Parker BSP-MT 10-95/D3 Operating Manual

Operating manual 14/02/2022 - rev02 EN Cod: 398H271981 ( Generation - 3)

BSP-MT 10-95/D3 1 Index Machine passport 3 General information 4 Manufacturer’s details .............................................................................................................. 4 Details on the dryer ................................................................................................................... 4 About these operating instructions ........................................................................................... 5 For your own safety 6 General safety notes ................................................................................................................. 6 Intended use of the dryer .......................................................................................................... 7 Signs, instruction plates and danger zones at the dryer ........................................................... 8 Transportation, installation and storage 10 Information on transportation packaging ................................................................................ 10 What to do in the case of transport damage occurring? ........................................................ 10 Transporting and installing the dryer ....................................................................................... 11 Storing the dryer ..................................................................................................................... 13 Technical product description 14 Summary Drawing Standard Dryer* ........................................................................................ 14 Function description ............................................................................................................... 14 Available options ..................................................................................................................... 17 Installation 18 Preconditions for installation .................................................................................................. 18 Connect piping ....................................................................................................................... 19 Installing the electrical connection .......................................................................................... 20 Start-up 22 Requirements for initial start-up ............................................................................................. 22 Setting times of the operating phases .................................................................................... 23 Overview of operating and control elements .......................................................................... 23 Start up dryer .......................................................................................................................... 26 Changing cycle mode (optional) ............................................................................................. 28 Monitoring dryer operation 29 With dewpoint-sensing control (optional) ............................................................................... 29 Shutdown and restart dryer 30 Emergency shutdown ............................................................................................................ 30 Depressurising and shutting down the dryer .......................................................................... 30 If work is to be carried out on the electrical system ............................................................... 31 Restart .................................................................................................................................... 31 Maintenance and repair of the dryer 33 Notes on maintenance ............................................................................................................ 33 Regular maintenance intervals ................................................................................................ 34 Instructions for use of the dongle ........................................................................................... 35 Daily maintenance tasks ......................................................................................................... 36 Maintenance work to be completed every 12 months ............................................................ 37 Notes on further maintenance work ........................................................................................ 39 Identify and eliminate faults 40 Summary of faults ................................................................................................................... 40 Annex with technical documentation 44

2 BSP-MT 10-95/D3 Technical data ......................................................................................................................... 45 Replacement and wear part list .............................................................................................. 47 Tightening torque values ......................................................................................................... 49 Logic control diagram ............................................................................................................. 50 Flow diagram .......................................................................................................................... 52 Dimensional drawing .............................................................................................................. 53

Machine passport BSP-MT 10-95/D3 3 Machine passport It is the responsibility of the owner, ◊ to enter for the fi rst time any appliance data not stated above, ◊ to keep these appliance data up to date. The above-stated appliance data provide for a clear identifi cation of the dryer and its compo- nents, and signifi cantly facilitate any service measures. Further important data on the dryer such as the details on the permissible operating pressure and the electrical connection are found on the type plate (for position of the type plate see page 8 )

General information 4 BSP-MT 10-95/D3 General information Manufacturer’s details Name and address Parker Hannifi n Manufacturing S.r.l. Sede Legale: Via Sebastiano Caboto 1, Palazzina “A” 20094 Corsico (MI) Italy Sede Operativa: Gas Separation and Filtration Division EMEA - Strada Zona Industriale, 4 35020 S.Angelo di Piove (PD) Italy tel +39 049 971 2111- fax +39 049 9701911 Web-site: www. parker.com/hzd Details on the dryer Standard equipment Standard dryer*, consisting of ◊ 1 double-chamber hollow section vessel, fi llied with drying agent ◊ 1 single-chamber hollow section vessel, fi lled with purifying agent ◊ 2 upstream fi lter ◊ 1 downstream fi lter ◊ Muffl er ◊ Control system Associated documents ◊ Operating instructions (present) ◊ Technical documentation (see annex) ◊ Circuit diagrams (see separate document) ◊ Operating manual for installed fi lters (separate document) Notes on supplementary documents Supplementary documents such as operating manuals for options or pertaining components must always be heeded. They contain additional information, e.g. regarding maintenance, and are therefore necessary for safe operation of the plant. * Planned dryers may be equipped with special components

General information BSP-MT 10-95/D3 5 About these operating instructions These operating instructions contain basic information on the safe use of the dryer. Characters and symbols used Work steps that you have to carry out in the sequence stated are marked by black tri- angles. ◊ Lists are marked by a small box Note: These notes provide you with hints and information on the safe and effi cient handling of machines and devices. Warning! These safety notes warn against damage to property and help you to avoid such damage. Danger! These danger notes with a grey background warn against personal injury and/ or danger to life and limb; danger notes help you to avoid serious or life-threa- tening situations for yourself and/or third parties. Target group of these operating instructions These operating instructions are intended for all persons working on and using the dryer. We assume that all such persons are specialist personnel according EN ISO 7396-1. Operating instructions: handling These operating instructions must be continuously available at the site where the adsorber is used. We recommend to prepare a copy and to keep the same in a safe and freely accessible place next to the adsorber. Keep the original document in a safe place.

For your own safety 6 BSP-MT 10-95/D3 For your own safety The dryer has been built in accordance with the state of the art and the recognized technical safety regulations. Nevertheless, there is a risk of personal injury and damage to property when the dryer is used, if ◊ it is operated by non-qualifi ed personnel, ◊ not used within its intended design specifi cations, ◊ is repaired or maintained incorrectly. Note: For your own safety and to prevent machine damage, please note the informa- tion and safety notes in these operating instructions when working with the dryer. General safety notes Warning against sudden air ejection When the hollow section vessels are depressurised, air fl ows suddenly out of the sound absorber. ◊ This causes a sudden loud cracking noise. ◊ Due to particles carried in the air fl ow, there is a very considerable risk of eye injury. When working on the dryer, always wear eye and ear protection equipment. Hazard due to a sudden release of pressure! Never remove any parts of the dryer, or manipulate the same in any way, for as long as the plant is still pressurised! A sudden escape of pressure may cause serious injuries. Before carrying out any work on the dryer, fi rst depressurise the plant. Risk of injury due to voltage-carrying parts! The electrical supply cable and external power lines are live even after the dryer is switched off and, in the event of body contact, may cause serious injury! Before carrying out any work on the electrical system, the electrical supply cable and all external power lines must be made voltage-free! Personnel qualifi cation Only authorized and qualifi ed specialist personnel may be tasked with the work on the dryer described in these operating instructions. Conversions and modifi cations Without prior approval by the manufacturer, no conversions and modifi cations must be made to the dryer! Any non-approved modifi cations may restrict the operational safety of the dryer and cause damage to property or personal injury. Handling drying agents The drying agents used do not pose any risk to health. However, when fi lling and emptying the hollow section vessels with drying agents, increased dust generation may occur. Please comply with the following instructions: ◊ When fi lling drying agents, wear a dust mask and eye protection! ◊ If a spillage occurs, any spilt drying agent must be taken up immediately. There is a risk of skidding!

For your own safety BSP-MT 10-95/D3 7 Disassembly and disposal ◊ Dispose all parts of the dryer, the drying agent, and all other operating materials in an envi- ronmentally safe way and in accordance with all current statutory regulations. Intended use of the dryer The dryer is exclusively intended for drying compressed air. Depending on defi ned input conditions, it dries compressed air for industrial use. The dryer is designed for compressed air, which is free from aggressive water, oil, and solid matter constituents. As standard, the dryer is intended to be sited within a building and protected against the weather. The dryer may be operated only in accordance with the data on the type plate and in accord- ance with the contractual conditions. Suspected misuse The dryer must not be misused as a climbing aid! Pipes, valves, and similar fi ttings have not been designed for such loads. They could fracture, tear off, or become damaged in another way.

