INSTRUCTION BOOK COMPRESSED AIR FILTERS DD 7+-630+, DDp 7+-630+, PD 7+-630+, PDp 7+-630+, QD 7+-630+, UD 7+-630+
Atlas Copco Compressed air filters DD 7+-630+, DDp 7+-630+, PD 7+-630+, PDp 7+-630+, QD 7+-630+, UD 7+-630+ Instruction book Original instructions COPYRIGHT NOTICE 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 is valid for CE as well as non-CE labelled machines.
Instruction book Table of contents 1 Safety............................................................................................................................... 4 1.1 SAFETY ICONS................................................................................................................................... 4 1.2 SAFETY PRECAUTIONS DURING INSTALLATION........................................................................................... 4 1.3 SAFETY PRECAUTIONS DURING OPERATION......
Instruction book 5.2 PRINCIPAL DATA...............................................................................................................................30 5.3 SPECIFIC DATA................................................................................................................................ 30 5.4 RATED FLOW AT REFERENCE CONDITIONS............................................................................................. 32 5.5 CORRECTION FACTORS.................................
Instruction book 1 Safety 1.1 Safety icons Explanation Danger to life Warning Important note 1.2 Safety precautions during installation 1. Install the equipment where the ambient air is cool and as clean as possible. Consult section Reference conditions and limitations. 2. During installation or any other intervention on the equipment or one of the connected machines, the machines must be stopped, de-energized and the isolating switch opened and locked before any maintenance or repair.
Instruction book 1.3 Safety precautions during operation All responsibility for any damage or injury resulting from neglecting these precautions, or non-observance of the normal caution and care required for installation, operation, maintenance and repair, even if not expressly stated, will be disclaimed by the manufacturer. 1. Persons switching on remotely controlled machines shall take adequate precautions to ensure that there is no one checking or working on the machine.
Instruction book 7. Never use a light source with open flame for inspecting the interior of the device. 8. All regulating and safety devices shall be maintained with due care to ensure that they function properly. They may not be put out of action. 9. Before clearing the device for use after maintenance or repair, check that operating pressures, temperatures and time settings are correct. Check that all control and shutdown devices are fitted and that they function correctly. 10.
Instruction book Disposal of other used material Used filters or any other used material (e.g. filter bags, filter media, desiccant, lubricants, cleaning rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and in line with the local recommendations and environmental legislation.
Instruction book 2 Description 2.
Instruction book 2.2 Filters with inPASS™ The premium range filters are equipped with an integrated inPASS™ valve in the housing. This inPASS™ valve will be used to service the filter and replace the filter element without interrupting operation and compressed air flow.
Instruction book In normal filtration operation the air flow is directed into the filter element and passes through several filter media layers before being guided to the outlet port of the filter. When the inPASS™ valve is activated, the compressed air flow is redirected through this valve to the filter outlet. This creates the opportunity to depressurize the filter housing, using the drain valve at the bottom of the filter, and service the filter element.
Instruction book 2.3 Filters without inPASS™ The standard range filter is not equipped with an integrated inPASS™. The DD+, PD+, UD+, DDp + and PDp+ filters have a differential pressure indicator for sizes 7+ to 45+ and a differential pressure gauge for sizes 45+ to 630+. At start-up and during normal operation, the differential pressure indicator will be yellow; it turns partially red when the pressure drop of the filter increases.
Instruction book The differential pressure gauge indicates the pressure drop on an indicative scale from 0 to 750 mbar. Refer to section Service intervals for more information on service intervals. 2.4 Options Filter connection kit If two or more filters are used in combination, build the filter heads together by means of a serial connection in the correct air flow direction. An arrow for the air flow direction is shown on the filter head or on the differential pressure indicator and gauge.
Instruction book Voltage-free contact A voltage-free switch, mounted in the differential pressure gauge, closes at a pressure drop of 0.35 bar (5 psi) and can be used for remote control or alarm purposes. The maximum switching voltage and current are 30 VAC/VDC and 0.2 A respectively. External power supply Optionally, the smart service indicator can be fitted with an external power supply and alarm contact. Alarm contact will be triggered based on the pre-defined service criteria.
Instruction book Referen ce Description 1 +VCC from external power supply 2 GND (ground) from power supply 3 Output signal NO (normally open). If needed, the contact can be changed to NC (normally closed) in the settings menu. 4 – Electronic drain The electronic drain is optional on the DD+, PD+ and UD+ filters. The electronic drain is a zero loss, electronically operated drain valve, specially designed to drain oil condensate. A sensor senses the condensate level.
