow does not exceed dryer capacity Remove desiccant screens and clean screens See purge exhaust troubleshooting Replace with new Empty towers remove screens and clean Clean See purge Exhaust Valve troubleshooting See purge Exhaust Valve troubleshooting Purge setting or clog full open purge valve to clean out and then set according to table Sec 4 See Purge valve troubleshooting See Inlet Valve Failure troubleshooting SUGGESTED ACTION y 20 02222 A 4 A 4 A Check at atmosphere Check electrical connections for short Ensure sampling of mid tower thru pneumatic check valves and plumbing Faulty controller replace after factory consultation ensure proper setting from table xx replace valve open full for clean out or dismantle and clean Install service kit check pilot valve pilot air supply pilot air filter flow control valve on actuator Check power to solenoid valves Backpressure silencers or mufflers are clogged install new muffler elements Install service kit check pilot valve pilot air supply pilot air filter flow control valve on actuator Check power to solenoid v
20. d air leaks Test the condensate drain on the pre filter After 1 minutes from start up the adsorption tower B will be depressurized 10 Wait for the dryer to make 10 full cycles i e the depressurization from tower A to tower B 11 The pressure swing cycles occurs every 5 minutes outlet dew point of 40 F NOTE During the first days in operation the dew point cannot be guaranteed because the adsorption material can contain humidity from storage At the first start up or start up after a long inactivity period or following maintenance shutdowns we recommend operating the dryer at a reduced nominal flow of 5096 during the first two days 13 5 3 o Es p General Operation The dryer may require up to 48 hours of operation to reach normal operating outlet dew point Therefore indicators and alarms do not need to be recognized during this time Applications where a dew point lower than 40 F is needed may require additional time to reach equilibrium The dryer will not perform without properly sized and installed pre filtration condensate drainage and correct purge flow adjustment After the initial start up some dusting may occur This is normal and will diminish with time although may accelerate the first maintenance interval of the exhaust valves exhaust silencers and post filter element Exhaust valves and silencers may have to be cleaned due to dusting from shipping and the initial start up and should be clean
21. desata IMS dUE 16 8 CONTROLLER INFORMATION AND OPERATION 17 8 1 Display OVervVIEN ee 17 O 18 E Ee L WE 19 EEN a MINCE 22 9 5 ALARMAS TOR e e bb o Saad Meath Ri ds as La bebo Mes E v eb Me DAR 23 EEN Ka LE NET pr 25 937 Qo qnie tio gin cA Rr c cT o 25 So FOWeNReQUIRCIMENAS RET EE 26 8 I NCWOKCONNE EE LO Dm E 26 9 TE Le E IA Le EE 27 91 IROULING Malltenante ida 27 9 2 IMalntenance anda service te EE 28 o pe JO O NA 28 94 DESICCANT Replacement EE 29 9 5 Inletana ExnaustValve E EE 29 10 TROUBLESHOOTING GUIDE 2102 lid 30 IL MAINTENANCE AND SPARE PARTS ete evasit tte A 33 LET requirea Maintenance Pares as 33 LL Spore Paris TE 35 12 DISMANTLING OF THE DRYER 552 3 rodito tur ined o S EO IR basin aU o0 ne EA ad 36 I3 ELECTRICAL WIRING DIAGRAM 55 eines hace Eo Eee dr aute i roa est Eh eo et data 37 14 GENERAL DESCRIPTION OF PARTS gees 38 For technical product support please call 1 800 235 6797 and select Option 2 1 SAFETY AND SYSTEM PRECAUTIONS 1 1 Definition of the Safety Symbols Before attempting any Electrical Hazard Warning General Warning nn service please read eg Possibility of Under Risk of damage or injury the manual electrocution pressure Warning Warning High temperature Non breathable air g Warning Warning W h arning ANNO All work to b Operations that can be Machine level noise performed by qualified f lif niay exceed e5 dBA protection performed by qualified opera
22. e of your dryer The end user is responsible for providing short circuit protection for the dryer 6 Points of access should be provided upstream and downstream of the dryer for periodic monitoring of dew point pressure and temperature prior to finalizing the installation Taking periodic dew point measurements just downstream of the dryer gives the best indication of whether the dryer is performing optimally We recommend using METPOINT instrumentation to ensure accurate measurements 7 All piping must be adequately supported and at least of equal size to the dryer connections Q Before any attempt is made to operate the dryer the operator must thoroughly read and understand this installation and operation manual Optimal Installation Diagram Air Compressor After Cooler CLEARPOINT Inline Water Separator CLEARPOINT 5 0 Micron Grade G Filtration Receiver Tank CLEARPOINT 1 0 Micron Grade F Filtration DRYPOINT XCp Desiccant Dryer with CLEARPOINT Pre and Post filtration Dry Air Outlet Condensate Drainage Points for BEKOMAT Optimal installation is with moderately sized receivers at the inlet and outlet side of the dryer This allows for the additional free cooling and moisture collection and more consistent dryer inlet flow provided by an upstream receiver while providing the most reliable shop air supply due to the downstream receiver Under no circumstances should the peak demand air flow exceed the maximum rated air
