ADE Operator - Morse Industrial Equipment

REFRIGERATED AIR DRYER
SÉCHEUR A CYCLE FRIGORIFIQUE
ADE 5 HGV to ADE 8 HGV Compact
ADE 8 HGV to ADE 23 HGV
GB
USER’S MAINTENANCE
AND SPARE PARTS MANUAL
GB
F
MANUEL D’INSTRUCTIONS ENTRETIEN
PIECES DE RECHANGE
F
AIR - COOLED
REFROIDISSEMENT A AIR
ISSUE • EDITION
2004
ADM 0005 51 Rev.00
CANADA
GB
Dear Customer,
Thank you for choosing our product. In order to get the best performance from this product, please read this
manual carefully. In order to prevent erroneous operating conditions and to avoid dangerous situations for
the operator, please note that it's strictly recommended to respect the instructions of this manual and the
safety rules in force in the country where the dryer is installed.
Each ADE-HGV series chilling cycle dryer before packaging is submitted to a rigorous test, in order to verify
the absence of any manufacturing faults and that the device can satisfy all the functions for which it has
been designed. Once the dryer will be properly installed on the basis of the instructions reported in this
manual, it will be ready for use without any further adjustment. The operation is fully automatic, and the
maintenance is limited to few controls and some cleaning operations, as detailed in the following chapters.
This manual must be maintained available in any moment for future references and it has to be
intended as inherent part of the relevant dryer.
Due to the continuous technical evolution, we reserve the right to introduce any necessary change without
giving previous notice. Should you experience any trouble, or for further information, please do not hesitate
to contact us.
IDENTIFICATION PLATE
The product identification plate,
on the back of the dryer, shows
all the primary data of the
machine.
Upon installation, fill in the table
copying the data shown on the
identification plate. These data
must always be referred to the
manufacturer or to the dealer
when information or spares are
needed, even during the
warranty period.
The removal or the alteration of
the identification plate will void
the warranty rights.
Model Serial No. Code Nominal Flow Rate Max Air Pressure Max Inlet Air Temp. Ambient Temp. Refrigerant Refrig. Design Pres. HP/LP
Electric Supply
Electric Nominal Power
Fuse Max.
Manufactured
Model
Serial No.
Code
Nominal Flow Rate
scfm
Max Air Pressure
psig
Max Inlet Air Temp.
°F
Ambient Temp.
°F
Refrigerant
type/oz
Refrig. Design Pres. HP/LP
Manufactured
Electric Supply
psig
V/ph/Hz
Electric Nominal Power
W/A
Fuse Max
A
WARRANTY CONDITIONS
For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty
covers faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and restaurant
expenses of our technician.
The warranty doesn’t cover any responsibility for direct or indirect damages to persons, animals or
equipment caused by improper usage or maintenance, and it’s limited to manufacturing faults only.
The right to warranty repairs is subordinated to the strict compliance with the installation, use and
maintenance instructions contained in this manual.
The warranty will be immediately voided in case of even small changes or alterations to the dryer.
To initiate repairs during the warranty period, the data reported on the identification plate must be provided.
GB
1.
SAFETY RULES
1.1
1.2
1.3
2.
INSTALLATION
2.1
2.2
2.3
2.4
2.5
2.6
2.7
3.
Control Panel
Operation
Flow Diagram
Refrigerating Compressor
Condenser unit
Dehydration Filter
Capillary Tube
Evaporator
Hot Gas By-pass Valve
Aftercooler
5-Micron Filter
Air-to-air Exchanger
Condensate Separator
Refrigerant Pressure Switch PV
DTT11 Electronic Controller
Electric Layout of the Dryers Series ADE 5 Compact to ADE 8 HGV Compact
Electric Layout of the Dryers Series ADE 8 HGV to ADE 23 HGV
MAINTENANCE AND SPARES
6.1
6.2
7.
Technical Features of the Dryers Series ADE 5 Compact to ADE 8 HGV Compact
Technical Features of the Dryers Series ADE 8 HGV to ADE 23 HGV
TECHNICAL DESCRIPTION
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
6.
Preliminary Operations
First Start Up
Operation and Switching Off
TECHNICAL CHARACTERISTICS
4.1
4.2
5.
Transport
Installation site
Installation layout
Correction factors
Connection to the Compressed Air System
Connection to the Mains
Condensate Drain
START UP
3.1
3.2
3.3
4.
Definition of the Conventional Signs Used in This Manual
Warnings
Proper Use of the Dryer
Controls and Maintenance
Suggested Spare Parts
TROUBLESHOOTING AND DISMANTLING
7.1
7.2
Troubleshooting
Dismantling of the Dryer
GB
1.1 DEFINITION OF THE SIGNS USED IN THIS MANUAL
Before attempting any intervention on the dryer, read carefully the instructions reported in this use
and maintenance manual.
General warning sign. Risk of danger or possibility of damage to the machine. Read carefully the
text related to this sign.
Electrical hazard. The relevant text outlines conditions which could result fatal. The related
instructions must be strictly respected.
Danger hazard. Part or system under pressure.
Danger hazard. Component or system which during the operation can reach high temperature.
Danger hazard. It’s absolutely forbidden to breath the air treated with this apparatus.
Danger hazard: It’s absolutely forbidden to use water to extinguish fire on the dryer on in the
surrounding area.
