Beko DRYPOINT RA 3 User manual

PNEUMATIG
www.pneumatig.eu
DRYPOINT®RA 3-160
COMPRESSED-AIR REFRIGERATION DRYER
Instructions for installation
and operation

PNEUMATIG.EU - GDYNIAUL.WIELKOPOLSKA158 - 58 622 49 22
2 DRYPOINT® RA 3-160
Dear customer,
Thank you for deciding in favour of the DRYPOINT® RA 3-160 compressed-air refrigeration dryer. Please
read these installation and operating instructions carefully before mounting and starting up the DRYPOINT®
RA 3-160, and follow our directions. Perfect functioning of the DRYPOINT® RA 3-160 and thus reliable
compressed-air drying can only be guaranteed when the provisions and notes stipulated here are strictly
adhered to.
PNEUMATIG
ul. Wielkopolska 158
81-534 Gdynia, POLAND
Phones
[phone]
[phone]
Fax
[phone]
E-mail
[email protected]
Our company is one of the most known pneumatic distributors in Poland.
More then 16 years of experience on the market is a solid package of experience, which we successfully use as our advantage.
We keep an eye on the market, and we can notice and urgently react on customers demands, and introduce new products they need.
Our company offers whole range of pneumatic equipment - everything our customers might ever need - compressors, tubes, air regulators,
filters, dryers, valves, air cylinder, air tools and more.
Please visit our on-line store www.pneumatig.eu where you can find more information, details, photos, user guides, and place an order.

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Contents
DRYPOINT® RA 3-160 3
1 Contents
1 Contents ................................................................................................................................................ 3
2 Type plate .............................................................................................................................................. 5
3 Safety instructions ................................................................................................................................. 5
3.1 Safety pictograms in accordance with DIN 4844................................................................................... 6
3.2 Signal words in accordance with ANSI.................................................................................................. 7
3.3 Overview of the safety instructions........................................................................................................ 7
4 Proper use ........................................................................................................................................... 10
5 Exclusion from a field of application .................................................................................................... 10
6 Special advice for plants under pressure in accordance with the
97/23/EC Pressure Equipment Directive............................................................................................. 10
7 Transport ............................................................................................................................................. 11
8 Storage ................................................................................................................................................ 11
9 Installation............................................................................................................................................ 12
9.1 Place of installation.............................................................................................................................. 12
9.2 Installation plan.................................................................................................................................... 13
9.3 Correction factors ................................................................................................................................ 14
9.4 Connection to the compressed-air system .......................................................................................... 15
9.5 Connection to the cooling-water network (water-cooled) .................................................................... 15
9.6 Electrical connections.......................................................................................................................... 16
9.7 Condensate drain ................................................................................................................................ 16
10 Start-up ................................................................................................................................................ 17
10.1 Preliminary stages ............................................................................................................................... 17
10.2 Initial start-up ....................................................................................................................................... 18
10.3 Removal from service and restart........................................................................................................ 19
11 Technical data ..................................................................................................................................... 20
11.1 Technical data DRYPOINT RA 3-60 /AC ............................................................................................ 20
11.2 Technical data DRYPOINT RA 80-160 /AC ........................................................................................ 21
11.3 Technical data DRYPOINT RA 55-160 /WC ....................................................................................... 22
12 Technical description........................................................................................................................... 23
12.1 Control panel ....................................................................................................................................... 23
12.2 Functional description.......................................................................................................................... 23
12.3 Flow diagram (air-cooled).................................................................................................................... 24
12.4 Flow diagram (water-cooled) ............................................................................................................... 24
12.5 Refrigerating compressor .................................................................................................................... 25
12.6 Condenser (air-cooled)........................................................................................................................ 25
12.7 Condenser (water-cooled) ................................................................................................................... 25
12.8 Cooling-water controller....................................................................................................................... 25
12.9 Filter dryer............................................................................................................................................ 26
12.10 Capillary tube....................................................................................................................................... 26
12.11 Aluminium heat exchanger .................................................................................................................. 26
12.12 Hot gas bypass valve .......................................................................................................................... 26
12.13 Refrigerant pressure switches PA-PB-PV.............................................................................................. 27
12.14 Safety temperature switch Ts.............................................................................................................. 27
12.15 DMC 14 electronics (control unit compressed-air dryer)..................................................................... 28
12.16 Electronically level-controlled BEKOMAT condensate drain............................................................... 29
13 Maintenance, troubleshooting, spare parts and dismantling............................................................... 30
13.1 Checks and maintenance .................................................................................................................... 30
13.2 Troubleshooting ................................................................................................................................... 31
13.3 Recommended spare parts ................................................................................................................. 34
13.4 Maintenance works at the refrigeration cycle ...................................................................................... 35
13.5 Dismantling of the dryer....................................................................................................................... 35
14 Appendices .......................................................................................................................................... 36
14.1 Dryer dimensions................................................................................................................................. 36
14.1.1 Dryer dimensions DRYPOINT RA 3-12 /AC........................................................................................ 36
14.1.2 Dryer dimensions DRYPOINT RA 18-23 /AC...................................................................................... 36
14.1.3 Dryer dimensions DRYPOINT RA 30-40 /AC...................................................................................... 37
14.1.4 Dryer dimensions DRYPOINT RA 55-60/AC....................................................................................... 37
14.1.5 Dryer dimensions DRYPOINT RA 80-100 /AC.................................................................................... 38
14.1.7 Dryer dimensions DRYPOINT RA 55-60 /WC..................................................................................... 39
PNEUMATIG

