Atlas Copco Air dryers

MD50
MD100-200-300-400-600 (W)
MD1000 W-1800 W
MD400-800-1300-2500 W VSD

Instruction Book

From following serial number onwards: AIQ-012 130

· Copyright 2002, Atlas Copco Airpower n.v., Antwerp, Belgium.

Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in
particular to trademarks, model denominations, part numbers and drawings.

· This instruction book meets the requirements for instructions specified by the machinery directive
98/37/EC and is valid for CE as well as non-CE labelled machines.

No. 2920 1443 01

Replaces No. 2920 1443 00

Registration code: APC MD / 38 / 989

2002-06 www.atlascopco.com
 Instruction book

This instruction book describes how to handle and operate the subject machine(s) to ensure safe operation, optimum working
economy and long service life.

Read this book before putting the machine into operation to ensure correct handling, operation and proper maintenance from
the beginning. The maintenance schedule contains a summary of the measures for keeping the dryer in good condition. The
maintenance procedures are simple but must be carried out regularly.

Keep the book available for the operator(s) and make sure that the dryer is operated and that the maintenance actions are carried
out according to the instructions. Record all operating data, maintenance work effected, etc. in an operator's logbook available at
Atlas Copco. Follow all applicable safety precautions, amongst others those mentioned on the cover of this book.

Repair operations must be performed by trained personnel from Atlas Copco, who can also be contacted if any further information
is desired.

In all correspondence always mention the dryer type and the complete serial number, shown on the data plate.

The company reserves the right to make changes without prior notice.

CONTENTS
Page Page
1 Leading particulars . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 Operating instructions . . . . . . . . . . . . . . . . . . . . . . . 31
1.1 General description . . . . . . . . . . . . . . . . . . . . . . . . 3 3.1 Initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2 Air drying circuit . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.2 Routine starting . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.1 Regeneration air circuit . . . . . . . . . . . . . . . 5 3.3 During operation . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.2 Rotor cooling air circuit . . . . . . . . . . . . . . 5 3.4 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3 Drain system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3.5 By-pass operation . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3.2 Testing the EWD . . . . . . . . . . . . . . . . . . . . 5 4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.3 Electrical connections of the EWD . . . . . . 5
1.4 Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.4.1 MD400/800/1300/2500 W VSD . . . . . . . . 8
1.4.2 All other MD dryers . . . . . . . . . . . . . . . . . 8 6 Principal data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.1 Dryer specifications . . . . . . . . . . . . . . . . . . . . . . 35
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 6.1.1 Reference conditions . . . . . . . . . . . . . . . . 35
2.1 Dimension drawings . . . . . . . . . . . . . . . . . . . . . . 16 6.1.2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Installation proposal . . . . . . . . . . . . . . . . . . . . . . 29 6.1.3 Typical data . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Cable section and setting of the circuit 6.1.4 Specific data . . . . . . . . . . . . . . . . . . . . . . 35
breaker of the fan motor on air-cooled dryers . . 30 6.2 Conversion list of SI units into British units . . . 42

2 2920 1443 01
Instruction book

1 LEADING PARTICULARS Each dryer is provided with a data plate including the type,
serial number and maximum permissible working pressure.
1.1 General description Drying circuit
The cool, wet compressed air passes through three quarters of
MD are adsorption-type air dryers, designed to remove moisture the rotor. The moisture of the compressed air is adsorbed by
from compressed air delivered by Atlas Copco ZE45 up to the drying material.
ZE132, ZR45 up to ZR750, ZR160 VSD up to ZR900 VSD,
ZT18 up to ZT250, ZR/ZT3, ZR4, ZR5 and ZR6 compressors. Regenerating circuit
Hot air, from upstream of the compressor aftercooler, is blown
The main component is a rotor (6-Fig. 1.3), made of a material through one quarter of the rotor and regenerates the drying
which adsorbs water. material.
The rotor rotates slowly and is passed by two air flows: a flow Pressure vessel
of cool, wet compressed air to be dried and a flow of hot The dryers include a cylindrical pressure vessel, which is
compressed air to regenerate the drying material. installed vertically on a frame.
An ejector (11-Fig. 1.4) is fitted in the air inlet chamber of the The bottom comprises the rotor drive assembly. The body
dryer. The regeneration air system includes a throttle valve (8- includes the electric motor driven rotor and is divided into two
Fig. 1.4) and a regeneration air cooler (17-Fig. 1. 4), which can compartments, one for the hot regeneration air and one for the
be either air- or water-cooled. MD50, MD100, MD200, air to be dried.
MD300, MD400, MD400 VSD, MD600 and MD800 VSD are
air-cooled dryers; MD100 W, MD200 W, MD300 W, MD400 The pressure vessel is equipped with two valves (1 and 2-Fig.
W, MD600 W, MD1000 W , MD1800 W, MD400 W VSD, 1.2) for measuring the pressure difference between the
MD800 W VSD, MD1300 W VSD and MD2500 W VSD are regeneration air inlet sealing sector and dry air compartment.
water-cooled dryers.

4
1 2 3

10

7
51336F

6 5

1 Safety valve 6 Electronic Water Drains (EWD)

2 Inlet pipe, hot regeneration air 7 Rotor motor with incorporated gearbox
3 Air inlet valve 8 By-pass valve
4 Control panel 9 Dry compressed air outlet
5 Inlet pipe, wet compressed air 10 Air outlet valve
Fig. 1.1 Installation example of ZR110 Pack/MD300 W compressor/dryer package

2920 1443 01 3
 Instruction book

1 2 3 1
2
3
6 4

11

10 5

8
4 51338F

1 Regeneration air sector

2 Nozzle
3 Ejector
4 Regeneration air cooler
5 Manual drain valve, dryer inlet water separator
6 Rotor

51337F Fig. 1.3 Inside view of MD300

7 6 5
1 Valve for (-) connection, pressure differential gauge
2 Valve for (+) connection, pressure differential gauge
3 Throttle valve
4 Regeneration air cooler
5 Electronic Water Drain, inlet air water separator
6 Electronic Water Drain, regeneration air water separator Sealing sectors
7 Rotor motor with incorporated gearbox Both end faces of the rotor are provided with a sealing sector
8 Manual drain valve, dryer inlet water separator for conducting the regeneration and cooling air flows through
9 By-pass valve the rotor. The sector on the regeneration air inlet is spring-
10 Air outlet valve loaded. Both sectors slide on an inner and an outer ring fixed to
11 Air inlet valve the rotor. A slight clearance is left between the faces of the
sectors and the rotor end faces.
Fig. 1.2 General view of MD600 W
The regeneration air inlet sealing sector covers a segment of 90
degrees of the dry side rotor face and is provided with a filter.
The outlet sealing sector is bigger, as it also accommodates the
cooling sector.

