Pneumatech PH 55 - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document is an instruction manual for Pneumatech Heatless Adsorption Air Dryers, specifically covering models PH 55, PH 75, PH 95, PH 120, PH 140, PH 190, PH 230, PH 275, PH 350, PH 420, and PH 550.

Function Description

The Pneumatech Heatless Adsorption Air Dryers are designed for normal indoor use to remove water vapor from compressed air, producing dry air. The operation cycle is repetitive and controlled by either a factory-set timer in the controller or an optional pressure dew point (PDP) sensor. The dryer module consists of two towers containing desiccant, a porous grain material that adsorbs large amounts of water vapor. While one tower dries compressed air, the other regenerates its desiccant using a small portion of dried purge air that expands to atmospheric pressure and flows downwards through the regenerating tower. The regeneration air is then released via solenoid valves and a silencer, controlled by the timer. The function of the towers reverses after a preset period or when triggered by the PDP sensor.

The controller, available in a basic DC1 version or an optional graphic PureLogic™ controller for High Efficiency (+) versions, automatically controls and protects the dryer. Its functions include maintaining a stable pressure dew point, monitoring pressure, temperature, and digital switches for safe operation, stopping the dryer when necessary, and restarting it when required. The PureLogic™ controller also features an Automatic Restart After Voltage Failure (ARAVF) function, which allows the dryer to automatically restart if power is restored within a programmed time period (15 to 3600 seconds, or 'Infinite').

Important Technical Specifications

The dryers are designed for specific operating conditions and offer various models with different capacities and dew point versions.

Reference Conditions:

Compressed air effective inlet pressure: 7 barg (101.5 psig)
Compressed air inlet temperature: 35 °C (95 °F)
Relative humidity of the air at inlet: 100 %
Pressure dew point (PDP -20 °C version): -20 °C (-4 °F)
Pressure dew point (PDP -40 °C version): -40 °C (-40 °F)

Limitations for Operation:

Maximum compressed air effective inlet pressure: 14 barg (203 psig)
Minimum compressed air effective inlet pressure: 4 barg (58 psig)
Maximum ambient air temperature: 45 °C (113 °F)
Minimum ambient air temperature: 1 °C (34 °F)
Maximum compressed air inlet temperature: 50 °C (122 °F)
Minimum compressed air inlet temperature: 2 °C (36 °F)

Dryer Data (Standard version, PDP -20 °C):

Model	Volume flow at dryer inlet (l/s)	Volume flow at dryer inlet (cfm)	Pressure drop at maximum flow (bar)	Pressure drop at maximum flow (psi)	Time to half a cycle (s)	Regeneration time (s)	Pressurization time (s)	Average regeneration air consumption (%)	Desiccant type	Desiccant amount per vessel (kg)	Desiccant amount per vessel (lb)	Inlet filter 1	Outlet filter 1	Maximum air outlet temperature (°C)	Maximum air outlet temperature (°F)	Minimum volume flow at inlet (l/s)	Minimum volume flow at inlet (cfm)
PH 55	25	53	0.030	0.44	87	65	20	16.5	Activated alumina	6.8	15.0	PF 3C HE	PF 3S HE	60	140	6.25	13.25
PH 75	35	74	0.059	0.86	87	65	20	17	Activated alumina	6.8	15.0	PF 4C HE	PF 4S HE	60	140	8.75	18.55
PH 95	45	95	0.098	1.42	87	65	20	17.5	Activated alumina	7.4	16.3	PF 5C HE	PF 5S HE	60	140	11.25	23.85
PH 120	55	116	0.159	2.31	87	65	20	17.5	Activated alumina	9.9	21.8	PF 5C HE	PF 5S HE	60	140	13.75	29.15
PH 140	65	138	0.238	3.45	87	65	20	17.5	Activated alumina	12.4	27.3	PF 6C HE	PF 6S HE	60	140	16.25	34.45
PH 190	90	191	0.482	6.99	87	65	20	17.5	Activated alumina	14.8	32.6	PF 6C HE	PF 6S HE	60	140	22.5	47.7
PH 230	110	233	0.159	2.31	87	65	20	17.5	Activated alumina	9.9	21.8	PF 6C HE	PF 6S HE	60	140	27.5	58.3
PH 275	130	275	0.238	3.45	87	65	20	18	Activated alumina	12.4	27.3	PF 7C HE	PF 7S HE	60	140	32.5	68.9
PH 350	165	350	0.405	5.87	87	65	20	18	Activated alumina	14.8	32.6	PF 8C HE	PF 8S HE	60	140	41.25	87.45
PH 420	195	413	0.238	3.45	87	65	20	18	Activated alumina	12.4	27.3	PF 8C HE	PF 8S HE	60	140	48.75	103.35
PH 550	260	551	0.447	6.48	87	65	20	18	Activated alumina	14.8	32.6	PF 9C HE	PF 9S HE	60	140	65	137.8

