Technical Documentation

Compressed Air Dryer DB 10

Order No.: 4500002307

Date of Order: October 31st, 2005
Material No.: 11.66211-0008
No. Ident: 50
PSP-Element: 5012431.B.040.070.070

Boge Order No.: 56089

 Bypass
Option

wall fastening

operation side minimum distance

Dryer Order No. Order No. Order No. Dryer Order No. Weight Cooling Air
Dryer Dryer Load-Dependent Bypass
Floating Drain Need
Bekomat Condensate Drain
Dimensional Drawing
Dryer DB 10
 Operating
Instruction

Compressed Air Dryer

Model DB 1...DB 12

www.boge.com
Type Code

Type Code
Compressed Air Dryer

Model Type No.

DB 1 794AT
DB 2 795AT
DB 3 796AT

DB 6 797AT
DB 7 798AT

DB 10 799AT
DB 12 800AT

BOGE KOMPRESSOREN
Postfach 10 07 13
33507 Bielefeld

Lechtermannshof 26
33739 Bielefeld

Fon: (0 52 06) 6 01-0

Fax: (0 52 06) 6 01-200
Mail: info@boge.de
Net: www.boge.com
Nr. 596.0706.01

2 06.03
 Table of contents
Page
Type code 2
Part 1 Important user infor- 1.1 General notes 4
mation 1.2 Safety regulations 5
1.3 Handling with refrigerant 6

All safety notes in this operating instruction which may cause harm to personnel
or equipment, when ignored, are marked by the following symbols:

!
General danger symbol Electrical danger symbol

1.4 First aid 7

1.5 Disposal 7

Part 2 Installation 2.1 Transportation 8

2.2 Requirements on the place
of installation 8
2.3 Installation (Mounting) 8
2.4 Compressed air connection 9
2.5 Electric connection 9
2.6 Connection condensate drain 10

Part 3 Description 3.1 Designation 11

3.2 Purpose 11
3.3 Unit layout 11
3.4 Nominal power of CA-dryer 12
3.5 Principle of operation 13
3.6 Mode of operation 13
3.7 Condensate draining 14

Part 4 Operation 4.1 Commissioning 15

4.2 Starting 15
4.3 Operation 15
4.4 Stopping 15

Part 5 Maintenance 5.1 Maintenance 16

5.2 Trouble shooting 17

Appendix Technical data

Wiring diagrams
Spare parts lists

02.03
06.03 3 3
Part 1 Important User Information
1.1 General notes • This compressed air-dryer is referred to below as CA-
dryer.

• The company does not accept responsibility if safety

regulations are not met during handling, operation,
maintenance and repair, even though these are not
strictly stated in this operating instruction.

• We recommend the notice of this operating instruc-

tion verified by the operating personnel in writing (per-
sonnel file).

• We recommend translation of this operating

instruction into native language of foreign workers.

• The usability and the life cycle of the compressed air-

dryer as well as the avoidance of premature repairs
depends on proper operation, maintenance, care and
competent repair under consideration of this operat-
ing instruction.

• Hints to figures and locations are in brackets, e.g.

(Fig. 5/2).

• Due to our position as supplier of components we do

not always know the final usage and total range of
products' applications. We constantly improve our prod-
ucts to the latest state of science and technology and
therefore, we assume that our products are free from
defects in the sense of product liability. However, it
cannot be excluded that during faulty operation in criti-
cal areas of application especially at danger to life and
limb of persons involved, additionally safety measures
may be necessary. Therefore, we request the user of
our components / units, to ensure in his own interest,
to inform us about the application of our products in
order to initiate additional safety measures, if neces-
sary.

4 06.03
 Part 1 Important user Information
1.2 Safety regulations

Attention!
The operator has to observe the national working-, op-
erating- and safety regulations. Also existing internal fac-

! tory regulations must be met.

Maintenance and repair work must only be carried out
by specially trained personnel and, if necessary, under
supervision of a person qualified for this work.

• None of the protective or safety devices must be

removed, modified or readjusted temporarily or
permanently.

• Use proper tools for maintenance and repair work only.

• Use original spare parts only.

• All maintenance and repair works must only be ex-

ecuted at stopped machine, disconnected power sup-
ply and pulled mains plug. Ensure that the CA-dryer
cannot be switched on by mistake.

