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
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.
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
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.
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.
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.
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
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).
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
2.6 CONNECTION TO THE COMPRESSED AIR SYSTEM
Operations to be performed by qualified personnel only.
Never work on compressed air system under pressure.
The user is responsible to ensure that the dryer will never be operated with pressure exceeding
the maximum pressure rating on the unit data tag.
Over-pressurizing the dryer could be dangerous for both the operator and the unit.
The temperature and the amount of air entering the dryer must comply with the limits reported on the data
plate. In case of treatment of air at particularly high temperatures, the installation of a Aftercooler could
result necessary. The cross section of the connecting piping, which must be free from dust, rust, chips and
other impurities, must be consistent with the flow-rate of the dryer.
In order to facilitate the maintenance operations, we suggest installing a by-pass group, as shown in the
following illustration.
Ø
BPY0001
In realising the dryer, particular measures have been taken in order to limit the vibration which could occur
during the operation.
Therefore we recommend to use connecting pipes able to insulate the dryer from possible vibrations
originating from the line (flexible hoses, vibration damping fittings, etc.).
CAUTION:
PIPING THE DRYER, INLET/OUTLET CONNECTIONS MUST BE SUPPORTED AS
SHOW IN THE DIAGRAM.
FAILING WILL RESULT IN DAMAGE
2.7 CONNECTION TO THE COOLING WATER NETWORK (Water-Cooled)
Operations to be performed by qualified personnel.
Never operate with plants under pressure.
The user is responsible to ensure that the dryer will never be operated with pressure exceeding
the nominal values.
Eventual over-pressure could be dangerous both for the operator and the machine.
The temperature and the amount of cooling water must comply with the limits indicated on the technical
characteristics chart.
The cross section of the connection pipes, preferably flexible, must be free from rust, chips and other
impurities, must be consistent with the flow-rate of the dryer.
2.8 ELECTRICAL CONNECTIONS
The connection to the mains, to be carried out by qualified personnel, and the safety systems must
comply with local rules and laws.
Before connecting the unit to the electric power, verify that the voltage and the frequency available on the
mains correspond to the data reported on the data plate of the dryer. In terms of voltage, a ±5% tolerance is
allowed.
The dryers RD come with an electric box for the connection to the mains.
The mains socket must be provided with a mains magneto-thermal differential breaker (I∆n=0.03A),
adjusted on the basis of the consumption of the dryer (see the nominal values on the data plate of the dryer).
The cross section of the power supply cables must comply with the consumption of the dryer, while keeping
into account also the ambient temperature, the conditions of the mains installation, the length of the cables,
and the requirements enforced by the local Power Provider.
Connect to a properly grounded outlet. Improper connection of the equipment-grounding
conductor can result in risk of electric shock.
Do not use adapters on the plug receptacle - if it does not fit the outlet, have a proper outlet
installed by a qualified electrician.
2.9 CONDENSATE DRAIN
The condensate is discharge at the system pressure.
Drain line should be secured
Never point the condensate drain line towards anybody.
The dryer comes with a flexible plastic drain tube.
The condensate drain occurs through a solenoid valve protected with a mechanical strainer.
The condensate coming from the separator is previously filtered, then discharged.
The solenoid valve coil is operated by electronic instrument (dryer controller).
If an electronic drainer is installed, the intervention times are determined by the internal capacitive sensor
(see specific paragraph).
The drainers cannot be connected to pressurized systems.
Don’t dispose the condensate in the environment.
The condensate collected in the dryer contains oil particles released in the air by the compressor.
Dispose the condensate in compliance with the local rules.
We suggest to install a water-oil separator where to convey all the condensate drain coming from
compressors, dryers, tanks, filters, etc.
3.1 PRELIMINARY OPERATION
Verify that the operating parameters match with the nominal values stated on the data nameplate of
the dryer (voltage, frequency, air pressure, air temperature, ambient temperature, etc.).
This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unit
could be damaged during transportation, check the integrity of the dryer during initial start-up and monitor
operation during the first hours of operation
Qualified personnel must perform the initial start-up.
