PS 4 – 30 - SIP Industrial Products Ltd

Refrigerated air dryer
- EN -
Targhetta dati
User’s maintenance manual
PS 4 – 30
7425MUM258_EN_2013-09
2 – EN
PS 4 – 30
Dear Customer,
thank you for choosing our product. In order to get the best performances out of this product, please read
this manual carefully.
To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and
strictly follow the instructions contained in this manual.
Note, these instructions are in addition to the safety rules that apply in the country where the dryer is
installed.
Before packing for shipment each PS series refrigerated air dryer undergoes a rigorous test to ensure the
absence of any manufacturing faults and to demonstrate that the device can perform all the functions for
which it has been designed.
Once the dryer has been properly installed according to the instructions 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.
PS 4 – 30
3 – EN
Contents
1 Identification plate
6 2 Warranty conditions
6 3 3.1 3.2 3.3 3.4 Safety rules
Definition of the conventional signs used in this manual
Warnings
Proper use of the dryer
Instructions for the use of pressure equipment according to PED directive 97/23/EC
7 7 8 8 9 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 Installation
Transport
Storage
Installation site
Installation layout
Correction factors
Connection to the compressed air system
Electrical connections
Condensate drain
9 9 9 10 10 11 12 12 12 5 5.1 5.2 5.3 Start-up
Preliminary operation
First start-up
Start-up and shut down
13 13 13 14 6 6.1 6.2 6.3 Technical data
Technical data PS 4 – 30 1/230/50-60
Technical data PS 4 – 30 1/115/60
Technical data PS 30 1/230/60
15 15 15 16 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10 7.10.1 7.10.2 7.10.3 7.10.4 7.10.5 7.10.6 Technical description
Control panel
Operation
Flow diagram
Refrigerating compressor
Condenser
Filter dryer
Capillary tube
Alu-Dry module
Hot gas by-pass valve
Electronic instrument DMC15
How to switch on the dryer
How to switch off the dryer
How a service warning / alarm is displayed
How is controlled the condenser fan
How is controlled the drain solenoid valve
How to change the operating parameters – SETUP menu
17 17 17 18 19 19 19 20 20 20 21 21 21 21 22 22 22 8 8.1 8.2 8.3 8.4 Maintenance, troubleshooting and dismantling
Checks and maintenance
Troubleshooting
Maintenance operation on the refrigeration circuit
Dismantling of the dryer
23 23 24 26 26 9 Attachments
Exploded views – List of components
Electric diagrams – List of components
9.1 Dryers dimensions
9.1.1 PS 4
9.1.2 PS 9 – 11
9.1.3 PS 17 – 24
4 – EN
27 27 27 28 28 29 30 PS 4 – 30
9.1.4 9.2 9.2.1 9.2.2 9.2.3 9.3 9.3.1 PS 30
Exploded views
PS 4
PS 9 – 24
PS 30
Electric diagrams
PS 4 – 30
31 32 32 33 34 35 35 Pos: 1 /Beko Technische Dokumentation/Überschriften/1/Sicherheitshinweise @ 0\mod_1183637609261_6.doc @ 5365
PS 4 – 30
5 – EN
Identification plate
1
Identification plate
The identification plate is located on the back of the dryer and shows all the primary data of the machine.
This data should always be referred to when calling the manufacturer or distributor. The removal or
alteration of the identification plate will void the warranty rights.
2
Warranty conditions
For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty
covers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and
restaurant expenses of our engineer.
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 require
repairs during the warranty period, the data reported on the identification plate must be notified.
6 – EN
PS 4 – 30
Safety rules
3
Safety rules
3.1
Definition of the conventional signs used in this manual
Carefully read instruction manual before attempting any service or maintenance procedures on the
dryer.
Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not
followed properly.
Electrical hazard. Warning message indicates practices or procedures that could result in personal
injury or fatality if not followed correctly.
Danger hazard. Part or system under pressure.
Danger hazard. High temperature conditions exist during operation of system. Avoid contact until
system or component has dissipated heat.
Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may
result if precautions are not followed.
Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptable
means in cases of fire.
Danger hazard. Do not operate equipment with panels removed.
Maintenance or control operation to be performed by qualified personnel only [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 performed by the operator of the machine, if qualified [1].
NOTE: Text that specifies items of note to be taken into account does not involve safety precautions.
In designing this unit a lot of care has been devoted to environmental protection:
 CFC free refrigerants
 CFC free insulation parts
 Energy saving design
 Limited acoustic emission
 Dryer and relevant packaging composed of recyclable materials
This symbol requests that the user heed environmental considerations and abide with suggestions
annotated with this symbol.
