FRIULAIR ACT VS Series Guide

Refrigerating air dryer
ACT VS
800 - 2500
Air – water cooled
EN - User’s maintenance and spare parts manual
74MD0059A4-EN_00

2 – EN ACT VS 800 - 2500
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 ACT VS 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.

ACT VS 800 - 2500 3 – EN
Contents
1Safety instructions 5
1.1Safety pictograms in accordance with DIN 4844 6
1.2Signal words in accordance with ANSI 8
1.3Overview of the safety instructions 8
2Proper use of the dryer 11
3Exclusion from a field of application 11
4Instructions for the use of pressure equipment according to PED directive 2014/68/EU 11
5Transport 12
6Storage 12
7Installation 13
7.1Place of installation 13
7.2Installation layout 14
7.3Correction factors 15
7.4Connection to the compressed air system 16
7.4.1Inlet / outlet flanged air connections (only ACT VS 800 – 1250) 16
7.5Connection to the cooling water network (Water-Cooled) 17
7.6Minimum cooling water requirements: 18
7.7Electrical connections 19
7.8Condensate drain 20
8Start-up 20
8.1Preliminary operation 20
8.2First start-up 21
8.3Start-up and shut down 22
9Technical data 23
9.1Technical data ACT VS 800 – 2500 3/460/60 23
10Technical description 24
10.1Control panel 24
10.2Operation 24
10.3Flow diagram (Air-Cooled) 25
10.4Flow diagram (Water-Cooled) 25
10.5Refrigerating compressor 26
10.6Condenser (Air-Cooled) 26
10.7Condenser (Water-Cooled) 26
10.8Condenser water regulating valve (Water-Cooled) 26
10.9Filter dryer 26
10.10Electronic Expansion Valve (EEV) 27
10.11Alu-Dry module 27
10.12Refrigerant pressure switches HPS 27
10.13Compressor crankcase heater 27
10.14Electrical panel fan 27
10.15DMC55 electronic control unit 28
10.15.1Starting the dryer (“ON” mode) 28
10.15.2Stopping the dryer (“STANDBY” mode) 28
10.15.3Performing the condensation drain test 28
10.15.4Chilling circuit process values 29
10.15.5WARNING condition 30
10.15.6ALARM condition 32
10.15.7Alarm history 34
10.15.8Installing and Removing the USB storage drive 35
10.15.9Compressor and fan drive process values 35
10.15.10Electronic expansion valve process values 36
10.15.11Energy saving data and operating hours 37
10.15.12Remote start/stop, remote reset of faults/alarms 38
10.15.13“Alarm” and "dryer running" signal contacts 38
10.15.144-20mA analogue output 38
10.15.15RS485 MODBUS RTU communication port 39
10.15.16Changing process user parameters 39

4 – EN ACT VS 800 - 2500
10.15.17List of spare parts 41
10.15.18System settings and weekly timer 42
10.16Electronic drainer 43
11Maintenance, troubleshooting, spare parts and dismantling 44
11.1Checks and maintenance 44
11.2Troubleshooting 45
11.3Spare parts 55
11.4Maintenance operation on the refrigeration circuit 56
11.5Dismantling of the dryer 56
12Attachments 57
Exploded views – List of components 57
Electric diagrams – List of components 57
12.1Dryers dimension 58
12.1.1ACT VS 800 – 1250 58
12.1.2ACT VS 1500 – 2500 58
12.2Exploded views 58
12.2.1ACT VS 800 – 1250 Air Cooled 58
12.2.2ACT VS 800 – 1250 Water Cooled 58
12.2.3ACT VS 1500 – 2500 Air Cooled 58
12.2.4ACT VS 1500 – 2500 Water Cooled 58
12.3Electric diagrams 58
12.3.1ACT VS 800 – 1250 58
12.3.2ACT VS 1500 – 1750 58
12.3.3ACT VS 2000 - 250 58

Safety instructions
ACT VS 800 - 2500 5 – EN
1 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 personnel prior
to installation, start-up and maintenance.
The operating instructions must be accessible at all times at the place of application of the 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 compressed-air refrigeration dryer only takes place within the permissible
limit values indicated on the name plate. Any deviation from these limit values involves 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 limited
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
manufacturer.