Danger hazard. It’s absolutely forbidden to operate the machine when the panels are not in place.
Maintenance or control operation to be very carefully performed by qualified personnel 1.
ARIA
AIR
LUFT
AIR
Compressed air inlet connection point.
ARIA
AIR
LUFT
AIR
Compressed air outlet connection point.
Condensate drain connection point.
Operations which can be worked out by the operator of the machine, if qualified 1.
NOTE :
Text to be taken into account, but not involving safety precautions.
In designing this unit a lot of care has been devoted to the protection of the environment:
• CFC free refrigerants
• Foamed insulation parts produced without CFC
• Energy saving design
• Limited acoustic emission
• Dryer and relevant packaging composed of recyclable materials
Not to spoil our commitment, the user should follow the few ecological suggestions marked with
this sign.
1
Experienced and trained personnel acquainted with the relevant rules and laws, capable to perform the needed activities and to
identify and avoid possible dangerous situations while handling, installing, using and servicing the machine.
GB
1.2 WARNINGS
Compressed air is a highly hazardous energy source.
Never work on the dryer with parts under pressure.
Never point the compressed air or the condensate drain jet towards anybody.
The user is responsible for the installation of the dryer, which has to be executed on the basis of
the instructions given in the “Installation” chapter. Otherwise, the warranty will be voided and
dangerous situations for the personnel and/or damages to the machine could occur.
Only qualified personnel can use and service electrically powered devices. Before attempting any
maintenance action, the following conditions must be satisfied :
• Be sure that no part of the machine is under voltage and that it cannot be connected to the
mains.
• Be sure that no part of the dryer is under pressure and that it cannot be connected to the
compressed air system
These refrigeration air dryers contain R134.a type refrigerant fluid, not considered potential ozone
depleting. Maintenance on refrigeration systems must be carried out only by refrigeration
engineers according to local rules. R134.a may be dangerous for men only if it is present in bulk
concentrations. In case of leaks the room is to be aired before any intervention.
Any change to the machine or to the relevant operating parameters, if not previously verified and
authorized by the Manufacturer, in addition to create the possibility of dangerous conditions it will
void the warranty.
Don’t use water to extinguish fire on the dryer on in the surrounding area.
1.3 PROPER USE OF THE DRYER
This dryer has been designed, manufactured and tested only to be used to separate the humidity normally
contained in compressed air. Any other use has to be considered improper. The Manufacturer will not be
responsible for any problem arising from improper use; the user will be in any case responsible for any resulting
damage. Moreover, the correct use requires the respect of the installation conditions, in particular :
• Voltage and frequency of the mains.
• Pressure, temperature and flow-rate of the incoming air.
• Ambient temperature.
This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to the
plant in compliance with the instructions given in the following chapters.
The purpose of the machine is the separation of water and eventual oil particles present in
compressed air. The dried air cannot be used for respiration purposes or for operations leading to
direct contact with foodstuff.
This dryer is not suitable for the treatment of dirty air or of air containing solid particles.
2.1 TRANSPORT
Once the integrity of the packaging is verified, place the unit near to the installation point and unpack the
contents.
• To move the packaged unit we suggest to use a suitable trolley or forklift. Transportation by hands is
discouraged.
• Keep the dryer always in vertical position. Turning it upside down some parts could be irreparably
damaged.
• Handle with care. Heavy blows could cause irreparable damage.
• Even when packaged, keep the machine protected from severity of the weather.
The packaging materials are recyclable. Each single material must be properly disposed
in a manner complying with the rules in force in the destination country.
GB
2.2 INSTALLATION SITE
Particular care is required in selecting the installation site, as an improper location could
jeopardize the proper operation of the dryer.
This unit is not suitable for use in an explosive atmosphere, where risk of fire could exist, or in the
presence of gaseous or solid polluting material.
Don’t use water to extinguish fire on the
dryer or in the surrounding area.
Minimal installation requirements :
• Select a clean room dry, free from dust, and
protected from atmospheric disturbances.
• The supporting area must be smooth, horizontal
and able to hold the weight of the dryer.
• Minimum ambient temperature +34 °F (1 °C).
• Maximum ambient temperature +113°F (45 °C).
• Allow at least a clearance of 40 in (1 m) on each
side of the dryer for proper ventilation and to
facilitate eventual maintenance operations.
The dryer does not need to be fixed to the
supporting surface.
2.3 INSTALLATION LAYOUT
-A-
6
2
7
3
OUT
1
8
8
-B-
8
8
6
2
3
1
Air compressor
2
Condensate separator
3
Pre-Filter
4
By-pass group
5
Dryer
6
Compressed air tank
7
Final filter
8
Condensate drain
7
1
8
8
8
8
Type A installation is suggested when the compressor operates at reduced intermittence and the total
consumption equals the compressor flow rate.
Type B installation is suggested when the air consumption can consistently change with peak values highly
exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensate
eventual instantaneous demanding conditions (peak air consumption).