23. ection to the plant and adjustment of the purge rate in compliance with the instructions given in this manual Factory settings are at nominal conditions at 100 psig and the stated model flow rate see page 5 The purpose of the machine is the separation of water vapor that is present in compressed air It is not intended to separate oil or other contaminants that are present in compressed air The dried compressed air output from this dryer cannot be used for respiration purposes of any kind gt 2 3 Location and Installation Serious consideration should be given when selecting the installation site for the dryer as an improper location could directly affect the proper operation of the dryer This unit is not suitable to be used in explosive atmospheres where risk of fire could exist in the presence of gaseous or solid pollutants or in outdoor applications or areas exposed to the elements T Do not use water to extinguish fire on the dryer or in the surrounding area Machine level noise could be higher than 85 dBA Install the unit in a dedicated area where people are not normally present The installer and or end user is responsible for the correct installation of the dryer in order to prevent excessive noise exposure in the work environment The installer and or end user is responsible to install proper safety signs at the installation site Technicians that service the machine must wear hearing and eye protection while serv
24. ed regularly to ensure proper operation Post filter elements should also be part of a regular preventative maintenance schedule Never service the dryer or filters without first relieving pressure from the dryer A desiccant dryer should never be pressurized or depressurized suddenly This will cause fluidizing and dusting of the desiccant bed The dryer is designed for a maximum operating pressure of 150 psig as standard ISOLATION AND SHUT DOWN PROCEDURES Users operating the machine must wear hearing and eye protection Each employee must select a proper personal protection device PPD hearing protector such as earmuffs ear canal caps or earplugs in order to prevent permanent hearing damage or loss Isolation 1 Allow the dryer to reach its re pressurization step and fully re pressurize Once fully re pressurized remove power from the dryer Open the bypass valve Close the outlet isolation valve Close the inlet isolation valve SUB ad odd e Depressurization and Shut Down 1 Open the bypass valve 2 Close the outlet isolation valve 3 Closethe inlet isolation valve 4 Allow the dryer to continue to run During the normal operating cycle both towers will blow down and depressurize Disconnect the power to the dryer 6 Open the manual ball valves on any filters with manual ball valves to allow full depressurization Also leave manual ball valves on filter open during maintenance and service x IMPORTANT Always
25. g before the next Programmed Maintenance Intervention System Alarms Spare Parts To monitor the system use a standard web browser and type the following IP address 192 168 30 130 PLC For additional information on how to use the controller network capability contact your local distributor For technical support contact BEKO Technologies Corp Only qualified personnel may carry out the service for the serial connection of the dryer Before any service make sure that no parts of the machine are powered 26 9 MAINTENANCE AND SERVICE 9 1 Routine Maintenance A y The service must be carried out only by a qualified technician Before any service is carried out always verify that The power has been disconnected following proper Lock out Tag out procedures Depressurize the unit and ensure the unit is isolated from the compressed air system see pg 14 The personnel that service the machine must wear hearing and eye protection before operating the dryer Each employee must select a proper personal protection device PPD hearing protector such as earmuffs ear Canal caps or earplugs in order to prevent permanent hearing damage or loss DAILY Check that pre filter condensate drain is working properly Check the differential pressure of any installed pre and post filtration Check that the tower switching operation takes place correctly at the set cycle times Check that the tower pressure gauge of the
26. h the condensate through the silencers The saturated inlet air is cycled through each of the two desiccant beds in an alternating sequence where one bed is on line at full line pressure and flow adsorbing the water vapor This is the drying bed The other bed is then considered to be in an off line state at atmospheric pressure and is being regenerated by a depressurized portion of the dried treated outlet air purge air This is the regenerating bed The purge air is routed from the dry outlet air through the purge flow control valve desiccant bed purge exhaust valve and finally exhausted to atmosphere through silencers to finish the regeneration process Purge air consumption is generally the highest cost involved with operating a heatless adsorption dryer and is non recoverable Therefore the air system where the dryer is installed must account for this usage approximately 15 of the inlet air flow Just before the freshly regenerated bed is brought to an on line state to become the drying bed it is slowly pressurized from atmospheric pressure up to line pressure This is the re pressurization step that prevents desiccant bed fluidization bed lifting and dusting The desiccant beds will now switch functions where the fresh desiccant bed is now drying and the saturated bed is now regenerating This cycle will continue automatically unless the dryer is shut down All desiccant dryers work using the principle of adsorption which is the