Instruction book If the microcontroller registers a malfunction, the automatic drain valve will automatically change to alarm mode. This alarm signal can be relayed via a potential-free contact. The electronic drain is available for 3 operating voltages: 220 V, 115 V and 24 V (50/60 Hz). An extra electric wiring can be foreseen to connect the potential free contacts and an external test button. Always remove the manual drain or the automatic drain of the filter before installing the electronic drain.
Instruction book 3 Installation 3.1 General remarks When installing the filter, keep in mind the following: • Be sure that the piping is internally clean, especially downstream of the filter. • Sizing of filter should be done carefully, taking into account the application requirements. Maximum flow capacity, as listed in Chapter 5.4 or 6.4 "Rated flow at reference conditions", should never be exceeded to make sure that filtration performance and filter lifetime are guaranteed.
Instruction book Process piping recommendations To reach class 1 for solid particles according to ISO8573-1, it’s recommended to use stainless steel piping or AIRnet aluminum piping. Other types of piping, like brass or copper piping’s are not recommended as the surface roughness is too high, which makes class 1 difficult to reach. inPASS™ filter When installing the filter with inPASS™, it is important that this inPASS™ is completely turned in filter mode.
Instruction book • Remove the back-cover and insert 3 AA batteries. Make sure to use high quality batteries to ensure functionality. Batteries should at least comply to the following specification: AA size, alkaline, capacity: 2xxx mAh, voltage: 1.5V. • The device will boot up automatically • At first start up, a selection needs to be made in function of the filter grade. By pushing once (<1s) you can scroll through the different options.
Instruction book Also, if the battery level is becoming too low, the warning mode will be activated, and the battery outline symbol will blink. Alarm mode The LED on the front of the device will be flashing once every 5 seconds in case an alarm mode is triggered. This means that one of the three parameters (pressure drop, time in use and running hours) reached its alarm threshold. Service of the filter and battery change are mandatory at this stage.
Instruction book Rotation of the Smart service indicator It is possible to rotate the display of the Smart service indicator for both installation directions of the filter. 1. Remove the top cover by removing the screw with the appropriate tool. 2. Remove the second screw inside with the appropriate tool, and make sure the tool is properly aligned with the screw. 3. Lift the Smart Indicator housing by max. 5cm to prevent any of the wiring from coming loose. 4.
Instruction book for benchmarking purposes. The testing will provide the user with an efficiency value on the required particle size and the initial pressure drop at nominal flow conditions.
Instruction book 4 Maintenance 4.1 Maintenance When maintaining the filter, keep in mind the following: • On filters with manual drain valve, open the latter at regular intervals to evacuate collected dust or liquid. • In case an automatic drain valve or a solenoid timer drain is installed, manual draining can be carried out by turning the connection nipple of the automatic drain valve counterclockwise.
Instruction book 2. Before operating the inPASS™, please check if the circlips (1) is correctly positioned (supported by the inPASS™ groove and the horizontal face on top of the filter head) just below the hexagonal nut. In case of any doubts, please contact your supplier. 3. Place the appropriate tool (wrench, spanner) over the hexagonal nut and make sure there is room for rotational movement as indicated on the lock-out feature.
Instruction book 2. Place the appropriate tool (wrench, spanner) over the hexagonal nut and make sure there is room for rotational movement as indicated on the lock-out feature. Rotate the inPASS™ valve over 90° in a fluent motion (to not hinder the air flow) in the direction indicated on the lock-out feature. Fully rotate the inPASS™ until it is stopped, but keep in mind the maximal torque values shown in the table below. 3.
Instruction book Filter size Expected torque Maximum torque Recommended tool Nm lb-ft Nm lb-ft 7 - 25 10 7.38 30 22.13 Open-ended spanner 45 - 75 15 11.06 45 33.19 Ring spanner 110 - 180 25 18.44 75 55.32 Ratchet spanner 240 - 300 35 25.81 105 77.44 Ratchet spanner 390 - 510 60 44.25 180 132.76 Ratchet spanner Filter element change The hand-tool icon on the figure indicates the items provided in a dedicated filter kit. 1.
Instruction book In case the filter cannot be depressurized by venting via the drain port, do not continue with the filter element change and contact your supplier for further assistance. 5. Discard the used filter element. 6. Position the new filter element on top of the bowl and align the filter element fin with the groove in the top of the hexagonal nut, as can be seen in the figure below.
Instruction book 4.3 Filter element change without inPASS™ The hand-tool icon on the figure indicates the items provided in a dedicated filter kit. 1. Before filter element change, check for any leakages at the bottom of the filter bowl (connection of manual and automatic drain) during normal filter operation. If any leakage is observed, replace the drain according to the instruction from section Drain replacement. 2. Isolate the filter from the air net. 3.