[1] Experienced and trained personnel familiar with national and local codes, capable to perform the needed activities, identify and
avoid possible dangerous situations while handling, installing, using and servicing the machine. Ensuring compliance to all statutory
regulations.
PS 4 – 30
7 – EN
Safety rules
3.2
Warnings
Compressed air is a highly hazardous energy source.
Never work on the dryer with pressure in the system.
Never point the compressed air or the condensate drain outlet hoses towards anybody.
The user is responsible for the proper installation of the dryer. Failure to follow instructions given in
the “Installation” chapter will void the warranty. Improper installation can create dangerous
situations for personnel and/or damages to the machine could occur.
Only qualified personnel are authorized to service electrically powered devices. Before attempting
maintenance, the following conditions must be satisfied:
 Ensure that main power is off, machine is locked out, tagged for service and power cannot be
restored during service operations.
 Ensure that valves are shut and the air circuit is at atmospheric pressure. De-pressurize the
dryer.
These refrigerating air dryers contain R134a HFC type refrigerant fluid. Refer to the specific
paragraph - maintenance operation on the refrigerating circuit.
Warranty does not apply to any unit damaged by accident, modification, misuse, negligence or
misapplication. Unauthorized alterations will immediately void the warranty.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of
electrical fire.
3.3
Proper use of the dryer
This dryer has been designed, manufactured and tested for the purpose of separating 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 bear
responsibility for any resulting damage.
Moreover, the correct use requires the adherence to the installation instructions, specifically:
 Voltage and frequency of the main power.
 Pressure, temperature and flow-rate of the inlet 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 breathing 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.
8 – EN
PS 4 – 30
Installation
3.4
Instructions for the use of pressure equipment according to PED directive 97/23/EC
To ensure the safe operation of pressure equipments, the user must conform strictly to the above directive
and the following:
1. The equipment must only be operated within the temperature and pressure limits stated on the
manufacturer’s data nameplate.
2. Welding on heat-exchanger is not recommended.
3. The equipment must not be stored in badly ventilated spaces, near a heat source or inflammable
substances.
4. Vibration must be eliminated from the equipment to prevent fatigue failure.
5. Automatic condensate drains should be checked for operation every day to prevent a build up of
condensate in the pressure equipment.
6. The maximum working pressure stated on the manufacturer’s data nameplate must not be exceeded.
Prior to use, the user must fit safety / pressure relief devices.
7. All documentation supplied with the equipment (manual, declaration of conformity etc.) must be kept for
future reference.
8. Do not apply weights or external loads on the vessel or its connecting piping.
TAMPERING, MODIFICATION AND IMPROPER USE OF THE PRESSURE EQUIPMENT ARE
FORBIDDEN. Users of the equipment must comply with all local and national pressure
equipment legislation in the country of installation.
4
4.1
Installation
Transport
Check for visible loss or damage, if no visible damage is found place the unit near to the installation point
and unpack the contents.
 To move the packaged unit we recommend using a suitable trolley or forklift truck. Hand carrying is not
recommended.
 Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid on
its side or if placed upside down.
 Handle with care. Heavy blows could cause irreparable damage.
4.2
Storage
SCC0001
Even when packaged, keep the machine
protected from severity of the weather.
Keep the dryer in vertical position, also when
stored. Turning it upside down some parts could
be irreparably damaged.
If not in use, the dryer can be stored in its
packaging in a dust free and protected site at a
maximum temperature of 50 °C, and a specific
humidity not exceeding 90%. Should the stocking
time exceed 12 months, please contact the
manufacturer.
The packaging materials are recyclable. Dispose of material in compliance with the rules
and regulations in force in the destination country.
PS 4 – 30
9 – EN
Installation
4.3
Installation site
Failure to install dryer in the proper ambient conditions will affect the dryer’s ability to condense
refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and
performance, overheated condenser fan motors, electrical component failure and dryer failure due
to the following: compressor loss, fan motor failure and electrical component failure. Failures of this
type will affect warranty considerations.
Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous gasses;
steam heat, areas of high ambient conditions or extreme dust and dirt.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of fire.
Minimum installation requirements:
 Select a clean dry area, 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 +1°C.
 Maximum ambient temperature +45°C.
 Ensure a proper cooling air replacement.
 Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitate maintenance
operations.
The dryer does not require attachment to the floor surface.
Do not block, even partially, ventilation grid.
Avoid any possible re-circulation of the exhaust cooling air.
Protect the dryer from air drafts or forced cooling air conditions.
4.4
Installation layout
1
Air compressor
2
Aftercooler
3
Condensate separator
4
Pre-Filter (min. 5 micron)
5
By-pass group
6
Dryer
7
Compressed air tank
8
Final filter
9
Condensate drain
In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend
the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the
heat exchanger.
