EKOM DK50 6X4VRT/M User Manual

DK50 4x4VRT/M

DK50 6x4VRT/M

User manual

COMPRESSOR

DK50 4x4VRT/M

DK50 6x4VRT/M

EKOM spol. s r. o.

Priemyselná 5031/18

SK-

921 01 Piešťany

Slovak Republic tel.: +421 33 7967255 fax: +421 33 7967223 www.ekom.sk email: [email protected]

DATE OF LAST REVISION 04/2022

NP-DK50-Nx4VRTM-AD-A-

EN-5_04-2022

112000555-0001

CONTENTS

CONTENTS

GENERAL INFORMATION ........................................................................................................... 5

1.

CONFORMITY WITH THE REQUIREMENTS OF THE EUROPEAN UNION .................. 5

2.

SYMBOLS ....................................................................................................................... 5

3.

DEVICE USE................................................................................................................... 6

4.

GENERAL SAFETY INSTRUCTIONS ............................................................................. 7

5.

STORAGE AND TRANSPORT CONDITIONS ................................................................ 8

PRODUCT DESCRIPTION ........................................................................................................... 9

6.

VARIANTS ...................................................................................................................... 9

7.

ACCESSORIES .............................................................................................................11

8.

PRODUCT FUNCTION ..................................................................................................13

TECHNICAL DATA ......................................................................................................................16

INSTALLATION ...........................................................................................................................20

9.

INSTALLATION CONDITIONS .......................................................................................20

10.

COMPRESSOR ASSEMBLY .........................................................................................21

11.

PNEUMATIC CONNECTION .........................................................................................25

12.

ELECTRICAL CONNECTION ........................................................................................28

13.

COMMISSIONING .........................................................................................................34

14.

PNEUMATIC DIAGRAMS ..............................................................................................35

OPERATION ................................................................................................................................38

15.

SWITCHING ON THE COMPRESSOR ..........................................................................39

16.

SWITCHING OFF THE COMPRESSOR ........................................................................47

PRODUCT MAINTENANCE ........................................................................................................48

17.

PRODUCT MAINTENANCE ...........................................................................................48

18.

LONG-TERM SHUTDOWN ............................................................................................63

19.

DISPOSAL OF DEVICE .................................................................................................64

TROUBLESHOOTING .................................................................................................................64

20.

REPAIR SERVICE .........................................................................................................66

ANNEX .........................................................................................................................................67

21.

MAPPING PARAMETERS .............................................................................................67

22.

INSTALLATION RECORD..............................................................................................69

NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022 4 04/2022

GENERAL INFORMATION


Carefully read this user manual before using the product and carefully store it for future reference. The user manual aids in the proper use, including installation, operation and maintenance, of the product.

The user manual corresponds to the configuration of the product and its compliance with applicable safety and technical standards at the time of its printing.

The manufacturer reserves all rights for the protection of its configuration, processes and names.

The Slovak version represents the original version of the user manual. The translation of the user manual is performed in accordance with the best available knowledge. The Slovak version is to be used in the event of any uncertainties.

The user manual is original and the translation is performed with the best available knowledge.

1. CONFORMITY WITH THE REQUIREMENTS OF THE EUROPEAN UNION

This product conforms to the requirements of the European Union 2006/42/EC,

2014/29/EU, 2014/35/EU, 2014/30/EU,

2011/65/EU and is safe if used in compliance with the intended use and if all safety instructions are followed.

User manual is in compliance with requirements of Directive 2006/42/EC.

2. SYMBOLS

The following symbols and marks are used in the User manual, on the device and its packaging:

General warning

Warning - risk of electric shock

Warning - compressor is controlled automatically

Warning - hot surface

General caution

Read the operating instructions

Refer to instruction manual

CE – marking

Serial number

Protecting earthing

Terminal for ground connection

04/2022 5 NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022


Fuse

Compressed air inlet

Compressed air outlet

Control wire input

Package handling label – fragile

Package handling label – this side up

Package handling label – keep dry

Package handling label – temperature limits

Package handling label – limited stacking

Package label – recyclable material

Manufacturer

3. DEVICE USE

3.1. Intended use

The compressor is used as source of clean oilfree compressed air intended to be used in industry and laboratories, where parameters and properties of the compressed air are suitable.

The compressor is exclusively intended to compress air without content of explosive or chemically unstable substances.

The compressor is intended for operation in clean and dry rooms

3.2. Incorrect use

Contamination risk.

Air from the compressor is without additional treatment not suitable for breathing and direct contact with food

Explosion risk.

The product is not intended for operation in rooms with explosion risk.

The compressor must not be used to compress aggressive gases.

The compressor must not be operated in premises with occurrence of flammable vapors.

The compressor must not be operated in other conditions as mentioned in Technical data.

Any other use of the product beyond the intended use is considered as incorrect use.

The manufacturer is not responsible for any damages or injuries as a result of incorrect use or disobedience to instructions stated in this User manual. All risks shall be solely borne by the user/operator.



4. GENERAL SAFETY INSTRUCTIONS

The product is designed and manufactured so that any risks connected with its use are minimized and the product is safe for the user and surrounding when used according to the intended use and the instructions stated below are followed.

4.1. Required qualification of the personnel



Each user must be trained by the manufacturer or an organization authorized by the manufacturer or instructed on the device operation by other trained user.



Installation, new settings, changes, extensions and repairs of the product may be performed by the manufacturer or an organization authorized by the manufacturer

(hereinafter qualified technician).

- Otherwise the manufacturer is not responsible for safety, reliability and correct functioning of the product.

4.2. General instructions



When operating the compressor, all acts and local regulations valid in the place of use must be observed. The operator and user are responsible for following the applicable regulations.



Before every use, the user must check, if the device is functioning correctly and safely. Before building the compressor in other devices, the supplier must assess, if the supplied air and construction of the device comply with the requirements of the specified intended use. Taking this into account, follow the product technical data. Assessment of conformity shall be performed by the manufacturer – supplier of the final product.

4.3. Protection from dangerous voltage and pressure



The equipment may only be connected to a properly installed socket connected to earth (grounded).



Before the product is plugged in, make sure that the mains voltage and frequency stated on the product are the same as the power mains.



Check for any damage to the connected compressed air system and electrical circuits before use. Replace damaged pneumatic and electrical conductors immediately.



Immediately disconnect the product from the mains (remove the power cord from the socket) in hazardous situations or when a technical malfunction occurs.



Never adjust or use the safety valve to release the air pressure in the air tank.



Never adjust or use pressure relief valves to release air pressure from the device.

4.4. Original spare parts and accessories



Only the use of original parts guarantees the safety of operating personnel and flawless operation of the product itself. Only accessories and replacement parts specified in the technical documentation or expressly approved by the manufacturer may be used.



The warranty does not cover damage resulting from the use of other accessories and replacement parts as specified or recommended by the manufacturer and the manufacturer has no related liability.



5. STORAGE AND TRANSPORT CONDITIONS

The compressor is shipped from the manufacturer in transport packaging. This protects the product from damage during transport.

Potential for damage to pneumatic components.

The compressor must be transported only when all air has been vented. Before moving or transporting the compressor, release all the air pressure from the tank and pressure hoses, from dryer chambers and drain condensate from the tank and from the condensate separator on the dryer.

Keep the original factory packaging in case the device needs to be returned Use the original factory packaging during transport as it provides optimum protection for the product. . If it is necessary to return the product during the warranty period, the manufacturer is not liable for damages caused by improper packaging.

The compressor is shipped in a vertical position and must be secured using transport straps.

Protect the compressor from humid and dirty extreme near any substances.

environments temperatures transport and storage. Do not store volatile

If not, please dispose of the original packaging material in an environmentally-friendly way. The packaging cardboard can be recycled with old paper.