When installing and operating this equipment, comply with all National Electrical Code and any
applicable federal, state and local codes.
Who is operating the unit is responsible for the proper and safe operation of the dryer.
Never operate equipment with panels removed.
3.2 FIRST START-UP
This procedure should be followed on initial start-up, after periods of extended shutdown or
following maintenance procedures.
Qualified personnel must perform the start-up.
Sequence of operations (refer to paragraph 5.1 Control Panel) :
DMC14 Electronic Instrument DMC20 Electronic Instrument
•Ensure that all the steps of the “Installation”
chapter have been observed.
•Ensure that the connection to the compressed air
system is correct and that the piping is suitably
fixed and supported.
•Ensure that the condensate drain pipe is properly
fastened and connected to a collection system or
container.
•Ensure that the by-pass system (if installed) is
closed and the dryer is isolated.
•Ensure that the manual valve of the condensate
drain circuit is open.
•Remove any packaging and other material which
could obstruct the area around the dryer.
•Activate the mains switch.
•Turn on the main switch - pos. 1 on the control
panel.
•Check that the mains detection light of the
ON/OFF button - pos. 4 of the control panel - is
ON.
•Wait at least two hours before starting the dryer
(compressor crankcase heater must heat the oil
of the compressor).
•Ensure the cooling water flow and temperature is
adequate (Water-Cooled).
•Switch ON the dryer button "I - ON" of the
ON/OFF switch - pos. 4 on the control panel.
•Ensure that DMC14 electronic instrument is ON.
•Ensure the consumption matches with the values
of the data plate.
•Check that the rotation direction of the fan
corresponds with the arrows on the
condenser (Air-Cooled).
•Allow the dryer temperature to stabilise at the
pre-set value.
•Slowly open the air inlet valve.
•Slowly open the air outlet valve.
•Slowly close the central by-pass valve of the
system (if installed).
•Check the piping for air leakage.
•Ensure the drain is regularly cycling - wait for its
first interventions.
•Ensure that all the steps of the “Installation”
chapter have been observed.
•Ensure that the connection to the compressed air
system is correct and that the piping is suitably
fixed and supported.
•Ensure that the condensate drain pipe is properly
fastened and connected to a collection system or
container.
•Ensure that the by-pass system (if installed) is
closed and the dryer is isolated.
•Ensure that the manual valve of the condensate
drain circuit is open.
•Remove any packaging and other material which
could obstruct the area around the dryer.
•Activate the mains switch.
•Turn on the main switch - pos. 1 on the control
panel.
•Check that "crankcase oil heater" and "Stand-by"
leds on DMC20 are ON.
•Wait at least two hours before starting the dryer
(compressor crankcase heater must heat the oil of
the compressor).
•Ensure the cooling water flow and temperature is
adequate (Water-Cooled).
•Switch ON the dryer keeping the “Dryer Start-up”
button on DMC20 pressed for at least 2 seconds.
•Check that “compressor ON” led on DMC20 is ON.
•Ensure the consumption matches with the values
of the data plate.
•Check that the rotation direction of the fan
corresponds with the arrows on the condenser
(Air-Cooled).
•Allow the dryer temperature to stabilise at the pre-
set value.
•Slowly open the air inlet valve.
•Slowly open the air outlet valve.
•Slowly close the central by-pass valve of the
system (if installed).
•Check the piping for air leakage.
•Ensure the drain is regularly cycling - wait for its
first interventions.
3.3 START-UP AND SHUT DOWN
Start-up (refer to paragraph 5.1 Control Panel) :
DMC14 Electronic Instrument DMC20 Electronic Instrument
•Check the condenser for cleanliness (Air-
Cooled).
•Ensure the cooling water flow and temperature is
adequate (Water-Cooled).
•Check that the mains detection light of the
ON/OFF button - pos. 4 of the control panel - is
ON.
•Switch ON the dryer button "I - ON" of the
ON/OFF switch - pos. 4 on the control panel.
