DST RECUSORB RZ-104R User manual

Dehumidier
RECUSORB RZ-104R
SPECIAL:
Energy saving step 2; 0-10VDC signal from external regulator
The product picture may differ from the actual product
INSTRUCTION MANUAL
Document version: EN.08 11.05
Product: RZ-104Rsp
Order: 110 231
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3
1. Safety .................................................5
1.1 Aim of this Documentation ....................... 5
1.2 Accentuations in the text ......................... 5
1.3 Inspection of goods ................................. 5
1.4 Safety ...................................................... 5
1.4.1 General advice ............................... 5
1.4.2 Intended use ................................... 5
1.4.3 Safety advice regarding transporta-
tion ................................................. 5
1.4.4 Safety advice - Mechanical ............ 5
1.4.5 Safety advice - Electrical ................ 6
1.4.6 Unit related safety advice ............... 6
1.4.7 Hazardous operating conditions ..... 7
1.4.8 Responsibilities of the operator ...... 7
1.4.9 Minimising hazards ......................... 7
2. General Description .........................8
2.1 Applications ............................................. 8
2.2 Construction ............................................ 8
2.3 Principle of operation ............................... 8
3. Design ................................................9
3.1 Housing and dismantling ......................... 9
3.2 Rotor ........................................................ 9
4. Components and features .............10
4.1 Standard conguration .......................... 10
4.1.1 Rotor motor .................................. 10
4.1.2 Filters ........................................... 10
4.1.3 Fans ............................................ 10
4.1.4 Heater and heater control ............. 10
4.1.5 Electric box design ....................... 10
4.1.6 Overheat protection and control ther-
mostat .......................................... 10
4.1.7 Pressure nozzles .......................... 10
4.2 Special congurations (Options) ................. 11
4.2.1 Filter guards ................................. 11
4.2.2 Humidistat control ......................... 11
4.2.3 Electronic controllers .................... 11
4.2.4 Automatic restart .......................... 11
4.2.5 Emergency stop ........................... 11
4.2.6 Rotation guard .............................. 11
4.2.7 Energy saving ............................... 11
4.2.8 Linear & binary control ................. 12
4.2.9 Adjustable rotor speed ................. 12
4.2.10 Frequency converter .................. 12
5. Installation .......................................13
5.1 Duct-work .............................................. 13
5.2 Electrical connection .............................. 13
5.3 Humidistat connections ......................... 13
5.4 Remote connection ................................ 13
5.5 Steam or hot water regeneration ........... 13
5.6 Positioning ............................................. 14
6. Operating .........................................15
6.1 Keys ....................................................... 15
6.2 Start ....................................................... 16
6.3 Stop ....................................................... 16
6.4 Run time - Heaters ................................ 16
6.5 Run time - Process fan .......................... 16
6.6 Adjusting TH2 &TH3 setpoint ................ 16
6.7 Reset buttons & switches ...................... 17
6.8 Reset the PLC & restart unit .................. 17
6.9 Conguration check ............................... 17
6.10 Remote operation ................................ 18
6.11 Start-up procedure ............................... 18
6.12 Shut down procedure .......................... 18
6.13 PLC operation messages .................... 18
7. Starting up .......................................19
7.1 Pre-operation Checks ............................ 19
7.2 Start-up .................................................. 19
7.3 Responsibilities of the operator ............. 19
8. Troubleshooting .............................20
8.1 PLC-error codes .................................... 20
8.2 Capacity troubleshooting ....................... 21
8.3 Capacity Test ......................................... 21
9. Maintenance ....................................22
Contents
See next page for appendix list and gure list
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Appendix
1. Component list
2. Dimensions
3. Specication: TTC25X
4. Speccation: Step controller SS-S4/D
5. Energy saving (option)
6. EC Declaration of conformity
Electric wiring diagram is located inside the electric
box (The electric diagram has a drawing number.
This number should correspond to the same drawing
number found inside the electric cabinet).
