Fini RD 185-810 User manual

7425MUM041_EN_2008-06
- EN -
USER’S,
MAINTENANCE MANUAL
RD
RD RD
RD 185
185185
185 -
--
- 810
810810
810
ISSUE
2008
Targhetta Dati
REFRIGERATED AIR DRYER

Fini S.p.a. Via F.lli Vignoli,3 40069 Zola Predosa – Bologna – ITALY
IT - Dichiara sotto la sua esclusiva responsabilità,che il
prodotto qui di seguito descritto è conforme alle prescrizioni
di sicurezza delle direttive: 98/37/CE, 97/23/CE,
73/23/CEE, 89/336/CEE
FI - vakuuttaa, että seuraavassa esitelty tuote vastaa alla
lueteltujen direktiivien turvallisuusvaatimuksia:
98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC
EN - Declares under its sole responsibility that the
product described below complies with the safety
requirements of directives:
98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC
EL - ∆ηλώνει µε αποκλειστικά δική του ευθύνη ότι το προϊόν
που περιγράφεται παρακάτω ανταποκρίνεται στις
προδιαγραφές ασφαλείας των οδηγιών: 98/37/EE, 97/23/EE,
73/23/EEC, 89/336/EEC
FR - Déclare sous son entière responsabilité que le produit
décrit ci-après est conforme aux prescriptions de sécurité
des directives :
98/37/CE, 97/23/CE, 73/23/CEE, 89/336/CEE
PL - oświadcza pod wyłącznąwłasnąodpowiedzialnością, e
opisany poni ej wyrób odpowiada wymaganiom dotyczącym
bezpieczeństwa zawartym w Dyrektywach 98/37/EC,
97/23/EC, 73/23/EC, 89/336/EC
DE - erklärt unter ihrer alleinigen Verantwortung, dass das
in Folge beschriebene Produkt den Sicherheitsvorschriften
der folgenden Richtlinien entspricht:
98/37/EG, 97/23/EG, 73/23/EWG, 89/336/EWG
CS - prohlašuje s plnou odpovědností, že uvedený výrobek
vyhovuje bezpečnostním požadavkům směrnic:
98/37/ЕS, 97/23/ЕS,73/23/ЕHS, 89/336/ЕHS
ES - Declara bajo su exclusiva responsabilidad que el
producto descrito a continuación responde a las
prescripciones de seguridad de las directivas :
98/37/CE, 97/23/CE, 73/23/CEE, 89/336/CEE
SK - Zodpovedne vyhlásuje, že uvedený výrobok zodpovedá
bezpečnostným požiadavkám smerníc:
98/37/ES, 97/23/ES, 73/23/EES, 89/336/EES
NE - Verklaart onder zijn eigen verantwoordelijkheid dat het
hieronder beschreven product in overeenstemming is met
de veiligheidsvoorschriften van de richtlijnen:
98/37/EG, 97/23/EG, 73/23/EEG, 89/336/EEG
HU - teljes felelısségének tudatában tanúsítja, hogy az
alábbiakban jellemzett termék a 98/37/ЕС, 97/23/ЕС,
73/23/ЕЭС és 89/336/ЕЭС sz. irányelvek biztonsági
követelményeinek megfelel.
N0 -
Erklærer under eget ansvar at produktet her beskrevet
er i overensstemmelse med sikkerhetsforskriftene i
direktivene:
98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC
LT - Su visa atsakomybe pareiškia, kad žemiau aprašytas
gaminys atitinka direktyvų98/37/ES, 97/23/ES, 73/23/EES ir
89/336/EES saugumo reikalavimams.
SV - Försäkrar under eget ansvar att den produkt som
beskrivs följande är i överensstämmelse med
säkerhetsföreskrifterna i EU-direktiv:
98/37/EG, 97/23/EG, 73/23/EEG, 89/336/EEG
LV - Apliecina, uzĦemoties pilnu atbildību, ka zemāk
aprakstītais produkts atbilst direktīvu 98/37/ЕС, 97/23/ЕС,
73/23/ЕEСun 89/336/ЕEСdrošības noteikumiem.
DA - Forsikrer på eget ansvar, at produktet, der beskrives
nedenfor, er i overensstemmelse med
sikkerhedsforskrifterne i direktiverne:
98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC
ET - Deklareerib omal vastutusel, et allpool kirjeldatud toode
vastab direktiivide 98/37/EÜ, 97/23/EÜ, 73/23/EMÜ ja
89/336/EMÜ ohutusnõuetele.
PT - Declara sob a sua exclusiva responsabilidade que o
produto descrito a seguir está em conformidade com as
prescrições de segurança das directivas:
98/37/CE, 97/23/CE, 73/23/CEE, 89/336/CEE
SL - Na lastno odgovornost izjavlja, da je spodaj opisani
izdelek v skladu z varnostnimi predpisi, ki veljajo za stroje
98/37/EU, 97/23/EU, 73/23/EEU in 89/336/EEU.
Amministratore delegato Toimitusjohtaja
CEO Dieuqu/nwn Su/mbouloj
PdG Dyrektor Zarządzający
Geschäftsführer Generální ředitel
Administrador delegado Generálny riaditeľ
President-directeur Vezérigazgató
Daglig leder Generalinis direktorius
Verkställande direktör Āenerāldirektor
Administrerende direktør Pea direktor
Administrador delegado Generalni direktor
Enrico Santoro