•Ensure that DMC14 electronic instrument is ON.
•Wait a few minutes; verify that the DewPoint
temperature displayed on electronic instrument
DMC14 is correct and that the condensate is
regularly drained.
•Switch on the air compressor.
•Check the condenser for cleanliness (Air-Cooled).
•Ensure the cooling water flow and temperature is
adequate (Water-Cooled).
•Check that "crankcase oil heater" and "Stand-by"
leds on DMC20 are ON.
•Switch ON the dryer keeping the “Dryer Start-up”
button on DMC20 pressed for at least 2 seconds.
•Check that “compressor ON” led on DMC20 is ON.
•Wait a few minutes; verify that the DewPoint
temperature displayed on electronic instrument
DMC20 is correct and that the condensate is
regularly drained.
•Switch on the air compressor.
Shut down (refer to paragraph 5.1 Control Panel) :
DMC14 Electronic Instrument DMC20 Electronic Instrument
•Check that the DewPoint temperature indicated
on the DMC14 is within range.
•Switch OFF the air compressor.
•After a few minutes, switch OFF the dryer
pressing the "O - OFF" button of the ON/OFF
switch - pos. 4 on the control panel.
•Check that the DewPoint temperature indicated on
the DMC20 is within range.
•Switch OFF the air compressor.
•After few minutes, switch OFF the dryer keeping
the “Dryer Stop” button on DMC20 pressed for at
least 2 seconds.
NOTE : A DewPoint within 0°C and +10°C displayed on the electronic controller is correct according
to the possible working conditions (flow-rate, temperature of the incoming air, ambient
temperature, etc.).
During the operation, the refrigerating compressor will run continuously. The dryer must remain on during
the full usage period of the compressed air, even if the air compressor works intermittently.
The number of starts must be no more than 6 per hour. The dryer must stop running for at
least 5 minutes before being started up again.
The user is responsible for compliance with these rules. Frequent starts may cause
irreparable damage.
4.1 TECHNICAL SPECIFICATIONS ACT 185-810 /AC
810
81000
4860
2862
0.30
DN125 PN16
11.00
15500
8500
14.6
11000
17.9
700
620
62000
3720
2191
0.20
9.80
15500
6700
11.5
8900
15.0
580
480
48000
2880
1696
0.23
DN100 PN16
9.00
15500
6500
11.1
8600
14.6
< 80
530
410
41000
2460
1449
0.30
4.60
6500
5000
9.0
6500
11.7
302
350
35000
2100
1237
0.19
0.24
4.00
4.00
6500
6500
4400
4400
8.7
8.7
5700
5700
11.
2
11.2
27
7
277
250
25000
1500
883
0.23
2.60
5300
3500
6.3
5400
8.9
242
Air
-
Cooled
185
18500
1110
654
+3 equal to 0.73 g/Nm
3
of H
2
O
+25 (+45)
+1
+35 (+55)
7
14
0.18
DN80 PN16
R404A
2.50
5300
-
-
-
-
-
-
3/400-415/50
3350
5.6
4700
7.4
< 75
232
[l/min]
[m
3
/h]
[scfm]
[°C]
[°C]
[°C]
[°C]
[barg]
[barg]
[bar]
[BSP
-
F]
[kg]
[m
3
/h]
[m
3
/h]
[m
3
/h]
[°C]
[barg]
[BSP
-
F]
[Ph/V/Hz]
[W]
[A]
[W]
[A]
[dbA]
[kg]
ACT MODEL
Air flow rate at nominal condition
1
Pressure DewPoint at nominal condition
1
Nom. ambient temperature. (max.)
Min. ambient temperature
Nomin
al inlet air temperature. (max.)