Figures
FIGURE 1: Principle of Operation..............................................8
FIGURE 2: Rotor matrix .............................................................9
FIGURE 3: Principle function of the rotor .................................9
FIGURE 4: Principle of design ...................................................9
FIGURE 6: Standard process and regeneration fan* ..............10
FIGURE 7: Electric regeneration *Heater*...............................10
FIGURE 5: Rotor motor* ..........................................................10
FIGURE 8: Inside electric cabinet............................................10
FIGURE 10: Pressure nozzles.................................................10
FIGURE 9: TH1 .......................................................................10
FIGURE 11: Differential U-tube manometers ..........................11
FIGURE 12: Electronic lter guard ..........................................11
FIGURE 13: Humidistat 1 & 2 illustration.................................11
FIGURE 14: Binary and linearly control ...................................12
FIGURE 15: Installation ...........................................................13
FIGURE 16: Locating bracket ..................................................14
FIGURE 17: Dehumidier leg ..................................................14
FIGURE 29: PLC alarm table and solution ..............................20
FIGURE 30: Troubleshooting and solution table .....................21
FIGURE 31: Correction diagram..............................................23
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1 Safety
1.1 Aim of this Documentation
This document is included at delivery and is therefore
an integral part of the equipment. It describes the
machine’s design and conguration at the time of
delivery.
In the interest of safety, please study this documentation
before installing or operating the equipment.
Instructions relating to safety, handling, operation and
maintenance are to be followed.
Non-compliance can result in serious personal injury
or damage to the machinery and may invalidate
manufacturers’ liabilities and warranties.
This documentation includes guidance for:
• Installers
• Operators
• Maintenance staff
Please retain this documentation throughout the
lifetime of the equipment.
1.2 Accentuations in the text
Attention! This is advice on safety!
Identies potential hazards that may cause
injury to personnel.
Actions which must be taken to reduce risk of
injury are marked like this.
Additional useful information is labelled like this.
1.3 Inspection of goods
The equipment was factory tested and inspected
before delivery.
Attention! Check for transportation damage!
Continue the use of this product only if you
assess it as being undamaged and faultless.
Any damage must be recorded by the forwarder
at time of delivery and reported to the supplier
of the equipment at the earliest opportunity.
Please check condition of the equipment
carefully for damage upon receipt and after
removal of all packaging.
1.4 Safety
1.4.1 General advice
This equipment conforms to the appropriate European
regulations and directives and is designed and
manufactured to be safe and reliable in operation.
Continued safety and reliability is entirely dependent
on correct handling, installation, operation and
maintenance of the equipment supplied.
1.4.2 Intended use
This equipment is specically designed for atmospheric
air drying. It is unsuitable for any other use. For further
advice please contact your DST representative.
Unless specically stated in this manual, the
following applications are prohibited:
• Conditioning of gases (other than air).
• Conditioning of air contaminated with chemicals
or aggressive elements.
• Conditioning of air containing ammable or
explosive elements.
• On rooms or air systems having a potentially
explosive atmosphere (Ex-Zones).
• Conditioning of air at elevated pressures.
• Unltered air (minimum lter standards required
are G4).
1.4.3 Safety advice regarding
transportation
Attention! Heavy equipment being dropped!
Only use tested and certied lifting equipment
to off-load and position the unit.
If a fork lift is used to move the unit, please
ensure the load is evenly balanced.
If lifting the unit on a pallet, ensure the unit is
rmly secured to the pallet.
Evacuate and secure the danger area during
lifting and positioning of the unit.
1.4.4 Safety advice - Mechanical
Attention! Mechanical hazards!
Installation, testing, commissioning preventative
and corrective maintenance must be carried
out by a qualied person or under supervision
of a qualied person. Wherever possible, all
mechanical work must be carried out with the
electric supply switched off.
A qualied person (mechanical) is dened in this
manual as:
• A mechanical technician or engineer qualied
to service and maintain air conditioning plant
and associated systems.
• Has completed the appropriate health and
safety training.
• Has read and is familiar with the contents of
this manual.
• Is professionally competent to commission and
service this type of equipment.