An Electronic Water Drain (EWD) is connected to the lower

part of the regeneration air compartment of the dryer.

Electrical control
Rotor The operation of the rotor motor is controlled by the electric
The sections of drying material are wrapped onto a core and regulator of the compressor.
contained in a jacket. The power of the motor is transmitted to
the rotor, through a pin-type coupling, a worm gear and a drive By-pass system
shaft. The dryers are standard equipped with a by-pass system
including an air inlet valve, an air outlet valve and a by-pass
A lip-seal (29-Fig. 1.4), fitted on the rotor jacket, separates the valve. A regeneration air shut-off valve and a connection pipe
wet and dry sides of the rotor. The lip of the seal rests on the set is also included in the dryer package. A safety valve may
surface of a ring clamped between the flanges of the vessel. also be fitted.

4 2920 1443 01
Instruction book

1.2 Air drying circuit (Fig. 1.4) 1.3 Drain system

Wet air from the compressor aftercooler (2) enters the dryer 1.3.1 Description (Fig. 1.5)
inlet, passes through inlet valve (5) and the nozzle of ejector
(11) into air inlet water separator (26). The air leaving the The condensate enters the Electronic Water Drain (EWD) via
aftercooler is normally saturated and has a temperature of approx. inlet (1) and accumulates in collector (2). A capacitive sensor
10°C above that of the inlet cooling water on water-cooled (3) continuously measures the liquid level. As soon as the
compressors or above that of the ambient temperature on air- collector is filled up to a certain level, pilot valve (4) is activated
cooled compressors. and diaphragm (5) opens outlet (6), discharging the condensate.

In the demister (27), the water droplets are removed from the When the collector has been emptied, the outlet closes quickly
air. The air is then led through rotor (12), which adsorbs the without wasting compressed air.
water vapour. The dried air then flows into air outlet When the controller registers a malfunction, the red alarm LED
compartment (30) and leaves the dryer through outlet valve (33). (Fig. 1.7) starts flashing and the electronic drain valve will
automatically change to the alarm mode, opening and closing
the valve according to a sequence as shown in (Fig. 1.6). This
condition continues until the fault is remedied. If the fault is not
remedied automatically, maintenance is required.

1.2.1 Regeneration air circuit

1.3.2 Testing the EWD
Hot regeneration air is branched off from pipe (1) upstream of
the compressor aftercooler. This air is unsaturated and has a Functional test
temperature of 130-190°C, depending on the operating pressure, Briefly press the TEST button (Fig. 1.7) and check that the valve
the cooling water inlet temperature or ambient temperature and opens for condensate discharge.
the air inlet temperature.
Checking the alarm signal
The regeneration air passes through shut-off valve (7), throttle - Press the test button for at least 1 minute
valve (8) and strainer (9) to inlet sealing sector (10), and is - Check that the alarm LED flashes
blown through the wet rotor channels. Since the hot air has a - If an alarm device is connected to the NO or NC contact
lower vapour pressure than the wet rotor channels, it will dry, (see section 1.3.3), check its operation.
i.e. regenerate, the rotor. - Release the test button.

The wet regeneration air leaving the rotor is collected in outlet

sealing sector (14). 1.3.3 Electrical connections of the EWD (Fig. 1.8)

The hot saturated air is then cooled down in regeneration air The indications on the data label must correspond to the mains
cooler (17) and passed to water separator (18), where the free supply voltage and frequency. Connect the electrical supply to
water is evacuated by the drain system. the EWD as shown in Fig. 1.8. Never operate the EWD without
an earth conductor connected. An alarm device can be connected
The regeneration air is then led to the suction chamber (28) of to the normally open or normally closed contact; see Fig 1.8.
ejector (11), where it is mixed with the wet compressed air from
the compressor aftercooler. In the ejector the velocity of the
wet compressed air is increased, resulting in a pressure drop in
the suction chamber of the ejector and the entire regeneration
air circuit up to throttle valve (8). The pressure drop prevents
regeneration air from entering the dry air outlet compartment.

1.2.2 Rotor cooling air circuit

After regeneration, the hot channels of the rotor are cooled by

air from the dry air compartment (30). The cooling air flow is
trapped by the regeneration air outlet sealing sector (14) and
mixed with the wet regeneration air.

2920 1443 01 5
 Instruction book

6 2920 1443 01
Instruction book

1 Compressor HP air delivery pipe 18 Water separator, regeneration cooler outlet air
2 Aftercooler, compressor 19 Venting tube, EWD regeneration air
3 Float valve, aftercooler water separator of compressor 20 EWD regeneration air
4 Manual drain valve, dryer inlet water separator 21 Drain tube, water separator regeneration air
5 Air inlet valve 22 Rotor drive assembly
6 By-pass valve 23 Drain pipe, water separator inlet air
7 Shut-off valve, hot regeneration inlet air 24 EWD, inlet air
8 Throttle valve, regeneration inlet air 25 Venting tube, EWD inlet air
9 Strainer 26 Water separator, inlet air
10 Sealing sector, regeneration air inlet (unsaturated side) 27 Demister
11 Ejector 28 Suction chamber
12 Rotor 29 Rotor sealing arrangement
13 Air dryer pressure vessel (rotor housing) 30 Dry air outlet compartment
14 Sealing sector, regeneration air outlet (saturated side) 31 Valve for (-) connection, pressure differential gauge
15 Shut-off valve, regeneration air cooler water outlet 32 Valve for (+) connection, pressure differential gauge
16 Shut-off valve, regeneration air cooler water inlet 33 Air outlet valve
17 Regeneration air cooler
Fig. 1.4 Air flow diagram of MD100 W, MD200 up to MD1000 W and MD400 W VSD up to MD2500 W VSD

51340F
1 2 3 4 5 6

1 Inlet
2 Collector
3 Sensor
4 Pilot valve
5 Diaphragm
6 Outlet

Fig. 1.5 Electronic water drain

2920 1443 01 7
 Instruction book

1.4 Electrical system

The motor must be wired to the electrical equipment of the

compressor as shown on the relevant circuit diagram.

1.4.1 MD400/800/1300/2500 W VSD (Figs. 1.13 up

to 1.15)

The worm gear motor must be connected to the frequency

converter for the dryer (A21) in the electrical cabinet of the
Fig. 1.6 Drain frequency during alarm condition compressor. The rotor speed of the dryer depends on the speed
of the compressor motor. When the compressor runs at
maximum speed, the dryer will also run at maximum speed and
vice versa. The dryer motor stops when the compressor runs
unloaded.