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
Dear Customer,
thank you for choosing our product. In order to get the best performances out of this product, please read
this manual carefully.
To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and
strictly follow the instructions contained in this manual.
Note, these instructions are in addition to the safety rules that apply in the country where the dryer is
installed. Before packing for shipment each RD series refrigerated air dryer undergoes a rigorous test to
ensure the absence of any manufacturing faults and to demonstrate that the device can perform all the
functions for which it has been designed.
Once the dryer has been properly installed according to the instructions in this manual, it will be ready for
use without any further adjustment. The operation is fully automatic, and the maintenance is limited to few
controls and some cleaning operations, as detailed in the following chapters.
This manual must be maintained available in any moment for future references and it has to be intended as
inherent part of the relevant dryer.
Due to the continuous technical evolution, we reserve the right to introduce any necessary change without
giving previous notice.
Should you experience any trouble, or for further information, please do not hesitate to contact us.
DATA NAMEPLATE
Model

Serial No.

Code

Nominal Flow Rate

Max Air Pressure

Max Inlet Air Temp.

Ambient Temp.

Refrigerant (Type and qty)

Refrig. Design Pres. HP/LP

Electric Supply

Electric Nominal Power

Fuse Max.

Manufactured

The data nameplate is located on
the back of the dryer and shows
all the primary data of the
machine. Upon installation, fill in
the table on the previous page
with all the data shown on the
data nameplate. This data should
always be referred to when
calling the manufacturer or
distributor.
The removal or alteration of the
data nameplate will void the
warranty rights.
Model
Serial No.
Nominal Flow Rate
Max Air Pressure
Max Inlet Air Temp.
Ambient Temp.
Refrigerant
Refrig. Design Pres. HP/LP
Electric Supply
Electric Nominal Power
Fuse Max.
Manufactured
Nl/min
barg
°C
°C
type/kg
barg
ph/V/Hz
W/A
A
www.finicompressors.com
BOLOGNA - ITALY
40069 - ZOLA PREDOSA
FINI S.p.A.
Fini
COMPRESSORS
WARRANTY CONDITIONS
For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty
covers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and
restaurant expenses of our engineer.
The warranty doesn’t cover any responsibility for direct or indirect damages to persons, animals or
equipment caused by improper usage or maintenance, and it’s limited to manufacturing faults only.
The right to warranty repairs is subordinated to the strict compliance with the installation, use and
maintenance instructions contained in this manual.
The warranty will be immediately voided in case of even small changes or alterations to the dryer. To
require repairs during the warranty period, the data reported on the identification plate must be notified.