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For your own safety, wear the appropriate
personal protective equipment (PPE).
1.4.5 Safety advice - Electrical
Attention! This equipment will contain high
voltage electrical components!
Wherever possible, all electrical work must be
carried out with the electric supply switched
off. It is recommended that electrical isolators
are locked in the off position. All electrical work
must be carried out by a qualied person or
under supervision of a qualied person.
A qualied person (electrical) is dened in this manual
as:
• An electrical technician or engineer qualied
to service and maintain air conditioning plant.
• Has completed the appropriate health and
safety training.
• Has read and is familiar with the contents of
this manual.
For your own safety, wear the appropriate
personal protective equipment (PPE).
Attention! If the unit control panel isolation
switch is off, the incoming cable terminals may
still be live!
If working on the unit’s isolation switch, ensure
that electrical power is isolated and locked to
prevent accidental resetting.
Attention! Permitted Voltage!
Check incoming electrical voltage and
operating frequency conform to the electrical
wiring diagram and the manufacturer’s type
plate attached to the unit.
Electrical connection to be made in accordance
with local regulations.
Attention! Loose terminal connections!
Due to vibration during transportation it is
advised that electrical terminals are checked
for security and retightened where necessary
The following connecting terminals in the electrical
control cabinet should be checked periodically and
retightened if necessary:
• Connecting terminals in the main isolator switch.
• Connecting terminals in main components of
the heater circuits.
• Connecting terminals in main components of
the fans circuits.
Periodical as dened in this manual means:
• During installation.
• Two months after commissioning date.
• During annual maintenance.
Attention! Electrical parameters!
Parameters used in the electrical protection and
alarm circuits must not be modied or adjusted.
Factory (default) parameters are shown in the
electrical wiring diagrams.
Attention! Safety functions!
The operation of all electric safety devices are
to be checked at commissioning and during
service/maintenance. Under no circumstances
are these devices to be deactivated (e.g.
adjustment or bridging).
Attention! Defective electrical components!
Defective electrical components and defective
wiring must be replaced immediately. The
equipment must not be operated until the defect
has been repaired and the unit re-tested
1.4.6 Unit related safety advice
Attention! Danger from incorrect installation!
The air dryer is designed for internal installation.
For external use it will require a weatherproof
enclosure. Water hoses must not be used
adjacent to this unit.
Use of the air dryer in areas having a potentially
explosive atmosphere (Ex-area) or treatment
of air with potential explosive/flammable
components is prohibited.
The air dryer requires installing on a horizontal
plane.
The air ducts shall be connected load and
vibration free.
Attention! As standard, the air dryer is
equipped with electrical resistive heater
elements (regeneration air heater).
For normal shut down, switch off the unit using
the OFF-button. If switching the unit off in an
EMERGENCY, the main isolator switch or
emergency stop button may be used. However,
residual heat from the heater elements will
remain in the unit and this can result in damage
to components close to the heater and release
of the safety thermostat TH1.
For maintenance purposes shut down the unit
using the OFF button and allow the system to
cool down before attempting to access internal
components.
Attention! Automatic restart after power failure!
(Option)
If the automatic restart function was selected
(option), to prevent unintentional restart, ensure
that the main isolator switch is off and power
isolated before servicing internal components.
Advise all operating & maintenance personnel
regarding automatic restart function if
applicable.
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Do not remove the warning notice on the
machine which alerts personnel to the dangers
of an automatic restart function.
Attention! Condensate in wet air outlet duct.
Due to concentrated water content in the wet
air outlet duct, incidental condensate may
ow back into the machine and damage the
equipment. To prevent this, install the wet air
outlet duct at a slight gradient. If the duct needs
to be installed at high level, x a condensate
drain at the lowest point of the duct.
In cold areas the wet air duct-work should also
be insulated.
Ensure that the condensate drain does not
create an ice hazard in winter.
Attention! Equipment fans can produce noise
levels above 80 dB (A) depending on duct-work
connection used.
Use ear protection, if remaining close to an
operating machine for any length of time.