1.4.2 All other MD dryers (Figs. 1.9 up to 1.12)

The worm gear motor (M40) is connected in the circuit of the

compressor air pressure switch or, in case of an Elektronikon-
controlled compressor, in series with a contact of the loading/
unloading relay. Thus the worm gear motor stops running when
the compressor is unloaded. This condition is required since
hot compressed air for regenerating the rotor is not available
when the compressor runs unloaded.

Fig. 1.7 Control panel

0.0 Line terminal 0.6 Normally closed terminal

0.1 Neutral terminal 0.7 Common terminal
0.2 Earth terminal 0.8 Normally open terminal

Fig. 1.8 Electrical connections

8 2920 1443 01
Instruction book

Fig. 1.9 Electrical circuit diagram of MD50 connected to ZT18/37

2920 1443 01 9
 Instruction book

Fig. 1.10 Electrical circuit diagram of MD300 (W)/MD1000 (W) connected to ZR/ZT3, ZR/ZT4 and ZR5 with pneumatic
regulator

10 2920 1443 01
Instruction book

Fig. 1.11 Electrical circuit diagram of MD300 W/MD1000 W connected to ZR3, ZR4 and ZR5 with Elektronikon regulator
with LED display as shown above

A double-pole circuit breaker must be installed in the cabinet of remain alight, thus indicating that the dryer will be operative
the compressor regulator and connected to the terminals as when the compressor is loaded. If, on the other hand, the contacts
shown on the circuit diagram. One pole is connected in the are open, the lamp will go out when the compressor is started,
circuit of the rotor motor. On compressors with relay-controlled indicating that the dryer is out of service. This will also be the
regulators, the other pole of the circuit breaker is connected in case if, during operation, the circuit breaker should trip due to
the circuit of the "MD-ON" indicator lamp (H12). an overload.

When voltage is supplied to a compressor with a relay-controlled For air-cooled dryers, a circuit breaker must be installed in the
regulator, the lamp will light up (lamp test). If the contacts are cabinet of the compressor. Consult section 2.3 for the correct
closed and the compressor subsequently started, the lamp will setting.

2920 1443 01 11
 Instruction book

Fig. 1.12 Electrical circuit diagram of MD300 W/MD1000 W connected to ZR5-ZR6 and ZR110 up to ZR750 with
Elektronikon regulator as shown above

12 2920 1443 01
Instruction book

Fig. 1.13 Electrical diagram of MD400 W VSD/MD800 W VSD connected to ZR160 VSD/ZR 315 VSD

A21 Frequency converter, dryer control M41 Fan motor

F41 Circuit breaker, worm gear motor of dryer Q2 Circuit breaker, dryer control
H12 "MD-ON" indicator lamp Q41 Circuit breaker, fan motor
M40 Worm gear motor

Figs. 1.9 up to 1.15 Electrical circuit diagrams of MD50 up to MD1000 W and MD400 W VSD up to MD2500 W VSD

2920 1443 01 13
 Instruction book

Fig. 1.14 Electrical diagram of MD1300 W VSD connected to ZR500 VSD

14 2920 1443 01
Instruction book

Fig. 1.15 Electrical diagram of MD2500 W VSD connected to ZR900 VSD

2920 1443 01 15
 Instruction book

2 INSTALLATION
2.1 Dimension drawings (Figs. 2.1 up to 2.13)

Fig. 2.1 Dimension drawing of MD50 air-cooled

16 2920 1443 01
Instruction book

Fig. 2.2 Dimension drawing of MD100/200 air-cooled

2920 1443 01 17
 Instruction book

Fig. 2.3 Dimension drawing of MD100/200 water-cooled

18 2920 1443 01
Instruction book

Fig. 2.4 Dimension drawing of MD300/400 air-cooled

2920 1443 01 19
 Instruction book

Fig. 2.5 Dimension drawing of MD300/400 water-cooled and MD400 VSD water-cooled

20 2920 1443 01
Instruction book

Fig. 2.6 Dimension drawing of MD600 air-cooled

2920 1443 01 21
 Instruction book

Fig. 2.7 Dimension drawing of MD600 water-cooled

22 2920 1443 01
Instruction book

Fig. 2.8 Dimension drawing of MD800 VSD air-cooled

2920 1443 01 23
 Instruction book

Fig. 2.9 Dimension drawing of MD800 VSD water-cooled

24 2920 1443 01
Instruction book

Fig. 2.10 Dimension drawing of MD1000 water-cooled

2920 1443 01 25
 Instruction book

Fig. 2.11 Dimension drawing of MD1300 VSD water-cooled

26 2920 1443 01
Instruction book

Fig. 2.12 Dimension drawing of MD1800 water-cooled

2920 1443 01 27
 Instruction book

Fig. 2.13 Dimension drawing of MD2500 VSD water-cooled

28 2920 1443 01
Instruction book

2.2 Installation proposal

A connection pipe set is included in the dryer package. All pipes must be mounted stress-free and the regeneration air pipe must
be insulated properly. Install the dryer on a level floor.

Fig. 2.14 Installation proposal for ZR900 VSD with water-cooled MD2500 VSD

2920 1443 01 29
 Instruction book

2.3 Cable section and setting of the circuit breaker of the fan motor on air-cooled dryers

50 Hz

Type Voltage Setting of circuit Cable section, Cable section,

breaker, fan motor fan motor gear motor
(V) (A)

MD50 230 1.6 4x1.5 3x1.5

MD50 400 0.6 4x1.5 3x1.5
MD100 230 1.63 4x1.5 3x1.5
MD100 400 0.95 4x1.5 3x1.5
MD200, -300, -400 230 2.2 4x1.5 3x1.5
MD200, -300, -400 400 3.8 4x1.5 3x1.5
MD200, -300, -400 500 1.8 4x1.5 3x1.5

60 Hz

Type Voltage Setting of circuit Cable section, Cable section,

breaker, fan motor fan motor gear motor
(V) (A)

MD200, -300, -400 440 2.4 4x1.5 3x1.5

MD200, -300, -400 460 2.3 4x1.5 3x1.5
MD200, -300, -400 575 1.8 4x1.5 3x1.5

4 1 Worm gear housing

2 Vent hole, worm gear housing
3 Worm gear motor
5 4 EWD, inlet air water separator
6 5 EWD, regeneration air water separator
6 Filler plug, worm gear housing
51344F
Fig. 2.15 Drain connections and worm gear housing