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
1. SAFETY RULES
1.1 Definition of the Conventional Signs Used in This Manual
1.2 Warnings
1.3 Proper Use of the Dryer
1.4 Instructions for the use of pressure equipment according to PED Directive 97/23/EC
2. INSTALLATION
2.1 Transport
2.2 Storage
2.3 Installation site
2.4 Installation layout
2.5 Correction factors
2.6 Connection to the Compressed Air System
2.7 Connection to the Cooling Water Network (Water-Cooled)
2.8 Electrical connections
2.9 Condensate Drain
3. START UP
3.1 Preliminary Operations
3.2 First Start Up
3.3 Start-up and shut down
4. TECHNICAL CHARACTERISTICS
4.1 Technical Specifications RD 185-810 /AC (Air-Cooled)
4.2 Technical Specifications RD 185-810 /WC (Water-Cooled)
5. TECHNICAL DESCRIPTION
5.1 Control panel
5.2 Operation
5.3 Flow Diagram (Air-Cooled)
5.4 Flow Diagram (Water-Cooled)
5.5 Refrigerating compressor
5.6 Condenser (Air-Cooled)
5.7 Condenser (Water-Cooled)
5.8 Condenser water regulating valve (Water-Cooled)
5.9 Filter Drier
5.10 Capillary tube
5.11 Alu-Dry Module
5.12 Hot gas by-pass valve
5.13 Refrigerant Pressure Switches P
A
-P
B
-P
V
5.14 Safety thermo-switch Ts
5.15 Compressor crankcase heater
5.16 DMC14 Electronic Instrument
5.17 DMC20 Electronic Instrument
5.18 Electronic level drain
6. MAINTENANCE, TROUBLESHOOTING AND DISMANTLING
6.1 Controls and Maintenance
6.2 Troubleshooting
6.3 Maintenance operation on the refrigeration circuit.
6.4 Dismantling of the Dryer
7. LIST OF ATTACHMENTS
7.1 Dryers Dimensions
7.2 Exploded View
7.3 Electrical Diagram

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
1.1 DEFINITION OF THE CONVENTIONAL SIGNS USED IN THIS MANUAL
Carefully read instruction manual before attempting any service or maintenance procedures on the
dryer.
Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not
followed properly.
Electrical hazard. Warning message indicates practices or procedures that could result in personal
injury or fatality if not followed correctly.
Danger hazard. Part or system under pressure.
Danger hazard. High temperature conditions exist during operation of system. Avoid contact until
system or component has dissipated heat.
Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may
result if precautions are not followed.
Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptable
means in cases of fire.
Danger hazard. Do not operate equipment with panels removed.
Maintenance or control operation to be performed by qualified personnel only 1.
ARIA
AIR
LUFT
AIR
Compressed air inlet connection point.
ARIA
AIR
LUFT
AIR
Compressed air outlet connection point.
Condensate drain connection point.
Cooling water inlet connection point (Water-Cooled).
Cooling water outlet connection point (Water-Cooled).
Operations which can be worked out by the operator of the machine, if qualified
1
.
NOTE : Text that specifies items of note to be taken into account does not involve safety precautions.
In designing this unit a lot of care has been devoted to the environment protection:
•CFC free refrigerants
•CFC free insulation parts
•Energy saving design
•Limited acoustic emission
•Dryer and relevant packaging composed of recyclable materials
Not to spoil our commitment, the user should follow the few ecological suggestions marked with
this sign.
1Experienced and trained personnel acquainted with the relevant rules and laws, capable to perform the needed activities and to identify and
avoid possible dangerous situations while handling, installing, using and servicing the machine.