Pay attention to accessibility requirements for
maintenance and service purposes.
1.4.7 Hazardous operating conditions
Operation of the system is deemed to be hazardous, if:
• Is not operated inside or is not protected within
a weatherproof enclosure.
• Is not operated within the permitted operating
parameters (see technical specications).
• Is operated outside the scope of ‘normal’ use
(see intended use).
1.4.8 Responsibilities of the operator
It is the responsibility of the operator of the system to
ensure that all personnel engaged with installation,
operation, maintenance and service of the equipment
have read and understand the relevant sections of
this manual.
1.4.9 Minimising hazards
To ensure risk to personnel is minimised:
• Ensure that all activities relating to this
equipment are carried out by qualied and
authorised staff only.
• Identify and prevent potential safety hazards in
the environment.
Failure-free Operation
• To ensure a failure-free operation, please make
the following arrangements:
• Keep this manual ready to hand with the unit.
• Use the machine as intended only.
• Only use the machine if it is fully functional.
• Check the condition of the machine before
using.
• Check the machine on operational efciency at
regular intervals.
• Carry out maintenance and testing at the
prescribed intervals.
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Rotor
Wet air outlet
Regeneration
air fan
Process-air
inlet
Dry air outlet
Rotor motor
RECUSORB is a continuous dehumidier with internal energy recovery and able to
reach very low dew points. During regeneration, sensible heat is adsorbed by the rotor
material. This heat is transferred to a purge sector where the incoming regeneration
air is preheated and its moisture content reduced. While less heat is now required to
reach the nal regeneration temperature, the air will also be at a much lower rela-
tive humidity. As a result of this, the dry air outlet is both cooler and drier than that
achieved by other desiccant systems.
Regeneration heater
Process air fan
FIGURE 1: Principle of Operation
2 General Description
2.1 Applications
DST desiccant type dehumidiers are normally used
where dry air is essential to the various manufacturing
processes used in chemical, pharmaceutical, food or
confectionery industries, or where a dry environment is
required for storing and handling of moisture sensitive
products and raw materials.
The well proven air drying technology using the
adsorption principle provides great exibility in solving
humidity problems. It offers the user independent
humidity control, down to dew points far lower than the
effective operating range of refrigeration dehumidiers.
2.2 Construction
The standard dehumidiers are made as complete
units including rotor, fans, rotor motor and rotor drive
transmission, heater for the regeneration, controls and
electrical equipment.
The regeneration heater is normally electric, but steam,
hot water or gas-heater is available as option.
The water vapour is effectively adsorbed from the
treated air in the SSCR silica gel rotor.
2.3 Principle of operation
It works on a continuous process with two air streams
of different ow rates, normally having a ow ratio of
approximately 3 to 1. The greater ow, process air,
is dried as it passes through the dehumidier, while
the smaller ow, regeneration air, is used to heat the
rotor material to drive the adsorbed moisture vapour
from the desiccant. The moisture which is removed
from the process air, is transferred over to the other
as the SSCR rotor turns slowly.
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FIGURE 2: Rotor matrix
3 Design
The unit should be electrically isolated
before dismantling. The main switch
should be in position "0", and can be
locked in this position.
If the unit has been in operation, wait until
the regeneration fan has stopped before
disconnecting and dismantling the unit.
The unit is designed so that it easily can
be lifted by a fork lift. To allow securing
of the unit to the oor or to a pedestal,
square washers are delivered with the
unit.
1. Electric equipment
2. Rotor
3. Rotor motor
4. Reg lter
5. Process lters
6. Process fan
7. Reg. fan, behind
electric cabinet
8. Regen. heater
9. Process air in
10. Dry air out
11. Regen. air in
12. By-pass
13. Wet air out, behind
electric cabinet
1
2
6
10
11
3
8
7
5
9
12
4
13
Section of a dehumidier rotor from Seibu Giken.
The high number of channels means that mois-
ture is adsorbed with extra
efciency!