Storing or shipping the equipment in any conditions other than those specified below is prohibited.

and during chemical

5.1. Ambient conditions

Products may only be stored and transported in vehicles that are free of any traces of volatile chemicals under the following climactic conditions:

Temperature

Relative humidity

–25°C to +55°C, 24 h at up to +70°C max. 90% (non-condensing)


PRODUCT DESCRIPTION


6. VARIANTS

The compressor is manufactured according to its intended application in the following variants:

DK50 4x4VRT/M

DK50 6x4VRT/M

Composed of modules:

1 compressor module with 4 or 6 aggregates and controls for the assembled unit

2 adsorption dryer with connecting hoses

3 air tank module

DK50 4x4VRTS/M Composed of modules:

DK50 6x4VRTS/M

1 compressor module together with a noise reducing enclosure and comprised of 4 or 6 aggregates and controls for the assembled unit

2 adsorption dryer with connecting hoses

3 air tank module

04/2022

DK 50 4x4VRT/M

9 NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022


DK 50 6x4VRT/M

NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022

DK50 4x4VRTS/M

10 04/2022


DK50 6x4VRTS/M

7. ACCESSORIES

Accessories that are not included in the standard order must be ordered separately.

DK50 4x4VRT/M performance upgrade kit

If DK50 4x4VRT compressor performance is not keeping up with demand, a simple solution is to contact the manufacturer about the DK50

Use

Central intake

Existing type of dryer

DK50 4x4VRT/M no AD 1000E

DK50 4x4VRTS/M

DK50 4x4VRT/M

DK50 4x4VRTS/M yes AD 1000E

6x4VRT/M performance upgrade kit.

The DK50 4x4 VRT/M conversion kit converts the existing compressor into a fully functional

DK50 6x4VRT/M compressor with the required parameters in an efficient manner at optimal cost.

New type of dryer

AD

1500E

AD

1500E

Rated voltage / working pressure

3x400 V / 50 Hz

(6-8 bar)

3x400 V / 50 Hz

(8-10 bar)

3x400 V / 50 Hz

(6-8 bar)

3x400 V / 50 Hz

(8-10 bar)

Article number

447000009-171

447000009-172

447000009-173

447000009-174

Central air pump intake kit

This kit provides a properly sized central intake filter located on the compressor module used to supply the intakes of the individual air pumps. This extends the central filter

04/2022 11 replacement interval (to every 2000 hours) compared to the interval for changing the filters on individual compressors, and ensures simpler and faster central filter replacement.


Use

DK50 4x4VRT/M

DK50 4x4VRTS/M

DK50 6x4VRT/M

DK50 6x4VRTS/M

Set of compressed air outlet filters

The compressor may be equipped with a set of filters if specified. The filter set may be equipped with an air pressure regulator.


Article number

447000001-021

447000001-020

447000001-019

447000001-018

Where a different level of air filtration is required, this requirement must be agreed upon with the supplier and specified in the order.

Type

FS 40F

FS 40M

FS 40S

FS 40AH

Type

FS 41F

FS 41M

FS 41S

FS 41AH

Use

DK50

4x4VRT/M

Use

DK50

6x4VRT/M

Level of filtration

( µm)

1

1+0.1

1+0.01

1+AC+HC (0.01)

Level of filtration

( µm)

1

1+0.1

1+0.01

1+AC+HC (0.01)

Bypass function * no

Bypass function * no

Article number

604014119-000

604014119-004

604014119-024

604014119-005

Article number

604014119-006

604014119-010

604014119-025

604014119-011

*) These FS do not contain a filter bypass, which will ensure a continuous flow of air when replacing the filter element. Such a set must be ordered separately. pressure regulator of the compressed air outlet if specified. The regulator must be selected according to the application to the filter set, or separately the regulator shall ensure constant pressure at the outlet.

Filter set regulator assembly

The compressor may be equipped with a

Type

Regulator complete

Use

DK50 4x4VRT/M

DK50 6x4VRT/M

Article number

604014125-000

Filter set brackets

A suitable bracket must be ordered for every filter set.

Type

Compressor-mounted bracket

Wall-mounted bracket


Use

DK50 4x4VRT/M

DK50 6x4VRT/M

12

Article number

603014139-000

603014120-000

04/2022


Compressor module enclosure (noise reducing)

Enclosing the compressor module reduces the noise generated by the compressor by up to 11 dB(a) compared to the compressor module without the enclosure while ensuring sufficient cooling for the air pumps themselves for S1 class continuous operation.

With central intake Article number Use

DK50 4x4VRT/M

DK50 6x4VRT/M

DK50 4x4VRT/M

DK50 6x4VRT/M yes no

447000001-022

447000001-023

8. PRODUCT FUNCTION

8.1. Compressor with adsorption dryer

Fig. 1: Compressor aggregates (12) draw in

atmospheric air through the intake filters and compress it through check valves into the compressed air system. A connecting hose

(13) connects this system to the external adsorption dryer (8). From the inlet to the dryer module, the air is first cooled in the integrated cooler (9) and then through the condensate separator (10), entering the active chamber with adsorbent (11), where the air is dried. A portion of the air is fed into the second, regeneration chamber, where this air is used to remove moisture from the adsorbent, after which it is released through the silencer (21). The active chamber switches on a cyclical basis. Dry and filtered air then passes through the check valve into the air tank (2). The treated compressed air is ready for additional use in the air tank.


Fig. 1 - Compressor with dryer




Fig. 2

– Electrical box / switchboard

Descriptions for figures 1-2:

1. Compressor module

2. Air tank

3. Electrical box / switchboard

4. Safety valve

5. Pressure sensor

6. Pressure gauge

7. Outlet valve

8. Adsorption dryer

9. Integrated cooler

10. Condensate separator

11. Dryer chamber

12. Air pump

13. Connecting hoses

14. Electrical cables

15. Drain valve

16. Display

17. Indicator - alarm

18. Start/stop button

19. Main switch

20. Temperature sensor

21. Noise silencer

22. Condensate drain solenoid valve

23. Non-return valve

24. Connector


TECHNICAL DATA

TECHNICAL DATA

Compressors are designed for operation in dry, ventilated and dust-free indoor rooms under the following climactic conditions:

Temperature

Relative humidity

+5°C to +40°C max. 70%

DK50

4x4VRT/M

DK50

4x4VRTS/M

DK50

6x4VRT/M

DK50

6x4VRTS/M

Working pressure 6 – 8 bar

Rated voltage

Frequency a)

Output at 6 bar (FAD) at

PDP20°C


PDP40°C

Working pressure b)

V, Hz l/min. l/min. bar

A Rated current

Main circuit protection device rating

Main electrical feeder

A mm 2

Enclosure

Motor output

Air tank capacity

Air quality – filtration

Maximum operating pressure of safety valve

Noise at 5 bar (L pA

)

Operating mode

PDP drying performance at 7 bar d)

Time to fill air tank from

0 to 7 bar

Net weight c)

Weight - compressor module

Weight - dryer module

Weight of air tank

Net dimensions

W x L x H

Dimensions - compressor module

(W x L x H)

Dimensions – dryer module

Air tank dimensions

(W x L x H)