27. i required personnel only Warning Do not operate if parts are missing or have been tampered with Warning Water cannot be used to extinguish fire Compressed air inlet connection Compressed air outlet connection Connection point for condensate drain 1 Experienced and trained personnel familiar with all of the relevant laws rules and regulations capable to perform the needed activities and to identify and avoid possible dangerous situations while handling installing using and servicing the machine 1 2 Operational Warnings WARNING VESSELS UNDER PRESSURE In most countries states cities and or local municipalities the installation operation and maintenance of devices where pressure vessels are in use are subject to local boiler and pressure vessel regulations Theend user is responsible for following all of the relevant laws rules and regulations and ensuring that only A experienced and trained personnel install and or operate the dryer In most countries states cities and or local municipalities the installation may only be carried out by a licensed installation company Inspections must be carried out by a qualified and licensed third party firm in accordance with all applicable laws rules and regulations for the region where the dryer is installed The pressure vessels used in this device are built according to the American Society of Mechanical Engineers ASME standard Section 8 Division 1 Compressed A
28. icing the dryer Each employee must select a proper personal protection device PPD hearing protector such as earmuffs ear canal caps or earplugs in order to prevent permanent hearing damage or loss Minimum Installation Location Requirements Select a clean dry room that is free of dust and protected from atmospheric disturbances The location must be smooth horizontally level able to bear the weight of the dryer and vibration free Minimum ambient temperature of 40 F Maximum ambient temperature of 120 F Allow a clearance of at least 3 on all sides of the dryer in order easily facilitate all maintenance needs The dryer is not required to be anchored to the supporting surface Coalescing pre filter with drain must be installed The location of an air receiver tank will vary depending on compressor type and application conditions N Incorrect installation may void warranty NOTE All piping and electrical connections should be inspected prior to installation to ensure they have maintained their integrity during shipping and locating the dryer First make the initial connections as follows 37 1 Inlet piping including an isolation valve 2 Outlet piping including an isolation valve 3 Coalescing pre filter and particulate post filter We recommend the dryer be installed with a 0 01 micron CLEARPOINT coalescing pre filter at the inlet and a 1 0 micron filters upstream of the dryer in order to maintain the opera
29. ing of operation or can be used for special factory consulted applications that can reach much lower desired dew points 7 5 Failure to Switch Optional Failure to Switch feature is provided by monitoring the pressure swing thru the dryer sequence Each dryer s tower pressure is monitored continuously by pressure transducers that detect the high and low pressure states The states or conditions are used to verify that each valve has switched accurately in a timely manner during the dryer sequence If a state is incorrect for too long the switch generates a signal to the PLC providing an alarm to notify the customer of the date and time of the event This major alarm stops the dryer so that further damage does not occur 7 6 Filter Contamination Optional Filter Contamination is detected for either the Pre or Post filter by using the Clearpoint pressure differential gauge along with electrical contacts When the pressure differential across the element is too great an electrical signal is generated to the PLC providing a minor alarm message to change the media or check for trouble 7 7 Drain Alarm Optional Drain feature is provided for customer by utilizing the BEKOMAT drain alarm features The BEKOMAT is able to let the PLC know when it is contaminated in trouble or simply reached its service interval The drain thus provides a signal to the PLC generating a minor alarm to notify the customer of the date and time of the event 7 8 Compressor
30. ing the date and time when the alarm was triggered Messages that have been acknowledged and addressed have an IO after the date and time indicating the moment in time when the alarm was reset Ex 1 1 1970 12 11 29 AM Drain Alarm RESET An alarm should only be LN after a corrective action to taken place to address the alarm If more than one alarm is triggered use the Alle arrows to toggle between alarms Notices that all past alarms are stored as history in the controller as well as when the alarm was reset Please see section TROUBLESHOOTING GUIDE for specific causes and recommended actions to return dryer to proper function 24 8 6 Histogram HISTOGRAM lt gt BEKOTOUCH ANALOG HISTOGRAM 10 29 Iz x 120 f 13 1 1 1970 12 03 49 AM ronn 1210294M 121349 AM AS 1 1 1 197 foom zom VIEW DEWPOINT START STOP RESET zoom Pressing HISTORGAM allow a real time trend line of the relative humidity of the dryer At full zoom a total of 80 minutes can be displayed START STOP mE RESET To start the histogram and trend data press To reset the trend line simple press The DRYPOINT XCp has an optional data logging function which stores the relative humidity data This can be used for example as part of a quality control system VIEW DEWPOINT To toggle between the dewpoint and humidity histogram press 8 7 Compressor Synchronization The controller has the capability t