FIGURE 3: Principle function of the rotor
FIGURE 4: Principle of design
high capacity for adsorbing water vapour. It has a
galvanized sheet metal lining, spokes and a hub and
two bearings on which it rotates around a xed steel
shaft.
3.1 Housing and dismantling
The RECUSORB RZ dehumidier has a housing
of galvanized sheet metal (AlZn). The unit housing
contains rotor, rotor motor with belt transmission,
regeneration heater and lters. The fans and the
electrical control equipment are placed externally on
the unit.
The regeneration fan removes residual heat from the
regeneration heater for ten minutes after the unit has
been switched off.
The access panel at the front of the unit can easily be
opened, to enable service and inspection. The panels
can be opened without any tools as they are xed with
hand wheels.
The rotor unit is located between the two panel doors
at the front. It contains rotor, rotor transmission and
rotor motor. The short side of the rotor unit has a
polycarbonate access panel, which is screwed to the
rotor unit. The panel is removed to gain access to the
rotor and the rotor transmission. The rotor motor can
be reached when the left hand panel door is opened.
The electric box with control panel and all electric
equipment is located on the top of the unit. The lids
of the electric box can be opened when the lock are
turned with a key that is attached with the unit.
The air connections are round galvanized spigots in
standard dimensions.
3.2 Rotor
The heart of a DST dehumidier is the very efcient
patented SSCR silica gel rotor. The rotor matrix
is manufactured from alternate layers of at and
corrugated sheets of silica gel and metal silicates,
chemically bonded into a tissue of inorganic bres. It
is made to form a vast number of axial air channels
running parallel through the structure. The large
internal surface area combined with the special micro
structure of the SSCR silica gel material, ensures
maximum contact area to give the rotor an extremely
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4.1 Standard conguration
4.1.1 Rotor motor
The rotor is driven by a single phase rotor motor with a
timing belt transmission. A belt tension device prevents
belt slipping and overload of the rotor motor.
The rotor has both peripheral
and radial seals.
The peripheral seals are
mounted with hose clips.
The radial seals are made
of teon and are held in
place by steel rulers.
4.1.2 Filters
The air lters are synthetic bre bag lters. Standard
class G4 lter.
4.1.3 Fans
The regeneration air fan is a medium pressure, single
inlet centrifugal fans, directly driven by three-phase
motor.
4.1.4 Heater and heater control
The regeneration heater is
normally an electric heater,
but steam, hot water or gas
heaters are also available.
For units with steam or hot
water, only battery is included.
At installation shall valve
and steamtrap be installed
externally, see steam coil
installation.
* Components may slightly differ from delivered product
4 Components and features
FIGURE 5: Rotor motor*
FIGURE 6: Standard process and regeneration fan*
FIGURE 7: Electric regeneration
FIGURE 9: TH1
ProcessReg
ProcessReg
FIGURE 10: Pressure nozzles
4.1.5 Electric box design
The PLC control panel is located at the front of the
control box. Inside, the electric box houses multiples
electronic devices and control units, such as contactors,
fuses, motor protectors, relays, transformer. They are
attached to the DIN-rails
Possible remote ON/OFF control (for example
humidistat) and potential free alarm contacts are to be
connected on this xed terminal, see wiring diagram
for installation.
4.1.6 Overheat protection and control
thermostat
TH1 is a mechanical overheat protector. The reset
button and adjustment are made on the thermostat.
TH2 (located inside heater champber) and TH3
(located on wet air out) are electronic temperature
transmitters, thermostat. The devices regulates the
regeneration heater temperature.
Note: If TH1 is triggered, the unit will stop and start
the cooling process for a pre-set time. The overheat
protector automatically triggers the regeneration
heater fuses as well. To restore operation, reset TH1
and Fuses F3 through F6.
See “10 Technical data” for default settings.
4.1.7 Pressure nozzles
Located on the rear side of the unit. Are to be used
with gauges and other pressure sensitive devices.
The electric heater battery has a
thermostat. The thermostat is found in
the electric box.
FIGURE 8: Inside electric cabinet
To reach the reset button,
unscrew the cap on TH1
counter-clockwise.
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