• Prior to dismounting a part under pressure, discon-

nect the CA-dryer from all pressure sources and de-
pressurize the CA-dryer.

• Do not use inflammable solvents for cleaning.

• Keep the environment absolutely clean during main-

tenance and repair works. Keep free of dirt by cover-
ing the parts and free openings with clean cloth, pa-
per or adhesive tape.

• Never weld at the pressure vessel or modify it in any

way.

• Ensure that no tools, loose parts or similar are left in

the system.

02.03
06.03 5 5
Part 1 Important user Information
1.3 Handling with • Wear eye protection and protective gloves.
refrigerant
• Avoid contact of liquid refrigerants with your skin (frost-
bite).

• Do not inhale refrigerant vapours.

• To avoid higher concentrations, all work rooms must

be ventilated very well. The opening of windows and
doors may not be sufficient, so an exhausting system
must be used directly at the supply point or near the
floor.

• Do not smoke, because fire might decompose the

refrigerant. The resulting substances are toxic and
must not be inhaled.

• Do not let refrigerants escape during filling or repair

work. Cover with tape.

• Leave the room immediately and only enter after the

room has been sufficiently ventilated when refrigerant
concentrations (e.g. pipe line leakages) appear sud-
denly.

• Execute welding and soldering works on refrigerating

systems in well ventilated rooms only. Refrigerants
will be decomposed in flames as well as in electrical
arcs.

• The resulting decomposition products are toxic.

• Before welding and soldering at refrigerating systems,

the refrigerant must be removed.

• A stinking smell indicates decomposition of refrigerant

due to overheating:
- Leave room immediately.
- Ventilate room very well.

6 06.03
 Part 1 Important user Information
1.4 First aid • Take victim immediately into the fresh air or into a
very well ventilated room.

• Splashes of refrigerant in the eyes must be blown out

with the mouth. Then rinse eyes with plenty of water.
Do not wipe with cloth!

• If the victim does not breathe, perform a mouth-to-

mouth resuscitation or use a respirator until the doctor’s
arrival.

• Call the doctor and inform him that accident has

been caused by refrigerants, for refrigerant type
see identification plate!

• Never leave the victim unattended!

1.5 Disposal • When disposing of used devices, pay attention to oil

and refrigerant in the hermetically sealed refrigerating
circuit of the CA-dryers. Therefore, before dismount-
ing, these operation media must be disposed by a
special company.

• The used materials are listed on the recycling label

inside the CA-dryer.

Attention!

! Do not dispose waste oil into the environment. Do not

mix with household rubbish and do not burn in unauthor-
ized plants.

• The escape of refrigerant into the atmosphere must

be prevented by appropriate measures.

02.03
06.03 7 7
Part 2 Installation
2.1 Transportation Transportation has to be carried out in the normal oper-
ating position of the CA-dryer. For a short time an inclined
position of 45 ° is allowed.

2.2 Requirements on At the site of installation, the CA-dryer can be installed

the place of in- without anchorage or special foundation at the location
stallation desired.
The CA-dryer is provided for an ambient temperature of
25 °C.

Attention!
To avoid corrosion at components of the CA-dryer, the

!
compressed and ambient air must be free of aggressive
parts.
The CA-dryers are provided for inside mounting.
Deviating conditions require the consultation of the
manufacturer.

To prevent the condensate from freezing, the room tem-

perature must not drop below +2 °C.

!
Attention!
At different ambient conditions pay attention to the lay-
out data!

2.3 Installation Install the CA-dryer with access to the front panel.
(Mounting) Furthermore, leave space for service purpose on both
sides of the CA-dryer (Fig. 1).

A wall mounting is possible with all types.

Fig. 1 Installation of
CA-dryer

yyy
;;;
;;;
yyy
y;yyy
;;;
y;
8 06.03
 Part 2 Installation
2.3.1 Version air cooled The cooling air for the refrigerant condenser will be
sucked in at the front panel (Fig. 3/8). This area must be
kept free and not be obstructed.
If necessary, sufficient cooling air supply must be pro-
vided by additional wall openings.
The cooling air outlet is positioned at the side of the unit
(Fig. 3/4). Ensure a free air outlet and do not obstruct the
outlet of the cooling air.
If the CA-dryer is connected to an exhaust trunk, an ad-
ditional fan must be installed to compensate the pres-
sure drop. The controlling of the fan must be provided
through the CA-dryer.