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Contents
4 DRYPOINT® RA 3-160
14.1.8 Dryer dimensions DRYPOINT RA 80-100 /WC................................................................................... 39
14.1.9 Dryer dimensions DRYPOINT RA 120-160 /WC................................................................................. 39
14.2 Exploded diagram................................................................................................................................ 40
14.2.1 Exploded diagram – diagram of the functional elements .................................................................... 40
14.2.2 Exploded diagram DRYPOINT RA 3-12............................................................................................. 41
14.2.3 Exploded diagram DRYPOINT RA 18-23........................................................................................... 42
14.2.4 Exploded diagram DRYPOINT RA 30-40............................................................................................ 43
14.2.5 Exploded diagram DRYPOINT RA 55-60............................................................................................ 44
14.2.6 Exploded diagram DRYPOINT RA 80-100........................................................................................ 45
14.2.7 Exploded diagram DRYPOINT RA 120-160........................................................................................ 46
14.3 Circuit diagrams................................................................................................................................... 47
14.3.1 Circuit diagram – diagram of the functional elements ......................................................................... 47
14.3.2 Circuit diagram DRYPOINT RA 3-40................................................................................................... 47
14.3.3 Circuit diagram DRYPOINT RA 55-60................................................................................................. 48
14.3.4 Circuit diagram DRYPOINT RA 80-160 .............................................................................................. 48
PNEUMATIG

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Type plate
DRYPOINT® RA 3-160 5
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2 Type plate
The type plate is on the back of the dryer and comprises all primary data of the device. Please complete the table on
this page during the installation with all data from the type plate and always refer to these when contacting the manu-
facturer or the sales department.
All guarantee claims will expire in the event that the type plate is modified or removed.
Model 

Product key 

Serial number 

Nominal flow rate 

Operating overpressure PS min/max 

Inlet temperature TS max 

Ambient temperature 

Refrigerant 

Refrig. Design pressure HP/LP 

Electrical connection 

Electric power 

Fuse protection max. 

