Fu Sheng Co FR005AP User manual

Operating Manual
Refrigerated Compressed-Air Dryer
Air Dryer
FR005AP
FR010AP
FR020AP
FR030AP
FR050AP
FR075AP
FR100AP
FR005A
FR010A
FR020A
FR030A
FR050A
FR075A
FR100A
FR150A
Ver.071203
zThis Air Dryer is designed for
industrial use. Handle with care.
zPlease read this manual carefully
and operate this equipment
accordingly.
zRetain this manual for future
Reference.

Thank you for your purchase.
Thank you for purchasing this Fu Sheng Co., Ltd product.
To ensure safe and efficient use, please install and operate this equipment in
accordance with the instructions provided in this manual.
Product specifications are subject to change without notice. Please be aware that
recent changes to product specifications may not be reflected in the content of
this manual.
ＣＯＮＴＥＮＴＳ
Important Notes...................................................... 1(1)
Names of Parts and Functions.......................................... 2(1)
1．Appearance.................................................. 2(1)
2．Control panel................................................ 2(1)
3．Switch board................................................. 3(1)
Installation Notes..................................................... 4(1)
1．Checking Model.............................................. 4(1)
2．Space for Installation.......................................... 5(1)
3．Forbidden places.............................................. 5(1)
Preparation for Operation............................................. 6(1)
1．Piping....................................................... 6(1)
2．Installation of Accessories....................................... 7(1)
3．Wiring........................................................ 9(1)
Operation............................................................ 10(1)
1．How to Start.................................................. 10(1)
2．How to Stop.................................................. 11(1)
Safety Devices......................................................... 12(1)
Daily Maintenance and Checks........................................... 13(1)
1．Daily Checks................................................... 13(1)
2．Maintenance................................................... 13(1)
1）Cleaning of Condenser...................................... 13(1)
2）Cleaning of Auto Drain Trap(ET3000 4000).................... 14(1)
3）Cleaning of Auto Drain Trap(AD-5).......................... 15(1)
Troubleshooting....................................................... 16(1)
After－Sale Service.................................................... 16(1)
Before Long Disuse.................................................... 17(1)
Table of Specifications.................................................. 18
Specification.......................................................... 20
Part list............................................................. 30

Important Notes.
1(1)
1. Do not carry the dryer turned aslant or upside
down．
3. Do not modify the wiring in the switchboard．
‧Do not modify the wiring except at the
primary-side power terminals.
5．Never turn the operation switch on and off
frequently.
2. Be sure to ground the unit to prevent electric
shock.
4．Before inspection, be sure to stop the air
compressor and turn off power to the air dryer.
Make sure that pressure is reliefed in the
air dryer.

Names of Parts and Functions
Illustrations used are those of FR020A
2 ( 1 )
1. Appearance
2. Control Panel
■FR005A、FR005AP、FR010A、FR010AP
■FR020A~075A、FR075AP~100AP
Air inlet
Wet compressed air inlet
Control Panel
Ai
r
Outlet
Dr
y
com
p
ressed ai
r
outle
t
.
Power Cord Hole
Lead the power cord out
from here.
Le
g
Use the aperture to fix
this device in place.
FR005A、FR005AP
FR010A、FR010AP
EVAP. Pressure Gauge
Indicates the EVAP. Pressure of the
Operation Switch (with lamp)
Press ON, and the lamp lights up, the dryer starts
operating. Press OFF, and the lamp goes out, the
dr
y
er sto
p
s
○6 AIR PRESSURE GAUGE
○4 START SWITCH (WHITE)
○5 REMOTE/LOCAL SWITCH
○2 RUNNING LAMP
○7 EVAP. PRESSURE GAUGE
○8 COND.PRESSURE GAUGE
○3 STOP SWITCH（RED
○1 ALARM LAMP ○1 ○2
○3 ○4
○5
○6
○7
○8
○2○3 ○4
○6 ○7

3(1)
3.Switchboard
Terminal Earth
FR020AP~050AP
FR030A~075A
Terminal Earth FR010AP
FR020A
FR100A 075AP FR150A 100AP
Terminal Earth Earth Terminal

Installation Notes
4(1)
1. Checking Model
After unpacking the dryer, check the Specifications Plate to make sure that you have received
the system that you ordered..
■ Accessories
Auto drain trap Ball valve
FR005AP 010AP 020AP 30AP050AP
FR005A 010A 020A FR030A 050A 075A Float type 1pc 1/2B 1pc
FR075AP 100APFR
FR100A 150A Discus type 1pc 1/2B 1pc
Also confirm that the unit has not suffered any shipping-relating damage. In the event of a
problem, please contact your dealer