GB
2.4 CORRECTION FACTORS
Correction factor for operating pressure changes :
Inlet air pressure
psig 60
70
85
100
barg 4.1
4.8
5.9
6.9
Factor (F1)
0.70 0.85 0.93 1.00
Correction factor for ambient temperature changes :
Ambient temperature ºF
90
ºC
32.2
Factor (F2)
1.15
115
7.9
1.06
130
9.0
1.11
140
9.7
1.15
100
37.8
1.00
155
10.7
1.18
170
11.7
1.21
110
43.3
0.82
200
13.8
1.25
218
15.0
1.28
113
45.0
0.75
Correction factor for inlet air temperature changes:
Air temperature
ºF
130
150
ºC
54.4
65.6
Factor (F3)
1.15
1.10
180
82.2
1.00
190
87.8
0.80
200
93.3
0.65
Correction factor for DewPoint changes:
DewPoint
ºF
38
ºC
3.3
Factor (F4)
0.75
41
5.0
1.00
46
7.8
1.05
50
10.0
1.15
40
4.4
0.90
How to find the air flow capacity:
How to select a suitable dryer for a given duty:
Factor
Air flow
Nominal Factor
Factor
Factor
capacity = duty X (F1) X (F2) X (F3) X (F4)
Minimum
Design
Std. air =
air
flow
flow rate
÷
Factor
(F1)
÷
Factor
(F2)
÷
Factor
(F3)
÷
Factor
(F4)
Example:
Example:
An ADE 18 HGV has a nominal duty of 64 scfm
3
(109 Nm /h). What is the maximum allowable
flow through the dryer under the following
operating conditions:
The procedure here is to list the operating
conditions and then to locate the corresponding
numerical factors:
−
Inlet air pressure = 100 psig (6.9 barg)
−
Ambient temperature = 110 °F (43.3 °C)
−
Inlet air temperature = 190 °F (87.8 °C)
−
Pressure DewPoint = 41 °F (5.0 °C)
Each item of data has a corresponding numerical
factor as follows:
Air flow
capacity =
64
X
1.00
X
0.82
X
0.80
X
1.00
= 42 scfm (71 Nm3/h) → This is the
maximum flow rate that the dryer can accept
under these operating conditions.
−
3
Design air flow = 50 scfm (85 Nm /h)
−
Inlet air pressure = 100 psig (6.9 barg)
−
Ambient temperature = 110 °F (43.3 °C)
−
Inlet air temperature = 190 °F (87.8 °C)
−
Pressure DewPoint = 41 °F (5.0 °C)
In order to select the correct dryer model the
required flow rate is to be divided by the correction
factors relating to above mentioned parameters:
Minimum
Std. air =
flow rate
50 ÷ 1.00 ÷ 0.82 ÷ 0.80 ÷ 1.00
= 76 scfm (129 Nm3/h) → Therefore the
model suitable for the conditions above is ADE 23
HGV (81 scfm, 138 Nm3/h - nominal duty).
GB
2.5 CONNECTION TO THE COMPRESSED AIR SYSTEM
Operations to be performed by qualified personnel. Never operate with plants under pressure.
The user is responsible to ensure that the dryer will never be operated with pressure exceeding
the nominal values. Eventual over-pressure could be dangerous both for the operator and the
machine.
The temperature and the amount of air entering the dryer must comply with the limits reported on the data
plate. In case of treatment of air at particularly high temperature, the installation of a final refrigerator could
be necessary.
The cross section of the connecting piping, which must be free from dust, rust, chips and other impurities,
must In order to facilitate the maintenance operations, it has been installed a by-pass group, as shown in
the following illustration.
Dryers Model
Ø [NPT-F]
ADE 5-8 HGV Compact
ADE 8÷18 HGV
ADE 23 HGV
3/4"
3/4”
1”
A [mm] By-Pass Code
405
305
305
2240GBP201
2240GBP308
2240GBP309
In realizing the dryer, particular measures have been taken in order to limit the vibration which could occur
during the operation. Therefore we recommend to use of connecting pipes able to insulate the dryer from
possible vibrations originating from the line (flexible hoses, vibration damping fittings, etc.).
2.6 CONNECTION TO THE MAINS
The connection to the mains, to be carried out by qualified personnel, and the safety systems
must comply with local rules and laws.
Before connecting the unit to the electric power, verify that the voltage and the frequency available on the
mains correspond to the data reported on the data plate of the dryer. In terms of voltage, a ±5% tolerance is
allowed.
The dryer comes with a mains connecting cable already installed and ending with a VDE 16A - Shucko
plug. The mains socket must be provided with a mains magneto-thermal differential breaker
(I∆n=0.03A), adjusted on the basis of the consumption of the dryer (see the nominal values on the data
plate of the dryer).
The cross section of the power supply cables must comply with the consumption of the dryer, while also
taking into account the ambient temperature, the conditions of the mains installation, the length of the
cables, and the requirements enforced by the local Power Provider.
It is mandatory to ensure the connection to the ground terminal.
Don’t use adapters on the mains socket. If necessary, have the pug replaced by qualified
personnel.
GB
2.7 CONDENSATE DRAIN
The condensate is discharged at the same pressure of the air entering the dryer.
Never point the condensate drain jet towards anybody.
The dryer comes already fitted with tubing in flexible plastics 1/4" in (6 mm) diameter and 60" in (1500 mm)
long for the connection to the collection plant.
Condensate drain operates through two separate circuits. The first circuit eliminates the condensate
through a 5 micron filter installed at the exit of the final refrigerator (aftercooler). The drainage occurs by
means of an automatic system. In the second circuit, the condensate collected from the separator, is first
filtered and than expelled by means of a solenoid valve controlled by the DTT11 electronic instrument.