Nominal inlet air pressure
Max. inlet air pressure
Air pressure drop
-
∆
p
Inlet
-
Outlet connections
Refrigerant type
Refrigerant quantity
3
Cooling air flow
Cooling water flow at 15°C (out 30°C)
Cooling water flow at 30°C (out 40°C)
Control of cooling water flow
Maximum water temperature
2
Maximum (min.) water pressure
Cooli
ng water connections
Standard Power Supply
3
Nominal electric absorption
Max. electric absorption
Max. level noise at 1 m
Weight
1
The n o mi n al c o ndi tio n r efe r s to an am b ie n t tem p era t ure o f + 25°C with in l et a i r at 7 ba r g a nd + 3 5 °C.
2
Othe r t em p era t ure o n r e qu e st.
3
Che c k th e d ata s h own o n t he id ent i fic ati o n pla t e.
4.2 TECHNICAL SPECIFICATIONS RD 185-810 /WC
810
81000
4860
2862
0.30
DN125 PN16
8.80
1.69
2.53
7800
13.4
10300
16.7
690
620
62000
3720
2191
0.20
4.70
1.27
1.90
6000
10.3
8200
13.8
570
480
48000
2880
1696
0.23
DN100 PN16
4.00
1.25
1.80
G 1”
5800
9.9
7900
13.4
520
410
41000
2460
1449
0.30
2.40
0.87
1.32
5800
9.9
7900
13.4
297
350
35000
2100
1237
0.24
1.80
0.75
1.13
3650
6.9
5000
9.5
227
250
25000
1500
883
0.23
1.45
0.62
1.94
3050
5.6
4600
8.1
237
Water
-
Cooled
ad acqua
185
18500
1110
654
+3 uguale a 0.73 g/Nm
3
di H
2
O
+25 (+45)
+1
+35 (+55)
7
14
0.18
DN80 PN16
R404A
1.35
-
0.54
0.82
Automatic valve
30
3 (10)
G 3/4"
3/400-415/50
2900
4.8
4200
6.6
< 75
227
[l/min]
[m
3
/h]
[scfm]
[°C]
[°C]
[°C]
[°C]
[barg]
[barg]
[bar]
[BSP-F]
[kg]
[m
3
/h]
[m
3
/h]
[m
3
/h]
[°C]
[barg]
[BSP
-
F]
[Ph/V/Hz]
[W]
[A]
[W]
[A]
[dbA]
[kg]
RD
MODEL
Air flow
rate at nominal condition
1
Pressure DewPoint at nominal condition
1
Nom. ambient temperature. (max.)
Min. ambient temperature
Nominal inlet air temperature. (max.)
Nominal inlet air pressure
Max. inlet air pressure
Air pressure drop
-
∆
p
Inlet - Outlet connections
Refrigerant type
Refrigerant quantity
3
Cooling air flow
Cooling water flow at 15°C (out 30°C)
Cooling water flow at 30°C (out 40°C)
Control of cooling water flow
Maximum water temperature
2
Maximum (min.) water pressure
Cooli
ng water connections
Standard Power Supply
3
Nominal electric absorption
Max. electric absorption
Max. level noise at 1 m
Weight
1
The n o mi n al c o ndi tio n r efe r s to an am b ie n t tem p era t ure o f + 25°C wi th in l et ai r a t 7 bar g a nd +3 5 °C.
2
Othe r t em p era t ure o n r e qu e st.
3
Che c k th e d ata s h own o n t he id ent i fic ati o n pla t e.
5.1 CONTROL PANEL
The control panel illustrated below is the only dryer-operator interface.
RD 185 - 810 - DMC14
K
2
set
DMC 14
°C
esc
°F
1
5
4
3
PQS0009
RD 185 - 810 - DMC20
K
3
PQS0010
1
Main switch
4
ON/OFF switch
2
Electronic control instrument (DMC14-DMC20) with mains detecting light
3
Air and refrigerating gas flow diagram
5
Alarm light
5.2 OPERATION
Operating principal -
The dryer models described in this manual operate all on the same principal. The hot moisture
laden air enters an air to air heat exchanger. The air then goes through the evaporator, also known as the air to
refrigerant heat exchanger. The temperature of the air is reduced to approximately 2°C, causing water vapor to condense
to liquid. The liquid is continuously coalesced and collected in the separator for removal by the condensate drain. The
cool moisture free air then passes back through the air to air heat exchanger to be reheated to within 8 degrees of the
incoming air temperature as it exits the dryer.