Produktschlüssel:
Product key:
Serial n° / year of building:
Serienr. / Baujahr:
Nominal flow rate (ISO1217): m /h
3
Working pressure PS min/max:
Nemmvolumenstrom (ISO1217):
Betriebsüberdruck PS min/max: bar(g)
Inlet temperature TS max:
Eintrittstemperatur TS max: °C
Ambient Temperature:
Umgebungstemperatur: °C
Refrigerant:
Kältemittel: kg
Refrig. Design Pres. HP/LP:
Kältem. Auslegungsdruck HD/ND: bar
Power supply:
Elektrischer Anschluß: ph/V/Hz
Electric Nominal Power:
Elektrische Leistung: W/A
Fuse protection max:
Absicherung max: A
DRYPOINT
BEKO TECHNOLOGIES GMBH
Im Taubental 7, 41468 Neuss
Germany
http:// www.beko.de
TAD0003
3 Safety instructions
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Please check whether or not these instructions correspond to the device type.
Please adhere to all advice given in these operating instructions. They include essential information
which must be observed during installation, operation and maintenance. Therefore, it must be ensured
that these operating instructions are read by the fitter and the responsible operator / certified skilled per-
sonnel prior to installation, start-up and maintenance.
The operating instructions must be accessible at all times at the place of application of the DRYPOINT®
RA 3-160 compressed-air refrigeration dryer.
In addition to these operating instructions, local and national regulations need to be observed, where
required.
Ensure that operation of the DRYPOINT® RA 3-160 compressed-air refrigeration dryer only takes place
within the permissible limit values indicated on the type plate. Any deviation from these limit values in-
volves a risk for persons and for the material, and may result in malfunction or a breakdown.
After installing the device correctly and in accordance with the instructions in this manual, the dryer is
ready to operate, further settings are not required. Operation is fully automatic and maintenance is lim-
ited to several examinations and cleaning measures which are described in the following chapters.
This manual must be available at all times for future reference and is a constituent part of the dryer.
If you have any queries regarding these installation and operating instructions, please contact BEKO
TECHNOLOGIES GMBH.
PNEUMATIG

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Safety instructions
6 DRYPOINT® RA 3-160
3.1 Safety pictograms in accordance with DIN 4844
Observe operating instructions
General danger symbol
Supply voltage
Danger: component or system under pressure
Hot surfaces
Non-breathable air
Do not use water to extinguish the fire
Do not operate with open cover (housing)
Maintenance works or controlling measures must only be carried out by qualified personnel1.
Do not smoke
Note
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6
ARIA
AIR
LUFT
AIR
Connection point compressed-air inlet
ARIA
AIR
LUFT
AIR
Connection point compressed-air outlet
Connection point condensate drain
Connection point cooling-water inlet (water-cooled)
Connection point cooling-water outlet (water-cooled)
PNEUMATIG

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Safety instructions
DRYPOINT® RA 3-160 7
3.2 Signal words in accordance with ANSI
Danger! Imminent hazard
Consequences of non-observance: serious injury or death
Warning! Potential hazard
Consequences of non-observance: possible serious injury or death
Caution! Imminent hazard
Consequences of non-observance: possible injury or property damage
Notice! Potential hazard
Consequences of non-observance: possible injury or property damage
Important! Additional advice, info, hints
Consequences of non-observance: disadvantages during operation and maintenance, no danger
3.3 Overview of the safety instructions
Certified skilled personnel
Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to
undertaking any measures on the DRYPOINT® RA 3-160 compressed-air refrigeration dryer, the certi-
fied skilled personnel shall read up on the device by carefully studying the operating instructions. The
operator is responsible for the adherence to these provisions. The respective directives in force apply to
the qualification and expertise of the certified skilled personnel.
For safe operation, the device must only be installed and operated in accordance with the indications in
the operating instructions. In addition, the national and operational statutory provisions and safety regu-
lations, as well as the accident prevention regulations required for the respective case of application,
need to be observed during employment. This applies accordingly when accessories are used.
Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping compressed
air or through bursting and/or unsecured plant components.
Compressed air is a highly dangerous energy source.
Never work on the dryer when the system is under pressure.
Never direct the compressed-air outlet or condensate drain hoses at persons.
The user is responsible for the proper installation of the dryer. Non-observance of the instructions in the
"Installation" chapter leads to the expiration of the guarantee. Improper installation may result in dan-
gerous situations for the personnel and/or the device.
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Danger!
Supply voltage!
Contact with non-insulated parts carrying supply voltage involves the risk of an electric shock
resulting in injuries and death.
Only qualified and skilled personnel are authorised to run electrically-operated devices. Prior to under-
taking maintenance measures at the device, the following requirements must be met:
Make sure that the power supply is switched off and that the device is off and marked for maintenance
measures. Please also ensure that the power supply cannot be re-established during the works.
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Caution!
Refrigerant!
The compressed-air refrigeration dryer uses HFC-containing refrigerants as a coolant.
Please observe the corresponding paragraph entitled "Maintenance works at the refrigeration cycle".
Warning!
Refrigerant leak!
A refrigerant leak involves the danger of serious injury and damage to the environment.
PNEUMATIG