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).
10 – EN
PS 4 – 30
Installation
4.5
Correction factors
Correction factor for operating pressure changes:
Inlet air pressure
barg
4
5
Factor (F1)
0.77
0.86
Correction factor for ambient temperature changes:
Ambient temperature
ºC
25
Factor (F2)
1.00
6
0.93
7
1.00
30
0.95
10
1.14
35
0.88
Correction factor for inlet air temperature changes:
Air temperature
ºC
30
35
Factor (F3)
1.11
1.00
Correction factor for DewPoint changes:
DewPoint
ºC
3
Factor (F4)
0.73
8
1.05
40
0.81
5
0.80
12
1.21
14
1.27
40
0.79
45
0.67
45
0.68
50
0.55
7
0.87
55
0.45
10
1.00
How to find the air flow capacity:
Air flow capacity = Nominal duty x Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)
Example:
An PS 11 has a nominal duty of 66 m³/h. What is the maximum allowable flow through the dryer under the
following operating conditions:
Inlet air pressure = 8 barg
Factor (F1) = 1.05
Ambient temperature = 40°C
Factor (F2) = 0.79
Inlet air temperature = 50°C
Factor (F3) = 0.55
Pressure DewPoint = 10°C
Factor (F4) = 1.00
Each item of data has a corresponding numerical factor which multiplied by the design air flow is as
follows:
Air flow capacity = 66 x 1.05 x 0.79 x 0.55 x 1.00 = 30 m³/h
30 m³/h This is the maximum flow rate that the dryer can accept under these operating conditions.
How to select a suitable dryer for a given duty:
Minimum std. air flow rate =
Design air flow
Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)
Example:
With the following operating parameters:
Design air flow = 80 m3/h
Inlet air pressure = 8 barg
Ambient temperature = 40°C
Inlet air temperature = 50°C
Pressure DewPoint = 10°C
Factor (F1) = 1.05
Factor (F2) = 0.79
Factor (F3) = 0.55
Factor (F4) = 1.00
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:
80
Minimum std. air flow rate =
= 175 m³/h
1.05 x 0.79 x 0.55 x 1.00
Therefore the model suitable for the conditions above is PS 30 (180 m³/h - nominal duty).
PS 4 – 30
11 – EN
Installation
4.6
Connection to the compressed air system
Operations to be performed by qualified personnel only.
Never work on system under pressure.
The user is responsible to ensure that the dryer will never be operated with pressure exceeding the
maximum pressure rating on the unit data tag.
Over-pressurizing the dryer could be dangerous for both the operator and the unit.
The air temperature and the flow entering the dryer must comply within the limits stated on the data
nameplate. The system connecting piping must be kept free from dust, rust, chips and other impurities, and
must be consistent with the flow-rate of the dryer. In case of treatment of air at particularly high temperature,
the installation of a final refrigerator could result necessary. In order to perform maintenance operations, it is
recommended to install a dryer by-pass system.
In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend
the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the
heat exchanger.
In realising the dryer, particular measures have been taken in order to limit the vibration which could occur
during the operation. Therefore we recommend to use connecting pipes able to insulate the dryer from
possible vibrations originating from the line (flexible hoses, vibration damping fittings, etc.).
CAUTION :
PIPING THE DRYER, INLET/OUTLET CONNECTIONS MUST BE SUPPORTED AS
SHOWN IN THE DIAGRAM.
FAILING WILL RESULT IN DAMAGE.
4.7
Electrical connections
Qualified personnel should carry out connecting unit to the main power.
Be sure to check the local codes in your area.
Before connecting the unit to the electrical supply, verify the data nameplate for the proper electrical
information. Voltage tolerance is +/- 10%.
Dryer are supplied with power cord and plug (two poles and ground).
Be sure to provide the proper fuses or breakers based on the data information located on the nameplate.
A residual-current device (RCD) with In =0.03A is suggested. The cross section of the power supply cables
must comply with the consumption of the dryer, while keeping into account also the ambient temperature,
the conditions of the mains installation, the length of the cables, and the requirements enforced by the local
Power Provider.
Important: ensure that the dryer is earthed.
Do not use any socket adapters at the mains plug.
If the mains plug needs to be replaced, this must only be done by a qualified electrician.
4.8
Condensate drain
The condensate is discharge at the system pressure.
Drain line should be secured.
Never point the condensate drain line towards anybody.
The dryer comes already fitted with a timed condensate drainer.
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 in 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 recommend to install a water-oil separator where to convey all the condensate drain coming
from compressors, dryers, tanks, filters, etc.