2.4 Compressed air con- The connection must be executed acc. to marking at the
nection CA-dryer (Fig. 3/1, 3/2).
For service purposes the installation of a bypass line is
recommended (additional equipment).

Attention!
Before mounting the CA-dryer, welding residues, rust or
other pollution must be removed from the pipelines to be

!
connected. If pollution cannot be excluded, proper filter
systems must be installed.
The compressed air pipes must be installed stress-free.
Expansion joints are recommended in case of vibrations
and pulsations.

2.5 Electric connection The CA-dryers are completely equipped and wired. They
merely have to be connected to a power supply. The CA-
dryers are to be protected by slow-blow fuses as defined
in the wiring diagram.

Voltage: acc. to name plate or wiring diagram resp.

Attention!
Due to transportation reasons the power connection cable
with installed cable bushing is located inside the housing
of the CA-dryer.
After removal of the side wall (Fig. 3/6) the cable bushing
is mounted and fastened in the corresponding passage
(Fig. 3/3) of the housing.

02.03
06.03 9 9
Part 2 Installation
2.6 Connection conden-
sate drain

A hose has to be connected at the condensate drain and

!
led out of the housing.
A passage (Fig. 3/9) is used for leading out the connection
hose.
Due to safety reasons the side wall must be shut again.

The CA-dryer separates water as well as oil from the com-

pressed air. The water/oil mixture must not be led into
the sewage. Water and oil must be separated by suitable
separators (additional equipment).

Attention!

! Install condensate outlet in a way that persons or objects

will not be struck by condensate (condensate outlet with
operating pressure)!

2.6.1 Version automatic A minimum operation pressure of 2 bar is required for

drain safe operation.

2.6.2 Connection conden- The condensate drain pipe (Fig. 2/1) may be fixed to the
sate drain wall with a rising slope of maximum 5 m. Thereby, the
minimum operation pressure increases by 0,1 bar per
meter. Over its whole length, the collecting pipe (Fig. 2/2)
should at least have the cross-section of the condensate
outlet.

Fig. 2: Connection conden-

sate drain 2

from CA-dryer to treatment

10 06.03
 Part 3 Description
3.1 Designation Refrigerated compressed air-dryer (CA-dryer).
For model see type code (page 2).

3.2 Purpose Compressed air will be dehumidified by the CA-dryer.

3.3 Unit layout The following components of the CA-dryer are accessible
from outside (Fig. 3).

Fig. 3: Complete unit

(2) (1)

(4)

(8) (7) (5) (3) (9) (6) (4)

1 Compressed air inlet

2 Compressed air outlet
3 Electric connection
4 Cooling air outlet
5 Pressure dew point indication
6 Service access
7 Operation switch
8 Cooling air inlet
9 Condensate drain

02.03
06.03 11 11
Part 3 Description
3.3.1 Indications
Operation switch “Off”.
Fig. 4: Symbols

Compressed air inlet / outlet.

Prior to maintenance works at the CA-

dryer, the unit must be disconnected
from the power supply.

If the CA-dryer is not disconnected,

the risk of injuries is given due to free
rotating fan wings.

The refrigerant compressor of the re-

frigeration system heats up during op-
eration, so the risk of burning is given
at maintenance works.

Fig. 5: Pressure dew point

indication

(1) (2) (3)

1 Blue area : Pressure dew point temperature too low.

2 Green area : Pressure dew point temperature normal.
3 Red area : Pressure dew point temperature too high.

3.4 Nominal power of The nominal power of the CA-dryer mentioned in the
CA-dryer technical data is related to a working pressure of 7 bar, a
compressed air inlet temperature of 35 °C as well as an
ambient temperature of 25 °C acc. to DIN ISO 7183.
Lower working pressure, higher compressed air inlet
temperature and/or higher ambient temperatures over-
loads the compressor. This causes an increased pres-
sure dew point and the CA-dryer can be stopped by in-
ternal safety devices.
At an essentially modified operation mode as mentioned,
ask the supplier of the CA-dryer for support.