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Safety instructions
8 DRYPOINT® RA 3-160
The DRYPOINT® RA 3-160 compressed-air refrigeration dryer contains fluorinated greenhouse
gas/refrigerant.
Installation, repair and maintenance works at the refrigeration system must only be carried out by certified
skilled personnel (specialists). A certification in accordance with EC regulation 303/2008 must be avail-
able.
The requirements of the EC 842/2006 directive must be met under all circumstances.
Please refer to the indications on the type plate as regards the type and amount of refrigerant.
Comply with the following protective measures and rules of conduct:
Storage: Keep the container tightly closed. Keep it in a cool and dry place. Protect it against
heat and direct sunlight. Keep it away from ignition sources.
Handling: Take measures against electrostatic charging. Ensure good ventilation/suction at
the workplace. Check fittings, connections and ducts for tightness. Do not inhale the gas.
Avoid contact with the eyes or the skin.
Prior to carrying out works on refrigerant-carrying parts, remove the refrigerant to such an ex-
tent that safe working is possible.
Do not eat, drink or smoke during work. Keep out of the reach of children.
Breathing protection: ambient-air-independent respirator (at high concentrations).
Eye protection: sealing goggles.
Hand protection: protective gloves (e.g. made of leather).
Personal protection: protective clothing.
Skin protection: use protective cream.
In addition, the safety data sheet for the refrigerant needs to be observed!
Caution!
Hot surfaces!
During operation, several components can reach surface temperatures of more than +60°C. There
is the risk of burns.
All components concerned are installed inside of the closed housing. The housing must only be opened
by certified skilled personnel.
Caution!
Improper use!
The device is intended for the separation of water in compressed air. The dried compressed air cannot be
used for breathing-air purposes and is not suitable for the direct contact with food.
This dryer is not suitable for the treatment of contaminated air or of air containing solids.
Note!
Contaminated intake air!
In the event that the intake air is strongly contaminated (ISO 8573.1 class 3.-3 or poorer quality), we rec-
ommend the additional installation of a prefilter (e.g. CLEARPOINT F040), to avoid clogging of the heat
exchanger.
Caution!
Heating-up through fire!
In the event of a heating-up through fire, the containers and pipes of the refrigerant system can
burst.
PNEUMATIG