Connect and properly fasten the condensate drain to a collecting plant or container.
The drain cannot be connected to pressurized systems.
Don’t dispose the condensate to the environment.
The condensate collected in the dryer contains oil particles released in the air by the compressor.
Dispose the condensate in compliance with the local rules.
We suggest the installation of water-oil separator where to collect all the condensate coming from
compressors, dryers, tanks, filters, etc.
3.1 PRELIMINARY OPERATION
Verify that the operating parameters match the nominal values reported on the data plate of the
dryer (voltage, frequency, air pressure, air temperature, ambient temperature, etc.).
Before delivery, each dryer is submitted to accurate tests simulating real operating conditions.
Nevertheless, the unit could be damaged during transportation. We therefore suggest that you check the
integrity of the dryer upon arrival and to keep it under close watch during the first hours of operation.
The start-up must be performed by qualified personnel.
It’s mandatory that the engineer in charge will adopt safety operational conditions complying with
the local safety and accident prevention requirements.
The same engineer will be responsible for the proper and safe operation of the dryer.
Never operate the dryer if their panels are not in place.
3.2 FIRST START-UP
At the first start-up, or in case of start-up after a long inactivity period or following to maintenance
operations, respect the instructions given below.
The start-up must be performed by qualified personnel.
Sequence of operations :
• Be sure that all the steps of the “Installation” chapter have been respected.
• Be sure that the connections to the compressed air system are properly fastened and that the piping are
suitably fixed.
• Be sure that the condensate drains are properly fastened and connected to a collection plant or container.
• Be sure that the by-pass system is closed.
• Be sure that the manual valves mounted on condensate drain circuit are open.
• Remove all the packaging and other material which could obstruct the area around the dryer.
• Activate the mains switch.
• Activate the main switch on the control panel (pos. 1).
• Be sure that the consumption matches with the values of the data plate.
• Verify the operation of the condensate drain circuit - wait for its first interventions.
• Allow the dryer temperature to stabilize at the pre-set value.
• Slowly open the air inlet valve.
• Slowly open the air outlet valve.
• Slowly close the central by-pass valve of the system.
• Check the piping for air leakage.
GB
3.3 OPERATION AND SWITCHING OFF
Operation :
•
•
•
•
Check the condenser for cleanliness.
Check the aftercooler for cleanliness.
Verify that the system is powered.
Activate the main switch on the control panel - pos. 1.
ON
• Check that both the main switch - pos. 1 - and the LED set on the DTT11 are glowing.
• Wait a few minutes, verify that the DewPoint displayed on the DTT11 is correct and that the condensate is
regularly drained.
• Switch on the air compressor.
Switching off :
• Verify that the DewPoint displayed on the DTT11 is correct.
• Switch off the air compressor.
• After few minutes, switch off the main switch on the control panel of the dryer - pos. 1.
Note :
A DewPoint included in the green operating area of the DTT11 is correct according to the possible
working conditions (flow-rate, temperature of the incoming air, ambient temperature, etc.).
During the operation, the refrigerating compressor will run continuously. The dryer must remain on during
the full usage period of the compressed air, even if the air compressor works intermittently.
GB
4.1 TECHNICAL FEATURES OF DRYERS SERIES ADE 5 HGV to ADE 8 HGV COMPACT
HGV MODEL
Air flow at nominal condition *
Pressure DewPoint at nominal condition *
Ambient temperature nominal (maximum)
Minimum ambient temperature
Nominal (maximum) inlet air temperature
Nominal inlet air pressure
Maximum inlet air pressure
Maximum outlet air pressure drop - ∆p
Inlet - outlet connections
Refrigerant type
Refrigerant quantity
Electric power supply
Nominal electric absorption
Maximum electric absorption
Fan electric power
Acoustic pressure level at 40 in (1 m)
Weight
[scfm]
[Nl/min]
[Nm³/h]
[°F / °C]
[°F / °C]
[°F / °C]
[psig / barg]
[psig / barg]
[psi / bar]
[NPT-F]
[oz]
[kg]
[V/Phase/Hz]
[A / W]
[A / W]
[A / W]
[dbA]
[lb / kg]
ADE 5 COMPACT
ADE 8 COMPACT
20
30
565
850
34
51
+41°F (+5°C) equal to 0.86 g/Nm³ of H2O
+100 (+113) / +38 (+45)
+34 / +1
+180 (+218) / +82 (+100)
100 / 7
218 / 15
5.1 / 0.35
3/4”
R134.a(HFC) - CH2F-CF3
10
10.1/2
0.285
0.300
115/1/60
4.6 / 360
4.4 / 400
5.5 / 430
5.2 / 500
0.85 / 70
< 70
88 / 40
90 / 41
* The nominal condition refers to an ambient temperature of +100 °F (+38 °C) with inlet air at 100 psig (7 barg) and +180 °F (+82 °C).