5(1)
2. Space for Installation
Locate the dryer with enough free space around.
To ensure a sufficient ventilation and accessibility, keep adequate distances
between the dryer and objects in its surrounding
3. Forbidden places
■Do not install in the place where unit will
be exposed to direct sunlight, rain, or
external heat. Such exposure may reduce
the ability of the condenser to release heat,
resulting in poor performance.
■Ambient temperature should be between 2
℃and 40℃. Ambient temperatures above
40℃. can impede heat release from the
condenser, resulting in safety-device
activation and equipment shutdown. If you
need to install the unit in an area where
ambient temperature may exceed 40 , set
up ductwork as necessary to supply outside
air directly to the air intake area on the
cabinet, or construct an outdoor exhaust
port to discharge the inside exhaust air
(warm air). Be sure that the design does
not result in a drop in the fan airflow.
■Do not install in a dusty location.
Dust accumulation on the condenser may
reduce the unit’s performance
Space for ventilatio
n
60cm or more
Side space
60cm or more
Space for ventilatio
n
60cm or more
Side space
60cm or more

Preparation for Operation
6(1)
1. Piping
■Air inlet∕outlet connection dimension
Model FR005AP FR010AP、015AP
020AP FR030AP、 050AP FR075AP FR100AP
Model FR005A、FR010A FR020A、030A FR050A、075A FR100A FR150A
Pipesize 1/2B 1B 1-1/2B 2B 21/2B
. ■Piping notes
1）Do not confuse the inlet and outlet of the air dryer.
2）Do not use any riser in the piping from air compressor to air dryer．
However, if it is inevitable, install a valve or a drain trap so that water can be purged．
3）Provide a by-pass circuit between the inlet and the outlet of the air dryer．
4）Do not allow the piping weight to bear on the air dryer．
5）In a cold place, cover the outdoor piping, if any, with heat insulator．
Even indoors, use heat insulator if the air dryer outlet piping develops condensation.
6）In piping, prevent dust and other foreign materials from entering the air circuit．
AIRINLET AIROUTLET
Suspend By-
p
ass circuit Check valve Heat Insulato
r
Inclination
Compressor Chamber Inside
Valve or drain trap
When providing a
riser in piping

7(1)
2. Installation ofAccessories
1) FR005AP、010AP、020AP、030A、050AP
FR005A、010A、020A、030A、050A、075A
■ Accessories
Auto drain trap Floattype 1pc
Ball valve 1/2B 1pc
Auto drain trap Floattype 1pc
1) As shown, install the ball valve and auto drain trap on the drain pipe with the marking
DRAIN .
2) After the installation, open the ball valve.
3) Install the auto drain trap so that the drain outlet is positioned below.
4) Use the following vinyl hose when the drainage is to be led out of the auto drain trap.
Hose inside diam.:16 mm
5) When connecting a pipe, screw it on the threaded part of the drain trap outlet.
Drain trap outlet thread diam: Rc 1/4
● Important
To remove the drain trap (when you need to replace it), proceed as follows:
(1)Close the ball valve;
(2)Release the pressurized air from the trap;
(3)Hold on to the ball valve so that it cannot turn, and rotate (unscrew) the trap to remove.
● Important
If attaching a pipe to the drain outlet, note that the pipe should not be too long and should not
move upward. Reverse pressure caused by excessive pipe length or upward flow may prevent
draining.

8(1)
2) FR050AP、075AP、100AP
FR050A、075A、100A、150A
■ Accessories
Auto drain trap Discus type 1 pc
Ball valve 1/2B 1 pc
● Important
To remove the drain trap (when you need to replace it), proceed as follows:
1) Close the ball valve;
2) Release the pressurized air from the trap;
3) Hold on to the ball valve so that it cannot turn, and rotate (unscrew) the trap to remove.
● Important
If attaching a pipe to the drain outlet, note that the pipe should not be too long and should not move
upward. Reverse pressure caused by excessive pipe length or upward flow may prevent draining.