31. ir Warning Compressed air is a highly dangerous energy source Never work on the dryer while components are under pressure Never point the compressed air stream or the condensate drain outlet towards anybody The end user is responsible for the installation of the dryer as laid out in this manual If proper commissioning steps are not followed the warranty will be void and dangerous situations involving injury or death and or damages to the machine could occur Only qualified personnel can use and service electrically powered devices Before attempting any maintenance Ensure that no part of the machine is powered and is locked out of the electrical mains by following proper AN Lock out Tag out procedures and requirements Ensure that no part of the dryer is under pressure by isolating the dryer from the compressed air system Any change to the machine or to the standard operating parameters see page 5 if not previously verified and authorized by the manufacturer in addition to creating a potentially dangerous situation will void the warranty Do not use water to extinguish fire on the dryer or in the surrounding area 2 INSPECTION AND INSTALLATION 2 1 Incoming Inspection and Transportation All dryers are tested and inspected at the factory prior to shipping Thoroughly inspect and verify the integrity of the packaging upon receipt and note any damage on the freight bill Place the unit as close as possible to the ins
32. ity through the PV A valve 2 and the silencers 3 At the end of this stage the adsorption material of vessel A is completely regenerated The purge exhaust valve PV A 8 is closed and then through the Purge Control Valve 6 vessel A is re pressurized up to the working pressure The sum of stages C D equals a half cycle time At the end the cycle starts up again from Stage A NOTE The cycles are symmetrical therefore 1 2 4 5 and 3 26 10 4 PURGE VALVE ADJUSTMENT The purge flow control valve must be set to match the inlet pressure of the dryer The valve must be opened to the corresponding number of turns referenced in the table below Always base the pressure adjustment on the lowest operating pressure of the system The initial setting from factory is for 100 psig operation The procedure for adjusting the purge flow control valve is as follows Rendered drawing of purge Turn knob clockwise Turn knob counter clockwise flow control valve to the right to close to the left to open The knob stem of the valve is numbered and a complete turn is considered turning the control knob 360 from number to number The number of turns expressed in the table below is based on the number of turns from the closed position 1 Loosen the set screw using a flathead screwdriver or allen head 2 Turn the purge flow control valve clockwise until the stopping point the valve is now closed 3 Turn the purge flow control valve cou
33. lace or if any componentry is missing or appears damaged Service to be performed by qualified personnel only The end user is responsible to ensure that the dryer will never be operated under pressure that exceeds the maximum pressure rating of the unit Operating the dryer at a pressure higher than the maximum rating could be dangerous for both the operator and the machine The inlet air temperature and air flow rate entering the dryer must be within the limits indicated on the data plate Installation precautions must be taken in order to limit the vibration that can occur during the operation of the dryer Therefore we recommend using flexible connecting pipes that are able to insulate the dryer from possible vibrations originating from the pipe line The connection to the main power is to be carried out by qualified personnel and the safety protocol must comply with local rules and laws Before connecting the unit to the electric power verify that the voltage and the frequency available on the mains correspond to the data on the data plate of the dryer In terms of voltage a 5 tolerance is acceptable The wire size feeding the dryer must comply with the consumption of the dryer while keeping into account also the ambient temperature the conditions of the main power junction box the length of the wire and the requirements enforced by the local power company AN It is mandatory to ensure the connection to the ground terminal The co
34. laws and regulations must be followed in disposing of the above listed materials pom J Steel 36 ELECTRICAL WIRING DIAGRAM 13 TOUCH SCREEN COLOR DISPLAY SIEMENS KTP 400 BAVO 64 0AA11 3AX0 CATS ETHERMET p ETHERNET CORD CONKECTED DIRECTLY TO HERG PLE PQ OPTIONAL FEATURES DRAN ALARM DV A 112 AFTER FILTER POST F an2 PRE FILTER PRE F AVDC 16 120VAC 16 RD FME 2 CUSTOMER SUPPLY 120 VOLT 1 PHASE GOHZ TOTAL AMPS 2 AMPS ELI de VOLTAGE 120VAC SD 15 RO E PU TATAG Te RD HUMIDTY SENSOR ENERGY MANAGEMENT SYSTEM 0 100 R H INPUTS xit MC X60 OO Es 1 ooo CPU 1211C ACIDCIRLY Er Es a Al ANALOG OO a Dia RELAY OUTPUTS ME Aa 2 aloo o fgaeggoee EK bebe AA 200 o 0 PM Oo S IE CN BIS ES S usc CHA ii i L 211 1BD30 0XBO s E Te pS ASS Fes ao uil LET Cp 120vAC 186 RD COLOR BOTTOM BOTTOM COLOR TOP COLOR TERMIMALS COLOR TOP CORD GND a GN PLOXIOGND C PLC X10 N PB 11 PLC X12 2 PLC X10 L1 PLC X11 1 BLOCK FUSE 2 2 AMP FAST ACTING SEINEN UM WH A flat NM pax JO al HMI X80 L i 3 PB X2 BU WH O o tMs ovpc E eH BU WH TB 6 GC CUST L O a CUST SIGNAL PLC X10 0 o O BU PLC X10 L BL RB 8T La LATERAL La JUMPER VERTICAL JUMPER SOLENOID PURGE VA