For your own safety 8 BSP-MT 10-95/D3 Signs, instruction plates and danger zones at the dryer Signs and instructions Front view Please note the above plates and instructions attached to the dryer. Ensure that they are not removed and are always readable. Type plate of the upstream fi lter Type plate of the dryer Vessel plate Type plate of the down- stream fi lter

For your own safety BSP-MT 10-95/D3 9 Hazard areas on the dryer Symbol Hazard area Warning against hazardous electrical voltage Different parts of the dryer carry electrical current. These parts may be connected, opened, and maintained by authorized specialist personnel only. Warning against overpressure The entire dryer is under pressure. Before commencing any work, the plant must be depressurised. Warning against sudden air ejection When the vessels are depressurised, air fl ows suddenly out of the sound absorber: ◊ This causes a sudden loud cracking noise. ◊ Due to particles carried in the air fl ow, there is a very considerable risk of eye injury. When working on the dryer, always wear eye and ear protection equipment. Skid risk When emptying and fi lling the vessels with drying agent, there is a risk of skidding caused by spilt drying agent. Hazard caused by overpressure Hazard caused by electrical voltage Hazard caused by sudden air ejection during expansion Risk of damage to eyes

Transportation, installation and storage 10 BSP-MT 10-95/D3 Transportation, installation and storage Danger due to incorrect transportation! The dryer must be transported by authorized and qualifi ed specialist personnel only. During transportation all applicable national regulations for accident pre- vention must be complied with. Otherwise there is a risk of personal injury. Always adhere to the stickers and notes on the packaging of the dryer! ◊ Only use suitable and technically perfect lifting gear with a suffi cient carrying capacity. During transportation the dryer must be carefully secured against falling over. The manufacturer will not be liable for any damage caused by incorrect storage or incorrect transportation. Please note therefore the following instructions as well as the storage instruc- tions on page 13. Information on transportation packaging Depending on the type of transportation, the dryer is delivered in different types of packag- ing: ◊ All transportation types: the apertures of the dryer are closed off by means of plugs. ◊ In addition, when transportation is effected by air: the dryer is packaged in a wooden box. ◊ In addition, when transportation is effected by ship: the dryer is packaged in a fi lm material and in a wooden box. If the packaging is undamaged The undamaged packaging should be removed only at the fi nal installation site, as it offers protection against any weather infl uences. What to do in the case of transport damage occurring? Check whether only the packaging or the dryer itself were damaged. Inform the haulier immediately in writing of any damages. Contact the manufacturer urgently in order to report the damage. Warning! A damaged dryer must not be taken into operation! Damaged components may lead to functional faults and possibly cause further damage.

Transportation, installation and storage BSP-MT 10-95/D3 11 Transporting and installing the dryer Requirements for the installation site The conditions at the installation site have a large infl uence on the functional capability of the dryer and the service life of the drying agent. In order to ensure a mode of operation, which is as continuous as possible, and low maintenance, the installation site must meet the following requirements: ◊ The installation site must be located within a building. Protect the dryer against moisture. ◊ The ambient temperature must not drop below +1,5 °C (34,7 °F). ◊ Heed the dryer’s noise emission when selecting the installation location. ◊ The installation area must be level, fi rm and vibration-proof. It must have the necessary car- rying capacity for the weight of the dryer. The weight of the dryer is specifi ed in the technical data section of the annex. ◊ The dryer should be installed with suffi cient spacing at the top, sides, and rear, in order to be able to carry out maintenance work and change the drying agent without any hindranc- es (see fi gure). If in doubt, the installation site must be inspect- ed by specialists. If you have any queries in this regard, please contact the manufacturer (see pag. 4 Necessary spacing at the top and sides = min. 1 m Transportation using lifting or forklift trucksr Warning against damage to property! The dryer is delivered standing on its side on a transportation pallet. Top and sides have not been designed for mechanical loads. Therefore do not place any load onto the top face. Do not stack. Therefore, always transport the dryer on a lifting or forklift truck. The dryer should only be transported in an upright position. Secure the dryer on the lifting or forklift truck against sliding movements. Transport the dryer to its installation site.

Transportation, installation and storage 12 BSP-MT 10-95/D3 Installing the dryer Caution! Always use the lifting lugs at the top of the tank to lift the dryer. Use a lifting beam with a suitable spacing for this purpose. This will ensure the tanks can- not come in contact with the upper pipe bridge and thus damage it. Remove the packaging of the dryer. Attach suitable lifting gear to the transport lugs of the vessels (see fi gure I). Raise the dryer (see fi gure II) and remove the transportation pallet. Place the dryer at its installation site. I: Transport lugs on pressure vessel II: Installing by crane Anchoring the dryer Use suitable attachment material to anchor the dryer to the fl oor. In the case of vibrating fl oors: place the dryer on suitable vibration dampers.

Transportation, installation and storage BSP-MT 10-95/D3 13 Storing the dryer If the dryer is to be stored for an extended period of time, the storage location must meet the following conditions: ◊ The dryer must not be stored in the open air. ◊ The storage room must be dry. ◊ The storage room must be free from dust or the dryer must be covered by a protective sheet. ◊ The storage room must have an ambient temperature of at least +1 °C (33,8 °F). In order to store the dryer proceed as follows: Take dryer out of operation as described on page 30. Ensure that the compressed air inlet valve installed by the owner, and the installed compressed air outlet valve installed by the owner, are both closed, and that the dryer is depressurised. Disconnect dryer from the compressed air system. Disconnect the dryer from the electrical power supply and all external lines. Use fi lm material or similar to close the compressed air inlet apertures and compressed air outlet apertures on the dryer in order to protect them against contamination. If possible cover dryer with a protective sheet. The dryer can now be stored for long periods. Note: If you wish to take the dryer back into service after an extended period of sto- rage, please proceed as described for its fi rst commissioning and start-up (see page 26). Store drying and purifying agents Do not store drying agents in the open air. Protect drying and purifying agents against humidity.

Technical product description 14 BSP-MT 10-95/D3 Technical product description Summary Drawing Standard Dryer* Function description The dryer dries and purifi es the compressed air supplied by the compressor and provides medical breathing air. The air is thereby dried alternately in one of the drying agent vessels. The dried air is subse- quently purifi ed in the third vessel, whereby oil residue and other contaminants are removed. Before the compressed air is fed into the dryer, it fl ows through upstream fi lters where dust, dirt, oil and water droplets are removed. Thus, the installed upstream fi lter is also used for extending the service life of the drying agent. The installed downstream fi lters clean the compressed air from drying agent abrasions, be- fore it is fed into the compressed air system. The two vessels contain an extremely porous drying agent by means of which humidity is removed from the compressed air and stored just as in a sponge. The stored humidity is then removed again from the drying agent and re-introduced into the ambient environment. To this end, the two vessels alternate between different operating modes. Whilst in one ves- sel, compressed air is de-humidifi ed (adsorption), in the other vessel the humid drying agent is prepared for another charge (regeneration). These two states, which run in parallel during compressed air preparation, are described below. Check valve block Compressed air outlet On/Off-Switch Compressed air inlet Upstream fi lter Power supply connector Downstream fi lter Control cabinet Muffl er Discharge point Vessel Vessel pressure gauge Pressure dew point Transport lugs Solenoid valve block

Technical product description BSP-MT 10-95/D3 15 Adsorption Via a compressor, humid compressed air is supplied to the upstream fi lter. From here, the compressed air fl ows upwards through the absorption vessel, which is pressurised. In so doing, the drying agent dehumidifi es the air. The dried compressed air is supplied to the pipe network via the purifying vessel and the downstream fi lter. Here, adsorption is shown in the left vessel. Regeneration (running in parallel to the adsorption) At the same time the other chamber is prepared for a renewed take-up of humidity. This process is called regeneration. The regeneration is subdivided into three phases: expansion, dehumidifi cation, and pres- sure build-up. With the dewpoint-sensing control option, the regeneration phase is followed by a standby phase. Expansion phase During the expansion phase the pressure in the right chamber is released via the muffl er down to ambient pressure within just a few seconds. The outfl ow of the compressed air becomes noticeable due to a sudden powerful fl ow noise at the muffl er. Dehumidifi cation phase Prior to being released into the pipe network, dried compressed air is bled by means of an orifi ce plate. This separate regeneration air fl ow is fed through the depressurised chamber. The humidity stored in the drying agent is taken up by the air fl ow and expelled into atmosphere via the muffl er. Here, regeneration is shown in the right vessel.

Technical product description 16 BSP-MT 10-95/D3 Pressure build-up phase After dehumidifi cation the pressure in the regenerated hollow section vessel is built up to operating pressure, so that the switchover from regeneration to adsorption can take place at operating pressure level. Pressure build-up Standby phase (only with the dewpoint-sensing control option) When in standby phase, the fully regenerated vessel is ready for absorption operation. The system is switched to this vessel, as soon as the measured dewpoint at the compressed air outlet has reached the set dewpoint value for switchover. Switchover When the drying agent in the adsorbing chamber has taken up a suffi cient level of humidity, then the switchover between the vessels will be effected between the vessels. Following switchover, the above-described process is repeated, with the adsorption and regeneration now taking place in the respective different vessel.