Refrigerant circuit -
Refrigerant gas is cycled through the compressor and exits at high pressure to a condenser
where heat is removed causing the refrigerant to condense to a high-pressure liquid state. The liquid is forced through
a capillary tube where the resulting pressure drop allows the refrigerant to boil off at a predetermined temperature. Low-
pressure liquid refrigerant enters the heat exchanger where heat from the incoming air is transferred causing the
refrigerant to boil; the resulting phase change produces a low pressure, low temperature gas. The low-pressure gas is
returned to the compressor, where it is re-compressed and begins the cycle again. During those periods when the
compressed air load is reduced the excess refrigerant is by-passed automatically back to the compressor via the Hot
Gas By-pass Valve circuit.
5.3 FLOW DIAGRAM (Air-Cooled)
12.1
T6
15
EC
1413 16
17
1
12
1c
T1
1b
1a
P
B
3 54
P
11 10
7
6
T
S
9 M
8
P
VA
T3
T2
12.1
12.1
T5
12.1
T4
12.1
12.1
T7
25
5
V1
P
V2
P
2
480-810
DGF0011
5.4 FLOW DIAGRAM (Water-Cooled)
10
11
6
1
7
12
P
2
P
B
4
T1
A
1a
1b
1c
13 16
EC
15
14
T
S
3
17
18
19
20
DGF0002
1
Alu-Dry Module
11
Capillary tube
a - Air-to-air heat exchanger
12
T1 Temperature probe (DewPoint)
b - Air-to-refrigerant exchanger Temp. Probes T2-T8 →DMC20 (if installed)
c - Condensate separator
13
Condensate drain service valve
2
Refrigerant Pressure Switches P
B
14
Y-shaped condensate drain strainer
3
Safety thermo-switch Ts
15
Condensate drain solenoid valve
4
Refrigerant Pressure Switches P
A
16
Coil for cond. drain solenoid valve
5
Refrigerant pressure-switch (fan) P
V
17
EC = Electronic control instrument
P
V1
- P
V2
(RD 480-810)
18
Condenser (Water-Cooled)
6
Compressor
19
Condenser water regulating valve (water-Cooled)
7
Hot gas by-pass valve
20
Liquid receiver (water-cooled)
8
Condenser (Air-Cooled) …
9
Condenser fan
25
Compressor crankcase heater
10
Filter Drier
Compressed air flow direction
Refrigerating gas flow direction
5.5 REFRIGERATING COMPRESSOR
The refrigerating compressor is the pump in the system, gas coming from the evaporator (low pressure
side) is compressed up to the condensation pressure (high pressure side). The compressors utilized are
manufactured by leading manufacturers and are designed for applications where high compression ratios
and wide temperature changes are present.
The hermetically sealed construction is perfectly gas tight, ensuring high-energy efficiency and long, useful
life. Dumping springs support the pumping unit in order to reduce the acoustic emission and the vibration
diffusion. The aspirated refrigerating gas, flowing through the coils before reaching the compression
cylinders cools the electric motor. The thermal protection protects the compressor from over heating and
over currents. The protection is automatically restored as soon as the nominal temperature conditions are
reached.
5.6 CONDENSER (Air-Cooled)
The condenser is the element in which the gas coming from the compressor is cooled down and condensed
becoming a liquid. Mechanically, it is formed by a copper tubing circuit (with the gas flowing inside)
immersed in an aluminium blades package.
The cooling operation occurs via a high efficiency axial ventilator which, in applying pressure on the air
contained within the dryer, forces it into the blades package.
It’s mandatory that the temperature of the ambient air will not exceed the nominal values. It’s important TO
KEEP THE UNIT FREE FROM DUST AND OTHER IMPURITIES.