12 06.03
 Part 3 Description
3.5 Principle of opera- The CA-dryer includes a refrigerant system cooling the
tion compressed air flow. The steam saturation limit is low-
ered causing condensate to fall out, which is removed by
the condensate drain.
The higher the cooling temperature difference of the air,
the higher is the amount of condensate.
The lower the cooling temperature of air, the lower is the
moisture content.
The lower limit of air cooling results from the operating
principle of the CA-dryer, i.e. the moisture separation in
liquid form can only occur above the freezing point of
water.

3.6 Mode of operation

3.6.1 Compressed air side The compressed air precooled in the aftercooler and
saturated with moisture enters into the CA-dryer and is
precooled in the first cooling stage, the air-to-air heat
exchanger, without additional energy. Cooling is carried
out in counterflow to the already cooled air heated dur-
ing this process.
The cooling to the pressure dew point is performed in the
second cooling stage, the refrigerant-to-air heat
exchanger cooled by the refrigerant ysystem installed.
Afterwards, the cooled compressed air is reheated in the
air-to-air heat exchanger as already described.
The pressure dew point temperature is indicated at the
operating panel (Fig. 3/5).

3.6.2 Refrigerant side The refrigerant is injected into the refrigerant-to-air heat
exchanger where it evaporates, thereby cooling the com-
pressed air. A capacity control system at the refrigerant
side controls the capacity required by the compressed
air to ensure a constant pressure dew point temperature
in all capacity ranges.
The refrigerant compressed by the refrigerant compressor
is condensed within the condenser and is available for
the evaporation again.

3.6.3 Pressure dew point The CA-dryer can be operated under partial load due to
control lower compressed air throughput or lower compressed
air inlet temperature in the range of 0 to 100% power in
permanent operation.

02.03
06.03 13 13
Part 3 Description
3.7 Condensate draining The condensate drain automatically drains the conden-
sate. A minimum pressure of 2 bar is required for safe
operation.

3.7.1 Version with auto- The condensate is collected within the condensate drain.
matic condensate With rising condensate a floater is lifted. This causes the
drain opening of an internal valve and the condensate is drained.
After the dropping of the condensate the internal valve
closes again.

14 06.03
 Part 4 Operation
4.1 Commissioning After installion, the CA-dryer is supplied with power via
power cable (Fig. 3/3).

Before operating the operation switch (Fig. 3/7), a waiting

period of at least 6 hours is necessary.

4.2 Starting The CA-dryer is switched on via the operation switch (Fig.
3/7). After approx. 5 minutes, the compressed air admis-
sion is possible by connecting the compressed air com-
pressor.

Attention!

! A period of 5 minutes must be kept between switching

off and switching on the CA-dryer to achieve a pressure
compensation within the refrigeraion system.

After some hours of operation under load, it should be

controlled whether condensate is generated and drained.
The CA-dryer is designed for continuous operation and
may remain switched on during periods of no load, as it
adapts to the required performance automatically.

4.3 Operation Operation is indicated by the luminous operation switch

(Fig. 3/7).
The pressure dew point indication (Fig. 5) shows the
pressure dew point reached by the CA-dryer.

4.4 Stopping At standstill periods, the CA-dryer is switched off with

the operation switch.
For longer standstill periods or service works, the CA-
dryer is additionally disconnected by pulling the power
cable (Fig 3/3).
For restarting, proceed as mentioned in item 4.2.

02.03
06.03 15 15
Part 5 Maintenance
5.1 Maintenance

!
Attention!
Prior to any maintenance works, all safety regulations
for electrical systems and units must be observed.

5.1.1 Daily maintenance Since maintenance intervals highly depend on the mode
of operation and the ambient conditions on site, the
intervals below are only to be understood as general re-
commendations.

a) Check function of condensate drain.

Check if water is drained (see 5.2.4.1).
b) Monitor pressure dew point (Fig. 5). In case of
deviations from normal values see 5.2.2 or 5.2.3.

5.1.2 Weekly maintenance Inspect condensate draining system and clean if

necessary.

Attention!

!
Maintenance work must be performed at the depressu-
rized condensate drain only. For this purpose, the instal-
lation of a bypass line is recommended (additional
equipment).