Required cooling air changes in space kW

 l m bar dB

%

°C s kg kg kg kg mm mm mm mm m 3 /h

3x400, 50

910

870

6.0 – 8.0

22

25

4

IP10

2.2

500

-

10.0

≤80

S1-100



-20



-40

150

439

268

44

127

2875 x 2090 x

705

1235 x 1720 x

630

530 x 965 x

350

730 x 2090 x

705

2250

3x400, 50

910

870

6.0 – 8.0

22

25

4

IP30

2.2

500

-

10.0

≤70

S1-100



-20



-40

150

572

401

44

127

2875 x 2090 x

705

1235 x 1755 x

705

530 x 965 x

350

730 x 2090 x

705

2250

3x400, 50

1370

1300

6.0 – 8.0

29

32

6

IP10

2.2

500

-

10.0

≤83

S1-100



-20



-40

115

531

350

54

127

2875 x 2090 x 705

1235 x 1720 x 630

530 x 1310 x

350

730 x 2090 x

705

3000

3x400, 50

1370

1300

6.0 – 8.0

29

32

6

IP30

2.2

500

-

10.0

≤72

S1-00



-20



-40

115

664

483

54

127

2875 x 2090 x

705

1235 x 1760 x

705

530 x 1310 x

350

730 x 2090 x

705

3000


TECHNICAL DATA a) Specify the compressor version when ordering b) Consult any other range of pressure with the supplier c) d)

Weight is indicative and only applies to the product without accessories

Applies to ambient temperatures of <30°C PDP – pressure dew point

Dependence of compressor output on working pressure


TECHNICAL DATA

Working pressure 8 – 10 bar

Rated voltage

Frequency a)


PDP20°C


PDP40°C

Working pressure b)

V, Hz l/min. l/min. bar

A Rated current

Main circuit protection device rating

Main electrical feeder

A mm 2

Enclosure

Motor output kW l

 m

Air tank capacity

Air quality – filtration

Maximum operating pressure of safety valve

Noise at 5 bar (L pA

)

Operating mode

PDP drying performance at 7 bar d)

Time to fill air tank from

0 to 7 bar

Net weight c)

Weight - compressor module

Weight - dryer module bar dB

%

°C s kg kg kg

DK50

4x4VRT/M

3x400, 50

700

660

8.0 – 10.0

23

25

4

IP10

2.2

500

-

11.0

≤80

S1-100



-20



-40

150

439

268

DK50

4x4VRTS/M

3x400, 50

700

660

8.0 – 10.0

23

25

4

IP30

2.2

500

-

11.0

≤70

S1-100



-20



-40

150

572

401

44 44

Weight of air tank

Net dimensions

W x L x H

Dimensions - compressor module

(W x L x H)

Dimensions – dryer module

Air tank dimensions

(W x L x H)

Required cooling air changes in space kg mm mm mm mm m 3 /h

127

2875 x 2090 x

705

1235 x 1720 x

630

530 x 965 x

350

730 x 2090 x

705

2250

127

2875 x 2090 x

705

1235 x 1755 x

705

530 x 965 x

350

730 x 2090 x

705

2250 a) Specify the compressor version when ordering b) Consult any other range of pressure with the supplier c) Weight is indicative and only applies to the product without accessories d) Applies to ambient temperatures of <30°C PDP – pressure dew point

DK50

6x4VRT/M

3x400, 50

1050

DK50

6x4VRTS/M

3x400, 50

1050

1000

8.0 – 10.0

30

32

6

IP10

2.2

500

-

11.0

≤83

S1-100



-20



-40

115

531

350

664

483

54

127

2875 x 2090 x 705

1235 x 1720 x 630

530 x 1310 x

350

730 x 2090 x

705

3000

54

127

2875 x 2090 x

705

1235 x 1760 x

705

530 x 1310 x

350

730 x 2090 x

705

3000

1000

8.0 – 10.0

30

32

6

IP30

2.2

500

-

11.0

≤82

S1-00



-20



-40

115


TECHNICAL DATA

Dependence of compressor output on working pressure

FAD correction of capacity for altitude

Capacity given in the form of FAD („Free Air Delivery“) applies to the following conditions:

Altitude 0 m.n.m.

Atmospheric pressure 101325 Pa

Temperature

Relative humidity

20°C

0%

To calculate FAD compressor capacity in dependence on altitude, it is necessary to apply correction factor according to the following table:

Altitude [m.n.m.]

FAD correction factor

0 -1500

1

1501 - 2500

0.80

2501 - 3500

0.71

3501 - 4500

0.60


INSTALLATION

INSTALLATION

Risk of incorrect installation.

Only a qualified technician may install the compressor and place it into operation for the first time. Their duty is to train operating personnel on the use and maintenance of the equipment. An entry is made in the equipment installation record to certify installation and operator training. (see the

Annex chapter)

9. INSTALLATION CONDITIONS



The compressor may only be installed and operating in dry, well-ventilated and clean environments under the conditions specified in the Technical

Data chapter.

Risk of damage to the device.

The equipment may not be operated outdoors or in otherwise wet or damp environments.

Risk of explosion.

Do not use the equipment in the presence of explosive gases, dust or combustible liquids.



The compressor must be installed so that it is accessible at all times for operating and maintenance. Please ensure that the nameplate on the device is readily accessible.



The compressor must stand on a flat, sufficiently stable base (be aware of the weight of the compressor, see the

Technical Data chapter).

 The compressor on the operator’s side must be at least 70 cm from the wall to allow air flow for cooling purposes and to ensure the safety of the operator and maintenance personnel.



Approximately 70% of the electrical energy used by the compressor aggregates is converted to heat, and

NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022 20 therefore the rooms in which the compressor is installed must have additional ventilation to provide sufficient air exchange for cooling purposes (see the Technical Data chapter).

Burn or fire hazard! Caution!

Hot surface!

Portions of the compressor, dryer and connecting hoses between the dryer and compressor may be hot and reach hazardous temperatures during compressor operation that may harm materials or operating staff.

High temperature hazard

Placing air flow impediments upstream or downstream of the cooler is prohibited. The temperature of internal and external parts of the equipment may rise to hazardous levels.

You may notice a “new product” odour when you first place the product into service

(for a short period of time). This odour is temporary and does not impede the normal use of the product. Ensure the space is properly ventilated after installation.

04/2022

INSTALLATION

Fig. 3: Equipment installation

Air outlet

Space conditions

-

Temperature +5°C ÷ +40°C

- Relative humidity 70%

10. COMPRESSOR ASSEMBLY

10.1. Handling and releasing the compressor



Unpack the compressor (compressor modules, dryer and air tank) from the packaging and remove the transport anchors from the pallet. All modules

Fig. 4: Handling the compressor module

Recommended flow of cooling air:

DK50 6x4VRT/M - 3000 m 3 /h.

DK50 4x4VRT/M – 2250 m 3 /h.

Applies for continuous operation and cooling air temperature of20°C

Cooling air inlet are secured to pallets.



Use a fork lift or similar hoisting equipment to handle and position the product.



Position the compressor module at the

site of installation (Fig. 4 A).

04/2022

A

21

B


Fig. 5: Levelling the compressor

INSTALLATION

Prior to installation, ensure that the compressor is free of all transport packaging and stabilizers to avoid any risk of damage to the product.

Remove all devices used to secure the aggregates once the compressor is installed and levelled at the site of final installation.


INSTALLATION

Fig. 6: Releasing the air pumps

Remove the transport stabilisers from the air

pumps (Fig. 6).



DK50 4x4VRT/M – 8 mounts.



DK50 6x4VRT/M – 12 mounts


INSTALLATION

Air tank assembly

Fig. 7:Handling the air tank



Position the air tank at the site of installation and anchor it to the floor.

(Fig. 7)

Assembly of the AD dryer



Remove the dryer from the packaging.



Install the dryer in its operating

position (Fig. 8).

At least two persons are needed to handle the equipment.

Integrated handles are installed on the lower brackets on the product. Each person must grasp the equipment with one hand on a handle and the other behind the dryer chamber when moving the equipment.