Technical product description BSP-MT 10-95/D3 17 Available options The following options are available for the dryer: ◊ Start-up device ◊ Signalling contacts of control system and compressor synchronisation ◊ Dewpoint-sensing control ◊ Fine fi lter muffl er ◊ Nozzle kit Start-up device A start-up device basically consists of a pressure holding device, which is located at the rear of the dryer. The pressure holding device ensures that pressure can build up in the dryer and adsorption take place. It is always required when an empty compressed air reservoir or an empty compressed air system must be fi lled downstream of the dryer (e.g. following weekend shutdowns and when the pressure in the compressed air system can frequently drop below the stated operating pressure). Signalling contacts of the control system & compressor synchronisation The control system is equipped with a digital input for the synchronised operation with a compressor. This feature allows for synchronised and thus effi cient dryer operation with discontinuous compressor operation. Compressor synchronisation helps reduce energy costs, as the dryer can be operated inde- pendently of the compressor. The compressor synchronisation controller is a higher-level controller than the pressure dew point controller (see below). When both options are in place, the compressor synchronisation controller is treated as the prime controller. The control system can also be equipped with an optional operation signalling contact with which the dryer operation can be monitored from an external device. Dryers with the optional dewpoint-sensing control are equipped with such a contact as standard. It is used for the transmission of operating signals and for the output of dewpoint alarms. Dewpoint-sensing control With a dewpoint-sensing control system, you can operate the dryer in fi xed or variable cycles. In the fi xed cycle, switchover is effected after a fi xed time period (usually after 5 minutes). In the variable cycle, the switchover is effected in relation to the dew point reached and the charging of the drying agent . The adsorption time in the variable cycle amounts to 60 minutes maximum. Fine fi lter muffl er A fi ne fi lter muffl er is used to reduce the noise emission of the dryer to lower levels than the standard muffl er can provide. If installed, the fi ne fi lter muffl er replaces the original installed muffl er. Nozzle kit In the case that the operating pressure deviates from the standard design pressure (7bare) it is possible that the amount of necessary regeneration air changes. This effect may have a negative impact on the cost-effectiveness of the dryer. To prevent this, it is possible to replace the built in regeneration air nozzle by a nozzle with a modifi ed bore. This replacement optimizes the regeneration air consumption and therefore restores the energy effi ciency of the dryer. To receive more information on this conversion, please contact the manufacturer.

Installation 18 BSP-MT 10-95/D3 Installation Only authorized and qualifi ed specialist personnel may carry out work on pipes and electrical systems. As soon as the dryer has been set up at its installation location, you can install the com- pressed air infeed and outlet lines make the electrical connections. Preconditions for installation For a correct installation the following preconditions must be met on the part of the owner. ◊ Connections and lines for the infeed and outfeed of compressed air must be provided. ◊ A compressed air inlet valve as well as a compressed air outlet valve must be installed by the owner, so that the dryer can be installed and maintained in a depressurised condition (see also the installation example on page 19). ◊ All pipes, couplings, and connections must have the correct diameter and match the oper- ating pressure. Hazard caused by exceeding the limit values! A safety device must be provided in order to protect against the maximum permissible operating pressure from being exceeded. The safety device must be installed so that the dryer is reliably protected from exceeding the maximum permitted operating pressure even when the tempera- ture of the compressed gas increases. The data required to meet these preconditions are contained in the technical documentation attached in the annex. Warning! If the above preconditions are not complied with, a safe operation of the dryer cannot be assured. Also, the functionality of the dryer may be detrimentally affected.

Installation BSP-MT 10-95/D3 19 Connect piping In order to ensure that the dryer operates optimally, the dryer must be assembled into the compressed air system free of all stresses. Ensure before connection that all infeed and outfeed compressed air lines and valves are clean and undamaged. Check the bolt connections and retighten if necessary, as they could have worked loose during transportation. Remove plugs on the pressure inlet and outlet. All piping must be free from any stress and tension whatever! Pipes subject to stress may burst due to the load placed on them during opera- tion. This may cause damage to property and personal injury. Use steel pipes to connect the dryer to the compressed air system. The following fi gure shows an installation example. Compressed air system Item. Component Example of an installation with bypass line 1 Entry, humid air 2 Compressed air inlet valve, owner end 3 Upstream fi lter 4 Dryer 5 Downstream fi lter 6 Compressed air outlet valve, owner end 7 Outlet, dry air The connection lines for the upstream fi lter (3) are to be installed at a slight incline in the direction of the upstream fi lter. One shutdown valve each (2, 6) is to be installed at the compressed air inlet and outlet ends of the dryer.

Installation 20 BSP-MT 10-95/D3 Installing the electrical connection Warning against electrical voltage Only qualifi ed specialist personnel may carry out work on the electrical system! Installing the supply cable The components of the dryer have been connected to the control cabinet at the factory. You only need to connect the control cabinet to the electrical supply cable. The switchbox is provided with a connector where electrical power must be connected. Ensure that the cross-section of the electrical supply cable corresponds to the power rating of the dryer and the electrical voltage provided by the customer. Make the electrical supply cable to the dryer voltage-free. Secure the electrical supply cable to the dryer against switch-on. Undo bolt (1) on the connector and withdraw connector with seal from the switchbox. Use a suitable tool to remove the terminal block from the connection box. Undo the PG union and pull the cable th- rough the aperture (3). The exposed phase ends should not be longer than 35 mm max. Now make the cable connection as follows: — .. Earth to terminal PE — ..L1 to terminal 1 — .. N to terminal 2 Terminal 3 is not used. Fit terminal block into the connector and use bolt to remount the connector with seal on the switchbox. Connect electrical cable to device adapter In all phases the dryer must be protected against short circuits by means of fuses. In order to relief cable strain, re-tighten the PG union. Connecting the external signalling lines Note: For the use of the dryer in redundant systems (according to the European Phar- macopoeia) with imposed control, we recommend - operation of the dryer in synchronised compressor mode, and - operating intervals of minimum 24 hours, in order to achieve the desired dewpoint and regular cycles.

Installation BSP-MT 10-95/D3 21 For compressor synchronisation The controller is fi tted as standard with a digital input which makes the dryer regeneration dependent on operation of the compressor (switch S1 on the controller’s circuit board, see also fi gure below). If switch S1 is in the ON position, operation of the compressor and dryer regeneration run synchronously: When the compressor is stopped, the dryer regeneration also stops. When the compressor is restarted, regeneration also restarts. If switch S1 is in the OFF position, any regeneration process which has been started, is always continued until completed. To install the external line, proceed as follows: Connect the signalling line to the potential-free busbar connection of the compressor to terminals 1 and 2 on the control board (see circuit diagram). Hinweis: The compressor synchronisation controller is a higher-level controller than the pressure dew point controller. When both options are in place, the compressor synchronisation controller is treated as the prime controller. For operation monitoring system (optional) Operators have the option to connect the dryer to a fault signalling system, connecting the respective line to a potential-free operation signalling contact. With this option, the following statuses and events can for example be transmitted to a remote control room: ◊ Dryer on (contact made) ◊ Power supply disconnected (no contact) ◊ Dewpoint alarm (only with dewpoint-sensing control option, no contact) To install the external lines, proceed as follows: Connect the lines of the fault signalling system to relay K5 (see circuit diagram). Check bolt connections Before the initial start-up: Check all unions and bolt connections as well as the terminals in the control cabinet for secure seating; re-tighten if necessary.

Start-up 22 BSP-MT 10-95/D3 Start-up Warning! The dryer must be taken into operation by trained personnel only! Untrained personnel does not have the required knowledge. Such personnel might cause serious faults. Note: You can order the initial commissioning and start-up from the manufacturer and have your personnel trained by the manufacturer. For telephone number, see page 4. ◊ Carry out all prescribed tests and checks. ◊ Before start-up, ensure that no tools or other foreign parts have been left lying in a part of the dryer where they might pose a hazard to the dryer being started up. Requirements for initial start-up For the fi rst start-up the following preconditions must have been met: ◊ The pipe system is free from contaminations. ◊ All shutdown valves are closed. ◊ The dryer is correctly sited and installed. Checks before start-up Ensure that ◊ all pipe, cable and bolt connections on the dryer have been retightened, ◊ no pipes chafe against body edges, ◊ all mountings are perfectly secure, ◊ the needle valve of the oil indicator is closed, ◊ the electrical connections are in safe contact and in good condition, ◊ owner-end and pressurised parts such as safety valves or other devices are not blocked up by dirt or paint, ◊ all compressed air system parts which are pressurised (valves, hoses etc.) are free from wear symptoms and defects.