5.1.3 Cleaning of the auto- a) Disconnect CA-dryer from compressed air system.
matic condensate b) Depressurize and wait.
drain (floater) c) Open service access (Fig. 3/6).
d) Remove condensate pipe (Fig. 6/1).
e) Remove insulation (Fig. 6/2).
Dismounting of con- f) Loosen and pull off condensate tank secured with
densate drain bayonet lock (Fig. 6/3, 6/4). The floater is loose within
the tank (Fig. 6/5)!
g) Clean condensate tank.

Mounting of conden- Mounting is done in reverse order.

sate drain

Fig.6: Dismounting of con-

densate drain

1 2 3 4 5

16 06.03
 Part 5 Maintenance

5.2 Troubleshooting

5.2.1 Function:
Cause Remedy

No function - Check and establish power supply if necessary.

- If the power supply is ok, call for service or send CA-
dryer to the manufacturer.
5.2.2 Pressure dew point
too high

Cause Remedy
5.2.2.1 Temporary overload of Reduce load,
the CA-dryer due to irregular check CA-dryer´s capacity (see 3.4).
compressed air consumption

5.2.2.2 Room temperatures too Reduce room temperature.

high

5.2.2.3 Overload due to Reduce CA-consumption or increase CA-dryer capacity.

volume flow too high, or com-
pressed air inlet temperature too
high

5.2.3 Pressure dew point Stop the unit and maintain compressed air flow. After
too low approx. half an hour, the pressure dew point will return to
normal value. Restart the unit. If the pressure dew point
decreases again call for service.

5.2.4 Water in compressed

air system
Cause Remedy
5.2.4.1 In the event of no con- Clean condensate drain with neutral cleaning agent.
densate discharge (blocked dis-
charge pipe, pressure below
required minimum)

(with installed bypass line)

5.2.4.2 Bypass valve of bypass Close bypass valve of the bypass line.
line opened

5.2.4.3 Bypass valve of bypass Seal or replace bypass valve of the bypass line.
line leaking

02.03
06.03 17 17
Part 5 Maintenance

5.2.5 Stopping CA-dryer

during operation:

Cause Remedy
- Stopping of CA-dryer by - Eliminate cause of trouble.
installed electric start and - The CA-dryer will return to operation mode automati-
protection device (Klixon) cally after protection device has cooled down.
due to overload Note: The immediate restarting of the unit is not pos-
sible because the protection device requires a mini-
mum time to cool down to an admissible operating tem-
perature.

5.2.6 High differential

pressure at CA-side:

Cause Remedy
5.2.6.1 CA-volume flow too Check CA-dryer´s capacity, increase CA-dryer´s capacity
high (see 3.4).

5.2.6.2 Operating pressure too Increase operating pressure, check CA-dryer´s capacity.
low

5.2.6.3 Icing of CA-dryer Characteristics: - Differential pressure at CA-side

increases.
- Volume flow decreases.
Disconnect unit and maintain compressed air flow. After
approx. half an hour, the differential pressure will return
to normal value. Restart the unit. If the heat exchanger
ices up again call for service.

18 06.03
 GB Technical Data

Size of Housing 1 2 3
Pos. Type-No. 735A, 794AT 736A, 795AT 737A, 796AT 738A, 797AT 739A, 798AT 740A, 799AT 741A, 800AT
m³/h 10 15 18 35 40 60 68
1 Volume flow
m³/min 0,17 0,25 0,3 0,58 0,67 1 1,13
2 Cooling air required m³/h 260 240 450
3 Power consumption (total) kW 0,13 0,14 0,15 0,16 0,25 0,27 0,33
4 Power consumption (fan) kW 0,029 0,031 0,036
5 Power supply 50 Hz 230V 1N~
6 Allowable pressure (compressed air) min./ max. bar 2 / 16
Allowable pressure low pressure side,
7 bar 16 / 50
(refrigerant) high pressure side
8 Compressed air connections G 3 / 8'' 1 / 2'' 3/4''
9 Weight kg 21 22 23 25 26 38 40
height 375 400 500
10 Dimensions width mm 350 350 450
depth 300 350 450
11 Refrigerant quantity R 134a kg 0,2 0,3 0,33
12 Sound pressure level dB (A) < 70
13 Type of protection IP 20
14 Condensate drain Hose mm da = 8 / di = 6

Specification:
Pos.1 : Volume flow reffered to the suction status of the air compressor +20°C 1 bar
at compressed air inlet temperature +35°C
operating pressure 7 bar
ambient temperature +25°C
pressure dew point at CA-dryer outlet +3°C

Pos. 3, 4: Power consumption at ambient temperature +25°C

Compressed air inlet temperature max. +60°C

Allowed ambient temperature: min. + 2°C

max. +50°C

Technical modifications are subject to change without notice!