GB
4.2 TECHNICAL FEATURES OF DRYERS SERIES ADE 8 HGV to ADE 23 HGV
ARIA
AIR
LUFT
AIR
ARIA
AIR
LUFT
AIR
HGV MODEL
Air flow at nominal condition *
Pressure DewPoint at nominal condition *
Ambient temperature nominal (maximum)
Minimum ambient temperature
Nominal (maximum) inlet air temperature
Nominal inlet air pressure
Maximum inlet air pressure
Maximum outlet air pressure drop - ∆p
Inlet - outlet connections
Refrigerant type
Refrigerant quantity
Electric power supply
Nominal electric absorption
Maximum electric absorption
Electric power of condenser fan
Electric power of aftercooler fan
Acoustic pressure level at 40 in (1 m)
Weight
[scfm]
[Nl/min]
[Nm³/h]
[°F / °C]
[°F / °C]
[°F / °C]
[psig / barg]
[psig / barg]
[psi / bar]
[NPT-F]
[oz]
[kg]
[V/Phase/Hz]
[A / W]
[A / W]
[A / W]
[A / W]
[dbA]
[lb / kg]
ADE 8
ADE 11
ADE 18
ADE 23
30
39
64
81
850
1100
1800
2300
51
66
109
138
+41°F (+5°C) equal to 0.86 g/Nm³ of H2O
+100 (+113) / +38 (+45)
+34 / +1
+180 (+200) / +82 (+93)
100 / 7
218 / 15
5.1 / 0.35
3/4”
1”
R134.a(HFC) - CH2F-CF3
10.1/2
12.1/4
13.1/4
14
0.300
0.350
0.375
0.400
115/1/60
5.1 / 400 4.9 / 450 5.7 / 500 7.6 / 660
6.0 / 480 5.8 / 540 6.6 / 600 8.8 / 800
0.54 / 45
0.85 / 70
< 70
99 / 45
104 / 47 108 / 49 112 / 51
* The nominal condition refers to an ambient temperature of +100 °F (+38 °C) with inlet air at 100 psig (7 barg) and +180 °F (+82 °C).
GB
5.1 CONTROL PANEL
The control panel illustrated below is the only dryer-operator interface.
1
2
1
0
3
1
Main switch
2
DTT11 Electronic Controller
3
Air and refrigerating gas flow diagram
K
5.2 OPERATION
The dryer described in this manual basically consists of two separated circuits: a compressed air circuit,
divided into three heat exchangers, and a refrigerating circuit.
The incoming warm and humid air, initially goes through the final refrigerator where it undergoes to a first
temperature drop so loosing part of the humidity it contains, than through the 5 micron filter where it is
purified and separated before being discharged by an automatic system. Thus it goes trough an air-to-air
exchanger before entering the evaporator (air-to-refrigerant exchanger) where, getting in contact with the
refrigerating circuit, it further cools down, so allowing the condensation of the residual humidity. This
condensed humidity is separated and ejected in the separator located after the evaporator.
The cooled air now goes through the air-to-air exchanger where, thanks to its low temperature, it cools
down the warmer air coming from the final refrigerator, operating a pre-cooling process.
The refrigerating circuit necessary for this process basically consists of a refrigerating compressor, a
condenser and the evaporator, also called air-to-refrigerant exchanger.
GB
5.3 FLOW DIAGRAM FOR DRYERS SERIES ADE 5 HGV Compact to ADE 23 HGV
M
17
8
9
11
20
5
7
PV
1
12
16
M
19
6
T1
4
3
15
13
14
DTT
18
10
1
Refrigerating compressor
2
Condenser
3
Dehydration filter
4
Capillary tube
5
Evaporator
6
Hot gas by-pass solenoid valve
7
Refrigerant pressure-switch PV
8
Aftercooler condenser
9
5 micron filter
10
Filter condensate drain solenoid valve
Compressed air flow direction
11 Air-to-air exchanger
12 Condensate separator
13 Condensate drain service valve
14 Condensate strainer
15 Condensate drain solenoid valve
16 Condenser unit fan
17 Aftercooler unit fan
18 DTT11 Electronic Controller
19 Temperature probe (DewPoint)
20 By-pass system (optional)
Refrigerating gas flow direction
2
GB
5.4 REFRIGERATING COMPRESSOR
The refrigerating compressor is the pump of the system where the gas coming from the evaporator (low
pressure side) is compressed up to the condensation pressure (high pressure side).
All the compressor used are manufactured by primary companies and are designed for applications where
high compression ratios and wide temperature changes are present.
The fully sealed construction is perfectly gas tight, so ensuring high energy efficiency and long useful life.
The pumping unit is supported by dumping springs, in order to consistently reduce the acoustic emission
and the vibration diffusion.
The electric motor is cooled down by the aspirated refrigerating gas, which goes through the coils before
reaching the compression cylinders. The internal thermal protection protects the compressor from over
heating and over currents. The protection is automatically restored as soon as the nominal temperature
conditions are reached.
5.5 CONDENSER UNIT
The condenser is the element in which the gas coming from the compressor is cooled down and condensed
becoming a liquid. Mechanically, it is formed by a copper tubing circuit (with the gas flowing inside)
immersed in an aluminum blades package. The cooling operation occurs via a high efficiency axial
ventilator which, in applying pressure on the air contained within the dryer, forces it into the blades package.
It’s mandatory that the temperature of the ambient air will not exceed the nominal values. It’s as well
important TO KEEP THE UNIT FREE FORM DUST AND OTHER IMPURITIES.