9(1)
3. Electrical Wiring
1) Power-cord capacities are as follows.
Model FR005AP、010AP、020AP FR030AP FR050AP FR075AP、100AP
FR005A、010A、020A、030A FR050A FR075A FR100A、150A
Power source
(standard type) Single phase 220V 50/60Hz 3 phase 220V 50/60Hz
Power cord (mm2) 1.25 or more 2.0 or more
Breaker capacity (A) 10A 20A
Ground line (mm2) 1.25 or more 2.0 or more
2) Install an overload leakage breaker (overload-protect function plus current leakage
function).
The breaker must be dedicated to the air dryer. (Use high-speed type with 30mA
current sensitivity.)
3) Connect up the power cord.
For single-phase models, connect the wires to terminals 1 and 2.
For three-phase models, connect to terminals R,S and T
4) Connect the ground.
Ground (earth) connection must be set up by a qualified electrician. The ground line
must be connected to the earth terminal. The line diameter must be at least 2mm2.
5) Power voltage should remain within 5% of the rated value while the dryer is operating.

Operation
＊Before starting operation, make certain that the power breaker is ON．
10(1)
1．How to start
c Press the operation switchON
The operation lamp lights up and operation starts．
FR005AP FR010AP above
FR005A、010A FR020AP
d 3 minutes later, start supplying compressed air．
About three minutes after the start of the dryer, supply compressed air by operating
the air compressor．
。
Caution At this time, be sure to close the by-pass valve in the piping。
By-pass valve
Open
Close
Open

11(1)
eCheck the indications on the gauges.
Soon after the flow of compressed air, EVAP. pressure gauge will normally start indicating within the
green-colored range．
● EVAP. pressure gauge：
The air dryer may not easily develop trouble even when it is operated with the EVAP. pressure
gauge indicating a little beyond the green range. Yet, take care to use it within the green range
so that the dryer can perform at its maximum efficiency．
【Note】When the ambient temperature drops, the fan may repeat stop and run operation．This is
to prevent the freezing inside the heat exchanger．
2．How to Stop
cStop the air compressor．
dPress the stop switch OFF．
The operation lamp goes out and operation stops．
Green range

Safety Devices
ÚThe dryer is provided with safety devices to ensure operational safety for you
12(1)
The air dryer will stop automatically at the operation of any safety device．
■Refrigerant circuit safety device ) High-pressure switch
The high-pressure switch operates when the condensation pressure reaches:
3.0±0.1MPa (30±1kgf/cm2G) (R407CRefrigerant)
2.0 ±0.1MPa (20±1kgf/cm2G) (R134aRefrigerant)
and stops the dryer．
■Electric circuit ) Motor protector
The motor protector will operate to stop the air dryer if the temperature of the compressor gets
high or an over current flows in the circuit.
How to reset
1．Remove the cause of stoppage.（See Troubleshooting．）
2．Press the operation switch ON on the control panel.

Daily Maintenance and Checks
13(1)
Dust or dirt accumulated on the condenser
will reduce the heat exchange efficiency．
At the worst，the dryer may stop with the
safety device operating．
1. Daily Checks
Checking of auto drain trap
Check the auto drain trap everyday.
2. Maintenance
1）Cleaning of condenser
Clean the condenser periodically, using a brush or air gun．
Caution In cleaning, exercise care so as not to deform the condenser fins．
Check items
● Air leakage
● Normal operation
(water draining)
Water
draining
No air
leakage

14(1)
2) Cleaning of auto drain trap (Float type)
. Overhaul the auto drain trap periodically (every week) so that it can always operate normally.
NO. PARTS NAME
1 Plat cover
2 Body
3 O-ring
4 Filter
5 Bowl
6 Bowl guard
7 Float
8 Orifice
9 Float level arm
10 Spring
11 Packing
12 Valve
13 Orifice spring
■ How to clean
(1) Close the ball valve.
(2) Remove the dirt and dust from the filter element, which is fit in the lower part of the auto
drain unit, using an air gun or like means.
(3) Wash the separated parts with a neutral detergent.
(4) Check for damaged parts. Make a particularly careful check of O-ring.
(2) Caution
Neverdisassembletheauto
drainunit.Otherwise
troubleswillresult.
(3) (4)
● The drain should not be exposed to direct sunlight, as such exposure may damage the drain
bowl.
● The following substances can damage the drain bowl. These substances should never be
present within the drain or in the atmosphere around the drain.
○ Oils based on phosphoric acid esters.
○ Organic solvents (aromatic, chloride, and hydrocarbon compounds)
─Benzene, toluene, phenol, trichloroethylene, gasoline, paint thinner, etc.
○ Sulfurous acid gas, chorine gas, CFC gas.
○ Acids: hydrochloric acid, sulfuric acid, acetic acid, etc.