Start-up BSP-MT 10-95/D3 23 Setting times of the operating phases In its standard version the dryer is delivered with a time-dependent control system. The phase sequence occurs in a fi xed cycle. With the optional dewpoint-sensing control, the dryer can also be operated at variable cycles (depending on the dewpoint). The following table provides information on the duration of the individual phases Phase duration Fixed cycle Variable cycle Adsorption 5 min 10 min, max Regeneration, total 5 min 5 min - of which: expansion time ~ 0,2 min ~ 0,2 min - of which: dehumidifi cation time ~ 4 min ~ 4 min - of which: pressure build-up ~ 1 min ~ 1 min Standby -- ~ 5 min, max. Overview of operating and control elements ON/OFF switch The ON/OFF switch (2) is located to the side of the switchbox and above the mains plug (1, see fi gure): ◊ If it is set to 0, the power supply is disconnected and the dryer is switched off. The main valves are (V1, V2) are open, while the expansion valves (V3, V4) are closed. This means that the air can circulate in the main processing direction, even if the dryer is switched off. ◊ If the switch is set to I, the dryer is switched on and begins to operate in fi xed cycle mode (i.e. time-controlled). ◊ If the switch is set to position II, the dryer is switched on and begins to operate — with compressor synchronisation — in variable cycle mode (i.e. dew-point-cont- rolled). Position II is only relevant for operation with the optional compressor synchronisation and/ or dewpoint-sensing control Switchbox with ON/OFF switch

Start-up 24 BSP-MT 10-95/D3 Display panel The display panel at the switchbox is equipped with LEDs (light emitting diodes) and a digital display, indicating the operating status of the dryer: Display panel at the switchbox LED Power (1) LED is on when dryer is switched on. Flow diagram (2) The current operating phases of the dryer are indicated by means of 4 LEDs: Depending on the operating phase, the following LEDs might be on simultaneously: Adsorption B1 and regeneration B2 or regeneration B1 and adsorption B2. Vessel B1 Regeneration 1 Adsorption 1 Vessel B2 Regeneration 2 Adsorption 2

Start-up BSP-MT 10-95/D3 25 Digital display (3) The digital display shows the individual programme steps and the respective remaining time. For details regarding the sequence of the individual processing steps and their duration, please refer to the logic control diagram, page 50. Display Explanation 2 215 Default display: The fi gure to the left indicates the current processing step; the fi gure to the right shows the remaining time in seconds. In this example, step 2 is being completed, whereby there are 215 seconds remaining. SEr After 8000 operating hours, “SEr.” (service) is displayed for periods of 1 minute, alternating with the default display. Notify the service personnel of the manufacturer, as a routine service is now due. -25 With the dewpoint-sensing control option, the display shows the currently measured dewpoint instead of the default data. The range of display is 100 °C (-148 °F) to +20 °C (68 °F). If the measured dewpoint exceeds the preset alarm limit (5 °C (41 °F) above the switchover value), the displayed dewpoint value is fl ashing. With the optional dewpoint-sensing control, the following error messages might be dis- played: Display Cause +20 ◊ Upper measuring range limit exceeded 999 ◊ Dewpoint sensor defective. sens o -999 ◊ Dewpoint sensor not powered ◊ Cable defective or disconnected ◊ Sensor defective LED Economy cycle (4) This LED is only relevant in units that are equipped with the optional dewpoint-sensing control. The diode lights up when the dryer is switched on and in the standby phase and no regeneration air is required.

Start-up 26 BSP-MT 10-95/D3 Start up dryer Warning against sudden air ejection! During expansion the pressure is released suddenly through the muffl er: ◊ A loud cracking noise occurs which can injure your hearing. ◊ Particles carried in the air fl ow act like bullets and can injure your eyes or skin. Always wear eye and ear protection, therefore, when you are in the vicinity of the dryer! Hazard due to a sudden release of pressure! Never remove any parts of the dryer, or manipulate the same in any way, for as long as the plant is still pressurised! A sudden escape of pressure may cause serious injuries. Before carrying out any work on the dryer, fi rst depressurise the plant. ◊ The more powerful the dryer is, the more noise may be generated during operation. There- fore, the operator must provide suitable protective equipment (e. g. ear protection). ◊ Only operate the dryer within the permissible limits. By operating the dryer in conditions for which it has not been designed, functional faults may be caused. ◊ Depending on the size of the dryer and the compressed air network and the respective legal requirements in your country, it may be necessary to perform initialisation according to the directive for pressure equipment. ◊ Check the dryer regularly for externally visible damage and defects. Any changes, even in its operating behaviour, must be reported immediately to the competent offi ce or person. ◊ In the event of an emergency or if a safety-relevant disruption occurs (e.g. escaping com- pressed air, defective component), the dryer must be shut down immediately as described in the section on page 30). The unit may only be restarted after all defects have been eliminated. Open compressed air supply and switch on dryer For start-up, please proceed in the sequence shown here. Ensure that the compressed air inlet and outlet valves installed by the owner are closed (see installation example on page 19). Ensure that the compressed air system upstream of the dryer is pressurised. If necessary, pressurise (switch on compressor). Slowly open compressed air inlet valve! Avoid sudden pressure build-up in any circumstance! If pressure builds up too fast, this may cause damage to the dryer. Therefore, the compressed air inlet valve must always be opened quite slowly! Slowly open the compressed air inlet valve, installed by the owner, upstream of the dryer. Switch on dryer: to this end, set the ON/OFF switch to I If the dryer is taken into operation for the fi rst time, or after a change of drying agent, the following intermediate step is meaningful. In the case of a restart situation, the following intermediate step can be skipped.

Start-up BSP-MT 10-95/D3 27 Operating the dryer for the fi rst time (or after a change of drying agent) separately Depending on the transportation and storage conditions, the drying agent in the chambers can already be loaded with humidity from the environment. At each fi rst start-up it makes sense therefore to operate the dryer from some time separately from the compressed air system. This causes the drying agent in each chamber to be regenerated repeatedly and thus to be prepared optimally for the take-up of humidity. Note: Depending on the pressure dew point to be achieved, we recommend to oper- ate the dryer at fi rst start-up: ◊ for pressure dew point of –25 to –40 °C: without compressed air consump- tion for at least 4 hours; ◊ for pressure dew point of –70 °C: without compressed air consumption for 1 day and then at a reduced nominal fl ow of 50% during the next 6 to7 days without regard for the dew point. If you wish to take the dryer into operation in accordance with our recommendation, proceed as follows: Ensure that the compressed air outlet valve installed by the owner is closed. Keep the compressed air outlet valve closed for the time period recommended above. Then the dryer can be taken into service in the compressed air system as described in the following section: Operate dryer immediately in the compressed air system Ensure that the compressed air system downstream of the dryer is pressurised or that a start-up device (option, see page 17) was installed into the compressed air system directly downstream of the dryer. The importance of this increases with the size of the compressed air system downstream of the dryer. Smaller compressed air systems can be pressurised also by means of compressed air fed through the dryer. Slowly open compressed air outlet valve! Avoid a sudden drop in pressure in any circumstance! If pressure drops too fast, this may cause damage to the dryer. Therefore, the compressed air outlet valve must always be opened quite slowly! Slowly open the compressed air outlet valve installed by the owner. The pressure should not drop below the operating pressure (if poss.). If necessary, keep the compressed air outlet valve in a slightly open position until the compressed air system downstream of the dryer has fi lled up completely; only then should the valve be opened fully. The dryer has then be taken into operation within the compressed air system. In the event of a fault In the event of an emergency or if a safety-relevant disruption occurs (e.g. escaping com- pressed air, defective component), immediately close the compressed air supply line and set the ON/OFF switch of the dryer to 0 in order to disconnect it from the power supply. After- wards depressurise the dryer (see also chapter , page 30). Then proceed as follows: Remedy fault: Look up possible cause of the fault, and how to remedy the same, in the table on page 40. Remedy fault. Repeat the start-up procedure.