5.6 DEHYDRATION FILTER
Traces of humidity and slag which could accumulate inside the chilling plant, or smudge which could occur
after a long use of the dryer, could limit the lubrication of the compressor and clog the expansion valves or
the capillary tube.
The function of the dehydration filter, located before the capillary tubing, is to stop the impurities, so
avoiding their circulation within the system.
5.7 CAPILLARY TUBE
It consists of a piece of reduced cross section copper tubing located between the capacitor and the
evaporator to form a throttling against the flow of the refrigerating fluid. This throttling creates a pressure
drop, which is a function of the temperature to be reached within the evaporator: the less is the capillary
tube outlet pressure, the less is the evaporation temperature.
The length and the diameter of the capillary tubing are accurately sized with the performance to be reached
by the dryer; no maintenance/adjustment operations are necessary.
5.8 EVAPORATOR
Also called an air-to-refrigerant exchanger. The liquid formed in the condenser is evaporated in this part of
the circuit. In the evaporation phase the refrigerator tends to absorb the heat from the compressed air
present in the other side of the exchanger. The evaporator is immersed in the base of the dryer and
insulated with non-CFC expanded insulating foam. The part is entirely constructed in copper and the cooler
goes in the opposite direction to the air, thus contributing to limit pressure loss and to provide efficient
thermal exchange.
GB
5.9 HOT GAS BY-PASS VALVE
This valve injects part of the hot gas (taken from the discharge side of the compressor) in the pipe between
the evaporator and the suction side of the compressor, keeping the evaporation temperature/pressure
constant at approx. +2 °C. This injection prevents the formation of ice inside the dryer evaporator at every
load condition.
ADJUSTMENT
The hot gas by-pass valve is adjusted during the manufacturing
testing phase. As a rule no adjustment is required; anyway if it is
necessary the operation must be carried out by an experienced
refrigeration engineer.
WARNING : the use of ¼” Schrader service valves must be
justified by a real malfunction of the refrigeration system. Each
time a pressure gauge is connected, a part of refrigerant is
exhausted.
Without compressed air flow through the dryer, rotate the adjusting
screw (position A on the drawing) until the following value is
reached:
Hot gas setting (R134.a) : temperature 0.5 °C (+0.5 / -0 °K)
pressure 2.0 barg (+0.1 / -0 bar)
A
4 mm
5/32 in.
-
+
5.10 AFTERCOOLER
The air aftercooler is the component where the hot air entering the dryer undergoes to a preliminary cooling
down. It consists of a circuit of copper tubing, supporting the circulation o compressed air, immersed in an
aluminum body provided with cooling blades. A high efficiency axial fan conveying ambient air onto these
blades provides the necessary cooling down of the system. It is mandatory that the ambient temperature will
not exceed the nominal value for the dryer. It is equally important to KEEP THIS SYSTEM FREE FROM
DUST AND FOREIGN MATERIALS eventually introduced by the fan.
5.11 5-MICRON FILTER
Positioned at the outlet of the aftercooler, the 5-micron filter ensures a good degree of purification of the
treated air. The filter unit is embodied in the container so as to ensure rapid and easy replacement.
5.12 AIR-TO-AIR EXCHANGER
The purpose of this exchanger is the transmission of the heat of the incoming air to the exiting cold air. The
benefits of this solution are basically two : the incoming air is partially cooled down, therefore the chilling
system can be sized for a lower thermal drop, thus allowing a 40÷50% energy saving; moreover, as cool air
will never reach the compressed air circuit, no condensate will form on the external surface of the piping.
5.13 CONDENSATE SEPARATOR
The cold air exiting the evaporator goes through the hi-efficiency condensate separator featuring a stainless
steel mesh. As the condensate transported by the air gets in contact with the mesh net it is separated and
expelled by means of the draining device. The resulting cold and dry air is then conveyed into the air-to-air
heat exchanger. The mesh type mist separator offers the benefit to be highly efficient even with variable
flow rates.
5.14 REFRIGERANT PRESSURE SWITCH PV
Condenser unit fan control pressure switch placed at the discharge side of compressor unit. It keeps the
condensation temperature/pressure constant within preset limits.
Calibrated pressure : R 134.a
Stop 116 psig / 97°F - Restart 160 psig / 118°F
Stop 8.0 barg / 36°C - Restart 11.0 barg / 117°C
GB
5.15 DTT11 ELECTRONIC INSTRUMENT (DIGITAL TIMER THERMOMETER)
set
ON
Button - access the set-up.
Button - condensate drain test / value increment.
set
ON
set
LED
- glowing = power on.
- flashing = set-up condition.
LED
- condensate drain solenoid valve on.
set
DISPLAY
The DTT11 controller performs a double function : it shows the current operating DewPoint through the
digital led display and it controls the functioning of condensate drain solenoid valve through the cyclic
electronic timer.
ON
is on. The 10 LED display indicates the current
OPERATION - During the dryer operation, the LED
operating DewPoint, shown by means of a three colours (blue-green-red) bar over the display itself.
• Blue section - the dryer is working with very low load conditions, the DewPoint of the dryer is quite low;
• Green section - operating conditions ensuring an optimal DewPoint;
• Red section - DewPoint of the dryer too high, the treatment of the compressed air may be improper.