35. me Section use the controller touch screen Cycle Time Selection h le Ti i i 10 min Th i and tap t e Cycle ime Section button to toggle between 5 min or 10 min e active 5 MIN CYCLE selection will be displayed BEKOTOUCH SPARE PARTS XCp 400 400 SPARE PARTS By pressing the SPARE PARTS button within SETTINGS an abbreviated spare parts list of the dryer can be accessed Use the touch screen to access this function to display the spare parts list on a new screen If a spare part is needed that is not on this list refer to Section 10 of this manual call your distributor or a BEKO Technologies representative for assistance ADMIN Lastly in SETTINGS there is an administrative button However this button is locked for use by a BEKO Technologies representative 8 5 Alarm History ALARM HISTORY BEKOTOUCH 12 11 51 Ai 1 1 1970 12 11 29 AMD Drain Alar 1 1 1970 12 11 15 AM 10 Alter Alber Alarm 11970 12 10 58 AM 1 Alberia Alem 11 1970 121042 AM 0 ewe Senor Tage 1 1 1970 120900 AM 1 Despolnt Sensor Fallure The controller has ability to continually monitor specific dryer characteristics along with any ancillary equipment provided it is connected to the controller If there is a functional issue associated with normal operation an alarm will be triggered and the pop up ribbon will be displayed on the bottom of the active screen The alarm types are listed below 11111970 12 11 29 AM Drain Alarm Alarm Type
36. n any way 9 3 Fuses Two different safety fuses are fitted on the electronic board of the controller in positions F1 and F2 The fuses protect the following circuits and are of the following type F1 Mains 2A type T 65x20 mm F2 Condensate drain solenoid valve 1A type T 65x20 mm The fuses can blow if there are any problems with the dryer In which case replace them but only after solving the problem that caused the malfunction first or refer to section 9 TROUBLESHOOTING page 29 28 9 4 Desiccant Replacement A CAUTION Activated alumina desiccant dust is considered a nuisance dust Proper precautions should be taken prior to replacing the desiccant material in the dryer Please refer to the Material Safety Data Sheet MSDS 37 1 Isolate and shut down the dryer see page 14 2 Placea suitable container at the edge of each drain port on the bottom of the towers that are located on the sides facing outward 3 Open the drain ports on the bottom of the towers and catch the desiccant in the containers 4 Refill each tower with the recommended type size and quantity of desiccant Only use manufacturer supplied desiccant which is high quality high capacity desiccant designed and sized for the dryers 5 Carefully knock on the sides of the tower chambers while filling so that the desiccant will pack tightly Some settling may be required in order to fit the specified fill amount into the tower Tank sizes may be
37. nable you to promptly carry out any required maintenance and or replace any parts that may fail without having to wait for the parts to be delivered If you need to replace any other parts please contact your local distributor or BEKO Technologies Corp Technical Service Department at 1 800 235 6797 for assistance 11 1 Required Maintenance Parts mew pscmemon Ordere Tomo 100 120 260 200 250 300 200 soo so 500 Us 40225 O as 4076 JO us gona Iso 40228 as 0 40229 feo Bos 402739 elei Dass 4073 jojo gp 402200 ao 4071 po 40272 of aso 402233 pep er 402714 peo Bo 1 Y 4715 jeto BR o 4078 eise W ExawtSlener f 4003 fe JO 1 Exhaust Silencer f 4003 1 Exhaust Silencer LL 4906220 o o W ExwstSlener 49085 deleje Jef ExwsSlener 400839 ele Float Drain for CLEARPOINT Standard Float Drain for CLEARPOINT Standard o FADOSO Float Drain 4953 4 jo 4 jo jo jo jojo o jojo Service Unit for CLEARPOINT with BEKOMAT Opti
38. ndensate is discharged at the same pressure as the air entering the dryer Never point the condensate drain discharge towards anybody Connect and properly fasten the condensate drain to a collection system or container The outlet condensate hose cannot be connected to pressurized systems The condensate collected in the dryer contains oil particles released into the air stream by the compressor Dispose of the condensate in a manner compliant with all local state and Federal rules and regulations We highly recommend the installation of either a QWIK PURE or WAMAT oil water separator at the final collection point for all condensate discharge lines within the facility i e from the main header O DO NOT DISPOSE OF CONDENSATE INTO THE ENVIRONMENT 12 5 2 Start up Procedures During the first start up or start up after a long period of inactivity or following maintenance the technician must comply with the instructions below The start up must be performed by qualified personnel only The employee that operates the machine must wear hearing and eye protection before operating the dryer Each employee must select a proper personal protection device PPD hearing protector such as earmuffs ear canal caps or earplugs in order to prevent permanent hearing damage or loss Start up Sequence Please read and understand the entire manual before operating the dryer Verify the factory settings Verify the wiring diagrams that pertain to
39. ng conditions Check purge exhaust valve for normal operation Ensure that the purge exhaust valve actuators is not closed Ensure pilot air reading is 80 psi Replace silencer filter elements if clogged See purge Exhaust Valve troubleshooting Purge setting or clog full open purge valve to clean out and then set according to table xx See Purge valve troubleshooting See Inlet Valve Failure troubleshooting Adjust and ensure correct setting based on table xx Backpressure due to clog install new mufflers Media is fouled replace new See Purge Exhaust Valve troubleshooting Increase to rated pressure ensure air inlet flow does not exceed dryer capacity ensure air inlet temperature does not exceed dryer capacity 30 High Pressure Drop Back pressure e Failure to Switch COMPONENT TROUBLE n Sensor failure Purge control Valve Purge Exhaust Valve Inlet Valve 4 Outlet Check Valve A JA JA A TUG 4 050505 yy 4 4 Inlet Valve Power Controller Desiccant Pre filter Post filter Capacity Desiccant screens Purge Exhaust valve Purge muffler fouled Vessel screen Restricted purge piping Bad Purge Exhaust Valve Purge Exhaust Valve Purge line Purge Valve Inlet Valve POSSIBLE CAUSE y 2 0222 2 VY 4 A Sensor Electrical Pneumatic Controller Setting Damaged Dirty Worn seals Pneumatic Electrical Restriction Worn seals Pneumatic Electrical Restri