Start-up 28 BSP-MT 10-95/D3 Changing cycle mode (optional) When can I change cycle mode? If the dryer has been successfully commissioned and is equipped with one of the following options: ◊ compressor synchronisation or ◊ dewpoint-sensing control it can be set to economy cycle mode. When should I change cycle mode? Cycle changes should be made during the pressure build-up phase and prior to switchover; during this phase, the pressure in both vessels is just below operating pressure so that a fast pressure build-up is prevented when the vessels are switched. During this period, only the adsorption LED is on in the diagram, and the digital display shows step 4 or step 9 for the duration of 1 minute (see logic control diagram; not displayed with dewpoint sensing). Which cycle modes can I choose? If the dryer is connected to a compressor synchronisation system and is equipped with the dewpoint-sensing control option, these two optional devices can only started together. The compressor synchronisation has thereby precedence over the dewpoint-sensing control. With compressor synchronisation If compressor synchronisation is enabled, the dryer can only be operated in conjunction with the compressor. As soon as the compressor is switched off, the dryer is automatically set to standby mode. In standby mode, the control system remains on, and the dryer is ready for the next switcho- ver, which is made as soon as the compressor is switched on. Note: The compressor synchronisation controller is a higher-level controller than the pressure dew point controller. When both options are in place, the compressor synchronisation controller is treated as the prime controller. With dewpoint-sensing control Dryers equipped with dewpoint-sensing control operated in variable cycle mode, based on the measured dewpoint of the dried air at the compressed air outlet. As soon as a certain dewpoint is reached, as the drying agent in the absorbing chamber is saturated, the cham- bers are switched. The dewpoint at which a switchover is made is preset at the factory. How do I change cycle mode? Wait until the dryer has reached the pressure build-up phase (phase prior to switchover). One LED for Adsorption B1/B2 is on in the fl ow diagram. Set the ON/OFF switch to position II. The programme continues the cycle.

Monitoring dryer operation BSP-MT 10-95/D3 29 Monitoring dryer operation The dryer operates fully automatically. However, you should carry out the regular checks described in the Chapter Maintenance and repair of the dryer. Warning against sudden air ejection! During expansion the pressure is released suddenly through the muffl er: ◊ A loud cracking noise occurs which can injure your hearing. ◊ Particles carried in the air fl ow act like bullets and can injure your eyes or skin. Always wear eye and ear protection, therefore, when you are in the vicinity of the dryer! With dewpoint-sensing control (optional) Display of dewpoint If the dryer is equipped with a dewpoint-sensing control system, the digital display at the front of the switchbox shows the currently measured dewpoint. The range of display is –100 °C (-148 °F) to +20 °C (68 °F). If the set dewpoint is exceeded, the system automatically completes a switchover between the chambers. The dewpoint at which a switchover is made is preset at the factory. After commissioning or extensive maintenance work, check the dewpoint display at the dryer. Under certain circumstances, the desired dewpoint is only reached after prolonged operation. Error messages If the measured dewpoint exceeds the preset alarm limit (5 °C (41 °F) above the switchover value), the displayed dewpoint value is fl ashing. In addition, an error message can be issued through the potential-free busbar. Error codes and their causes: Display Cause +20 ◊ Upper measuring range limit exceeded 999 ◊ Dewpoint sensor defective sens o -999 ◊ Dewpoint sensor not powered ◊ Cable defective ◊ Sensor defective For instructions on how to eliminate faults, see chapter Identify and eliminate faults

Shutdown and restart dryer 30 BSP-MT 10-95/D3 Shutdown and restart dryer In the following cases, the dryer must be fully shut down and depressurised: ◊ In the event of an emergency or malfunction ◊ For maintenance work ◊ For dismantling Risk of injury from escaping compressed air! Never remove any parts of the dryer, or manipulate the same in any way, as long as the unit is pressurised! Suddenly escaping compressed air might cause serious injuries. Prior to any work, release all pressure from the unit. Caution! Risk of damage to the dryer, if it is switched off during the expansion or drying phase. During these phases, the pressure in the regenerating chamber is released to ambient pressure: If the main valve is opened, as the dryer is switched off, there is a sudden pressure build-up in the chamber. This might result in ◊ damage to the drying agent, and ◊ excessive abrasion, with negative impact on the regeneration capacity. Before switching off the dryer, wait until it has reached the pressure build-up phase or is in standby mode (before switchover). Note: If the unit is equipped with a compressor synchronisation system, fi rst switch off the compressor and then wait until the dryer has reached the standby phase before switching it off with the ON/OFF switch. This ensures that the regeneration cycle is completed, and that the pressure in both chambers is at the same level. As soon as the dryer is switched on again, the programme continues the cycle from the point at which it has been stopped. Emergency shutdown To emergency shut-down the dryer heed to the following instructions: Close shut off valves upstream and downstream of the dryer (if applicable) Disconnect the electrical power supply (i.e. by switching the On/Off switch to 0). ◊ The dryer is now off-line. If applicable, depressurise the dryer now. Before re-commissioning of the dryer ensure that the emergency situation has been solved and that the dryer is not damaged. Never commission a damaged dryer! Depressurising and shutting down the dryer Close compressed air feed line Close the compressed air inlet valve (provided by the operator). Disconnect voltage supply Switch off the dryer by setting the ON/OFF switch to position 0. Disconnect dryer from compressed air system Close the compressed air outlet valve installed by the owner.

Shutdown and restart dryer BSP-MT 10-95/D3 31 If available, open bypass line. Depressurise dryer Depressurise dryer, e.g. by opening the manual drain at the downstream fi lter. If work is to be carried out on the electrical system Depressurise and shut down the dryer, following the instructions in the above chapter. Risk of injury due to voltage-carrying parts! The electrical supply cable and external power lines are live even after the dryer is switched off and, in the event of body contact, may cause serious injury! Before carrying out any work on the electrical system, the electrical supply cable and all external power lines must be made voltage-free! Make the electrical supply cable to the dryer voltage-free. Secure the electrical supply cable to the dryer against switch-on. Restart Depending on the fi ttings installed by the operator and the actual pressure conditions, the unit might have to be restarted at operating pressure. The following general rules apply: ◊ When switched off, the dryer is open in main fl ow direction. With the optional start-up de- vice , the set minimum pressure must however be reached prior to restart. ◊ If the dryer is equipped with a dewpoint-sensing control system, it is depressurised gradu- ally, according to the read measuring current. If compressed air system and dryer have remained at operating pressure Ensure that the compressed air inlet valve (provided by the operator) is open. Set ON/OFF switch to I. The programme continues the cycle from the point at which it was interrupted. Slowly open compressed air outlet valve! Avoid a sudden drop in pressure in any circumstance! If pressure drops too fast, this may cause damage to the dryer. Therefore, the compressed air outlet valve must always be opened quite slowly! Slowly open the compressed air outlet valve installed by the owner. The pressure should not drop below the operating pressure (if poss.). If necessary, keep the compressed air outlet valve in a slightly open position until the compressed air system downstream of the dryer has fi lled up completely; only then should the valve be opened fully. The dryer is now in operation again and operates fully automatically. If compressed air system and dryer have not remained at operating pressure If disconnected, reconnect the voltage supply of the dryer. Ensure that the manual drain on the downstream fi lter is closed. Pressurise and switch on the dryer as described in the section Open compressed air supply and switch on dryer on page 26. The dryer is now in operation again and operates fully automatically. After the purifying agent has been replaced The newly fi lled purifying agent contains minute dust particles that can block the downstream fi lters. We therefore recommend to complete the following steps before you restart the dryer, in order to protect your equipment: Remove the housing base and the fi lter element from the downstream fi lter.

Shutdown and restart dryer 32 BSP-MT 10-95/D3 Wear eye protection and dust mask due to increased dust generation! If the dryer is operated without downstream fi lter, there is a risk of increased dust generation. In order to avoid any eye irritations, wear protective goggles! In order to avoid any dust inhalation, wear dust mask! Restart the dryer: Switch on the dryer and pressurise as described in section Open compressed air supply and switch on dryer, page 26. The compressed outlet valve must be closed and the downstream fi lter housing must be open: Operate the dryer for approx. thirty minutes, blowing the dust particles off from the down- stream fi lter. Shut down the dryer: Close the compressed air inlet valve installed by the owner. Switch off the dryer by setting the ON/OFF switch to position 0. Reassemble the fi lter and commission the dryer (see the operating manual of the fi lter for the reassembly). Switch on the dryer and pressurise as described in section Open compressed air supply and switch on dryer, page 26. Check that the vessel and the downstream fi lter are leak tight.