The condensate drain solenoid valve is activated for 2 seconds (TON) LED on - each minute (TOFF), if
button.
standard setting. To perform the manual test for the condensate drain, press the
The "out of scale" conditions are indicated by the intermittent flashing of the first and the last LED of the
display, respectively showing the exceeding of the lower or the upper range.
set
SET-UP - The DTT11 is adjusted during the final test of the dryer. In case of particular requirements
concerning the operation management, the user can change the setting of the programmed parameters.
The parameters which can be set up are the following :
• TON - activation time of the condensate drain solenoid valve.
• TOFF - pause time between two consecutive activation of the condensate drain solenoid valve.
ON
LED flashing confirms the
To access the set-up, keep pressed the set button for at least 2 seconds;
command. First appears the (TON) parameter; to access the other parameters, press sequentially
the set button. To change the value of the selected parameter, keep pressed the set button and operate on
; the current value is shown on the LED display. For the value range and the resolution (value of
button
each single LED), see the following table :
set
Parameter
Description
TON
Activation time of the
condensate drain solenoid valve
TOFF
Pause time of the condensate
drain solenoid valve
Display
Value range Resolution Set value
Synchronous flashing
1 - 10 sec
1 sec
2 sec
LED +LED
Non-synchronous flashing
1 - 10 min
1 min
1 min
LED +LED
ON
set
ON
set
To exit the set-up condition in any moment, press the
button. In case no operations are made during 2
minutes, the system exits automatically the set-up condition.
GB
4
5.16 ELECTRICAL LAYOUT OF DRYERS SERIES ADE 5 HGV to ADE 8 HGV COMPACT
4
Digital Timer Thermometer
POWER
PE
5
5
2
2
3
3
Vc
M
M
4
5.17 ELECTRICAL LAYOUT OF DRYERS SERIES ADE 8 HGV to ADE 23 HGV
4
Digital Timer Thermometer
POWER
2
2
3
3
5
5
PE
Va
M
Legend :
IG : Main switch
K : Refrigerating compressor
KR : Compressor start-up relay
KM : Compressor electric motor
KT : Compressor thermal protection
VC
VA
PD
EVD
Vc
M
: Condenser unit fan
: Aftercooler unit fan
: DewPoint probe
: Condensate drain solenoid valve
M
GB
6.1 CONTROLS AND MAINTENANCE
The maintenance and the service operations for all dryers must be performed by qualified
personnel only.
Before performing any service or maintenance on the equipment the technician must
insure the following :
• must take every precaution to insure that no part of the machine being serviced or
maintained has live power to it. The main disconnect on the unit and from the main power
supply must be switched off before performing service. In order to insure safety it is also
recommended that the main power wiring leading to the equipment be disconnected.
• must depressurize the equipment in order to insure a safe working environment. It is also
recommended that a by-pass be used in order to isolate the unit under service and prevent any
unwanted pressurizing to occur during service and maintenance. If required the unit may also be
disconnected at the air inlet and outlet to insure safety.
Before attempting any maintenance operation on the dryer, switch it off and wait at least 30
minutes. During operation the copper piping connecting the compressor to the condenser can
reach dangerous temperature able to burn the skin.
DAILY
• Verify that the DewPoint displayed on the controller is correct.
• Check the proper operation of the condensate drain systems.
• Verify that the condenser and the aftercooler are clean.
EVERY 200 HOURS OR MONTHLY
• With an air jet (Max. 29 psig, 2 barg) blowing from inside towards outside clean the condenser
and the aftercooler; repeat this operation blowing from outside towards inside; be careful not to
damage the aluminum blades of the cooling package.
• Close the manual condensate drain valve, unscrew the mechanical filter and clean it with
compressed air and a brush. Reinstall the filter properly tight, then open the manual valve.
• At the end, check the operation of the machine.
• Verify the automatic drain function, eventually clean it.
EVERY 1000 HOURS OR YEARLY
• Verify for tightness all the screws of the electric system and that all the “Faston” type
connections are in their proper position.
• Check the conditions of the condensate drain flexible hoses, and replace if necessary.
• At the end, check the operation of the machine.
5 MICRON FILTER
ONCE A YEAR OR MORE FREQUENTLY IF NECESSARY
• Disconnect the 5-micron filter from the relevant condensate
drainage circuit.
• Unscrew the clogged cartridge.
• Apply a silicon lubricant to the grommet of the new cartridge.
• Screw the new cartridge firmly by hand to the head of the filter.
• Connect the relevant condensate drainage circuit.
Screw / Visser
Unscrew / Devisser
GB
6.2 SUGGESTED SPARE PARTS
The suggested spare parts list will enable you to promptly intervene in case of abnormal operation, so
avoiding to wait for the spares delivery. In case of failure of other parts, for example inside the refrigerating
circuit, the replacement must mandatory be worked out by a refrigerating systems specialist or in our factory.