INSTALLATION

Fig. 8: Handling the dryer

11. PNEUMATIC CONNECTION

Connect compressor module, dryer module, and the air tank with the provided hoses. (Fig. 9)

Fig. 9: Connecting the compressor module, dryer and air tank


INSTALLATION

Fig. 10: Connecting the enclosed compressor module, dryer and air tank hose length 1 [mm] hose length 2 [mm]

DK50 4x4VRT/M 1000 600

DK50 4x4VRTS/M 600

DK50 6x4VRT/M 1300

DK50 6x4VRTS/M 600

600

1000

1000

AD dryer compressed air inlet



Connect to the compressor outlet

(Fig. 10).

 A G 3/4” connection is installed

NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022 26

Fig. 11: Compressed air inlet

04/2022

INSTALLATION

Burn or fire hazard! Caution!

Hot surface!

When installing the connecting hoses at the inlet to the air dryer, ensure that the temperature is not hazardous if it was to come into contact with an operator or other material.

AD dryer compressed air outlet



Connect the outlet from the dryer (1) to the air inlet on the air tank.

 A G 3/4” connection is installed.

Condensate outlet from dryer



Connect a hose to the outlet (1) from the automatic condensate drain (2) to drain piping or to the provided

Fig. 12: Compressed air outlet collection vessel.

A noise silencer is recommended when connecting directly to drain piping.

Fig. 13: Condensate drain


INSTALLATION

A G3/4” ball valve is installed on the compressed air outlet from the air tank.

Fig. 14: Air outlet from the air tank


Ensure the air hoses are not kinked.

12. ELECTRICAL CONNECTION

Unauthorised hazard interference

Only a qualified electrician may install electrical components!

Risk of damage to the device.

The operator is obliged to provide circuit protection devices for the equipment per the specifications in valid technical standards.

The product is delivered without a power cord.



Connect the compressor module to the

dryer module using cable W22 (Fig.

15).



Connect the compressor module to pressure sensor B1 located on the air tank using cable W23, which is terminated with a valve connector.

(Fig. 17)

The manufacturer recommends protecting cabling loose on the floor (W22 and W23) with a cable bridge.



Connect the individual power cord conductors to the power terminals L1,

L2, L3, N(BU), PE(GNYE). (Fig. 19)



Recommended configuration of phase conductors: L1-BN, L2-BK, L3-GY.



Cord type (minimum requirements)

H05 VV-F_ 5G6

Route the power cord out of the enclosure as

illustrated. (Fig. 18)


INSTALLATION

Fig. 15: Connecting the compressor to the dryer

Fig. 16: Connecting the control signal

1. Harting connector

04/2022



Proper routing of the electrical cable to the dryer

29 NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022

Fire hazard and risk of electric shock.

Ensure the electrical cable does not touch hot parts of the device or connecting hoses.

Fig. 17: Connecting the compressor to the pressure sensor

INSTALLATION

Cable bridge


INSTALLATION

Fig. 18: Electrical cord

Fig. 19: Connecting the power cord

Description of air pump controls

The air pumps are controlled in trios based on real demand. One trio is always set as the

MASTER (e.g. M1-3) and the others as

SLAVE (e.g. M4-6). The set of three Slave air pumps operate under the following conditions

(see Fig. 20)

- A waiting period (pressurising to the upper limit) of 1 minute under strong demand and 2 minutes under weak demand

- Pressure drops below 6.2 bar (SLAVE)

- Motor failure in the MASTER section

The lower limit settings ROTATE every 50 hours to ensure all the air pumps are evenly loaded.


INSTALLATION

Fig. 20: Air pump controls

A – motors M1-M3

B – motors M4-M6

UL – upper limit

BL – bottoms limit → Master = 6.2, SLAVE = 6.0

Description of adsorption dryer solenoid valve control

The inlet valves (Inlet A and B) switch every

120 seconds.

Fig. 21: Solenoid valve diagram

The regeneration valves open variably based on the real load, e.g. if all motors are running, flushing is set to 110 seconds, while if one trio set is running, flushing is set to 55 seconds.


INSTALLATION

Ethernet connection

The compressor may be connected to an

Ethernet 10/100 M network via the controller as follows:

1 Use the RJ-45 connector on the switchboard door to connect a cable to the Ethernet network.

2 The user shall then request IT staff to connect the compressor to the customer’s Ethernet network. The equipment’s default IP addresses are:

BM=192.168.0.3, TDE=192.168.0.2, sub-mask =255.255.255.0.

3 The user shall request the configuration of IP addresses (specific or requested) from the manufacturer



Open the web browser on a PC, smartphone or tablet and enter the IP address of the controller (in this case

192.168.0.3). before the compressor is shipped.

4 The user then configures the IP addresses (specific, requested) based on the manual (see the service manual) or uses the compressor manufacturer’s technical support for such purposes.

Web server

The controller has an integrated Web Server function that facilitates compressor monitoring via a PC, smartphone or tablet using a conventional web browser (Mozilla, Opera,

Safari, Google Chrome, etc.)

The process for logging into the Web Server function once the compressor is connected to an Ethernet network is as follows:

 Enter the password “LOGO” and click on the “LOG on” button.



After logging in, the browser displays the first screen showing the system information for the controller itself: module generation, type, firmware

(FW), IP address and activity status.

 Click on the “LOGO! BM” function in the browser to display the current virtual status of the display screen. Navigate through the screen using the ESC and cursor keys the same as on the real display.


Monitoring memory variables

The “LOGO! Variable” function is the other option for monitoring compressor parameters using selected memory variables. Click the

“LOGO! Variable” button on the display to bring up a screen and then use the “Add

Variable” button to select specific memory variables for monitoring based on the mapping provided by the compressor manufacturer.

INSTALLATION

Variables assigned based on addresses and models may be viewed in the MAPPING

PARAMETERS table (see the Annex chapter).

Select the variable parameters (per the annex) sequentially in the Range, Address,

Type and Display Format columns. Variable values are shown in the Value column. The monitoring table may then appear as follows:

Note:



Time values are displayed in minutes.

For instance, address 10 displays

120000 in minutes, which is 2,000

Logging out from the Web server:



Click on the button in the upper left corner.

13. COMMISSIONING



Make sure all transport stabilizers were removed.



Check that all compressed air hose connections are correct.



Ensure the power cord is properly connected to the mains and other cables are connected (compressorhours.



Analogue values (pressure and temperature) are displayed without decimal places. dryer and compressor-air tank).



Check to ensure the outlet valve is in the OFF position.

The compressor is not equipped with a backup power supply.


INSTALLATION

14. PNEUMATIC DIAGRAMS

DK50 4x4VRT/M, DK50 4x4VRTS/M


DK50 6x4VRT/M, DK50 6x4VRTS/M

INSTALLATION


INSTALLATION

Description to pneumatic diagrams:

1. Inlet filter

2. Air pump

3. Compressor fan

4. Solenoid valve

5. Safety valve

6. Non-return valve

7. Pressure relief valve

8. Condensate separator

9. Jet

10. Pressure sensor

11. Pressure gauge

12. Cooler

13. Cooler fan

14. Air tank

15. Drain valve

16. Outlet valve

17. Dryer solenoid valve

18. Central fan

19. Condensate collection vessel

20. Noise silencer

21. Coarse inlet filter

22. Adsorption filtration

23. Coarse outlet filter

24. OR logic valve

25. Dryer chamber 1

26. Dryer chamber 2


OPERATION

OPERATION

ONLY TRAINED PERSONNEL

MAY OPERATE

EQUIPMENT!

THE

Risk of electric shock.

In case of emergency, disconnect the compressor from the mains (pull out the mains plug).

Burn or fire hazard.

When the compressor is running, the connecting hose between the compressor and dryer and parts of the dryer and aggregate may be hot enough to burn people or other material.

Warning - compressor is controlled automatically.