5.7 CONDENSER (Water-Cooled)
The condenser is the element in which the gas coming from the compressor is cooled down and condensed
becoming a liquid. Basically it is a water/refrigerating gas exchanger where the cooling water lowers the
temperature of the refrigerating gas.
The temperature of the inlet water must not exceed the nominal values. It must also guarantee an adequate
flow and that the water entering the exchanger is free from dust and other corrosive substances.
5.8 CONDENSER WATER REGULATING VALVE (Water-Cooled)
The condenser water regulating valve is used to keep the condensing pressure/temperature constant when
the Water-Cooled is being used. Thanks to the capillary tube, the valve detects the pressure in the
condenser and consequently adjusts the water flow. When the dryer stops the valve automatically closes
the cooling water flow.
The condenser water regulating valve is an operating control device.
The closure of the water circuit from the pressure condenser water regulating valve cannot be used
as a safety closure during service operations on the system.
ADJUSTMENT
The condenser water regulating valve is adjusted during the testing phase to a pre-set value that
covers 90% of the applications. However, sometimes the extreme operating conditions of the dryer
may require a more accurate calibration.
During start-up, a qualified technician should check the condensing pressure/temperature and if
necessary adjust the valve by using the screws on the valve itself.
To increase the condensing temperature, turn the adjusting screws counter-clockwise; to lower it turn
the screws clock-wise. Adjust the valve in order to guarantee a condensing temperature of 42-45 °C.
5.9 FILTER DRIER
Traces of humidity and slag which could accumulate inside the chilling plant, or smudge which could occur
after a long use of the dryer, could limit the lubrication of the compressor and clog the capillary tube. The
function of the Filter Drier, located before the capillary tubing, is to stop the impurities, so avoiding their
circulation within the system.
5.10 CAPILLARY TUBE
It consists of a piece of reduced cross section copper tubing located between the condenser and the
evaporator to form a throttling against the flow of the refrigerating fluid. This throttling creates a pressure
drop, which is a function of the temperature to be reached within the evaporator: the lower the capillary tube
outlet pressure, the lower the evaporation temperature. The length and the diameter of the capillary tubing
are accurately sized with the performance to be reached by the dryer; no maintenance/adjustment
operations are necessary.
5.11 ALU-DRY MODULE
The heat exchanger module houses the air-to-air, the air-to-refrigerant heat exchangers and the demister
type condensate separator. The counter flow of compressed air in the air-to-air heat exchanger ensures
maximum heat transfer. The generous cross section of flow channel within the heat exchanger module
leads to low velocities and reduced power requirements. The generous dimensions of the air-to-refrigerant
heat exchanger plus the counter flow gas flow allows full and complete evaporation of the refrigerant
(preventing liquid return to the compressor). The high efficiency condensate separator is located within the
heat exchanger module. No maintenance is required and the coalescing effect results in a high degree of
moisture separation.
5.12 HOT GAS BY-PASS VALVE
This valve injects part of the hot gas (taken from the discharge side of the compressor) in the pipe between
the evaporator and the suction side of the compressor, keeping the evaporation temperature/pressure
constant at approx. +2 °C. This injection prevents the formation of ice inside the dryer evaporator at every
load condition
RD 185-410
A
4 mm
5/32 in.
+
-
VLY0001
ADJUSTMENT
The hot gas by-pass valve is adjusted during the manufacturing
testing phase. As a rule no adjustment is required; anyway if it is
necessary the operation must be carried out by an experienced
refrigeration engineer.
WARNING : the use of ¼” Schrader service valves must be
justified by a real malfunction of the refrigeration system.
Each time a pressure gauge is connected, a part of refrigerant
is exhausted.
Without compressed air flow through the dryer, rotate the adjusting
screw (position A on the drawing) until the following value is
reached:
Hot gas setting (R404A) : temperature 0.5 °C (+0.5 / -0 °K)
pressure 5.2 barg (+0.1 / -0 bar)
RD 480-810
A
8 mm
5/16 in.
-
+
VLY0003
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