Dryer Data (Standard version, PDP -40 °C):

Model	Volume flow at dryer inlet (l/s)	Volume flow at dryer inlet (cfm)	Pressure drop at maximum flow (bar)	Pressure drop at maximum flow (psi)	Time to half a cycle (s)	Regeneration time (s)	Pressurization time (s)	Average regeneration air consumption (%)	Desiccant type	Desiccant amount per vessel (kg)	Desiccant amount per vessel (lb)	Inlet filter 1	Outlet filter 1	Maximum air outlet temperature (°C)	Maximum air outlet temperature (°F)	Minimum volume flow at inlet (l/s)	Minimum volume flow at inlet (cfm)
PH 55	25	53	0.030	0.44	87	65	20	18.5	Activated alumina	6.8	15.0	PF 3C HE	PF 3S HE	60	140	6.25	13.25
PH 75	35	74	0.059	0.86	87	65	20	18.5	Activated alumina	7.4	16.3	PF 4C HE	PF 4S HE	60	140	8.75	18.55
PH 95	45	95	0.107	1.55	87	65	20	18.5	Activated alumina	9.9	21.8	PF 5C HE	PF 5S HE	60	140	11.25	23.85
PH 120	55	116	0.171	2.48	87	65	20	18.5	Activated alumina	12.4	27.3	PF 5C HE	PF 5S HE	60	140	13.75	29.15
PH 140	65	138	0.251	3.64	87	65	20	18.5	Activated alumina	14.8	32.6	PF 6C HE	PF 6S HE	60	140	16.25	34.45
PH 190	90	191	0.107	1.55	87	65	20	18.5	Activated alumina	9.9	21.8	PF 6C HE	PF 6S HE	60	140	22.5	47.7
PH 230	110	233	0.171	2.48	87	65	20	18.5	Activated alumina	12.4	27.3	PF 6C HE	PF 6S HE	60	140	27.5	58.3
PH 275	130	275	0.251	3.64	87	65	20	18.5	Activated alumina	14.8	32.6	PF 7C HE	PF 7S HE	60	140	32.5	68.9
PH 350	165	350	0.447	6.48	87	65	20	18.5	Activated alumina	18.8	41.4	PF 8C HE	PF 8S HE	60	140	41.25	87.45
PH 420	195	413	0.251	3.64	87	65	20	18.5	Activated alumina	14.8	32.6	PF 8C HE	PF 8S HE	60	140	48.75	103.35
PH 550	260	551	0.494	7.16	87	65	20	18.5	Activated alumina	18.8	41.4	PF 9C HE	PF 9S HE	60	140	65	137.8

Usage Features

The dryer is operated via a control panel with a display, ON/OFF button, LEFT/RIGHT buttons for navigation and data modification, an ENTER button for selection and confirmation, an Alarm LED, and a Power On LED. The main screen displays the current working phase countdown, measured dew point (if enabled), and the working phase of each vessel.