Automatic compressor start. The automatically switches on when the pressure in the air tank drops to the pressure switch’s lower limit level. The compressor automatically switches off once the pressure in the tank reaches the shut-off pressure .


The working pressure settings for the pressure switch set by the manufacturer cannot be changed. Compressor operation at a working pressure below the switching pressure indicates high air usage (see the

Troubleshooting chapter).

Risk of damage to the dryer.

The dryer may suffer damage if operated at ambient temperatures above its maximum working pressure as specified in the Technical Data chapter .

Required drying performance can only be achieved when following the defined operating conditions.

Drying performance will decline and the achieved dew point will drop if the dryer is operated at any pressure below the minimum working pressure.

During prolonged operation of the compressor, the temperature inside the enclosed model may increase to over 40°C. At this point the cooling fan in the enclosure and the compressor fan automatically switch on. The fans switch off automatically once the space is cooled to below 32°C.


OPERATION

15. SWITCHING ON THE COMPRESSOR

 Turn the main switch (19) into the “I” position on the compressor switchboard. The white indicator P1

(17) lights up and the display (16) on the switchboard door shows the following message:

RUN HOURS: operating hours

PRESSURE: current pressure

TEMP_IN: internal temperature (only for enclosed version)

TEMPˇOUT: outdoor temperature

 Press the "START” button (18) on the switchboard.

The display shows:


STAND BY MODE or RUN MODE

Time-To-Go MTN: shows the time remaining until compressor maintenance is required

Note: TEMP_IN reads “N/A” for compressor models with no cover

TEMP_OUT: ambient temperature around the compressor

Press the START button to turn on all the compressor aggregates. The pressure sensor monitors the pressure in the air tank.

The aggregates operate in automatic mode, and are switched on and off (see the section on working pressures in the Technical Data chapter) by the controller depending on the compressed air usage. The compressors sequentially turn off once the switching pressure is reached.

The motors may be shut down by pressing the

STOP button (18), after which the display returns to the start screen.

Note: The START button is pre-set to

"RETENTIVITY=ON", which means that if the compressor has been activated once using the START button, the system remembers this action and there is no need to press the

START button to start up the compressor in the event of a power loss or if the compressor has been turned off.

Normal operation

Aggregates operate in automatic mode and are switched on and off based on the demand for compressed air. When the pressure in the air tank drops to the switching pressure, the compressors automatically switch on in a sequence. This ensures that the required pressure is delivered to the air tank in the shortest possible time.

Two screens are shown on the display during the normal operation of the equipment:


OPERATION



Motors are on

RUN MODE – all aggregates are switched on


TIME-TO-GO MN - time to the next maintenance / service work (in hours).



Motors are switched off

PRESSURE: current working pressure

STANDBY MODE – all aggregates are switched off


TIME-TO-GO MN - time to the next maintenance / service work (in hours).

The pressure sensor monitors the pressure in the air tank. The pressure is shown on the display.

Check all air line connections and check for compressed air leaks. Remedy all leaks that are identified.

Slowly open the outlet valve to the ON position. The compressor starts and runs until the pressure in the entire compressed air system stabilises. The aggregates then gradually turn off at the switching pressure.

Complete a record for the installation of the compressor assembly and commissioning

(see the Annex chapter).

Shutting down the compressor

Press the STOP button (18) to shut down the compressors.


15.1. Controller – operation and alarms

The controller controls the aggregates, monitors their operation, analyses faults, reports alarms and indicates when maintenance is required after defined intervals are met.

The controller assesses the ambient and internal temperature of the compressor, working pressure and operating hours.

These values, alarms and service interval information are shown on the display.

Temperatures above the critical values are shown as alarms.

The control panel on the controller has four cursor buttons ▲, ▼, ►, ◄, ESC and OK buttons, and four function buttons F1-F4, which trigger the following:

F1 - in alarm display mode, press to switch back to normal operating mode for

60 seconds. Backlit screen.

04/2022

OPERATION

F2 – information on operating hours and maintenance intervals.

F3 – scrolls through:

- Motor malfunctions

- Number of motor starts

- Maximum temperatures


OPERATION

F4 - SERVICE TECHNICIAN BUTTON

(after completing service or maintenance work

- hold for 5 seconds to reset the 2,000 hour maintenance interval.)

Note: Pressing F1-3 on the control panel turns on the display back light for 30 seconds.

HOURS METER - aggregate operating hours

TIME –TO –GO MN - time to next maintenance/service

TOTAL HOURS: - total compressor operating hours

NUMBER of MN – number of completed maintenance (service) checks confirmed using the F4 button

The screen automatically returns to the home screen after 10 seconds.

Equipment operation

Normal operating mode is shown when the equipment is operating and the functional and control buttons are used to browse through the following:

Pressing F2:


OPERATION

Pressing F3:

This permits browsing through different auxiliary screens. E.g. displays the number of overload faults for motors M1 to M6 (motor circuit breaker disconnects the motor from power). The circuit breakers must be manually turned to the

ON position to remedy the malfunction.

The screen automatically returns to the home screen after 10 seconds.


OPERATION

Pressing F4:

F4 is only active if the maintenance screen appears once 2000 hours of operation have been passed (see the maintenance alarm).

Press and hold F4 for at least 5 seconds to set a new interval. The screen switches back to normal operating mode once the new interval is set.

Note: Only service personnel are authorised to configure a new service interval using the F4 button.

Alarms

The equipment has an intelligent monitoring system that generates an alarm signal based on priority (medium priority alarms have higher priority than low priority alarms).

Alarm signals have a higher priority than maintenance/service interval signals.

The maintenance/service interval is measured from the first time the equipment is energised.

All alarms are accompanied by a blinking red

P2 (Alarm) indicator.

Low priority alarm conditions



Expiry of defined maintenance / service interval

This alarm activates once the 2,000 hour maintenance/service interval expires. The display shows the following details:

SERVICE ACCORDING

INSTRUCTIONS FOR USE

TO

TOTAL HOURS - total time the equipment has been connected to power

RUN HOURS – equipment operating hours

The display flashes orange.

Note: Press F1 to switch to the normal operating mode screen for 60 seconds.

The compressor supplies air to the compressed air system as needed and without restriction.

Call in service personnel to perform the required service.

Note: Only service personnel are authorised to configure a new service interval.

Press F4 and hold for at least 5 seconds to confirm the completion of maintenance/service.


The display then changes to the normal operating mode screen.

This indicates the new maintenance interval has been set on the controller from this time forward.

Any maintenance or service work must be recorded in the compressor’s service log.



Compressor module ambient temperature exceeds the limit.

04/2022

OPERATION

WARNING - high ambient temperature alarm.

The display flashes orange.

This alarm appears if the ambient temperature exceeds the 40°C limit for at least 30 seconds. The aggregates operate normally.

The display otherwise shows the current ambient air temperature.

The alarm clears when the temperature drops below the limit.




Compressor module internal temperature exceeds the limit.

WARNING - high temperature alarm inside an enclosed compressor. The display flashes orange.

This alarm appears if the temperature inside the enclosed compressor module exceeds the 70°C limit for at least 30 seconds. The aggregates operate normally.

Note: The internal temperature monitoring function is not included on unenclosed compressors.

The display shows the current temperature inside the enclosed compressor module.

The alarm clears when the temperature drops below the limit.





Low pressure alarm during compressor start-up.

SIGNALING - Low pressure alarm during compressor start-up. The display is backlit and the P2 alarm indicator flashes.

LOW PRESSURE MODE - low pressure signalling in the system with the aggregates switched on.

DRYER - REGENERATION NOT

CYCLING - no purging of the dryer chambers.

PRESSURE - current pressure in the system.

The information on the display automatically disappears once the air pressure is above 3 bar.