12 – EN
PS 4 – 30
Start-up
5
5.1
Start-up
Preliminary operation
Verify that the operating parameters match with the nominal values stated on the data nameplate
of the dryer (voltage, frequency, air pressure, air temperature, ambient temperature, etc.).
This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unit
could be damaged during transportation, check the integrity of the dryer during first start-up and monitor
operation during the first hours of operation.
Qualified personnel must perform the first start-up.
When installing and operating this equipment, comply with all National Electrical Code and any
applicable federal, state and local codes.
Who is operating the unit is responsible for the proper and safe operation of the dryer.
Never operate equipment with panels removed.
5.2
First start-up
This procedure should be followed on first start-up, after periods of extended shutdown or following
maintenance procedures.Qualified personnel must perform the start-up.
Sequence of operations (refer to paragraph 7.1 Control Panel).
 Ensure that all the steps of the “Installation” chapter have been observed.
 Ensure that the connection to the compressed air system is correct and that the piping is suitably fixed
and supported.
 Ensure that the condensate drain pipe is properly fastened and connected to a collection system or
container.
 Ensure that the by-pass system (if installed) is closed and the dryer is isolated.
 Ensure that the manual valve of the condensate drain circuit is open.
 Remove any packaging and other material which could obstruct the area around the dryer.
 Activate the mains switch.
 Turn ON the switch - pos. 1 on the control panel.
 Ensure that electronic instrument is ON.
 Ensure the consumption matches with the values of the data plate.
 Ensure the fan works properly – wait for its first interventions.
 Allow the dryer temperature to stabilise 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 (if installed).
 Check the piping for air leakage.
 Ensure the drain is regularly cycling - wait for its first interventions.
PS 4 – 30
13 – EN
Start-up
5.3
Start-up and shut down
Start-up (refer to paragraph 7.1 Control Panel)




Check the condenser for cleanliness.
Turn ON the switch - pos. 1 on the control panel.
Ensure that electronic instrument is ON.
Wait a few minutes; verify that the DewPoint temperature displayed on electronic instrument is correct
and that the condensate is regularly drained.
 Switch on the air compressor.
Shut down (refer to paragraph 7.1 Control Panel)
 Check that the DewPoint temperature indicated on the electronic instrument is within range.
 Shut down the air compressor.
 After a few minutes, turn OFF the switch - pos. 1 on the control panel.
NOTE : A DewPoint included in the green operating area of the electronic controller is correct according to
the possible working conditions (flow-rate, temperature of the incoming air, ambient temperature, etc.)
During the operation, the refrigerant 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.
The number of starts must be no more than 6 per hour.
The dryer must stop running for at least 5 minutes before being started up again.
Frequent starts may cause irreparable damage.
The user is responsible for compliance with these rules.
14 – EN
PS 4 – 30
Technical data
6
Technical data
6.1
Technical data PS 4 – 30
1/230/50-60
6.2
Technical data PS 4 – 30
1/115/60
PS 4 – 30
15 – EN
Technical data
6.3
Technical data PS 30
16 – EN
1/230/60
PS 4 – 30
Technical description
7
7.1
Technical description
Control panel
The control panel illustrated below is the only dryer-operator interface.
ON
1
PQS0015
0
DMC15
sec - min
Set
1
2
1 ON-OFF Switch
2 Electronic instrument
7.2
Operation
Operating principle - The dryer models described in this manual operate all on the same principle. The hot
moisture laden air enters an air to air heat exchanger. The air then goes through the evaporator, also known
as the air to refrigerant heat exchanger. The temperature of the air is reduced to approximately 2°C, causing
water vapor to condense to liquid. The liquid is continuously coalesced and collected in the separator for
removal by the condensate drain. The cool moisture free air then passes back through the air to air heat
exchanger to be reheated to within 8 degrees of the incoming air temperature as it exits the dryer.
Refrigerant circuit - Refrigerant gas is cycled through the compressor and exits at high pressure to a
condenser where heat is removed causing the refrigerant to condense to a high-pressure liquid state. The
liquid is forced through a capillary tube where the resulting pressure drop allows the refrigerant to boil off at
a predetermined temperature. Low-pressure liquid refrigerant enters the heat exchanger where heat from
the incoming air is transferred causing the refrigerant to boil; the resulting phase change produces a low
pressure, low temperature gas. The low-pressure gas is returned to the compressor, where it is recompressed and begins the cycle again. During those periods when the compressed air load is reduced the
excess refrigerant is by-passed automatically back to the compressor via the hot gas by-pass valve circuit.
