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.