40. nter clockwise until the setting for the desired operating pressure value is reached the valve is now open 4 Tighten the set screw using a flathead screwdriver or allen head Purge Adjustment Table Approximate Purge Valve Setting number of turns to open Dryer Inlet Se Rate m 90 psig H zT 32 38 53 057 56 au Consult a factory representative for more information so o XC 200 11 5 START UP 5 1 Verification Prior to Start up Verify that the operating parameters match with the acceptable ranges indicated on the data plate of the N dryer voltage frequency air pressure air temperature ambient temperature etc This is not the same as the ASME UW plate on the vessels and may be lower than what is stamped on the ASME UW plate Before delivery each dryer is submitted to accurate tests simulating real operating conditions Nevertheless the unit could be damaged during transportation Therefore we suggest checking the integrity of the dryer upon arrival see page 4 and observing the dryer during the first hours of operation Me The start up must be performed by qualified personnel only It is mandatory that the engineer in charge will verify safe operational conditions complying with the local safety and accident prevention requirements The same engineer will be responsible for the proper and safe operation of the dryer Never operate the N dryer if all panels are not properly in p
41. o synchronize the dryer with 1 1 1970 compressor when the compressor switches ON and OFF This is RECETAS detailed in the STANDARD AND OPTIONAL FUNCTION amp FEATURES T men T2 OPERATION TIME section of the manual When synchronization occurs and the PLEASE WAIT AE GE E compressor is OFF the controller display screen shows this GE 5 3 HOURS information ZS B DRYPOINT XCp 400 DRYPOINT XC Series Heatless Regenerated Dryers I0M10001 Rev D 25 8 8 Power Requirements The controller is able to operate using different voltages 100 120VAC 50 60Hz or 220 240VAC 50 60Hz The units are shipped with an installed standard US 120 volt cord for convenience Before starting up the machine it is necessary to have a qualified electrician review the electrical requirements schematic and install to the National Electric Code Please refer to Section 12 The optional BEKOMAT on the pre filter at the dryer inlet is supplied according to the power voltage indicated in the order verify its compatibility with the information given on the type plate 8 9 Network Connection The controller is fitted with a PC Ethernet cable which allows for a network connection The PLC has connection features standard from Siemens that allow the PLC to be monitored for status An optional web server function is also available This feature enables the following information available through a web page Operating Status and Times Operating Parameters Time Remainin
42. onal S Service Unit for CLEARPOINT with BEKOMAT Optional BEOMATe31SewieUnt 4023608 4 9 4 o O o jojo ojo o BEKOMAT 32 Service Unit 4025061 o fofo fofo fofo oo Inlet ie Body Valve Actuator Only Inlet Valve 2 mlet valve actuator Actuator mma Ill mme LS o o mee Somos Jo permitir RR fo To om o pem PS LIT T TTL TL eo 33 Interval DESCRIPTION OrderNo 080 100 120 160 200 250 300 650 800 Exhaust Angle Body Valve Actuator Only ETT e TE esmo w meme il EPI ELE EET ECKER RRE ERR meme e EL EE E EPI JET r Eis AA E E Service Seal Kit W sewikeSealKt a a o o eos o 1 Service Sealkit L 40789 a pa 2 1 Service Seal Kit S 40790 a ll 1 Service Sealkit S 497900 fofo fofo 2 2 senicesealkt LL 40792 fofo fofo 2 2 Service Sealkit 407503 fofo fofo fofo fofo fo n Desiccant Adsorption Material d Y Activated Alumina m total weight in Ibs per dryer 4027023 95 150 150 230 230 340 340 480 625 795 940 34 pa 1 2 Spare Parts DESCRPTON ordeno 080 190 120 160 200 250 300 400 soo 650 800 Outlet Poppet Check Valve 40020 do 1 Outlet Poppet Check Valve 40022 0 0
43. r connections during installation are made to this device Electric Solenoid An electromechanical device used for controlling the flow of liquid or gas 38 For technical product support please call 1 800 235 6797 and select Option 2 The product categories Condensate drainage Filtration BEKOMAT CLEARPOINT O Condensate processing Drying Process technology OWAMAT QWIK PURE BEKOSPLIT DRYPOINT BEKOKAT Measurement technology METPOINT BEKO TECHNOLOGIES CORP 900 Great Southwest Pkwy SW Atlanta GA 30336 USA Phone 1 404 924 6900 Fax 1 404 629 6666 BEKO beko bekousa com www bekousa com BLU COMPETENCE Alliance Member Partner of the Engineering Industry Sustainability Initiative Subject to technical changes without prior notice the information provided does not represent characteristics of state within the meaning of the German Civil Code BGB Registered Trademarks by BEKO TECHNOLOGIES GmbH Neuss Germany and BEKO TECHNOLOGIES CORP Atlanta GA USA DRYPOINT XC Series Heatless Regenerated Dryers IOM10001 Rev D