Safety instructions
6 – EN ACT VS 800 - 2500
1.1 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 personnel 1
Do not smoke
Note
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6
Connection point compressed-air inlet
Connection point compressed-air outlet
Connection point condensate drain
Connection point cooling-water inlet (water-cooled)
Connection point cooling-water outlet (water-cooled)
1Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technical training, who are well-
grounded in the respective provisions and laws and capable of carrying out the required works and of identifying and avoiding any
risks during the machine transport, installation, operation and maintenance.
Qualified and authorised operators are persons who are instructed by the manufacturer regarding the handling of the refrigeration
system, with experience and technical training, and who are well-grounded in the respective provisions and laws.
ARIA
AIR
LUFT
AIR
ARIA
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LUFT
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Safety instructions
ACT VS 800 - 2500 7 – EN
Works can be carried out by the operator of the plant, provided that they are skilled accordingly 2.
NOTE: Text that contains important specifications to be considered – does not refer to safety precautions.
The device was carefully designed with particular attention paid to environmental protection:
CFC-free refrigerants
CFC-free insulation material
Energy-saving design
Limited acoustic emissions
Dryer and packaging comprise reusable materials
This symbol advises the user to observe the environmental aspects and comply with the recommendations
connected with this s
y
mbol.
2Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technical training, who are well-
grounded in the respective provisions and laws and capable of carrying out the required works and of identifying and avoiding any
risks during the machine transport, installation, operation and maintenance.
Qualified and authorised operators are persons who are instructed by the manufacturer regarding the handling of the refrigeration
system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

Safety instructions
8 – EN ACT VS 800 - 2500
1.2 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
1.3 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 compressed-air refrigeration dryer, the certified 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
regulations, 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
g
erous 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
undertaking 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 suppl
y
cannot be re-established durin
g
the works.
Prior to carrying out maintenance works at the dryer, switch it off main switch (control panel pos.1) and
wait for at least 30 minutes.
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Caution!
Refrigerant!
The compressed-air refrigeration dryer uses HFC-containing refrigerants as a coolant.
Please observe the correspondin
g
para
g
raph entitled "Maintenance works at the refri
g
eration c
y
cle".

Safety instructions
ACT VS 800 - 2500 9 – EN
Warning!
Refrigerant leak!
A refrigerant leak involves the danger of serious injury and damage to the environment.
The 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
available.
The requirements of the EC 842/2006 directive must be met under all circumstances.
Please refer to the indications on the name plate as regards the type and amount of refrigerant.
Comply with the following protective measures and rules of conduct:
1. 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.
2. 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.
3. Prior to carrying out works on refrigerant-carrying parts, remove the refrigerant to such an extent that
safe working is possible.
4. Do not eat, drink or smoke during work. Keep out of the reach of children.
5. Breathing protection: ambient-air-independent respirator (at high concentrations).
6. Eye protection: sealing goggles.
7. Hand protection: protective gloves (e.g. made of leather).
8. Personal protection: protective clothing.
9. 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 3.
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.
3Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technical training, who are well-
grounded in the respective provisions and laws and capable of carrying out the required works and of identifying and avoiding any
risks during the machine transport, installation, operation and maintenance.
Qualified and authorised operators are persons who are instructed by the manufacturer regarding the handling of the refrigeration
system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

Safety instructions
10 – EN ACT VS 800 - 2500
Note!
Contaminated intake air!
In the event that the intake air is strongly contaminated (ISO 8573.1 class 3.-3 or poorer quality), we
recommend the additional installation of a prefilter (5 micron minimum), 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.
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
temperatures.
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
countr
y
of installation.
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. Failures of this type will affect warranty considerations.
Do not install the dryer in an environment in which chemicals with a corrosive effect, explosive gases,
toxic
g
ases, evaporation heat, hi
g
h ambient temperatures or extreme dust and dirt can be found.
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