DESCRIPTION OF THE SPARE PARTS
Condensate Y-type drain filter
Fan motor
Fan motor
Fan blade
Fan blade
Fan grid
Fan grid
DTT11 Electronic Controller 115V
DTT11 Temperature probe
Condensate drain solenoid valve
Coil for condensate drain solenoid valve
5 micron filtering cartridge
5 micron filtering cartridge
5 micron filtering cartridge
5 micron filtering cartridge
Hot gas by-pass valve
Glowing switch 2P 0/1
Refrigerating compressor
Refrigerating compressor
Refrigerating compressor
Refrigerating compressor
Refrigerant pressure switch Pv
CODE
64355FF011
5210135015
5210135010
5215000022
5215000019
5225000015
5225000010
5620130095
5625NNN008
64320FF005
64N22MM035
15000FP006
15000FP012
15000FP018
15000FP023
64140SS160
5450SZN005
5015135105
5015135007
5015135009
5015135011
5655NNN160
ADE-HGV COMPACT
5
8
8
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
2
1
1*
1
1*
1
1*
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
ADE-HGV
11
18
23
1
1*
1
1*
1
1*
1
1
1
2
2
1
1*
1
1*
1
1*
1
1
1
2
2
1
1
1
1
1*
1
1*
1
1*
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* Aftercooler
Suggested spare part.
NOTE : To order the suggested spare parts or any other part, it’s necessary to quote the data reported
on the identification plate.
GB
7.1 TROUBLESHOOTING
The troubleshooting and the eventual checks have to be worked out by qualified personnel. Pay
particular attention in case of interventions on the refrigerating circuit. The refrigerating fluid, if
under pressure, while expanding could cause congelation burns and serious damage to the eyes,
should it gets in contact with them.
SYMPTOM
The dryer doesn't start.
POSSIBLE CAUSE - SUGGESTED ACTION
Check for mains failure.
Verify the electric wiring.
The compressor doesn’t work. Activation of the internal thermal protection - wait for 30 minutes, then retry.
Verify the electric wiring.
Replace the internal thermal protection.
Where installed - Replace the start-up relay.
Where installed - Replace the start-up capacitor.
Where installed - Replace the operation capacitor.
If the compressor still doesn’t work, replace it.
The fan of the condenser Verify the electric wiring.
doesn’t work.
PV pressure switch is faulty - contact a refrigeration engineer to
replace it.
If the fan still doesn’t work - replace it.
The fan of the aftercooler Verify the electric wiring.
doesn't work.
If the fan still doesn’t work, replace it.
The dryer doesn’t drain the condensate.
Verify the electric wiring.
The condensate drain strainer is clogged - remove and clean it.
The drain solenoid valve is jammed - remove and clean it.
The coil of the condensate drain solenoid valve is burned - replace it.
The DTT11 electronic controller doesn’t work - replace it.
The DewPoint is too low - the condensate is frost - see specific point.
The drain solenoid valve of the 5-micron filter is jammed - remove and
clean it.
The coil of the 5-micron filter condensate drain solenoid valve is
burned out - replace it.
The dryer continuously drains condensate.
The drain solenoid valve is jammed - remove and clean it.
Verify the electric wiring.
The DTT11 controller doesn’t work - replace it.
The drain solenoid valve of the 5-micron filter is jammed - remove and
clean it.
The coil of the 5-micron filter condensate drain solenoid valve is
burned out - replace it.
Water within the line.
The dryer is off - switch it on.
Where installed - Untreated air flows through the by-pass unit - close
the by-pass.
The dryer doesn’t drain condensate - see specific point.
DewPoint too high - see specific point.
GB
DewPoint too high.
The dryer is off - switch it on.
The refrigerating compressor doesn’t work - see specific point.
The fan of the condenser doesn’t work - see specific point.
The fan of the aftercooler doesn’t work - see specific point.
The inlet air is too hot - restore the nominal conditions.
The inlet air pressure is too low - restore the nominal conditions.
The inlet air flow rate is higher than the rate of the dryer - reduce the
flow rate - restore the normal conditions.
The ambient temperature is too high or the room aeration is
insufficient - provide proper ventilation.
The condenser is dirty - clean it.
The aftercooler is dirty - clean it.
The dryer doesn’t drain the condensate - see specific point.
The hot gas by-pass valve is out of setting - contact a refrigeration
engineer to restore nominal setting.
There is a leak in the refrigerating fluid circuit - contact a refrigerating
systems engineer.
Excessive pressure drop within The dryer doesn’t drain condensate - see specific point.
the dryer.
The DewPoint is too low - the condensate is frost and blocks the air see specific point.
5 micron filters is clogged - replace the cartridges.
Check for throttling the flexible connection hoses.
DewPoint too low.
The fan is always ON - Pv pressure switch is faulty - replace it.
The hot gas by-pass valve is out of setting - contact a refrigeration
engineer to restore nominal setting.
7.2 DISMANTLING OF THE DRYER
If the dryer is to be dismantled, it has to be split into homogeneous groups of materials.
Part
Refrigerant fluid
Canopy and Supports
Refrigeration Compressor
Heat-Exchanger and Condensate Separator
Condenser Unit
Pipe
Fan
Valve
Insulation Material
Electric cable
Electric Parts
Material
R134.a – HFC, Oil
Carbon steel, Epoxy paint
Steel, Copper, Aluminum, Oil
Copper, Steel
Aluminum, Copper, Carbon steel
Copper
Aluminum, Copper, Steel
Brass, Steel
Synthetic gum without CFC, Polyurethane
Copper, PVC
PVC, Copper, Brass
We recommend to comply with the safety rules in force for the disposal of each type of material.
The chilling fluid contains droplets of lubrication oil released by the refrigerating compressor. Do not
dispose this fluid in the environment. Is has to be discharged from the dryer with a suitable device
and then delivered to a collection centre where it will be processed to make it reusable.
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