44. rds system alerts DRYPOINT XC Series Heatless Regenerated Dryers IOM 10001 Rev D 17 8 2 Controller Startup The main power button on the dryer face panel powers the controller When pressed the controller startup sequence begins This includes a system boot process which takes about 60 seconds Once the startup sequence is complete The START window will be displayed This screen allows access to limited system controls however it should only be accessed by persons with proper knowledge of its function DRYER STATUS PLEASE vu OPERATION TIME 35 HOURS WAIT FOR ENERGY SAVINGS T u STARTTE 5 3 HOURS The START screen is only displayed for 3 seconds after which the HOME screen will be displayed and the controller will automatically begin its drying sequence DRYPOINT XC Series Heatless Regenerated Dryers IOM10001 Rev D 18 8 3 Home Screen 5 19 27 AM DRWER STATUS n OPERATION TIME STEP 1 sus in VESSEL B DEPRESSURIZING SJ ENERGY SAVINGS 2 3 HOW After the controller startup the HOME screen dryer operation is displayed This screen can be accessed at any time by pressing the HOME button BEKOTOUCH Date 1 1 1970 OUTLET 5 19 27 AM Time DRYER STATUS 3 5 m OPERATION TIME B 2 inii Step STEP 1 vs 25 HOURS Time in Use Vessel a VESSEL B Operation DEPRESSURIZING ENERGY SAVINGS Savings in Hours Time Remaining in Cycle 85 SEC 33 HOURS System Relative Humidity Gase R H 3 0
45. remove all pressure and disconnect all power before servicing the dryer To restart the dryer follow the start up procedure in 5 START UP on pages 12 13 14 7 STANDARD AND OPTIONAL FEATURES 7 1 Humidity Control Standard Humidity control comes as a standard programmable function on the DRYPOINT XCp line of dryers providing the unit with an energy management function and to provide early moisture detection within the desiccant bed The energy management function can be used to save energy for low load hours or during times of year with lower ambient temperatures or pressure dewpoint The high moisture detection protects the desiccant bed from oversaturation Humidity control utilizes a humidity sensor located within a sampling chamber that monitors the mid tower compressed air from of the online drying vessel The humidity sensor continuously checks the vessel to see if the dryer s desiccant has a moisture level below the humidity control set point If the humidity is below the set point the controller program will extend the drying cycle on that vessel thus saving energy by not switching vessels and using purging air The system controller allows for a maximum of 30 minutes of energy savings per vessel before it is forced to switch in the event a sensor anomaly occurs If the humidity in the vessel is too high above the alarm value it will trigger the system a minor alarm This feature is to protect the bed from oversaturation and to provide
46. s High Humidity Alarm Occurs when the mid vessel humidity becomes higher than the desired alarm setting High Dewpoint Alarm Optional Occurs when the system outlet dewpoint becomes higher than the desired alarm setting This function can be activated only if the dew point sensor is installed Dewpoint or Humidity Sensor Failure Each sensor also has a sensor failure feature to help identify faulty probes and default the system into a time cycle gt bb DRYPOINT XC Series Heatless Regenerated Dryers I0M10001 Rev D 23 Drain Alarm This alarm can only be used if the BEKOMAT drain is installed The BEKOMAT drain can be plugged into the controller and the drain alarm will display on the controller Failure to Switch Alarm Optional This alarm continuously monitors the time rate of pressurization and depressurization for each tower through a pressure switch If the time rate is to slow the system will set off an alarm gt D Pre filter Filter Contaminated The system can be setup to monitor the differential pressure measured off the pressure housing electrical switch When this alarm is activated it means that the dryer inlet filter is contaminated and therefore it must be replaced This alarm does not affect the operation of the dryer but maintenance is needed Please refer to the user manual of the filter itself Post filter Contaminated Like the pre filter the system can be setup to monitor the differential press
47. sel B continues the process of drying system air while vessel A s purge exhaust valve closes thus allowing the vessel to re pressurize Savings Extended Drying 30 min max In extended drying vessel B will continue drying for an extended period of time up to 30 min maximum or until the moisture control sensor is triggered At that point extended drying is terminated and the next step will start Here energy savings is calculated in hours and totaled on the screen 1 1 1970 SAVINGS VESSEL B SAVINGS 29 MIN 1 1 1970 STEP 4 VESSEL A DE PRESSURIZING 83 SEC 1 1 1970 STEP 5 WESSEL A REGENERATION 85 SEC R H 5 0 1 1 1970 STEP 6 VESSEL A RE PRESSURIZING 1 1 1970 SAVINGS VESSEL B SAVINGS 30 MIN DRYPOINT XC Series Heatless Regenerated Dryers OM10001 Rev D 12 20 46 AM DRYER STATUS OPERATION TIME 35 HOURS 5 3 HOURS DRYPOINT XCp 400 12 21 59 AM DRYER STATUS OPERATION TIME 35 HOURS ENERGY SAVINGS 5 3 HOURS DRYPOINT XCp 400 5 18 22 AM DRYER STATUS OPERATION TIME 35 HOURS ENERGY SAYINGS 5 3 HOURS DRYER STATUS OPERATION TIME 35 HOURS ENERGY SAYINGS 5 3 HOURS DRYPOINT XCp 400 5 27 58 AM DRYER STATUS OPERATION TIME 35 HOURS 5 3 HOURS DRYPOINT XCp 400 21 After this second Savings step the controller will continue back to Step 1 Note that the Savings step function is only applicable if it has been enabled in