Maintenance and repair of the dryer BSP-MT 10-95/D3 33 Maintenance and repair of the dryer In order to allow maintenance work on the dryer to be carried out effi ciently and without dan- ger for maintenance personnel, you should comply with the following instructions. Notes on maintenance Danger! There is a very considerable risk of personal injury, when carrying out work on the activated and pressurised dryer. Danger! Before commencing any maintenance tasks always shut down the dryer as described on page 30 ! Warning! Maintenance tasks may be carried out only by authorized and qualifi ed spe- cialist personnel, and only with the plant in a switched off and depressurised condition. Note: In order to ensure perfect maintenance and reliable operation we recommend that you conclude a maintenance contract. When exchange or replacement parts are ordered, always state the dryer type and the build no. of the dryer. These data are found on the type plate. ◊ Carry out all maintenance work only when the plant has been shut down and depressur- ised! ◊ Bolt connections must be undone with care! Note ram pressure values! Otherwise emerging media may cause personal injury. ◊ Do not modify the factory settings of the control system in any way without prior consulta- tion with the manufacturer. ◊ Never carry out any manipulations on a hollow profi le vessel or modify the same in any way! ◊ Following maintenance work, always check all fl ange and bolt connections for leakage and secure seating. ◊ Never use pipes and fi ttings as steps or holding points! The components might fracture, or the distortions which occur may cause internal damage on the dryer. There is a risk of injury by slipping off the components, components breaking off, and expanding compressed air! ◊ Never leave tools, loose parts or cloths at or on the dryer. ◊ Only use replacement parts that are suitable for the relevant function and meet the techni- cal requirements stipulated by the manufacturer. This is always the case, if you use original replacement parts only.

Maintenance and repair of the dryer 34 BSP-MT 10-95/D3 Regular maintenance intervals Note: If a chamber has been depressurised, e.g. after completion of the ex-pansion phase, and the pressure remains above 0 bar, the chamber is pressurised by what is known as ram pressure. This might be due to ◊ blockage at the muffl er(s) ◊ contamination of the perforated plates ◊ spent drying agent To prevent such malfunctions, regularly service the dryer as described below. The table provides an overview of the maintenance work to be carried out. The following pages describe some of these tasks. Maintenance work requiring the dryer to be largely disassembled is not described. We recommend to have this work to be performed by author- ised specialists. Component Maintenance task to be carried out Maintenance interval daily 12 months 24 months See page Complete dryer Carry out visual checks and function checks. • 36 Vessel pressure gauge Check dam pressure. For a dam pressure exceeding 0.3 bar: – Check muffl er. – Check dust sieve. – Check drying agent. • 36 Air quality Must be check. • 37 muffl er Replace muffl er after 1 year of operation and after renewing the dessicant. • 37 fi ne fi lter muffl er-dämpfer Replace silencer element annually and after each desiccant change. • 37 Dew point sensor (with optional dew point sensing-control) Renew • 38 Purifying agent Renew. If the fed compressed air is humid, the maintenance interval is reduced to 6 months • 39 drying agent Renew • 39 Pilot valves Renew • 39 Main valves V1/V2 Renew • 39 Expansion valves V3/V4 Renew • 39 Check valves V5/V6 Renew • 39 Solenoids Renew • 39

Maintenance and repair of the dryer BSP-MT 10-95/D3 35 Upstream and down- stream fi lter Please see the enclosed operating instructions for the attached fi lters. Maintenance work has to be carried out as specifi ed in this document. When carrying out any maintenance work, comply with the following safety instructions: Danger! There is a very considerable risk of personal injury, when carrying out work on the activated and pressurised dryer. Danger! Before commencing any maintenance tasks always shut down the dryer as described on page 30 ! Warning against electrical voltage! Only qualifi ed specialist personnel may carry out work on the electrical system! Instructions for use of the dongle If the message SEr, is displayed on the display of the Multitronic controller, the dryer is due for servicing. The message appears, fl ashing every 60 seconds, once the preset number of operating hours (e. g. 8000 oh) has been reached. After maintenance has been carried out, you can use the dongle to reset the counter to 0 and delete the message from the display. A dongle is enclosed with every service kit. Each dongle can only be used once. Switch off the controller. Caution! The electric line is still live. Do not touch live parts! Open the lid to the Multitronic controller. The circuit board in housed underneath it. Slot the dongle into the dongle interface X9 PC. Press and hold the reset key S3. Switch on the controller. The following appears in the display: for a short time 0.SET then fl ashing OFF The service counter is then reset to 0. If the following appears in the display for a short time FAIL then fl ashing OFF this means that the dongle has already been used once and cannot be used again. Switch off the controller again and remove the dongle. Dispose of the unusable dongle and use a new one.

Maintenance and repair of the dryer 36 BSP-MT 10-95/D3 Daily maintenance tasks Carry out visual and function check on the complete dryer Check dryer for external damage or unusual noise generation. Duly eliminate any defects found. If message SEr. is displayed, a routine service must be completed: Contact the service department of the manufacturer. Clean dryer Remove any loose dust by means of a dry cloth, and, if required, also by means of a moist and well wrung cloth. Clean the surfaces with a moist well wrung cloth. Check dam pressure If, following depressurisation of a vessel, e.g. after the expansion phase, the overpressure has not decreased to 0 bar, then there is a residual pressure, designated as dam pressure, in the vessel. Check for dam pressure: if the dryer functions correctly, the respective pressure gauge indicates 0 bar. Then there is no dam pressure. If the dam pressure is greater than 0.3 bar: Depressurise the dryer and shut it down (see page 30). Dam pressure can be caused by: - a blocked muffl er, - a blocked dust sieve or - drying agent which is too old. The respective necessary maintenance measures are described in the following sections.

Maintenance and repair of the dryer BSP-MT 10-95/D3 37 Maintenance work to be completed every 12 months Check air quality Especially for critical applications, we recommend to annually check the quality of the pro- cessed medical breathing air (this check should be carried out by a qualifi ed authority). Renew muffl ers The dryer is equipped with a muffl er. If the muffl er becomes blocked, a dam pressure is gen- erated which in extreme cases may cause the muffl er to burst. Hazard caused by blocked muffl er! Blocked muffl ers can cause a dangerous overpressure to build up which may cause the muffl ers to burst. Flying fragments may cause personal injury and damage to property. Therefore, the muffl ers must be replaced every 12 months and after each change of desiccant. Warning against sudden air ejection! During expansion the pressure is released suddenly through the muffl er: ◊ A loud cracking noise occurs which can injure your hearing. ◊ Particles carried in the air fl ow act like bullets and can injure your eyes or skin. Always wear eye and ear protection, therefore, when you are in the vicinity of the dryer! Depressurise the dryer and shut it down (see page 30 ). Unscrew muffl er as shown in the opposite fi gure. Replace muffl er and secure it. Restart dryer (see page 31). Undo muffl er Replace the element in the fi ne fi lter muffl er Depressurise the dryer and shut it down (see page 30 ). Undo knurled screw on the lid cap and remove cap. Unscrew old fi lter element. Arrows on the element bottom mark the direction of rotation. Insert new fi lter element and screw on tightly. Renew muffl er element Re-engage lid cap at the top section of the housing and fi x in position by means of the knurled screw. Restart dryer (see page 31 ).

Maintenance and repair of the dryer 38 BSP-MT 10-95/D3 Renew dewpoint sensor To ensure precision dew point measurement, it is recommended to replace the dew point sensor every year. This period depends howev- er on the actual application and might thus be extended accordingly. Dewpoint sensor (1) Warning! The dew point sensor is a sensitive measuring device. It can be damaged if subjected to forceful vibrations or shocks. Therefore, please handle the dew point sensor with great care at all times. In order to limit the impact on the dryer operation to a minimum, we recommend that you contact the manufacturer well in advance and order a new dewpoint sensor. After receipt of the new pressure dewpoint sensor, replace the sensor as follows: Hold the box of the dewpoint sensor ready. Release pressure from dryer and shut down the unit (see page 30 ) Loosen the screw at the adapter (1) and disconnect signal cable with the adapter and seal. Remove dewpoint sensor from the sensor cell (3) by turning the nut (2). Take the new dewpoint sensor (2) from the box, remove the protective caps (4, 5) and screw it into the sensor chamber (3). Place seal onto sealing face; connect adapter (1) and secure it by tightening the screw. If no other maintenance work is to be carried out: Restart the dryer (see page 31 ). Place the protective caps (4, 5) onto the old dew point sensor and dispose of it in accor- dance with the applicable regulations.