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
1.2 WARNINGS
Compressed air is a highly hazardous energy source. Never work on the dryer with parts under
pressure. Never point the compressed air or the condensate drain jet towards anybody. The user is
responsible for the installation of the dryer, which has to be executed on the basis of the instructions
given in the “Installation” chapter. Otherwise, the warranty will be voided and dangerous situations
for the personnel and/or damages to the machine could occur.
Only qualified personnel are authorized to service electrically powered devices. Before attempting
maintenance, the following conditions must be satisfied:
•Ensure that main power is off, machine is locked out, tagged for service and power cannot be
restored during service operations.
•Ensure that valves are shut and the air circuit is at atmospheric pressure. De-pressurize the dryer.
These refrigeration air dryers contain R134a or R404A HFC type refrigerant fluid. Refer to the
specific paragraph for maintenance operation on the refrigeration circuit – maintenance operation
on the refrigeration circuit.
Warranty does not apply to any unit damaged by accident, modification, misuse, negligence or
misapplication. Unauthorized alterations will immediately void the warranty.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of
electrical fire.
1.3 PROPER USE OF THE DRYER
This dryer has been designed, manufactured and tested for the purpose of separating the humidity normally
contained in compressed air. Any other use has to be considered improper.
The Manufacturer will not be responsible for any problem arising from improper use; the user will bear
responsibility for any resulting damage.
Moreover, the correct use requires the adherence to the installation instructions, specifically:
•Voltage and frequency of the main power.
•Pressure, temperature and flow-rate of the inlet air.
•Pressure, temperature and cooling water capacity (Water-Cooled).
•Ambient temperature.
This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to the
plant in compliance with the instructions given in the following chapters.
The purpose of the machine is the separation of water and eventual oil particles present in
compressed air. The dried air cannot be used for breathing purposes or for operations leading to
direct contact with foodstuff.
This dryer is not suitable for the treatment of dirty air or of air containing solid particles.

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
1.4 INSTRUCTIONS FOR THE USE OF PRESSURE EQUIPMENT ACCORDING TO
PED DIRECTIVE 97/23/EC
To ensure the safe operation of pressure equipments, the user must conform strictly to the above directive
and the following :
1. The equipment must only be operated within the temperature and pressure limits stated on the
manufacturer’s data nameplate.
2. Welding on heat-exchanger is not recommended.
3. The equipment must not be stored in badly ventilated spaces, near a heat source or inflammable
substances.
4. Vibration must be eliminated from the equipment to prevent fatigue failure.
5. Automatic condensate drains should be checked for operation every day to prevent a build up of
condensate in the pressure equipment.
6. The maximum working pressure stated on the manufacturer’s data nameplate must not be exceeded.
Prior to use, the user must fit safety / pressure relief devices.
7. All documentation supplied with the equipment (manual, declaration of conformity etc.) must be kept for
future reference.
8. Do not apply weights or external loads on the vessel or its connecting piping.
Users of the equipment must comply with all local and national pressure equipment
legislation in the country of installation.
2.1 TRANSPORT
Check for visible loss or damage, if no visible damage is found place the unit near to the installation point
and unpack the contents.
•Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid
on its side or if placed upside down.
•Store machine in a clean, dry environment, do not expose to severe weather environments.
•Handle with care. Heavy blows could cause irreparable damage.

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
2.2 STORAGE
SCC0001
Even when packaged, keep the machine
protected from severity of the weather.
Keep the dryer in vertical position, also when
stored. Turning it upside down some parts could
be irreparably damaged.
If not in use, the dryer can be stored in its
packaging in a dust free and protected site at a
maximum temperature of 45 °C, and a specific
humidity not exceeding 90%. Should the
stocking time exceed 12 months, please contact
the manufacturer.
The packaging materials are recyclable. Dispose of material in compliance with the rules
and regulations in force in the destination country.
2.3 INSTALLATION SITE
Failure to install dryer in the proper ambient conditions will affect the dryer’s ability to condense
refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and
performance, overheated condenser fan motors, electrical component failure and dryer failure due
to the following: compressor loss, fan motor failure and electrical component failure. Failures of
this type will affect warranty considerations.
Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous
gasses; steam heat, areas of high ambient conditions or extreme dust and dirt.
In case of fire, use an approved fire
extinguisher, water is not an acceptable
means in cases of fire.
Minimal installation requirements :
•Select a clean dry area, free from dust, and
protected from atmospheric disturbances.
•The supporting area must be smooth, horizontal
and able to hold the weight of the dryer.
•Minimum ambient temperature +1 °C.
•Maximum ambient temperature +45°C.
•Allow at least a clearance of 1 m on each side of
the dryer (2 m RD 480-810 dryers, Air-Cooled
models), for proper ventilation and to facilitate
eventual maintenance operations.
The dryer doesn't require to be fixed to the
supporting surface. The dryer needs to be fixed to
the supporting surface only with particular installation
procedures (dryer on brackets, hanging units, etc.)
2m
(480-810)
1m
1m
(480-810)
2m
1m
1m
LGT0003