Low pressure alarm at elevated compressed air demand.

SIGNALING – low pressure alarm at elevated compressed air demand. The display flashes orange.

PRESSURE - current pressure in the system

The display automatically disappears once the air pressure is above 3 bar.


OPERATION


OPERATION

Medium priority alarm conditions



Air pump malfunction

The message on the display (FAULT) and indicator P2-ALARM (17) indicate that the aggregate is not running (a motor circuit breaker (Q1 - Q6) is tripped due to current overload). The display flashes red.

The other aggregates are working normally.

The screen disappears once the malfunction is remedied and the motor circuit breaker is manually placed back in the “ON” position.

The display for normal operation is shown.

The compressor only supplies compressed air to the central line through the functional aggregates.

All alarms are automatically recorded on an

SD card.

Alarm signals have priority over maintenance interval signals.

As such, the light will indicate an alarm from any of the aggregates.

All error signals are connected to controller output K3:Q3.2 and to terminals X1:44 and

X1:45 (in the control panel) as

NON VOLT ALARM SIGNAL.

Data collection

Data is recorded on a micro SD card in a slot in the base module. Malfunction and operating event data is recorded on this card.

Information is saved in “.csv” formatted files.

The system sequentially saves data into 50 files, each of which may have up to 20,000 lines.

To copy data from the SD card, manually remove the card and load the data using

Excel onto a PC or remotely via the Ethernet network.

Fig. 22: Data collection

16. SWITCHING OFF THE COMPRESSOR

Use the main switch, Q10, to switch off the compressor for maintenance or other reasons; the switch also functions as a central stop button. The compressor is disconnected from the mains with the exception of the mains terminal block X0.

Vent the air tank by disconnecting from the

04/2022 47 central compressed air circuit and opening the

outlet valve (Fig. 14) or the drain valve.

Power terminals X0 remain energised even when main switch Q10 is in the “O” (off) position.


PRODUCT MAINTENANCE

17. PRODUCT MAINTENANCE

The operator shall secure the completion of repeated testing of the equipment at least once every 24 months (EN 62353) or at the intervals defined by the applicable national regulations.

A record of the test results must be made (e.g.: as per EN 62353,

Annex G), along with the measurement methods.

The equipment has been designed and manufactured to keep maintenance to a minimum. The following work must be performed to preserve the proper and reliable operation of the compressor.

Unauthorised hazard. interference

Repair work outside the framework of standard

maintenance (see Chapter17.1)

may only be performed by a qualified technician (an organisation authorized by the manufacturer) manufacturer’s service. or the customer

Standard maintenance work

(see Chapter 17.1) may only be

performed by the operator’s trained personnel.

Only use manufacturerapproved replacement parts and accessories.


Danger of injury or equipment damage.

Prior to commencing compressor maintenance, it is necessary to:

- check if it is possible to disconnect the compressor from the appliance in order to avoid any risk of injury to the person using the appliance or other material damage;

- turn off the compressor;

- disconnect it from the mains (pulling the cord out of the mains socket);

- vent the compressed air from the air tank .

Prior to commencing dryer maintenance work, first:

- shut off the compressed air supply to the dryer

- turn the main switch on the side of the switchboard to the “0” position;

- check the pressure indicator on the dryer and if there is still pressure, it must first be vented from the dryer chamber.

Venting compressed air poses an injury hazard.

Wear eye protection, i.e. goggles, when venting compressed air from the compressed air circuit (air tank) and from the dryer chamber.



Burn hazard.

When the compressor is running or shortly thereafter, certain portions of the air pump, the compressor’s compressed air system, parts of the dryer and connecting hoses between the compressor and dryer may be hot - do not touch these components.

Allow the equipment to cool down before maintenance, service or connecting/disconnecting the compressed air supply!

The work below may only be performed by trained personnel as follows:

Before beginning any of the following maintenance work, first switch the main switch on the side of the switchboard to the “0” position.

Please follow the recommended service intervals for the equipment to ensure proper and safe operation.


17.1. Maintenance intervals operator qualified technician



PRODUCT MAINTENANCE qualified technician


qualified technician




17.2. Check of product operation



Check aggregate condition – the aggregates should be operating normally without excessive vibration or noise. Troubleshoot any problem or call in service personnel if trouble is detected.



Visually inspect fan operation – the fans must be operating when the aggregates are running. Troubleshoot any problem or call in service personnel if trouble is detected.



Check to ensure the power cord, the cable for the pressure sensor on the air tank and the connecting compressed air hoses are undamaged. Replace damaged components or call in service personnel.



Check the ambient temperature at the display – the ambient temperature must be below the temperature limit

(40°C). Cool the space if the temperature is high.



Check for alarm conditions on the display – troubleshoot and remedy all alarms.

17.3. Check the compressed air connections for leaks and inspect the equipment

Leak testing



Check the compressor's compressed air lines for leaks during operation – pressure supplied by the compressor.



Use a leak analyser or soapy water to check all joints and connections for leaks. Tighten or reseal the connection where leaks are found

Inspecting the equipment



Check the condition of the compressor aggregate for normal operation and noise levels.



Fan operation check – the fans must be running during the defined compressor work cycles.



Check the filter condition – clean dirty

04/2022 53 filters or replace with new filters.



Check the solenoid valves in the valve module.



Check the operation of the automatic condensate drain.



Call in service personnel if a malfunction is suspected.

17.4. Inspection of electrical connections


Inspect the product’s electrical connections when the mains are disconnected.



Check the mechanical function of the main switch Q10 and the START-

STOP buttons, S1 and S2.



Check the power cord, conductors connected to the X1 terminal strip and the main switch to ensure they are undamaged. Inspect to ensure the connection terminals are properly supported to relieve tension.



Check to ensure all threaded conductor terminals are tight (on motor circuit breakers Q1-6, circuit protection devices F1-3, contactors Q11-16 and

Q20-21, etc.). Tighten all loose terminals with a screwdriver.



Visually inspect the connection of individual cables to the terminal strip

X1 (spring clips) and the LOGO!

Control system (screw terminals).



Inspect all screw terminals for the protective green and yellow PE grounding conductors in the switchboard, the motor section, the cooling unit and the pressure vessel.

Tighten any loose terminals.



Inspect the connector X50 (dryer and cooler) and the pressure sensor (B1)

(in the pressure vessel).

17.5. Condensate drain

A wet floor resulting from overflow from the vessel poses a slip hazard.



Condensate from compressors with air dryers is automatically drained into a vessel to collect condensate.



Monitor the level in the vessel using the markings (depending on the volume of the vessel), and empty at least once a day.

Fig. 23: Check of the condensate collection vessel

17.6. Inlet filter replacement

The filters located in the compressor aggregate enclosure cover must be replaced at defined intervals.

Intake filter replacement:



Pull out the rubber plug by hand

(2).



Remove the dirty intake filter (1).



Insert a new filter and replace the rubber plug.

Pre-filter replacement:



Pull out the pre-filter by hand (3).



Replace with a new one and insert it back.

17.7. Check of safety valve

Damage to the safety valve could cause pressure to rise to hazardous levels.

Never use the safety valve to release the air pressure in the air tank. This could damage the safety valve. The valve is set to the maximum permitted pressure by the manufacturer.

Never adjust a safety valve.


Fig. 24: Inlet filter replacement

Venting compressed air poses an injury hazard.

Wear safety glasses when inspecting a safety valve.

04/2022




Turn the screw on the safety valve several rotations to the left until the safety valve releases air.



Let the safety valve vent for only a few seconds.



Turn the screw to the right until it seats, closing the valve.

17.8. Compressor intake filter cleaning/replacement

Only applicable to enclosed products.