Maintenance and repair of the dryer BSP-MT 10-95/D3 39 Notes on further maintenance work Note: In accordance with national regulations, a pressure vessel inspection may be prescribed to be carried out at regular intervals by an independent supervisory offi ce. For an inspection of the pressure vessel, the purifying- and drying agent must be removed. When inspecting the pressure vessel, it is recommended to check the conditi- on of all fi ttings such as e.g. sieve bottom and dust sieve, including gaskets. If necessary, these fi ttings must be cleaned or renewed. In the event of comprehensive maintenance or repair tasks, contact the manu- facturer. Every 12 months Replacing pilot valves The pilot valves are part of every service kit and must be replaced every 12 months. Renew purifying agent Note: To the layers of different purifying agent in chamber, you fi nd an overview of technical data in annex. The active surface of the purifying agent can be reduced by oil residue and other contami- nants. The purifying agent must therefore be replaced once every 12 months (after approx. 8,500 operating hours). If the compressed air is insuffi ciently dried before it reaches the adsorber (see technical data in the appendix), the service life of the purifying agent can be considerably shortened. In this case, the agent must be replaced every 6 months (after ap- prox. 4,000 operating hours). Renew drying agent The service life of the drying agent is usually approx. 3 to 5 years. However, in favourable installation conditions, the change of drying agent may be carried out at a substantially later date. The change interval depends very signifi cantly from the degree of contamination in the compressed air (or the quality of the compressed air upstream fi lters). Oil, dust, and dirt parti- cles cover the drying agent surface and reduce its effective surface, in part quite irreversibly. Every 24 months Replacing inlet valves (V1/V2) and check valves (V5/V6) The inlet valves (main valves) and the check valves are part of the 24-month service kits. Replace them every 2 years as a precautionary measure. Expansion valves (V3/V4) In addition to the inlet valves and the check valves, the expansion valves have to be re- placed every 24 months as a precautionary measure. Replacing solenoid coils Solenoid coils come with the 24-month service kits. Replace them every 2 years.

Identify and eliminate faults 40 BSP-MT 10-95/D3 Identify and eliminate faults The following table provides information on what designatory abbreviations are to be used for the various components. These designations are also found in the technical documentation. Used abbreviation Component PDI Differential pressure gauge V1–V2 (Y2–Y1) Main valves (solenoid valves) V3–V4 (Y3–Y4) Expansion valves (solenoid valves) RV1–RV2 Check valves Summary of faults There are different fault types. In the case of most electrically caused faults (e.g. short circuit, defective fuse, etc.) the expansion valve closes and the regeneration is interrupted. In the case of some process faults, the dryer will continue to operate for some time. Other faults on the dryer become noticeable e.g. due to unusual noises and ran pressures. The following table shows who is allowed to remedy a fault: the owner’s specialist personnel or the manufacturer’s service engineer. Table of possible faults Fault Possible cause Remedy Specialised personnel Service technician Excessive dam pres- sure during regener- ation Muffl er or fi lter element of the muffl er is contaminated. Check muffl ers or fi lter elements for contamination, clean if nec., and poss. renew. • • Expansion valve V3/V4 does not open correctly. Check expansion valve for contamination, if nec. clean/ renew. • • Dust sieves are contami- nated. Clean or renew dust sieves. • • Vessel pressure is too low Excessive differential pres- sure on the upstream fi lter. Check differential pressure on the upstream fi lter, if. nec. renew fi lter element. • No pressure build-up The compressed air system upstream of the dryer is not pressurised. Check whether the compressed air system upstream of the dryer is pressurised. Remove any faults. • Solenoid valve Y1/Y2 does not open correctly. Check supply voltage, ca- ble, contacts and solenoid; replace, if necessary. • • Excessive compressed air consumption Leakage Check condensate trap at the upstream fi lter; clean, if necessary. • •

Identify and eliminate faults BSP-MT 10-95/D3 41 Fault Possible cause Remedy Specialised personnel Service technician Dryer does not switch over Solenoid valve Y1/Y2 does not open correctly. Check supply voltage, ca- ble, contacts and solenoid; replace, if necessary. • • Solenoid valve Y1/Y2 can- not be opened properly (audible humming sound or valve fl apping). Check supply voltage. Check pilot valves; replace, if necessary. • • Control board defective. Check fuse in supply line and in the switchbox; re- place, if necessary. • • Power supply interrupted, cable broken. Reconnect the unit to the power supply. • • Compressor might be off. Check compressor synchro- nisation circuit. • Error in control programme. Restart programme. • No expansion Solenoid valve Y3/Y4 can- not be opened. Check supply voltage, ca- ble, contacts and solenoid; replace, if necessary. • • Solenoid valve Y3/Y4 can- not be opened properly (audible humming sound or valve fl apping). Check supply voltage. Check spring and solenoid; replace, if necessary. Check solenoid valve for contam- ination; clean or replace, if necessary. • • Dryer is continuously bled Solenoid valve Y3/Y4 cannot be closed properly (audible humming sound or valve fl apping). Check supply voltage. Check spring and solenoid; replace, if necessary. Check diaphragm; replace, if necessary. • • Main valve V1/V2 does not open. Check main valve, replace if nec. • • Dryer is excessively bled Solenoid valve Y1/Y2 can- not be closed Check solenoid and diaphragm; replace, if necessary. • • Pressure dew point is not reached Operating pressure is too low. Increase operating pressure. • Compressed air volume fl ow is too high. Reduce compressed air volume fl ow •

Identify and eliminate faults 42 BSP-MT 10-95/D3 Fault Possible cause Remedy Specialised personnel Service technician Pressure dew point is not reached Compressed air inlet tem- perature is too high. Reduce compressed air inlet temperature or pre-connect a compressed air cooler. • • Control board is defective. Check control board, if nec. renew. • Differential pressure on the upstream fi lter is too high. Check differential pressure on the upstream fi lter, if nec. renew fi lter element. • Condensate trap on the up- stream fi lter does not work. Check function of the con- densate trap, if nec. clean or renew. • • Drying agent is contaminat- ed or too old. Check upstream fi lter for contamination, if nec. renew element. • Check drying agent for contamination, if nec. renew drying agent. • • Regeneration gas too low. Check function of expansion valve V3/V4 and muffl er, if nec. renew muffl er or fi lter element. • • sensor is defective Replace sensor • •

Identify and eliminate faults BSP-MT 10-95/D3 43 With dewpoint-sensing control (optional) Fault code Description of fault Possible cause Remedy Specialised personnel Service technician +20 Upper measuring range limit exceeded Drying capacity exceeded. See instructions for commissioning. If the drying agent is wet, replace it. • Error in programme. Restart programme. 999 Dewpoint sensor defective Sensor defective or irreversibly contam- inated. Replace sensor. • • sens o –999 Sensor not powered, or cable or sensor defective Sensor, sensor cable or sensor adapter defective. Visual inspection; check power supply (24 V to terminals 4 and 6). Replace defective com- ponent(s). • • SEr Display for service interval. Regular maintenance tasks must be carried out. The display appears after every 8000 operating hours. Inform the manufactur- er’s service staff and order the appropriate service kit. The package includes a dongle with which you can reset the operating hours counter after maintenance has been carried out. For instructions on how to use the dongle see the enclosed information sheet (in the service kit). • •

Annex with technical documentation 44 BSP-MT 10-95/D3 Annex with technical documentation This annex comprises the following information and technical documentation: ◊ Technical data ◊ Replacement and wear parts list ◊ Logic control diagram ◊ Flow diagram ◊ Dimensional drawing