30 2920 1443 01
Instruction book

3 OPERATING INSTRUCTIONS On MD1300 VSD and MD2500 VSD check the rotation
direction of the fan of the drive motor, the correct rotation
direction is indicated by an arrow. If the rotation direction
3.1 Initial start-up (Fig 1.2) is wrong, switch off the voltage and reverse two of the input
It is assumed that the dryer and the parts delivered loose with it line connections.
are installed properly. An example of an installation of a dryer 10. Slightly open the air inlet valve (11) to pressurize the dryer.
with by-pass system is given in Figs. 1.1 and 2.14. Insulate the Fully open the valve after pressurizing.
regeneration air pipe properly. 11. Open the regeneration air inlet valve (7-Fig. 1.4) fully. Open
air outlet valve (10) and close by-pass valve (9).
1. On dryers equipped with a worm gear housing as shown in 12. Open the valve (if installed) to the air net or air receiver
Fig. 2.15, check that the worm gear housing of the dryer is and blow off some air from the air net to keep the compressor
filled with oil to overflow level and remove the plug from running loaded.
vent hole (2-Fig. 2.15). 13. Open valve (1) marked (-) of the U-tube. Slightly open
2. Close the regeneration air inlet valve (7-Fig. 1.4), as well valve (2) marked (+), while watching the water levels in
as the air inlet and air outlet valves (10 and 11). Open the the U-tube. Two conditions are possible:
by-pass valve (9). - The water level in the leg marked (+) rises. Close valve
3. Close the valves (1 and 2). Fill a transparent tube halfway (2) at once, decrease the regeneration air inlet pressure
with water. Install the tube to valves (1 and 2). (see step 14). Do this as often as necessary, until the
4. Check that circuit breaker (F41 or Q2-Figs. 1.9 up to 1.15) water level drops.
is in the "I" position. - The water level in the leg marked (-) rises, which should
5. On air-cooled dryers, check that circuit breaker (Q41-Figs. normally be the case. If the level in this leg rises 30 mm
1.9 up to 1.10) is in the "I" position. above the level in the leg marked (+), close valve (2) at
6. Close the manual drain valve (8). Also close the manual once, as there is a risk that the water will be ejected
drain valve of the aftercooler drain trap of the compressor. from the U-tube and disappear into the pressure vessel.
7. On water-cooled dryers, open the cooling water cocks (15 Increase the regeneration air inlet pressure (see step 14)
and 16-Fig. 1.4) of the regeneration air cooler. Also open and open valve (2) again.
the main cooling water inlet valve (if provided).
8. On compressors with relay-controlled regulator, check
that toggle switch (S3) on the control and indicator panel
of the compressor is placed in the UNLOADed position.
9. Switch on the voltage at the mains. On compressors with
relay-controlled regulator, check that "MD-ON" indicator
lamp is alight.
On air-cooled compressors, start and stop the compressor
at the slightest rotation. Check for correct rotation
direction of the fan motor of the dryer. The correct
rotation direction is indicated on the fan housing. If the
rotation direction is wrong, switch off the voltage and
reverse two of the input line connections. Start and load
6 1
the compressor as per instructions given in the relevant
instruction book.

5 2

4 3
51345F

1 EWD, inlet air water separator

2 Electric cable entry
3 Automatic condensate drain
4 Automatic condensate drain
1 Worm gear housing 5 Electric cable entry
2 Worm gear motor 6 EWD, regeneration air water separator

Fig. 2.16 Worm gear housing Fig. 2.17 Drain connections

2920 1443 01 31
 Instruction book

14. Once the water column has stabilized, adjust the pressure dry, a blow-off valve should be installed between the dryer and
differential as follows: the air net to blow off the air until the moisture indicator shows
Remove the protecting cap from the adjusting screw, loosen blue.
its check nut and turn the screw in to increase or out to
decrease the pressure differential. Tighten the check nut and 7. On water-cooled dryers, regulate the cooling water flow
reinstall the protection cap. through the regeneration air cooler while the compressor is
The water level in the leg marked (-) must be: running loaded, until the temperature rise between cooling
- For MD400/800/1300/2500 W VSD and MD dryers water inlet and cooling water outlet is approx. 5°C. Regulate
connected to a Z VSD compressor, at minimum flow by means of cooling water outlet cock (15-Fig. 1.4).
(compressor running loaded at minimum speed) between
5 and 10 mm above that in the leg marked (+). Also
check the water level at maximum flow (compressor
running at maximum speed). The water level in the leg
marked (-) will be approximately 30 mm above that in 3.3 During operation
the leg marked (+).
- For MD dryers connected to Z compressors with Consult section 4, under "Daily".
fixed motor speed, between 20 and 40 mm above that
in the leg marked (+). Attention: Avoid short compressor loading periods and
15. On water-cooled dryers, regulate the cooling water flow operation at very low working pressures as otherwise the
through the regeneration air cooler by means of the outlet performance of the dryer will diminish. Avoid operation at too
cock (15-Fig. 1.4) until the temperature rise between cooling low a regeneration air inlet temperature (minimum 130°C).
water inlet and cooling water outlet is approx. 5°C.
16. Check the dryer connections for air leaks.
17. Check that the moisture indicator shows blue after
approximately 30 minutes of operation. If the moisture
indicator still shows pink after 2 hours of operation, the 3.4 Stopping
pressure dewpoint is too high; consult section 5.
18. Close the blow-off valve of the air net, unload and stop the 1. Close the air outlet valve of the dryer.
compressor. Close the air outlet valve of the dryer. 2. Unload and stop the compressor. Switch off the voltage.
19. Switch off the voltage. 3. On water-cooled dryers, close the cooling water inlet cock
20. On water-cooled dryers, close the cooling water inlet cock (16-Fig. 1.4) of the regeneration air cooler.
(16-Fig. 1.4) of the regeneration air cooler. 4. Open the drain valve (8- Fig. 1.2).
21. Open drain valve (8). If freezing temperatures are expected, drain the water from
the regeneration air cooler. Drain plugs are provided.

3.2 Routine starting

3.5 By-pass operation (Fig 1.2)
1. Close drain valve (8-Fig. 1.2).
2. Carry out the steps mentioned in section "Before starting" 1. Close the air outlet valve (10) of the dryer.
of the relevant compressor instruction book. 2. Unload and stop the compressor. Switch off the voltage.
3. On water-cooled dryers, open the cooling water inlet cock 3. Open the door of the compressor regulator cabinet and move
(16-Fig. 1.4) of the regeneration air cooler. the circuit breaker (F41 or Q2-Figs. 1.9 up to 1.15) to
4. Switch on the voltage. On compressors with relay- position "0".
controlled regulator, check that the "MD-ON" lamp on On air-cooled dryers, also switch off circuit breaker (Q41-
the control and indicator panel of the compressor is alight Figs. 1.9 and 1.10) of the fan motor. Close the door of the
(lamp test). cabinet.
5. Start the compressor. The dryer motor does not yet operate 4. Open by-pass valve (9).
at this stage, as the compressor still runs unloaded. 5. Close air inlet valve (11).
6. Open the air outlet valve of the dryer and close by-pass 6. Close regeneration air shut-off valve (7-Fig. 1.4).
valve (6-Fig. 1.4). The rotor of the dryer starts rotating as 7. Depressurize the dryer
soon as the compressor loads. Note that the rotor stops 8. Switch on the voltage and start the compressor.
when the compressor runs unloaded.
When the dryer is put into service again, switch off the voltage,
re-engage the circuit breaker(s) and close the drain valve. Open
Note: The dewpoint of the air leaving the dryer will be higher air inlet valve (11), open air outlet valve (10), open regeneration
than normal after starting. The normal operating condition will air shut-off valve (7-Fig. 1.4) and close by-pass valve (9). Start
be reached after approx. 15 minutes. If the air net is to remain the compressor.