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Safety instructions
DRYPOINT® RA 3-160 9
In this case, please proceed as follows:
Switch off the refrigeration plant.
Switch off the mechanical ventilation of the machinery compartment.
Use ambient-air-independent respirators.
Containers and plants which are filled with refrigerant can burst violently in the event of fire.
The refrigerants themselves are incombustible, but they are degraded to very toxic products at high tem-
peratures.
Remove the container/plant from the fire zone, as there is the risk of bursting!
Cool down containers and bottles via a directed water jet from a safe position.
In the event of fire, please use an approved fire extinguisher. Water is not a suitable agent to extinguish
an electrical fire.
This must only be carried out by persons who are trained and informed about the hazards emanating
from the product.
Caution!
Unauthorised intervention!
Unauthorised interventions may endanger persons and plants and lead to malfunction.
Unauthorised interventions, modification and abuse of the pressure devices are prohibited.
The removal of sealings and leadings at safety devices is prohibited.
Operators of the devices must observe the local and national pressure equipment regulations in the
country of installation.
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Note!
Ambient conditions!
In the event that the dryer is not installed under suitable ambient conditions, the ability of the device to
condense refrigerant gas is impaired. This can result in a higher load of the refrigerating compressor, and
in a loss of efficiency and performance of the dryer.
This in turn leads to overheated condenser fan motors, to malfunction of electric components and to a
breakdown of the dryer.
Do not install the dryer in an environment in which chemicals with a corrosive effect, explosive gases,
toxic gases, evaporation heat, high ambient temperatures or extreme dust and dirt can be found.
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Proper use
10 DRYPOINT® RA 3-160
4 Proper use
This dryer was designed, manufactured and tested to separate the moisture which normally exists in compressed air.
Any other use is considered improper.
The manufacturer shall not be liable for problems occurring as a consequence of improper use. The user alone is re-
sponsible for any damage resulting from that.
Furthermore, the correct use includes the compliance with the installation instructions, in particular in respect of:
The voltage and frequency of the main voltage supply.
The pressure, temperature and flow rate of the inlet air.
The pressure, temperature and cooling-water throughput (water-cooled).
The ambient temperature.
When delivered, the dryer is tested and fully assembled. The customer only needs to connect the device to the system
in accordance with the instructions in the following chapters.
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5 Exclusion from a field of application
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Note!
Improper use!
The device is intended for the separation of water in compressed air. The dried compressed air cannot
be used for breathing-air purposes and is not suitable for the direct contact with food.
This dryer is not suitable for the treatment of contaminated air or of air containing solids.
6 Special advice for plants under pressure in accordance with the 97/23/EC Pressure
Equipment Directive
The DRYPOINT® RA 3-160 compressed-air refrigeration dryer contains pressure equipment in the sense of the
97/23/EC Pressure Equipment Directive. Therefore, the entire plant needs to be registered with the supervisory author-
ity in accordance with the local regulations, and requires the approval of the latter.
The category of the respective pressure device is indicated in the declaration of conformity.
For the examination prior to the start-up and for periodic inspections, the national regulations need to be observed,
such as the industrial safety regulation in the Federal Republic of Germany. In countries outside the EU, the respective
regulations in force there need to be adhered to.
The proper use of pressure devices is the basic requirement for safe operation. As regards pressure devices, the fol-
lowing points need to be observed:
The DRYPOINT® RA 3-160 compressed-air refrigeration dryer must only be employed within the pressure and
temperature range limits indicated by the manufacturer on the type plate.
No welding must be carried out on the housing and bottom of the devices.
The DRYPOINT® RA 3-160 compressed-air refrigeration dryer must neither be installed in insufficiently venti-
lated rooms nor near heat sources or inflammable substances.
To avoid fractures resulting from material fatigue, the refrigeration dryer should not be exposed to vibrations
during operation.
The maximum operating pressure indicated by the manufacturer on the type plate must not be exceeded. It is
the operator's responsibility to install the appropriate safety and control devices. Prior to the start-up of the
DRYPOINT® RA 3-160 compressed-air refrigeration dryer, the connected pressure generator (compressor
etc.) must be fused to the max. permissible operating pressure. The integrated safeguard needs to be checked
by an approved inspection agency.
The documents related to the DRYPOINT® RA 3-160 compressed-air refrigeration dryer (manual, operating
instructions, manufacturer's declaration etc.) must be kept safe for future reference.
No objects whatsoever must be installed at or placed on the DRYPOINT® RA 3-160 compressed-air refrigera-
tion dryer and the connecting lines.
Installation of the plant in frost-free places only.
Operation of the plant is only permissible with fully closed and intact housing and cover panels. Operation of
the plant with damaged housing/cover panels is prohibited.
PNEUMATIG