Instruction book 7. Screw the bowl (with the filter element resting on top) completely on the head. A small amount of acid-free vaseline may be applied to the threads and O-ring of the bowl to facilitate the assembly. No lubricant of any sort should be used on the filter element seal. 4.4 Drain replacement The hand-tool icon on the figure indicates the items provided in a dedicated filter kit.
Instruction book 1. Start by isolating the filter housing from the compressed air flow. • For a filter without inPASS™ valve, this is done externally. • For a filter with inPASS™ valve, this is done by rotating the inPASS™ valve into inPASS™ mode, following the instructions in section inPASS™ instructions. 2. Depressurize the filter by turning the connection nipple of the automatic drain valve counterclockwise or by opening the manual drain valve. 3.
Instruction book 5 Technical data 5.1 Reference conditions 5.2 5.
Instruction book Solid particle 1µm removal 0.1µm (2) efficiency 0.01µm according to ISO12500-3:2 009 DD+ PD+ UD+ % > 99.999 > 99.999 > 99.999 % 97.03 99.67 99.94 % > 99.999 > 99.999 > 99.
Instruction book 5.
Instruction book 5.5 Correction factors When the actual working pressure differs from the reference pressure, multiply the nominal capacity of the filter with the corresponding correction factor to obtain the correct capacity. Pressure correction factors (all filtration grades) Working pressure (bar(e)) 1 2 3 4 5 6 7 8 10 12 14 16 Working pressure (psig) 15 29 44 58 73 87 102 116 145 174 203 232 correction factor 0.38 0.53 0.65 0.75 0.83 0.92 1 1.06 1.20 1.31 1.41 1.
Instruction book Filters with inPASS™ Type Net mass (kg) A B C D E F G 7+ 1.18 338 263 52 90 106 7 G 1/2 NPT 1/2 15+ 1.24 338 263 52 90 106 7 G 1/2 NPT 1/2 25+ 1.45 390.5 315.5 52 90 106 7 G 1/2 NPT 1/2 45+ 2.35 418 343 63 110 135 9 G 3/4 NPT 3/4 75+ 2.8 503 428 63 110 135 9 G1 NPT1 110+ 5.4 559.5 459.5 84.5 143 175 8.5 G1 1/2 NPT1 1/2 145+ 5.93 629.5 529.5 84.5 143 175 8.5 G1 1/2 NPT1 1/2 180+ 6.45 699.5 599.5 84.
Instruction book Filters without inPASS™ Type Net mass (kg) A B C D E F G 7+ 1.2 338 263 52 90 106 7 G 1/2 NPT 1/2 15+ 1.25 338 263 52 90 106 7 G 1/2 NPT 1/2 25+ 1.43 390.5 315.5 52 90 106 7 G 1/2 NPT 1/2 45+ 2.43 418 343 63 110 135 9 G 3/4 NPT 3/4 75+ 2.87 503 428 63 110 135 9 G1 NPT1 110+ 5.08 559.5 459.5 84.5 143 175 8.5 G1 1/2 NPT1 1/2 145+ 5.6 629.5 529.5 84.5 143 175 8.5 G1 1/2 NPT1 1/2 180+ 6.12 699.5 599.5 84.
Instruction book 5.7 Supplied components The table below gives an overview of the components provided on the different types of filters. Abbreviations: • • • • • PDSG .... Pressure Differential Smart service Indicator PDI .... Pressure Differential Indicator PDG .... Pressure Differential Gauge AD .... Automatic Drain MD ...
Instruction book Type DD+, PD+, UD+ DDp+, PDp+ QD+ 630+ PDG+AD PDG+MD MD 2920 7199 41 37
Instruction book 6 Pressure equipment directives Components subject to 2014/68/EU Pressure Equipment Directive The following table contains the necessary information for the inspection of all pressure equipment according to the Pressure Equipment Directive 2014/68/EU. Size Connection type Connection size Total volume (litres) Maximum working pressure (bar) PED category 7+ G 1/2 " 0.63 16 art. 4 par 3 NPT 1/2 " 0.63 16 art. 4 par 3 G 1/2 " 0.64 16 art. 4 par 3 NPT 1/2 " 0.
Instruction book Size Connection type Connection size Total volume (litres) Maximum working pressure (bar) PED category 630+ G 3" 18.31 16 CAT II NPT 3" 18.
We stand by our responsibilities towards our customers, towards the environment and the people around us. We make performance stand the test of time. This is what we call — Sustainable Productivity. www.atlascopco.com No. 2920 7199 41 / 2021 - 07 - Printed in Belgium Atlas Copco Airpower NV. All rights reserved. Designs and specifications are subject to change without notice or obligation.