48. tallation point before unpacking the contents and inspect for concealed damage Freight claims are to be filed with the carrier immediately and the manufacturer s technical service department notified thereafter To move the packaged unit we suggest the use of a suitable crane or forklift We do not recommend moving the unit by any hand operated or manual mechanism Handle with care Heavy blows could cause irreparable damage Even when packaged keep the machine protected from severe weather Es 2 2 Design and Use of the Dryer The packaging materials are recyclable Each material must be properly disposed in a manner complying with the rules and regulations of the local municipality government This dryer has been designed manufactured and tested to be used only to separate the humidity normally contained in compressed air any other use is considered to be improper The manufacturer is not responsible for any problems arising from the improper use of this machine The end user in any and all cases is responsible for any resulting damages Moreover the correct use of this machine requires the verification of certain installation conditions in particular Voltage and frequency of the electrical power supplied Pressure temperature flow rate and chemical composition of the incoming compressed air Ambient temperatures The dryer is supplied as tested and fully assembled The only operation left for the end user is the conn
49. tional lifespan of the inlet filter to the 1 0 micron CLEARPOINT particulate post filter at the outlet It is recommended to install both 5 0 micron and dryer In addition we recommend the use of a BEKOMAT zero air loss drain on the pre filter and at all other condensate collection points especially those upstream of the dryer Locate the coalescing pre filter as close to the dryer as possible while still maintaining sufficient space for routine maintenance and service Inlet air entering the dryer must pass through a coalescing pre filter in order remove entrained condensate and oil to prevent fouling of the desiccant and maintain standard operation Any liquid condensate entering the desiccant bed will lead to overloading of the dryer poor dew point performance and rapid deterioration of the desiccant material Any oil entering the desiccant bed may permanently reduce the capacity of the desiccant material Desiccant dust traveling downstream of the dryer may cause contamination and or accelerated wear to other components and equipment Therefore a particulate post filter should be provided to prevent desiccant dust from traveling downstream Activated alumina is considered a nuisance dust and proper precautions should be taken when handling desiccant refer to applicable MSDS sheet 37 4 IMPORTANT Bypass piping is necessary Only bubble tight valves should be used 5 Make the required electrical connections please refer the type plat
50. ure measured off the pressure housing electrical switch optional on the post filter When this alarm is activated it means that the dryer post filter is contaminated and therefore it must be replaced This alarm does not affect the operation of the dryer but maintenance is needed Please refer to the user manual of the filter itself Filter Maintenance Timer This service alarm is for when the filters in the flow diagram are flashing at the same time the timer for the programmed maintenance of the filters has gone off Desiccant Maintenance Timer If the service alarm for the desiccant the timer for the programmed maintenance of the desiccant material has gone off When an alarm is triggered it will appears on the bottom of the controller screen regardless of the active screen with the date time and type of alarm When an alarms is active it will remain on the screen until it is addressed To find out additional detail and to address the alarm go to the ALARM HISTORY screen On the ALARM HISTORY screen all previous alarms are shown 1 1 1970 ALARMS 12 11 51 AM e 1 1 1970 12 11 29 AM I Drain Alarm along with the current active alarm The alarms are shown in ASAS descending order with the most recent at the top of the screen 1 1 1970 12 10 58 AM I After Filter Alarm 1 1 1970 12 09 42 AM IO Dewpoint Sensor Failure 1 1 1970 12 09 08 AM I Dewpoint Sensor Failure Incoming messages have an T designation immediately follow
51. ves PVA and PVB 5 and 6 are closed for a period of 70 seconds to help guarantee the complete pressurization of the dryer Step 1 2 Step 3 Step 4 5 Step 6 The purge exhaust valve PV B 2 is powered open to depressurize vessel for regeneration Simultaneously the solenoid valve IV B 1 is powered closed The compressed air flow is directed to vessel A where the desiccant material adsorbs the humidity down to the target dew point Through the purge control valve 6 a defined amount of dry air coming out from tower A is expanded into vessel B This dry air while crossing vessel B dries the adsorbent material dragging away the humidity through the PV B valve 2 and exits the silencers 3 At the end of this stage the adsorption material of vessel B is completely regenerated The purge exhaust valve PV B 2 is closed and then through the Purge Control Valve 6 vessel B is re pressurized to the working pressure The sum of stages A B equals a half cycle time The purge exhaust valve PV A 2 is powered open to depressurize vessel for regeneration Simultaneously the solenoid valve IV B 1 is powered closed The compressed air flow is directed to vessel B where the desiccant material adsorbs the humidity down to the target dew point Through the purge control valve 6 a defined amount of dry air coming out from tower A is expanded into vessel B This dry air while crossing vessel A dries the adsorbent material dragging away the humid
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