32 2920 1443 01
Instruction book

4 MAINTENANCE
Preventive maintenance schedule 1)

The schedule contains a summary of the maintenance instructions. Read the related notes before taking maintenance measures.

The "longer interval" checks should include the "shorter interval" checks.

Period 2) Running Consult See notes Operation

hours 2) section below table

Daily 4 -- -- Check that the electronic water drains are working correctly
" ------ 3.4 -- Drain condensate after dryer has been stopped

Weekly 50 -- -- Check that moisture indicator shows blue

" ------ -- -- Inspect all air pipes. Tighten leaking connections; replace damaged
gaskets or pipes

Monthly ------ -- 1 Check oil level of worm gear housing

" ------ -- -- Clean dryer
" ------ 3.1 step 14 -- Check pressure differential of rotor compartments. Adjust, if
necessary

3-monthly 500 -- 2 Check safety valve, if installed, by manually blowing air

Yearly 8000 -- 3 Change oil of worm gear housing

" ------ -- -- Inspect drain system
" ------ -- 4/5 Check cooling efficiency of regeneration air cooler and pressure-
test cooler
" ------ -- -- On air-cooled dryers, clean regeneration cooler externally

2-Yearly 16000 -- -- Replace demister sponge

Notes
1. Dryers equipped with a worm gear housing as shown in Fig. 2.16 are filled for life and do not need maintenance. On dryers
equipped with a worm gear housing as shown in Fig. 2.15, stop the compressor and depressurize the dryer, remove plug (6-
Fig. 2.15) and check that the oil is level with the bottom of the plug hole. Top up, if necessary, with oil as specified in note 3.
2. Operate the valve several times for some seconds while there is pressure in the system, by screwing the cap of the valve anti-
clockwise with a gloved hand. Retighten the cap by hand after testing.
3. Dryers equipped with a worm gear housing as shown in Fig. 2.16 are filled for life and do not need maintenance. On dryers
equipped with a worm gear housing as shown in Fig. 2.15, replenish the housing after draining to level with the hypoid gear
lubricant Roto M. Roto M can be ordered at Atlas Copco in 1-l cans, ordering number 2908 8506 00
4. The temperature difference between the incoming water and the outgoing air of the cooler during the loading periods of the
compressor should never exceed 10°C. A contact thermometer should be used to measure the temperature of the pipes. Have
the cooler cleaned if the cooling efficiency is insufficient.
Note: In checking the cooling efficiency of the compressor coolers of combined ZR3/ZR5-MD units, the temperature difference
of 25°C as mentioned in the instruction book of the compressor should be replaced by 10°C.
5. Preferably to be carried out by an Atlas Copco Service representative.

Footnotes chapter 4

1) Use only authorized parts. Any damage or malfunction caused by the use of unauthorized parts is not covered by Warranty or Product
Liability.
2) Whichever interval comes first.

2920 1443 01 33
 Instruction book

5 PROBLEM SOLVING c Regeneration cooler clogged internally

c Consult Atlas Copco
The chart below helps to solve non-electrical faults.
3 Only on water-cooled dryers, water flows from one or
Warning: Before starting any repair work on the dryer, make both electronic water drains during unloaded operation
sure that the circuit breaker(s) (F41, Q2 and Q41- and after dryer has been stopped
Figs. 1.9 up to 1.15) are in the "0" position and a Regeneration air cooler core tube broken
that the dryer is depressurized. An electrical fault a Remove cooler, plug broken tube or replace cooler core
must be traced by an electrician. Make sure that
the wires are not chafed, damaged or broken and 4 Regeneration air inlet temperature too low
that they are clamped tight to their terminals. a Compressor loading periods too short
a See 1a
b Nozzle of ejector partly obstructed
Possible faults and their remedies b Remove and clean nozzle. Investigate cause
Explanation about the table below: c Compressor does not operate properly
- Conditions of the dryer, always preceded by a number, are c Consult section "Problem solving" of compressor instruction
printed in bold. book
- Each possible fault is followed by its related suggested
remedy and both are preceded by the same letter. 5 LED’s of electronic water drain do not light up
a Power supply to EWD’s faulty
1 Pressure dewpoint too high a Check power supply. Compare power supply with voltage
a Compressor loading periods repeatedly too short mentioned on data label of EWD
a Take necessary action to increase duration of loading periods b Power supply board defective
b Incorrect pressure difference between dryer compartments b Check and replace as necessary
b Check pressure difference which should be within the range
specified in section 3.1, step 14. Never operate the dryer 6 No condensate discharged when pressing test button on
with a pressure difference beyond the specified range. EWD
Always be sure that the connections of the U-tube are airtight a Condensate inlet and/or outlet blocked
c Operating pressure too low a Check and correct as necessary
c Do not operate dryer at a pressure less than 4 bar(e) (2.5 b Control board defective
bar(e) for dryers connected to a ZE compressor) b Check and replace if necessary
d Rotor does not turn c Solenoid valve defective
d Consult Atlas Copco c Check and replace if necessary
e Rotor compartment sealing ring, sealing sectors and rotor
need inspection 7 Condensate only discharged when test button is pressed
e Consult Atlas Copco a Sensor dirty
f Aftercooler air outlet temperature too high a Clean sensor
f On water-cooled compressors, check cooling water inlet b Air pressure below minimum pressure
temperature and increase water flow. If temperature cannot b Increase air pressure
be decreased sufficiently, consult Atlas Copco
On air-cooled compressors, clean cooler externally. If 8 EWD continuously discharges air
temperature cannot be decreased sufficiently, consult Atlas a Control air blocked
Copco a Check and correct as necessary
g Regeneration cooler air outlet temperature too high b Sensor dirty
g See 1f b Clean sensor
h Regeneration cooler air outlet temperature too low
h Consult Atlas Copco
i Drain system malfunctioning
i Inspect system and replace parts where necessary