The controller offers several menus for monitoring and configuration:

Selection Menu: Provides access to Alarms, Settings, Counters, Service, and Exit options.
Alarm Screen: Displays active alarms, their descriptions, and guidance on how to clear them. The Alarm LED blinks for active alarms and is fixed red if technical assistance is needed.
Editing Parameters: Allows modification of unprotected parameters such as Automatic Restart After Voltage Failure (ARAVF), language, and display time-out. PDP sensor parameters (control, dewpoint setpoint, temperature unit) can also be configured with a specific password.
Inputs Menu: Shows measured data and the status of inputs like vessel pressure, blower pressure, and dryer inlet temperature.
Outputs Menu: Displays the actual status of outputs such as the dryer motor, PDP alarm, general shut-down, and general warning.
Counters Menu: Tracks running hours, loaded hours, dryer starts, regulator power-on hours, actual state time, programmed state time, actual half cycle time, programmed half cycle time, regeneration cycles for each vessel, standby time, energy saving from PDP sensor, average heating power, and module hours.
Event History Menu: Provides data on the last shutdown and emergency stop events, including date, time, and dryer status.
Test Menu: Allows depressurization of vessels and testing of output contacts when the dryer is stopped.
Service Menu: Used to reset service plans, check upcoming service plans, review past service actions, and modify programmed service intervals. Service levels (A, B, C) are defined with programmed running hours and real-time hours, triggering warnings when intervals are reached.
Protections Menu: Lists all shutdown and shutdown warning settings and actual readings, with active alarms highlighted.
Week Timer Menu: Enables programming of time-based start/stop commands and change-over commands for the net pressure band. Four different week schemes can be programmed, and a week cycle of 10 weeks can be defined, with each week assigned one of the schemes. A "Remaining Running Time" can be set to override the week timer for continuous operation.
Info Menu: Displays the Pneumatech internet address.
Modifying Settings: Allows modification of various settings including network settings (Ethernet, CAN), general settings (language, time, date, date format), regulation settings (PDP Extended Cycle, PDP Switching Temperature, PDP Alarm Offset, Heatless Backup Mode, Pulsed Purge Mode), and automatic restart settings (Maximum Power Down Time, Restart Delay). Access key and user password settings are also available for security.
Extra Menu: Shows actual readings for pressure dew point, relative humidity, and LAT setpoint.
Web Server: Controllers have a built-in web server for direct connection to a company network or PC via LAN, allowing remote consultation of data and settings.

Maintenance Features

The manual outlines a comprehensive preventive maintenance schedule to ensure safe and efficient operation:

Daily:

Check the display panel for information and service messages.

Every 6 months or every 4000 hours of operation (Service plan A):

Check for damaged wiring or loose connections.
Check for air leaks.
Replace the in- and outlet filter cartridges (if installed).
Replace the blow-off silencer.
Replace the regeneration silencer (if installed).

Every year or every 8000 hours of operation (Service plan B):

Perform Service plan A.
Calibrate/replace the pressure dew point (PDP) sensor (if installed).

Every five years or every 40000 hours of operation (Service plan C):

Perform Service plan B.
Replace the desiccant.
Replace the blow-off valve.
Replace the regeneration angle seat valve (if installed).
Replace the regeneration solenoid valve (if installed).
Always replace all O-rings, seals, and nylon washers during scheduled maintenance.

General Maintenance Guidelines:

All maintenance work must be performed by authorized, trained, specialized personnel.
Before any maintenance, the dryer must be stopped, depressurized, and the power isolating switch opened and locked.
Only genuine spare parts and correct tools should be used.
Cleanliness must be observed during maintenance; parts and openings should be covered.
Safety devices, guards, and insulation must never be removed or tampered with.
Operating pressures, temperatures, and time settings must be checked after maintenance.
The desiccant has an approximate lifetime of 5 years and should be replaced by a qualified service technician.
Service timers must be reset after maintenance.

Nozzle Replacement:

Nozzles are located on the top of the upper manifold.
Replacement involves releasing push-fits on elbow fittings, pulling out the nozzle assembly, and installing a new nozzle suitable for the working pressure. Spare nozzles should be stored inside the unit.

Disposal:

At the end of its life, the machine must be stopped, secured (LOTO, cool-down, depressurize, discharge), and harmful components separated.
The equipment is marked with the crossed-out wheelie bin symbol, indicating it must be taken to separate collection according to European Directive 2012/19/EU (WEEE).
Used filters, filter bags, filter media, desiccant, lubricants, cleaning rags, and machine parts must be disposed of in an environmentally friendly and safe manner, in line with local regulations.