Designation: Type-No.: Technical Data Sheet: Date: Page 1 of

Refrigerated Compressed Air Dryer 735A - 741A, 794AT - 800AT I1T 5007 8GB 2003-06-23 1
 1 2 3 4 5 6 7 8

L1.1
/2.1*

A
A

B B

M1
L
C C C
2 5
4
S1 S4 P> M
1 4
(PS)
1 1
Betr.-schalter Pressostat
operation switch manostat PE

A1
D D
M2 1M N

N1.1
/2.1*
L1 N PE (M200) (V100)
X0 Ventilator Kälteverdichter
E max.
fan fridge compressor
E
10A

Einspeisung durch Netzstecker

supply by plug
220-230V1N~/50Hz
*: nur fuer Optionen
only for options
F Datum 25.04.03 Typ: =
F
Kälte-Drucklufttrockner
Bearb. RAH 735A-739A +
Gepr. JN refrigerated dryer 794AT-798AT Zeichn.Nr./drawing no. Blatt 1
Zustand Änderung Datum Name Norm DIN 40719 Urspr. E2A0735000 Ers. f. E2A0735000 von 1/2* Bl.
1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

L1.1
/2.1*

A
A

B B

M1
L
2 5 C

S1
C 1 4
4
M C
Betr.-schalter
S4 P> 1
1
operation switch (PS)
Pressostat PE
manostat
A1

M2 1M N
D D

N1.1
/2.1*
L1 N PE
X0 (M200) (V100)
Ventilator Kälteverdichter
max. fan fridge compressor
10A

E E
Einspeisung durch Netzstecker
supply by plug
220-230V1N~/50Hz

*: nur fuer Optionen

d A1 geaend. 11.06.03 RAH only for options
F c K2,Y1 entf.11.06.03 RAH Datum 11.06.03 Typ: =
F
Kälte-Drucklufttrockner 740A-741A
b Typen erg. 24.04.03 RAH Bearb. RAH +
a A1 ers. 13.02.03 RAH Gepr. JN refrigerated dryer 799AT-800AT Zeichn.Nr./drawing no. Blatt 1
Zustand Änderung Datum Name Norm DIN 40719 Urspr. E2A0740000 Ers. f. E2A0740000 von 1/2* Bl.
1 2 3 4 5 6 7 8
 GB Spare Parts List DIN 24 420

Details by the manufacturer Details by the user

Wiring
P&I diagram Qty. Unit Denomination Dryer type Short description Identnumber Remarks Order quantity
diagram
A100 1 Pcs. Automatic drain 735A-739A, 794AT-798AT C710026000
A100 1 Pcs. Automatic drain 740A-741A, 799AT-800AT 0112352000
S1 1 Pcs. Operation switch 735A-741A, 794AT-800AT 0108673000
M200 M2 1 Pcs. Fan motor 735A-737A, 794AT-796AT C710014000
M200 M2 1 Pcs. Fan motor 738A-739A, 797AT-798AT C710033000
M200 M2 1 Pcs. Fan motor 740A-741A, 799AT-800AT 0102404000
TI00 1 Pcs. Pressure dewpoint indication 735A-741A, 794AT-800AT 0110194000
PS00 S4 1 Pcs. Pressure switch 735A-741A, 794AT-800AT 0112138000

Denomination: Type-No.: Sheet No.: Date: Page 1 of

735A-741A
Refrigerated Compressed Air Dryer I17 5007 QGB 2003-06-06 1
794AT-800AT
 21.02.2006

Machine Data Sheet

Order No. : 56089

Clients No. / Name : 1105664 / MAN B&W Diesel AG
---------------------------------------------------------------------------------------------------

Type of Machine : Compressed Air Dryer DB 10

Year of Manufacture :

Cooler
Manufacturer / Serial No. : DB 10 / 061/18373/75