Annex with technical documentation BSP-MT 10-95/D3 45 Technical data Operating Range Site Selection frost-free indoor installation in a non-hazardous environment Ambient temperature 1,5 to 50 °C (24,7 to 122 °F) Compressed air inlet temperature 25 to 50 °C (68 to 122 °F) Max. operating pressure 16 bare Min. operating pressure 5 bare Medium Compressed air Fluid group 2 Electrical connection Mains voltage, standard 230 V, 50-60 Hz Alternative voltage 115 V, 50-60 Hz and 24 V DC Protection class IP65 Please note type plate and attached electrical circuit diagram! Performance details Type Volumetric fl ow¹ in m3/h Nominal pipe2 1. Upstream fi lter 2. Upstream fi lter Downstream fi lter Nominal Press. in bare Nominal temper. °C BSP-MT 10 158 1 AOP025EGFI AAP025EGMI AOP025EGMI 16 50 BSP-MT 15 210 1 AOP025EGFI AAP025EGMI AOP025EGMI 16 50 BSP-MT 20 274 1 AOP025EGFI AAP025EGMI AOP025EGMI 16 50 BSP-MT 25 371 1 1/2 AOP030GGFI AAP030GGMI AOP030GGMI 16 50 BSP-MT 35 484 1 1/2 AOP030GGFI AAP030GGMI AOP030GGMI 16 50 BSP-MT 45 589 1 1/2 AOP035GGFX AAP035GGMX AOP035GGMX 16 50 BSP-MT 60 839 2 AOP040HGMX AAP040HGFX AOP040HGMX 16 50 BSP-MT 75 1129 2 AOP040HGMX AAP040HGFX AOP040HGMX 16 50 BSP-MT 95 1371 2 ½ AOP045IGFX AAP045IGFX AOP045IGMX 16 50 1 . m3/h, relating to 1 bara and 20 °C at the compressor suction capacity. Subsequently com- pressed to 13 bare and 35°C inlet temperature to the dryer at 100 % relative humidity – for pressure dewpoints of -25 °C and -40 °C. 2 . In accordance with DIN ISO 228 (BSP-P) Noise emission Noise level : +3 dB (A)1 65 – 95 dB(A) 1 .. relative to free fi eld measurement, 1 m surr. fi eld Dimensions Please heed to the dimensional drawings and the according table containing dimensions and weight on page 53.

Annex with technical documentation 46 BSP-MT 10-95/D3 Drying agent Chamber 1 100 % molecular sieve Chamber 2 100 % molecular sieve Chamber 3 down middle top 33 % activated carbon 33 % catalyst 33 % activated carbon Limits for breathing air Industrial breathing air with brating- air unit BSP-MT Medical air Europe UK USA Australia Europe EN 12021 BS 4275 ANSI/CGA AS 1715 Ph.European Carbon monoxide CO < 15ppm < 5ppm < 10ppm < 10ppm < 2ppm < 5ppm Carbon dioxidv CO2 < 500ppm < 500ppm < 1000ppm < 800 ppm < 150ppm < 500ppm humidity H2O < 5 °C * < 5 °C * < 10 °F * <100mg/m3 < 15 ppm** < 67 ppm oxygen O2 21 (±1) % 20 – 23 % 21,5 % – 20,8–21,1% 20,4 – 21,4 % Oil quantity < 0,5 mg/m3 < 0,5 mg/m3 < 0,5 mg/m3 < 1,0 mg/m3 < 0,003mg/m3 < 0,1 mg/m3 odoriferous / aro- matic substance Free free Free Free Free free Sufur dioxideSO2 – – – – < 0,1 ppm < 1 ppm mitrous gases NO/NO2 – – – – < 1 ppm < 2 ppm * Pressure dewpoint below inlet temperature ; **Corresponding pressure dewpoint -50°C to -45°C at 7 bare . .. All values refer to customary concentration levels present in the inlet air.

Annex with technical documentation BSP-MT 10-95/D3 47 Replacement and wear part list Note: When exchange or replacement parts are ordered, always state the dryer type and the build no. of the dryer. These data are found on the type plate. Service-kits 12 and 36 months For model Mains voltage Order-ID. Scope of delivery BSP-MT 10 to BSP-MT 20 115V, 230V SKK10-K20/BP3/12 Reset-module, muffl er, fi lter elements, pilot-valves BSP-MT 25 115V, 230V SKK25/BP3/12 BSP-MT 35 115V, 230V SKK35/BP3/12 BSP-MT 45 115V, 230V SKK45/BP3/12 BSP-MT 60 to BSP-MT 75 115V, 230V SKK60-K75/BP3/12 BSP-MT 95 115V, 230V SKK95/BP3/12 Service-kits 24 and 48 months For model Mains voltage Order-ID. Scope of delivery BSP-MT 10 to BSP-MT 20 115V SKK10-K20/BP3/24/115 Reset-module, muffl er, fi lter elements, inlet- expansion- and check valves, solenoid 230 V SKK10-K20/BP3/24 BSP-MT 25 115V SKK25/BP3/24/115 230V SKK25/BP3/24 BSP-MT 35 115V SKK35/BP3/24/115 230 V SKK35/BP3/24 BSP-MT 45 115V SKK45/BP3/24/115 230V SKK45/BP3/24 BSP-MT 60 to BSP-MT 75 115V SKK60-K75/BP3/24/115 230 V SKK60-K75/BP3/24 BSP-MT 95 115V SKK95/BP3/24/115 230V SKK95/BP3/24

Annex with technical documentation 48 BSP-MT 10-95/D3 Additional spare parts Order no. Maintenance interval Quantity Scope of delivery ZHM100/450 12 months 1 Dewpoint sensor LS5/ZR 12 months 1 Element fi ne fi lter muffl er RK-MANO.063SR0219-1 12 months 1 Vessel pressure gauge Dessicant and activated carbon packages Order-ID. BSP-MT 10 BSP-MT 15 BSP-MT 20 BSP-MT 25 BSP-MT 35 BSP-MT 45 BSP-MT 60 BSP-MT 75 BSP-MT 95 12 months – purifying agent DESPAC3AK 2 3 1 2 2 DESPAC10AK 1 1 1 2 2 4 5 DESPAC1KTY 1 7 4 5 2 2 DESPAC4KTY 2 2 3 4 6 7 10 14 18 12 months – drying agent DESPAC6EF 2 1 DESPAC20EF 1 2 2 3 4 5 7 9 12 Replacement Element fi lter : P - TYPE - GRADE Sample: Filter AAP025EGFI (Element P025AA) Filter AOP030GGMI (Element P030AO)

Annex with technical documentation BSP-MT 10-95/D3 49 Tightening torque values After the performance of maintenance activities, reconnect the aluminum elbows (indicated in the images) to the valves’ blocks and to the vessels by applying to the screws a tightening torque between 8 Nm (min) and 10 Nm (max)

Annex with technical documentation 50 BSP-MT 10-95/D3 Logic control diagram Adsorption in B1 and regeneration in B2

Annex with technical documentation BSP-MT 10-95/D3 51 Regeneration in B1 and adsorption in B2

Annex with technical documentation 52 BSP-MT 10-95/D3 Flow diagram Pos. Designation Pos. Designation 2 Dust sieve 200 Muffl er 50 Check valve block V5–V6 350 Control system 56 Regeneration gas orifi ce plate 65 Upstream fi lter * Optional devices: 70 Upstream fi lter 380 Dewpoint-sensing unit 80 Downstream fi lter 400 Start-up device 100 Solenoid valve block V1–V4 500 Regeneration gas return line

Annex with technical documentation BSP-MT 10-95/D3 53 Dimensional drawing BSP-MT 10 & BSP-MT 95 Type connec- tion Dimensions [mm] Weight [kg] A A1 B C C1 C2 D E BSP-MT 10 G 1 1300 880 1420 490 400 60 1070 1070 165 BSP-MT 15 G 1 1300 880 1750 490 400 60 1320 1320 197 BSP-MT 20 G 1 1100 930 1530 490 400 60 1160 1160 197 BSP-MT 25 G 1½ 1100 930 1760 530 400 60 1320 1320 239 BSP-MT 35 G 1½ 1390 1220 1810 585 400 60 1320 1320 288 BSP-MT 45 G 1½ 1460 1250 1820 605 400 80 1320 1320 342 BSP-MT 60 G 2 1515 1290 1870 635 500 80 1320 1320 437 BSP-MT 75 G 2 1670 1440 2000 640 500 80 1515 1515 564 BSP-MT 95 G 2½ 1715 1490 2020 670 500 80 1515 1515 707

Sede Legale: Via Sebastiano Caboto 1, Palazzina “A” 20094 Corsico (MI) Italy Sede Operativa: Gas Separation and Filtration Division EMEA - Strada Zona Industriale, 4 35020 S.Angelo di Piove (PD) Italy tel +39 049 971 2111- fax +39 049 9701911 Web-site: www. parker.com A division of Parker Hannifi n Corporation