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
2.4 INSTALLATION LAYOUT
1
Air compressor
2
Aftercooler
3
Condensate separator
4
Pre-Filter (min. 5 micron)
5
By-pass group
6
Dryer
7
Compressed air tank
8
Final filter
9
Condensate drain
2
8
9
2
1
9
9
3 4
6
IN
OUT
99
8
7
- A -
- B -
1
9
3 4
9
7
9
5
6
IN
OUT
5
In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend the
additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the heat
exchanger.
Type A installation is suggested when the compressor operates at reduced intermittence and the total
consumption equals the compressor flow rate.
Type B installation is suggested when the air consumption can consistently change with peak values highly
exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensate
eventual instantaneous demanding conditions (peak air consumption).

40069 Zola Predosa (BO) - ITALY
[email protected]
- EN -
2.5 CORRECTION FACTORS
Correction factor for operating pressure changes :
Inlet air pressure barg 4 5 7 8 10 12 14
Factor (F1) 0.77 0.85 1.00 1.06 1.15 1.21 1.25
Correction factor for ambient temperature changes (Air-Cooled):
Ambient temperature ºC < 25 30 35 40 45
Factor (F2) 1.00 0.98 0.95 0.90 0.80
Correction factor for inlet air temperature changes:
Air temperature ºC < 30 35 40 45 50 55
Factor (F3) 1.20 1.00 0.85 0.75 0.61 0.49
Correction factor for DewPoint changes:
DewPoint ºC 3 5 7 10
Factor (F4) 1.00 1.09 1.18 1.38
How to find the air flow capacity: How to select a suitable dryer for a given duty:
Air flow
capacity =XFactor (F1)
Factor
(F2)
XFactor
(F3)
X X Factor
(F4)
Nominal
duty
= ÷
Factor
(F1)
Factor
(F2)
÷
Factor
(F3)
÷ ÷
Factor
(F4)
Design
air flow
Std. air
flow rate
Minimum
Example: Example:
An RD 185 has a nominal duty of 18500
l/min. What is the maximum allowable flow
through the dryer under the following operating
conditions:
−Inlet air pressure = 8 barg
−Ambient temperature = 45°C
−Inlet air temperature = 50°C
−Pressure DewPoint = 10°C
Each item of data has a corresponding numerical
factor which multiplied by the design air flow is as
follows:
The procedure here is to list the operating
conditions and then to locate the
corresponding numerical factors:
−Design air flow = 16200 l/min
−Inlet air pressure = 8 barg
−Ambient temperature = 45°C
−Inlet air temperature = 50°C
−Pressure DewPoint = 10°C
In order to select the correct dryer model the
required flow rate is to be divided by the correction
factors relating to above mentioned parameters:
= 13206 l/min →This is the maximum
flow rate that the dryer can accept under these
operating conditions.
= 22693 l/min →Therefore the model
suitable for the conditions above is RD 250 (25000
l/min - nominal duty).
=
x
x
x
x
1.06
18500
0.80
1.38
0.61
capacity
Air flow
=
÷
÷
÷
÷
1.06
16200
0.80
1.38
0.61
flow rate
Minimum