PS 4 – 30
17 – EN
Technical description
7.3
Flow diagram
6
1a
7
9
1
1b
17
EC
8
M
12
T1
12.1
1c
11
10
T2
DGF0003
15
1
1a
1b
1c
6
7
8
9
10
13
14
16
EC
Alu-Dry module
Air-to-air heat exchanger
Air-to-refrigerant heat exchanger
Condensate separator
Compressor
Hot gas by-pass valve
Condenser
Condenser fan
Filter dryer
Compressed air flow direction
18 – EN
11
12
12.1
13
14
15
16
17
Capillary tube
Temperature probe T1 – DewPoint
Temperature probe T2 – Fan control
Condensate drain service valve
Condensate drain strainer
Condensate drain solenoid valve
Coil for condensate drain solenoid valve
Electronic instrument
Refrigerant gas flow direction
PS 4 – 30
Technical description
7.4
Refrigerating compressor
The refrigerating compressor is the pump in the system, gas coming from the evaporator (low pressure side)
is compressed up to the condensation pressure (high pressure side). The compressors utilized are
manufactured by leading manufacturers and are designed for applications where high compression ratios
and wide temperature changes are present.
The hermetically sealed construction is perfectly gas tight, ensuring high-energy efficiency and long, useful
life. Dumping springs support the pumping unit in order to reduce the acoustic emission and the vibration
diffusion. The aspirated refrigerant gas, flowing through the coils before reaching the compression cylinders
cools the electric motor. The 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.
7.5
Condenser
The condenser is the component in which the gas coming from the compressor is cooled down and
condensed becoming a liquid. Mechanically, a serpentine copper tubing circuit (with the gas flowing inside)
is encapsulated in an aluminum fin package.
The cooling operation occurs via a high efficiency fan, creating airflow within the dryer, moving air through
the fin package. It’s mandatory that the ambient air temperature does not exceed the nominal values. It is
also important to keep the condenser unit free from dust and other impurities.
7.6
Filter dryer
Traces of humidity and slag can accumulate inside the refrigerant circuit. Long periods of use can also
produce sludge. This can limit the lubrication efficiency of the compressor and clog the expansion valve or
capillary tube. The function of the filter drier, located before the capillary tubing, is to eliminate any impurities
from circulating through the system.
PS 4 – 30
19 – EN
Technical description
7.7
Capillary tube
It consists of a piece of reduced cross section copper tubing located between the condenser and the
evaporator, acting as a metering device to reduce the pressure of the refrigerant. Reduction of pressure is a
design function to achieve optimum temperature reached within the evaporator: the smaller the capillary
tube outlet pressure, the lower the evaporation temperature.
The length and interior diameter of the capillary tubing is accurately sized to establish the performance of
the dryer; no maintenance or adjustment is necessary.
7.8
Alu-Dry module
The heat exchanger module houses the air-to-air, the air-to-refrigerant heat exchangers and the demister
type condensate separator. The counter flow of compressed air in the air-to-air heat exchanger ensures
maximum heat transfer. The generous cross section of flow channel within the heat exchanger module leads
to low velocities and reduced power requirements. The generous dimensions of the air-to-refrigerant heat
exchanger plus the counter flow gas flow allows full and complete evaporation of the refrigerant (preventing
liquid return to the compressor). The high efficiency condensate separator is located within the heat
exchanger module. No maintenance is required and the coalescing effect results in a high degree of
moisture separation.
7.9
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
A
phase. As a rule no adjustment is required; anyway if it is necessary
the operation must be carried out by an experienced refrigerating
engineer.
4 mm
Hot gas setting :
20 – EN
5/32 in.
-
VLY0001
WARNING
the use of ¼” Schrader service valves must be justified by a real
malfunction of the refrigerating 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:
+
R134.a pressure 2.0 barg (+0.1 / -0 bar)
PS 4 – 30
Technical description
7.10 Electronic instrument DMC15
ON
ON
DMC15
Led - Drain ON
Led – Condenser fan ON
sec - min
PQS0036
Led – Power ON
Set
Set
Button – Setup menu access
Button – Increase / Drain test
DISPLAY
The DMC15 displays DewPoint temperature, controls the condenser fan activation and the timed drainer.
7.10.1 How to switch on the dryer
Power the dryer and switch it on using the ON-OFF switch (pos.1 paragraph 7.1).
ON is ON and the display shows the DewPoint temperature by means of
During normal operation led
two coloured areas (green and red) above a 10 Led display :
Green area - operating conditions ensuring an optimal DewPoint;
Red area - DewPoint too high, the dryer is operating with high thermal load (high inlet air temperature, high
ambient temperature, etc.). Compressed air treatment may be improper.
Led
shows that condensate drain solenoid valve is ON.