2 Dryer air inlet temperature is higher than aftercooler

air outlet temperature
a Regeneration cooler air outlet temperature too high
a On water-cooled dryers, increase water flow through
regeneration air cooler
On air-cooled dryers, clean cooler externally
b On water-cooled dryers, cooling water temperature too
high
b Arrange so as to decrease temperature

34 2920 1443 01
Instruction book

6 PRINCIPAL DATA
6.1 Dryer specifications

6.1.1 Reference conditions

Ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 20
Compressed air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 28
Relative vapour pressure of inlet air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Cooling air/water temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 20
Regeneration air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 150
Moisture content of compressor intake air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . g/m³ 10

6.1.2 Limitations

Max. compressed air inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 10.5

Min. compressed air inlet pressure:
- MD connected to ZR, ZT compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 4
- MD connected to ZE compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 2.5
Max. cooling water pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 0
Max. compressed air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 45
Min. regeneration air inlet temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 130

6.1.3 Typical data

Oil capacity of worm gear housing (approx.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 0.65

6.1.4 Specific data

50 Hz 50 Hz 60 Hz 60 Hz
Air dryer type MD50 MD100 MD50 MD100
Compressor type ZT18-37 ZT45-55 ZT18-37 ZT45-55

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 7 7 7

Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 41.4 101 46.4 106
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 87.4 127 87.8 133
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -25 -25 -25 -25
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 40 40 40 40
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.1 0.1 0.1 0.1
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.25 0.20 0.25 0.25
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1000 1200 1000 1200
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 200 460 300 4) 700 4)

2920 1443 01 35
 Instruction book

50 Hz 60 Hz
Air dryer type MD100 W MD100 W
Compressor type ZR45-55 ZR45-55

Compressed air effective inlet pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar(e) 7 7

Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 106 113
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 129 146
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -24 -24
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -29 -29
Temperature of dried compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C 40 40
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.17 0.21
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.21 0.27
Cooling water consumption (approx.) with temperature rise of 5°C . . . . . . . . . . . . . l/s 0.8 0.8
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . W 120 144

50 Hz 50 Hz 60 Hz 60 Hz
Air dryer type MD200 MD200 W MD200 MD200 W
Compressor type ZT75-90 ZR75-90 ZT75-90 ZR75-90

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 7 7 7

Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 186 186 210 210
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 227 234 241 261
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -28 -28 -28 -28
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 40 40 40 40
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.20 0.20 0.24 0.22
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.25 0.25 0.27 0.27
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1400 --- 1400 ---
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s --- 0.8 --- 0.8
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 920 120 1344 144

36 2920 1443 01
Instruction book

50 Hz 50 Hz 60 Hz 60 Hz
Air dryer type MD300 MD300 W MD300 MD300 W
Compressor type ZT110 ZR110 ZT110 ZR110
ZT132 ZR132 ZT132 ZR132
ZT145 ZR145 ZT145 ZR145

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 7 7 7

Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 304 311 292 301
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 379 387 364 375
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -28 -28 -28 -28
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 42 42 42 42
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.20 0.20 0.20 0.20
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.25 0.25 0.25 0.25
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1900 --- 1900 ---
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s --- 0.8 --- 0.8
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 920 120 1344 144

50 Hz 50 Hz 60 Hz 60 Hz
Air dryer type MD400- MD400 W- MD400- MD400 W-
7.5 7.5 7.5 7.5
Compressor type ZT160 ZR160 ZT160 ZR160

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 7 7 7

Volume flow at dryer inlet 1) . . . . . . . . . . . . . . . . . . . . . l/s 452 465 410 410
Dewpoint of dried compressed air 2) . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 41 41 41 41
Pressure drop over dryer (approx.) 3) . . . . . . . . . . . . . . bar 0.27 0.27 0.27 0.27
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1900 --- 1900 ---
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s --- 0.8 --- 0.8
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 920 120 1344 144

2920 1443 01 37
 Instruction book

50 Hz 50 Hz 60 Hz 60 Hz
Air dryer type MD400- MD400 W- MD400- MD400 W-
10 10 10 10
Compressor type ZT160 ZR160 ZT160 ZR160
ZT200 ZR200 ZT200 ZR200

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 10.5 10.5 10.5 10.5
Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 372 386 346 360
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 482 500 434 448
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -25 -25 -25 -27
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 41 41 41 41
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.21 0.21 0.22 0.22
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.27 0.27 0.27 0.27
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1900 --- 1900 ---
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s --- 0.8 --- 0.8
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 920 120 1344 144

50 Hz 50 Hz 60 Hz 60 Hz
Air dryer type MD600- MD600 W- MD600- MD600 W-
7.5 7.5 7.5 7.5
Compressor type ZT200 ZR200 ZT200 ZR200
ZT250 ZR250 ZT250 ZR250

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 7 7 7

Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 557 599 513 513
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 703 718 712 712
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -25 -25 -25 -28
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 41 41 41 41
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.20 0.21 0.18 0.18
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.25 0.25 0.25 0.25
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 3000 --- 3000 ---
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s --- 2 --- 2
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 1220 120 1944 144

38 2920 1443 01
Instruction book

50 Hz 50 Hz 60 Hz 60 Hz
Air dryer type MD600- MD600 W- MD600- MD600 W-
10 10 10 10
Compressor type ZT275 ZR275 ZT275 ZR275

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 10.5 10.5 10.5 10.5
Volume flow at dryer inlet 1) . . . . . . . . . . . . . . . . . . . . . l/s 581 765 614 650
Dewpoint of dried compressed air 2) . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 41 41 41 41
Pressure drop over dryer (approx.) 3) . . . . . . . . . . . . . . bar 0.25 0.25 0.25 0.25
Cooling air flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 3000 --- 3000 ---
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s --- 2 --- 2
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 1220 120 1944 144

50 Hz 50Hz 60 Hz 60Hz
Air dryer type MD1000 W- MD1000 W- MD1000 W- MD1000 W-
7.5 10 7.5 10.4
Compressor type ZR300 ZR300 ZR300 ZR300
ZR425 ZR425 ZR425 ZR425

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 10.5 7 10.5

Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 775 689 744 677
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1162 830 1015 936
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -28 -28 -28 -28
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 41 41 41 41
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.17 0.21 0.18 0.18
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.25 0.25 0.25 0.25
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 2.5 2.5 2.5 2.5
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 120 120 144 144

2920 1443 01 39
 Instruction book

50 Hz 50Hz 60 Hz 60Hz
Air dryer type MD1800 W- MD1800 W- MD1800 W- MD1800 W-
7.5 10 8.6 10
Compressor type ZR450 ZR450 ZR450 ZR450
ZR750 ZR750 ZR750 ZR750