Clean or replace the intake filters are defined intervals:



Remove the nuts (1) and covers (4) on the lower part of the enclosure beneath the aggregates two times and remove the filters (5).

Fig. 25: Check of safety valve



Remove the nuts (1) and covers (2) inside the enclosure three times and remove the filters (3).



Clean or wash the filters, if heavily contaminated, in a solution of soapy water and allow to dry completely.



Reinstall the filters once dry (reverse the procedure to reassemble).

Fig. 26: Compressor inlet filter cleaning/replacement



At Point A, remove the foam, remove the 4 screws (5), washers (6) and remove the suction filter cover (7).

(Fig. 27)



Remove the 2 nuts (8) on the filter bracket (9) and remove the filter (10).



At Point B (on the sides (11), remove the 2 nuts (12), washers (13), release the filter bracket (14) and remove the filter (15).



Clean or wash the filters, if heavily contaminated, in a solution of soapy water and allow to dry completely.



Reinstall the filters once dry (reverse the procedure to reassemble).



Fig. 27: Compressor inlet filter cleaning/replacement

17.9. Compressor performance check



Turn off the compressor using the

STOP button.



Vent the air pressure in the air tank to zero.



Turn on the compressor using the

START button.



Measure the time to fill the air tank from 0 to 7 bar.



The measured value must be less than the d ata provided in the “Technical

Data” table.

17.10. Check of non-return valve operation

Compressed air line:

Check for the proper operation of all nonreturn valves in the compressed air line and the disconnection of pressure hoses from air pumps.

One aggregate must be running at all times, while the others may be shut off using the current protection device in the switchboard. No compressed air may leak from the check valves.

Air tank:

Check for proper operation of the non-return valve on the air tank by disconnecting the pressure hose from the valve.

Check the check valve operation once the air tank has come up to pressure and with the compressor off. No compressed air may leak.



17.11. Check of solenoid valve operation

Check their operation using the

“Magnetic indicator” fixture as follows:



Attach the fixture to the valve coil and if the motors are active at the valve coil, the indicator must rotate and if they are out of inactive, the indicator must not rotate.

Fig. 28: Check of solenoid valve operation

17.12. Check of temperature sensor switching

Checking the functionality of temperature



This check is conducted using the LOGO! TDE display where the instantaneous temperature values are shown on the starting screen in STOP mode.



The check is based on a slight change in temperature around the sensor, i.e. caused by heating, or the temperature shown on the display must also change. The B4 sensor is not connected on uncovered versions and the display shows

N/A. sensor B3 (external) and B4 (internal).

The B4 sensor is only used on covered models.

Fig. 29: Check of temperature switch switching

17.13. Check the function of the pressure sensor

This check is performed visually using the

TDE screen, which shows the compressed air value. The pressure level shown on the display must change with changes in air demand.

17.14. Cleaning and disinfection of the exterior surfaces of the product

Clean and disinfect the exterior surfaces with neutral cleaning products.

Use of aggressive detergents and disinfectants containing alcohol and chlorides can lead to surface damage and discolouration.

AD dryer maintenance

17.15. Venting pressure from the dryer

The equipment is designed to permit the safe venting of pressure within 10 seconds after the compressor is shut off.

If pressure is not automatically vented from the dryer, then the pressure may be vented


manually.

Venting compressed air poses an injury hazard

Wearing hearing protection is recommended given the noise generated by the venting process.

Shut off the compressed air source before venting pressure from the equipment

Venting pressure using the display screen

Press ESC+▼ in the display screen to vent pressure from the equipment.




First, shut off the compressed air source.

 Then press and hold ESC+▼, which will open all the solenoid valves (inlet and regeneration) for 10 seconds and then vent the pressure from the equipment and connected pneumatic circuits and elements that are not separated from the equipment by the check valve

Manual venting of pressure



Turn off the compressor.



Open the vent plugs on the outlet

module on the equipment (Fig. 30).

Fig. 30: Venting pressure from the dryer chambers



Disconnect the hose (2) from the lower part of the condensate separator (3) (Fig. 31).

Fig. 31: Venting pressure from the cooler and condensate separator

The process of manually venting pressure from the equipment is complete after approximately 2 minutes.



17.16.

Replacement of the dryer’s internal filters

Working with pressurised pneumatic components poses a risk of injury.

Prior to any work, disconnect the equipment from the mains, shut off the compressor and vent all pressure in the equipment to zero.

In normal operation, filter replacement must be performed in the upper part of the dryer at the defined interval.






Check the pressure in the dryer.



If the dryer chambers are under pressure, proceed in accordance with Chapter

17.15.



Unscrew the 8 screws (1).



Disassemble the outlet panel (2) on which the filters (3) are mounted.



Unscrew the dirty filters (3) and replace with new filters.



Check the seal (4) on the bottom of the outlet module and replace if necessary.



Reverse the procedure to reassemble.



Switch on the compressor.



Check for any dryer leaks.

17.17. Replacement of cassettes with adsorbent media

In normal operation, the replacement of the

Fig. 32: Replacement of internal filters cassettes with adsorbent media must be performed at the defined interval.











If the dryer chambers are under pressure, proceed in accordance with Chapter 17.15.






Remove the outlet panel (2).



Pull out and replace the cassettes (3) with new parts.



Check the seal (4) on the bottom of the outlet module and replace if necessary.










Fig. 33: Replacement of cassettes with adsorbent media

17.18. Replacement of the logic valve ball









If the dryer chambers are under pressure, proceed in accordance with

Chapter 17.15.



Unscrew the 4 screws (1) and remove the cover (2).



Remove the ball cover (3).



Replace the ball (4).



Check the nozzles (5) and clean as necessary.






Check for leaks and the operation of the logic valve and nozzles – check for the cyclical switching of the chambers.

Fig. 34: Replacement of the logic valve ball

17.19. Replacement of the dryer’s silencer


Operating the equipment without silencers generates high levels of noise. Only replace silencers when the equipment is shut down.





Unscrew the silencer (1).



Install a new silencer.

17.20. Inspecting the cooler and fan

The equipment, in particular the compressor fan, cooler fan, and the cooler, must be kept clean to ensure efficient drying. Remove dust from the surface of the cooling fins and fans by vacuuming or blowing down with compressed air.

17.21. Replacement of solenoid valves


Shut off the compressed air source, turn off the equipment and disconnect it from the mains before working on the equipment.


Disconnect the equipment from the mains and vent the pressure in the equipment and the pneumatic system to zero before working on the equipment.

In normal operation, the solenoid valves in the bottom of the dryer must be replaced at the defined interval.




Fig. 35: Replacement of the silencer






If the dryer chambers are under pressure, proceed in accordance with

Chapter 17.15.



Unscrew the 1 screw from the valve connector (1).



Disconnect the valve connector (2).






Remove the solenoid valve (4).



Remove the valve seal (4-1) from the body.



Physically clean the valve seat surface to remove any impurities.



Physically clean the 16 screws to remove the thread locking adhesive.



Install the solenoid valve (Fig. 37).



Install the new valve seal (4-1).



Install the new solenoid valve using the 4 screws (3) and use a thread locking adhesive on the threads of the screws (such as Loctite 243).



Reattach the solenoid valve connector and attach with a screw (1).









Fig. 36: Solenoid valve replacement

Solenoid valve assembly

Replacement solenoid valves are delivered as disassembled replacement parts. The new valve must be assembled before a solenoid valve is replaced.



Mount the valve coil (4-5) onto the valve body (4-4) and secure with the nut (4-6).



Insert the valve membrane spring (4-

3) into the membrane (4-2) and the insert into the assembled valve coil and body assembly.



Then mount the valve seal (4-1) onto the dryer body.