Led
shows that condenser fan is ON.
The condensate drain test is always active using the button
.
7.10.2 How to switch off the dryer
Switch it off using the ON-OFF switch (pos. 1 paragraph 7.1).
7.10.3 How a service warning / alarm is displayed
A service warning / alarm is an unusual event that must recall the attention of the operators / maintenance
technicians. It does not stop the dryer.
Service warnings / alarms are automatically reset as soon as the problem is solved.
NOTE: the operator / maintenance technician must inspect the dryer and verify / solve the problem
that generated the service warning.
Service Warning / Alarm
Description
Display 1st (left) and 10th (right) led are flashing
Failure T1 (DewPoint) temperature probe.
Led
is flashing
Failure T2 (fan control) temperature probe.
NOTE : fan is forced always ON.
Display 10th (right) led is flashing
DewPoint too high
Display 1st (left) led is flashing
DewPoint too low
(lower than -1°C / 30°F).
PS 4 – 30
21 – EN
Technical description
7.10.4 How is controlled the condenser fan
A temperature probe T2 is located on the discharge side of the condenser. The condenser fan is activated
is ON.
(ON) when the T2 temperature is higher than FANon setting (standard 35°C / 96°F) and led
Condenser fan stops at T2 temperatures 5°C / 10°F lower than FANon setting (standard 30°C / 86°F).
7.10.5 How is controlled the drain solenoid valve
Drain solenoid valve is activated (ON) for Ton seconds (standard 2 seconds) every Toff minutes (standard 1
shows that condensate drain solenoid valve is ON.
minute). Led
The condensate drain test is always active using the button
.
7.10.6 How to change the operating parameters – SETUP menu
The setup menu can be used to change the dryer’s operating parameters.
Only qualified personnel must be allowed to access to the setup menu. The manufacturer
is not responsible for malfunctioning or failure due to modification to the operating
parameters.
Set
for at least 3 seconds to enter the setup menu.
With dryer ON press button
ON and
Access to the menu is confirmed by led
flashing (first parameter of menu).
Set
Set
Keep
pressed and use arrows
to change the value. Release the button
to confirm
Set
the value. Press shortly
to skip to following parameter.
Press
to exit setup menu (if no button is pressed after 2 minutes the menu is exited automatically).
Display
Description
Limits
Resolution
Synchronous flashing
ON + led
led
FANon : condenser fan activation
(ON) temperature
31 … 40 °C
or
88 … 104 °F
1 °C
or
2 °F
Standard
setup
35
or
96
Synchronous flashing
ON + led
led
Ton – drain time ON : time ON
condensate drain valve
1 … 10 sec
1 sec
2
Non-Synchronous flashing
ON + led
led
ToF - drain time OFF : pause
time for condensate drain valve
1 … 20 min
1 min
1
NOTE : parameter values are displayed on the 10 led display where 1st (left) led is the lowest limit and 10th
(right) is the highest limit.
22 – EN
PS 4 – 30
Maintenance, troubleshooting and dismantling
8
Maintenance, troubleshooting and dismantling
8.1
Checks and maintenance
Only qualified personnel should perform troubleshooting and or maintenance
operations.
Prior to performing any maintenance or service, be sure that :
 no part of the machine is powered and that it cannot be connected to the mains
supply.
 no part of the machine is under pressure and that it cannot be connected to the
compressed air system.
 maintenance personnel have read and understand the safety and operation
instructions in this manual.
Before attempting any maintenance operation on the dryer, shut it down and wait at
least 30 minutes. Some components can reach high temperature during operation.
Avoid contact until system or component has dissipated heat.
Daily
 Verify that the DewPoint displayed on the electronic instrument is correct.
 Check the proper operation of the condensate drain systems.
 Verify the condenser for cleanliness.
Every 200 hours or monthly
 With an air jet (max. 2 bar / 30 psig) blowing from inside towards outside
clean the condenser; repeat this operation blowing in the opposite way; be
careful not to damage the aluminum fins of the cooling package.
 Close the manual condensate drain valve, unscrew the strainer (if installed) and clean it with
compressed air and brush. Reinstall the strainer properly tight, and then open the manual valve.
 At the end, check the operation of the machine
Every 1000 hours or yearly
 Verify for tightness all the screws of the electric system and that all the “Disconnects-Tabs” type
connections are in their proper position inspect unit for broken, cracked or bare wires.
 Inspect refrigerating circuit for signs of oil and refrigerant leakage.
 Measure and record amperage. Verify that readings are within acceptable parameters as listed
in specification table.
 Inspect flexible hoses, and replace if necessary.
 At the end, check the operation of the machine.