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 9 7 9

Volume flow at dryer inlet 1)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1257 1047 1306 1144
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 2075 1704 1939 1739
Dewpoint of dried compressed air 2)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -28 -28 -28 -28
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -30 -30 -30
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 40 40 40 40
Pressure drop over dryer (approx.) 3)
- Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.14 0.10 0.15 0.11
- Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.37 0.25 0.32 0.26
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 4.5 4.5 4.5 4.5
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 120 120 144 144

50/60 Hz 50/60 Hz 50/60Hz 50/60Hz

Air dryer type MD400 W MD400 W MD800 W MD800 W
VSD-8.6 VSD-10.4 VSD-8.6 VSD-10.4
Compressor type ZR160 VSD ZR160 VSD ZR315 VSD ZR315 VSD

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 8.6 10.4 8.6 10.4
Volume flow at dryer inlet 1)
- At minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 107 107 212 212
- At maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 412 412 815 815
Dewpoint of dried compressed air 2)
- At minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -23 -23 -30 -30
- At maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -27 -27 -40 -40
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 40 40 40 40
Pressure drop over dryer (approx.) 3)
- At minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.03 0.03 0.03 0.03
- At maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.33 0.33 0.32 0.32
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 0.8 0.8 2 2
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 144 144 144 144

40 2920 1443 01
Instruction book

50/60 Hz 50/60 Hz 50/60Hz 50/60Hz

Air dryer type MD1300 W MD1300 W MD2500 W MD2500 W
VSD-8.6 VSD-10.4 VSD-8.6 VSD-10.4
Compressor type ZR500 VSD ZR500 VSD ZR900 VSD ZR900 VSD

Compressed air effective inlet pressure . . . . . . . . . . . . . bar(e) 7 9 7 9

Volume flow at dryer inlet 1)
- At minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 358 361 908 775
- At maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 1318 1164 2456 2057
Dewpoint of dried compressed air 2)
- At minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -35 -35 -18 -18
- At maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . °C -30 -35 -20 -20
Temperature of dried compressed air . . . . . . . . . . . . . . . °C 38 36 48 48
Pressure drop over dryer (approx.) 3)
- At minimum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.08 0.05 0.1 0.07
- At maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . bar 0.5 0.38 0.5 0.4
Cooling water consumption (approx.) with temperature
rise of 5°C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/s 3.4 3 6 5
Max. electric power input . . . . . . . . . . . . . . . . . . . . . . . W 144 144 144 144

2920 1443 01 41
 Instruction book

6.2 Conversion list of SI units into British units

1 bar = 14.504 psi

1 g = 0.035 oz
1 kg = 2.205 lb
1 km/h = 0.621 mile/h
1 kW = 1.341 hp (UK and US)
1 l = 0.264 US gal
1 l = 0.220 Imp gal (UK)
1 l = 0.035 cu.ft
1 m = 3.281 ft
1 mm = 0.039 in
1 m³/min = 35.315 cfm
1 mbar = 0.401 in wc
1 N = 0.225 lbf
1 Nm = 0.738 lbf.ft
x °C = (32 + 1.8 x) °F 5)

Footnotes chapter 6

1) At an absolute pressure of 1 bar and a temperature of 20°C.

2) When dryer operates under reference conditions. If actual operating conditions differ, consult Atlas Copco.
3) At reference conditions.
4) For MD50 and MD100 air-cooled dryers for USA and CANADA, the maximum electric power input is 1800 W.
5) A temperature difference of 1°C = a temperature difference of 1.8°F.

42 2920 1443 01
O WNERSHIP DA TA
Compressor type: ........................................ Unit serial No. compressor: ....................................
Air dryer type: .......................................... Unit serial No. dryer: .........................................
Motor type: ............................................. Motor serial No.: ............................................
Delivery date: ........................................... First start-up date: ...........................................
Service Plan: ............................................ Owner's machine No.: ........................................
Selected lubricants
Compressor: ............................................ Capacity: ..................................................
Bearing grease type, electric motor: .........................
Dryer gearbox ........................................... Capacity ...................................................
Printed Matter Nos.
Atlas Copco compressor instruction book: .................... Atlas Copco air dryer instruction book: ..........................
Atlas Copco compressor parts list: .......................... Atlas Copco air dryer parts list: ................................
Atlas Copco logbook: ....................................................................................................
Local Atlas Copco Representative
Name: ...............................................................................................................
Address: ..............................................................................................................
Telephone: ................................... Contact persons: Service: .........................................
Telex: ...................................... Parts: ...........................................
E-mail ...............................................................................................................

SAFETY PRECA U T I O N S
To be read attentively and acted accordingly before installing, operating or repairing the unit.
These recommendations apply to machinery processing or consuming air or inert gas. Processing of any other gas requires
additional safety precautions typical to the application which are not included herein.

In addition to normal safety rules which should be observed with stationary If necessary, install a suction duct. Never obstruct the air inlet. Care
air compressors and equipment, the following safety directions and shall be taken to minimize the entry of moisture with the inlet air.
precautions are of special importance.
4. The aspirated air shall be free from flammable fumes or vapours,
When operating this unit, the operator must employ safe working practices e.g. paint solvents, that can lead to internal fire or explosion.
and observe all related local work safety requirements and ordinances.
5. Air-cooled units shall be installed in such a way that an adequate
The owner is responsible for maintaining the unit in a safe operating flow of cooling air is available and that the exhausted air does not
condition. Parts and accessories shall be replaced if unsuitable for safe recirculate to the inlet.
operation.
6. Arrange the air intake so that loose clothing of people cannot be
Installation, operation, maintenance and repair shall only be performed sucked in.
by authorized, trained, competent personnel.
7. Ensure that the discharge pipe from the compressor to the aftercooler,
Normal ratings (pressures, temperatures, time settings, etc.) shall be air dryer or air net is free to expand under heat and that it is not in
durably marked. contact with or close to flammable material.
Any modification on the compressor or air dryer shall only be performed
8. No external force may be exerted on the air outlet valve; the connected
in agreement with Atlas Copco and under supervision of authorized,
pipe must be free of strain.
competent personnel.
If any statement in this book, especially with regard to safety, does not 9. If remote control is installed, the unit shall bear an obvious sign
comply with local legislation, the stricter of the two shall apply. reading:

These precautions are general and cover several machine types and DANGER: This machine is remotely controlled and may start
equipment; hence some statements may not apply to the unit(s) described without warning.
in this book.
As a further safeguard, persons switching on remotely controlled
units shall take adequate precautions to ensure that there is no one
Installation checking or working on the machine. To this end, a suitable notice
shall be affixed to the start equipment.
Apart from general engineering practice in conformity with the local
safety regulations, the following directives are specially stressed: 10. On units with automatic start-stop system, a sign stating "This
machine may start without warning" shall be attached near the
1. A compressor or air dryer shall be lifted only with adequate equipment instrument panel.
in conformity with local safety rules.
11. In multiple compressor systems manual valves shall be installed to
Loose or pivoting parts shall be securely fastened before lifting. It is isolate each compressor. Non-return valves (check valves) shall not
strictly forbidden to dwell or stay in the risk zone under a lifted load. be relied upon for isolating pressure systems.
Lifting acceleration and retardation shall be kept within safe limits.
12. Never remove or tamper with the safety devices, guards or insulations
W ear a safety helmet when working in the area of overhead or lifting
fitted on the unit. Every pressure vessel or auxiliary installed outside
equipment.
the unit to contain air above atmospheric pressure shall be protected
2. Any blanking flanges, plugs, caps and desiccant bags shall be by a pressure-relieving device or devices as required.
removed before connecting up the pipes. Distribution pipes and
connections shall be of correct size and suitable for the working 13. Pipework or other parts with a temperature in excess of 80 degrees
pressure. celsius and which may be accidentally touched by personnel in normal
operation shall be guarded or insulated. Other high-temperature
3. Place the unit where the ambient air is as cool and clean as possible. pipework shall be clearly marked.

2920 1377 03 1/2 (continued on inside of cover)

 SAFETY PRECA UTIONS (continued)
14. If the ground is not level or can be subject to variable inclination, 5. Never use flammable solvents or carbon tetrachloride for cleaning
consult Atlas Copco. parts. Take safety precautions against toxic vapours of cleaning
liquids.
15. The electrical connections shall correspond to the local codes. The
units shall be grounded and protected against short circuits by fuses. 6. Scrupulously observe cleanliness during maintenance and repair.
Keep dirt away by covering the parts and exposed openings with a
Operation clean cloth, paper or tape.

1. Air hoses shall be of correct size and suitable for the working pressure. 7. Never weld or perform any operation involving heat near the oil
Never use frayed, damaged or deteriorated hoses. Use only the correct system. Oil tanks must be completely purged, e.g. by steam-cleaning,
type and size of hose end fittings and connections. When blowing before carrying out such operations.
through a hose or air line, ensure that the open end is held securely.
A free end will whip and may cause injury. Make sure that a hose is Never weld on, or in any way modify, pressure vessels.
fully depressurized before disconnecting it.
Whenever there is an indication or any suspicion that an internal
Never play with compressed air. Do not apply it to your skin or part of a machine is overheated, the machine shall be stopped but no
direct an air stream at people. Never use it to clean dirt from your inspection covers shall be opened before sufficient cooling time
clothes. When using it to clean equipment, do so with extreme caution has elapsed; this to avoid the risk of spontaneous ignition of the oil
and use eye protection. vapour when air is admitted.

2. The compressor is not considered as capable of producing air of Never use a light source with open flame for inspecting the interior
breathing quality. For breathing air quality, the compressed air must of a machine, pressure vessel, etc.
be adequately purified according to local legislation and standards.
8. Make sure that no tools, loose parts or rags are left in or on the unit.
3. Never operate the units when there is a possibility of taking in
flammable or toxic fumes. 9. Before clearing the unit for use after maintenance or overhaul, check
that operating pressures, temperatures and time settings are correct
4. Never operate the units at pressures below or in excess of their limit and that the control and shut-down devices function correctly. If
ratings as indicated on the Principal Data sheet. removed, check that the coupling guard of the compressor drive shaft
has been reinstalled.
5. Keep all bodywork doors shut during operation. The doors may be
opened for short periods only, e.g. to carry out checks. W ear ear 10. Every time the separator element is renewed, examine the discharge
protectors when opening a door. pipe and the inside of the oil separator vessel for carbon deposits; if
excessive, the deposits should be removed.
6. People staying in environments or rooms where the sound pressure
level reaches or exceeds 90 dB(A) shall wear ear protectors. 11. Protect the motor, air filter, electrical and regulating components,
etc. to prevent moisture from entering them, e.g. when steam-cleaning.
7. Periodically check that:
a. All guards are in place and securely fastened 12. Make sure that all sound-damping material, e.g. on the bodywork
b. All hoses and/or pipes inside the unit are in good condition, secure and in the air inlet and outlet systems of the compressor, is in good
and not rubbing condition. If damaged, replace it by genuine Atlas Copco material
c. There are no leaks to prevent the sound pressure level from increasing.
d. All fasteners are tight
e. All electrical leads are secure and in good order 13. Never use caustic solvents which can damage materials of the air
.
f Safety valves and other pressure-relief devices are not obstructed net, e.g. polycarbonate bowls.
by dirt or paint
g. Air outlet valve and air net, i.e. pipes, couplings, manifolds, 14. The following safety precautions are stressed when handling
valves, hoses, etc. are in good repair, free of wear or abuse refrigerant:

8. If warm cooling air from compressors is used in air heating systems, a. Never inhale refrigerant vapours. Check that the working area
e.g. to warm up a workroom, take precautions against air pollution is adequately ventilated; if required, use breathing protection.
and possible contamination of the breathing air.
b. Always wear special gloves. In case of refrigerant contact with
9. Do not remove any of, or tamper with, the sound-damping material. the skin, rinse the skin with water. If liquid refrigerant contacts
the skin through clothing, never tear off or remove the latter;
flush abundantly with fresh water over the clothing until all
Maintenance refrigerant is flushed away; then seek medical first aid.
Maintenance and repair work shall only be carried out under supervision
of someone qualified for the job. c. Always wear safety glasses.

1. Use only the correct tools for maintenance and repair work. 15. Protect hands to avoid injury from hot machine parts, e.g. during
draining of oil.
2. Use only genuine spare parts.

3. All maintenance work, other than routine attention, shall only be Note: W ith stationary machine units driven by an internal combustion
undertaken when the unit is stopped, the main power supply is engine, allowance has to be made for extra safety precautions, e.g. spark
switched off and the machine has cooled down. Take positive arrestors, fuelling care, etc. Consult Atlas Copco.
precaution to ensure that the unit cannot be started inadvertently.

In addition, a warning sign bearing a legend such as "work in All responsibility for any damage or injuryresulting from neglecting
progress; do not start" shall be attached to the starting equipment. these precautions, or by non-observance of ordinary caution and due
carerequired in handling, operating, maintenance or repair, even if
4. Before removing any pressurized component, effectively isolate the not expressly mentioned in this book, will be disclaimed by Atlas
unit from all sources of pressure and relieve the entire system of Copco.
pressure.

2920 1377 03 2/2