Fig. 37: Solenoid valve assembly

17.22. Pressure relief valve

The pressure relief valve automatically begins

NP-DK50-Nx4VRTM-AD-A-EN-5_04-2022 62 to vent air from the system if the pressure in the compressed air circuit exceeds its pre-set value. The pressure relief valve closes as the

04/2022

PRODUCT MAINTENANCE pressure drops.

The pressure in the compressed air circuit can only increase because of an increase in flow resistance in the compressed air lines or as a result of a dryer malfunction

(e.g. solenoid valve malfunction), and therefore the repeated opening of the relief valve requires a dryer function check and repairs if necessary!

Consultation with the manufacturer is required before any adjustment is made to the relief valve!

The outlet openings on the relief valve may not be blocked and the egress of compressed air through them may not be restricted.

1 Compressor pressure relief valve

2 Dryer pressure relief valve

Fig. 38: Pressure relief valve

18. LONG-TERM SHUTDOWN

If the compressor will not be used for a prolonged time period, it is recommended to drain all condensate from the air tank and the condensate separator. Then turn on the compressor for 10 minutes, keeping the drain

valve on the air tank open (15) (Fig. 1). Switch

off the compressor using the main switch (19)

(Fig. 2), close the condensate drain valve and

disconnect the equipment from the mains.


TROUBLESHOOTING

19. DISPOSAL OF DEVICE



Disconnect the equipment from the mains.



Release the air pressure in the pressure tank by opening the drain

valve (15) (Fig. 1).



Dispose of the equipment following all

TROUBLESHOOTING applicable regulations.



Entrust a specialised company to sort

 and dispose of waste.

Worn out components have no negative environmental impact.


Before interfering with the equipment, first disconnect it from the mains (remove the power socket).


Before interfering with the equipment, vent the air tank and the compressed air system to zero pressure.

Malfunction Possible cause

Problem with electrical power source

Troubleshooting may only be performed by a qualified service technician.

Damage to the safety valve could cause pressure to rise to hazardous levels.

Never adjust a safety valve.

Compressor does not start

Power loss

Pressure switch failed

Loss of power to motor

Any of the air pumps does not start up

(indicator is on)

Motor winding shorted, damaged /open thermal protection/ high ambient temperature

Seized up piston or other moving component (mechanical damage to a moving part)

Solution

Main breaker is off

Check mains voltage

Loose terminal in switchboard – tighten

Check the primary power connection - replace if damaged

Check terminals and operation of the pressure switch - replace if damaged

Check mains voltage

Check the function of the contactor, and thermal relays - replace if damaged

Loose terminals at the motor terminal strip - tighten or replace if damaged or broken

Replace the motor / decrease the ambient temperature

Replace damaged parts

Controller malfunction

RUN/STOP indicator is not green

Loss of connection between controller and expansion module

Power loss

Check controller operation, check to ensure software is present - replace if damaged or upload the correct program

Check connection – replace if damaged

Check mains voltage


TROUBLESHOOTING

Air pumps switch often, even without demand for air

Problem with electrical power source

Controller or expansion module malfunction

Air leak in compressed air distribution system

Leaky check valves

Leak through solenoid valves once regeneration is complete

Leak at pressure sensor and safety valve

Air pump leaking

Loose terminal in switchboard – tighten

Check the primary power connection - replace if damaged

Main breaker is off

Replace failed controller or expansion module

Check compressed air distribution system – seal loose joints

Test check vales and clean, or replace if damaged

Clean the check valve - replace if damaged

Test their function and clean, or replace if damaged

Check connections on the air pump for leaks – tighten leaking connections

Replace worn piston

Output of certain air pumps is reduced, extended run cycle

Worn piston rings

Gasket between cylinder head and valve plate damaged

Intake filter is plugged

Replace gasket, tighten

Damaged motor bearing

Replace old filter with a new filter

Replace damaged bearing

One of the air pumps is noisy (knocking, metal noises)

Damaged piston bearing, piston rod Replace damaged piston

Failed (cracked) rubber mount spring

Replace damaged spring with new spring

Lack of ventilation in compressor room Secure suitable ambient conditions

High ambient temperature causes compressors to switch off in vertical stacks (overheating)

Cooling fans for aggregates, cooler and enclosure do not work

Defective fans - replace

Defective temperature switch - replace

Low operating pressure

Reduce the demand for air, check the output from the compressed air source, fix any leaks in the distribution system

Degraded drying performance – highpressure dew point

(condensed water in the air)

Regeneration solenoid valve not working

Air regeneration nozzle plugged

Cooling fan not working

Dirty cooler

Check coil operation, replace if damaged

Dryer emitting high levels of noise

Air leaking through relief valve at dryer inlet

Silencer plugged regeneration valve

Damaged fan

Damaged silencer at outlet from

Air leaking through relief valve at dryer inlet

Compressor running at high working pressure

Dryer inlet solenoid valve not working

Clean or replace the nozzle

(see product maintenance)

Check the power source to the fan

Replace damaged fan

Inspect the cooler and clean as necessary

Inspect the silencers. Clean or replace the silencer if flow resistance is too high or if heavily soiled.

Replace damaged fan

Replace the silencer

Check the dryer connection to the mains and dryer connections, check dryer operation, check the dryer’s working pressure, and replace defective components.

Check the compressor’s working pressure setting

Check coil operation, replace if damaged

Inspect the condition of the valve - clean


TROUBLESHOOTING

High pressure in equipment resulting from plugged filters the valve or replace if problems persist

Check the internal filters and accessory filter assemblies.

Clean or replace dirty filters.

Once a fault is cleared and after reassembling the dryer, the condensate must be drained from the air tank, then dry the air tank, and the dryer must be regenerated, best when using continuous compressor operation at a pressure of around 7.0 bar for a period of at least 1 hour.

Check the moisture content of the air exiting the air tank (see the Technical data chapter) to prevent damage to connected downstream equipment.

20. REPAIR SERVICE

Warranty and post-warranty repairs must be done by the manufacturer, its authorized representative, or service personnel approved by the supplier.

Attention.

The manufacturer reserves the right to make changes to the equipment without notice. Any changes made will not affect the functional properties of the equipment.


ANNEX

ANNEX

21. MAPPING PARAMETERS


ANNEX


ANNEX

22. INSTALLATION RECORD

1. Product: (model)

DK50 4X4VRT/M

DK50 6x4VRT/M

3.1. User’s name:

DK50 4x4VRTS/M

DK50 6x4VRTS/M

2. Serial number:

3.2. Address of installation:

4. Equipment connected to the compressor:

5. Installation / Commissioning:

Product completeness check **

Y

N

Documentation completeness check **

Y

N

Installation/connection to equipment **

Y

Functional test **

N

Y

N

6. Contents of operator training:

Description of the product and functions**

Y

N

Product operation: turning on/off, controls, control procedures, data on the display panel, alarms, operation in alarm conditions**

Y

N

Product maintenance: maintenance intervals, maintenance procedure, service intervals, operating activities**

Y

N

Safety measures, warnings – their meaning and compliance **

Y

N

Notes:

7. Operator instructed on safety measures, operations and maintenance:

Name: Signature:

Name: Signature:

Name:

8. Installation and instruction performed by:

First name/Last name

Signature:

Signature:

Company: Address:

Phone:

Date: Email:

9. Distributor:

Company: Address:

Contact person:

Phone: Email:

** mark with an “X” in points 5 and 6 (Y - yes /N - no). Enter any observations from points 5 and 6 into the “Notes” section.


DK50 4x4VRT/M

DK50 6x4VRT/M

EKOM spol. s r.o.,

Priemyselná 5031/18, 921 01 PIEŠŤANY, Slovak Republic tel.: +421 33 7967255, fax: +421 33 7967223 e-mail: [email protected], www.ekom.sk


112000555-0001

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