PS 4 – 30
23 – EN
Maintenance, troubleshooting and dismantling
8.2
Troubleshooting
Only qualified personnel should perform troubleshooting and or maintenance
operations.
Prior to performing any maintenance or service, be sure that :
 no part of the machine is powered and that it cannot be connected to the mains
supply.
 no part of the machine is under pressure and that it cannot be connected to the
compressed air system.
 maintenance personnel have read and understand the safety and operation
instructions in this manual.
Before attempting any maintenance operation on the dryer, shut it down and wait at
least 30 minutes. Some components can reach high temperature during operation.
Avoid contact until system or component has dissipated heat.
SYMPTOM
 The dryer
doesn't start.
POSSIBLE CAUSE - SUGGESTED ACTION
 Verify that the system is powered.
 Verify the electric wiring.
 The compressor  Activation of the compressor internal thermal protection - wait for 30 minutes, then
doesn’t work.
retry.
 Verify the electric wiring.
 If installed - Replace the internal thermal protection and/or the start-up relay
and/or the start-up capacitor and/or the working capacitor.
 If the compressor still doesn’t work, replace it.
 Condenser’s
fan doesn’t
work.




 DewPoint too
high.
 The dryer doesn't start - see specific point.
 The DewPoint probe T1 doesn’t correctly detect the temperature - ensure the
sensor is pushed into the bottom of probe well.
 The Compressor doesn’t work - see specific point.
 The ambient temperature is too high or the room aeration is insufficient - provide
proper ventilation.
 The inlet air is too hot - restore nominal conditions.
 The inlet air pressure is too low - restore nominal conditions.
 The inlet air flow rate is higher than the rate of the dryer - reduce the flow rate restore nominal conditions.
 The condenser is dirty - clean it.
 The condenser fan doesn’t work - see specific point.
 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 refrigerant circuit - contact a refrigeration engineer.
24 – EN
Verify the electric wiring.
The DMC15 electronic instrument is faulty – replace it.
There is a leak in the refrigerant circuit - contact a refrigeration engineer.
If the fan still doesn't work, replace it.
PS 4 – 30
Maintenance, troubleshooting and dismantling
SYMPTOM
POSSIBLE CAUSE - SUGGESTED ACTION
 Dew Point too
low
 The fan is always ON - the
yellow LED of DMC15 electronic instrument is
flashing - see specific point.
 Ambient temperature is too low - restore nominal conditions.
 The hot gas by-pass valve is out of setting - contact a refrigeration engineer to
restore nominal setting.
 Excessive
pressure drop
within the dryer.
 The dryer doesn’t drain the condensate - see specific point.
 The DewPoint is too low - the condensate is frost and blocks the air - see specific
point.
 Check for throttling the flexible connection hoses.
 The dryer
doesn’t drain
the condensate







 The dryer
continuously
drains
condensate.
 Water within the
line.
The condensate drain service valve is closed - open it.
Condensate strainer is clogged – remove and clean it.
The drain solenoid valve is jammed – remove and clean it.
Verify the electric wiring.
The coil of the drain solenoid valve is failed – replace it.
Electronic instrument is faulty – repace it.
The DewPoint is too low - the condensate is frost and blocks the air - see specific
point.
 Inlet compressed air pressure is too low and condensate is not drained – restore
nominal conditions.
 The drain solenoid valve is jammed – remove and clean it.
 Try to remove the electric connector on the solenoid valve - if drain stops verify the
electric wiring or the electronic instrument is faulty - replace it




The dryer doesn't start - see specific point.
If installed - Untreated air flows through the by-pass unit - close the by-pass.
The dryer doesn’t drain the condensate - see specific point.
DewPoint too high - see specific point.
 DMC15
The first and the
last led of display
are flashing
syncronous.
 Verify the electric wiring of T1 DewPoint probe.
 The T1 DewPoint probe is faulty - replace it.
 The electronic instrument is faulty - replace it.
 DMC15
yellow
The
led is flashing
 Verify the electric wiring of T2 fan control probe.
 The T2 fan control probe is faulty - replace it.
 The electronic instrument is faulty - replace it.
 DMC15
The first led of the
display is flashing
 DewPoint too low - see specific point.
 The T1 DewPoint probe is faulty - replace it.
 The electronic instrument is faulty - replace it.
 DMC15
The last led of the
display is flashing
 DewPoint too high - see specific point.
 The T1 DewPoint probe is faulty - replace it.
 The electronic instrument is faulty - replace it.
PS 4 – 30
25 – EN
Maintenance, troubleshooting and dismantling
8.3
Maintenance operation on the refrigeration circuit
Maintenance and service on refrigerating systems must be carried out only by certified refrigerating
engineers only, according to local rules.
All the refrigerant of the system must be recovered for its recycling, reclamation or destruction.
Do not dispose the refrigerant fluid in the environment.
This dryer comes ready to operate and filled with R134a type refrigerant fluid.
In case of refrigerant leak contact a certified refrigerating engineer. Room is to be aired before any
intervention.
If is required to re-fill the refrigerating circuit, contact a certified refrigerating engineers.
Refer to the dryer nameplate for refrigerant type and quantity.
Characteristics of refrigerants used:
8.4
Refrigerant
Chemical formula
TLV
GWP
R134a - HFC
CH2FCF3
1000 ppm
1300
Dismantling of the dryer
If the dryer is to be dismantled, it has to be split into homogeneous groups of materials.
Part
Material
Refrigerant fluid
R134a, Oil
Canopy and Supports
Carbon steel, Epoxy paint
Refrigerating compressor
Steel, Copper, Aluminium, Oil
Alu-Dry Module
Aluminium
Condenser Unit
Aluminium, Copper, Carbon steel
Pipe
Copper
Fan
Aluminium, Copper, Steel
Valve
Brass, Steel
Electronic Level Drain
PVC, Aluminium, Steel
Insulation Material
Synthetic rubber without CFC, Polystyrene, Polyurethane
Electric cable
Copper, PVC
Electric Parts
PVC, Copper, Brass
We recommend to comply with the safety rules in force for the disposal of each type of material.
Refrigerant 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.
26 – EN
PS 4 – 30
Attachments
9
Attachments
Exploded views – List of components
1
1.1
6
7
8
9
9.1
9.2
9.3
10
11
12
Alu-Dry module
Insulation material
Compressor
Hot-gas bypass valve
Condenser
Condenser fan
Motor
Blade
Grid
Filter dryer
Capillary tube
Temperature probe
13
14
15
16
17
22
51
55
56
59
61
Condensate drain service valve
Condensate drain strainer
Condensate drain solenoid valve
Coil for condensate drain solenoid valve
Electronic instrument
Main switch
Front panel
Cover
Base plate
Support bracket
Electric connecting plug
Electric diagrams – List of components
MC1
KT
KR
CS
MV1
Compressor
Compressor thermal protection
Compressor starting relay
Compressor starting capacitor
Condenser fan
DMC15
BT1-2
EVD
S1
NT4
Provided and wired by customer
NT5
BN
BU
BK
YG
Brown
Blue
Black
Yellow / Green
PS 4 – 30
OR
RD
WH
WH/BK
Electronic instrument
Temperature probes
Timed condensate drain solenoid valve
ON-OFF switch
Limit of equipment
Orange
Red
White
White / Black
27 – EN
Attachments
9.1
9.1.1
Dryers dimensions
PS 4
28 – EN
PS 4 – 30
Attachments
9.1.2
PS 9 – 11
PS 4 – 30
29 – EN
Attachments
9.1.3
PS 17 – 24
30 – EN
PS 4 – 30
Attachments
9.1.4
PS 30
PS 4 – 30
31 – EN
Attachments
9.2
9.2.1
Exploded views
PS 4
32 – EN
PS 4 – 30
Attachments
9.2.2
PS 9 – 24
PS 4 – 30
33 – EN
Attachments
9.2.3
PS 30
34 – EN
PS 4 – 30
PS 4 – 30
(*) See dryer nameplate
SUPPLY BY PLUG
1/230V/50Hz+PE (*)
OR
1/230V/60Hz+PE (*)
OR
1/115V/60Hz+PE (*)
FUSE MAX 10 A
RCD Id 0.03A suggested
PE
BU-2 4
N
PE
BN-1 1
L1
1
5
2
4
2
2
CS
S
KT
MC1
M
1~
C
3
KR
R
4
5
7
11
10
11
10
9
M
1~
7
BN-1
EVD
8
8
2
NTC 2k
4
T1
BT1
sec - min
BT2
1
T2
ON
9
Sheet
01
of
01
00
Note :
Rev.
Drawing no. :
FRSLSEL0104
Technical modifications are subject to change without notice; errors not excluded.
MV1
6
DMC15 - Air Dryer Controller
6
BU-2
9.3.1
BN-1
9.3
BU-2
0
Attachments
Electric diagrams
PS 4 – 30
35 – EN
Istruzioni originali in ITALIANO - Con riserva di modifiche ed errori
Original instructions are in ITALIAN - Subject to technical changes without prior notice; errors not excluded
EN - Subject to technical changes without prior notice; errors not excluded / Translation of original instructions
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