15(1)
3) Cleaning of auto drain trap ( Discus type )
Overhaul the auto drain trap periodically (every week) so that it can always operate normally.
■Parts name
■Draining
Discharge the drainage once a week by turning the drain plug clockwise．During a
cold season, perform the drainage after every operation to prevent freezing．
■Draining before a long suspension of operation．
Be sure to discharge the water from the bowl by turning "clockwise" the drain plug
at the bottom of the drain trap．
■Adjustment of drainage discharge
The operating interval of this drain trap varies with the load, pressure，etc．
Turning the needle valve in the "＋"direction will shorten the interval and increase
the drainage discharge．Adjust the interval in such a way that water will not
accumulate in the bowl．
■Disassembly
If some abnormality, such as excessive dirt on the screen or longer interval, is found,
overhaul the drain trap as follows：
Turn the cap counterclockwise and remove it．
Blow the dust off from the filter, using compressed air．
Clean the disc cap and disc．
Turn the ring counterclockwise and remove it.
Remove the screen．
Blow the dust off the screen．
Wash the bowl with a neutral detergent. Never use any organic solvent．
Check all the parts for damage. Never fail to check the O-rings, packings and washer

Troubleshooting
16(1)
■ Should any trouble arise during operation of the dryer, correct it using the troubleshooting chart
below
Problem PossibleCause Solution
Dryer does not operate with
operation switch ON
pressed．
(RUN lamp does not light up.)
‧Lamp disconnected
‧Switch faulty
‧Low power supply voltage
‧Magnetic contactor faulty
‧Protector faulty
‧High pressure switch faulty
‧Replace.
‧Replace.
‧Use specified voltage.
‧Replace．
‧Replace．
‧Replace.
Dryer does not operate with
operation switch ON pressed
(RUN lamp lights up.)
‧Magnetic contactor faulty
‧Protector fault ‧Replace． ‧Replace
Dew point is normal but
water or oil drops occur．‧Drainage hindered by foreign
material in auto drain trap
‧Drainage in auto drain trap frozen
‧Disassemble and clean
auto drain trap．
‧Take proper measures to
prevent freezing．
Dew point is high and water
or oil drops occur．‧ Too high air processing rate
‧Lowered cooling capacity
‧Condenser clogged up
‧Too high ambient temperature
‧Fan motor faulty
‧Correct air processing
rate．
‧Check for gas leak．
‧Clean．
‧Lower ambient
temperature.(below 40
℃)
‧Replace．
Machine stops suddenly
during operation．‧Magnetic contactor faulty
‧Too high air processing rate
‧Condenser clogged up
‧Too high ambient temperature
‧Abnormal voltage
‧Fan control pressure switch faulty
‧Replace．
‧Correct air processing
rate．
‧Clean
‧Lower ambient
temperature. (below 40
℃)
‧Use rated voltage．
‧Replace．
After-Sale Service
■Should any trouble arise, correct it according to the troubleshooting chart．If you can not
correct it, contact your dealer and ask for the repair. When you request an after-sale service on
the dryer, give information on the following particulars：
●Application for repair
(1) Model and Serial No．of the air dryer
(2) Defective part and trouble
(3) Date of purchase
(4) Sketch map of your location
●Application for parts
(1) Model and Serial No．of the dryer
(2) Number, name and quantity of part(s)

Before Long Disuse
17(1)
1. Turn off the power
Turn off the main power supply（power supply
breaker）．
2. Purge drainage out
Discharge the drainage inside the air dryer
completely through the auto drain trap.
3. Store
Store the air dryer in a place free from dirt,
dust, rain, water, snow, etc．
■For operation after a long disuse
Perform checks of the parts of the air dryer. Then resume operation according to the
instructions on preparation and operation in this manual．

Table of Specifications
規格表
18
Model機型 FR 005A 010A 020A 030A 050A 075A 100A 150A
Measurement conditions on air processing
處理空氣條件
Air processing capacity
空氣處理量 m3/ min 0.6 1.2 2.4 4.4 7.0 11.0 14.0 23.5
Inlet air pressure
入口空氣壓力 MPa 0.69
Inlet air temperature
入口空氣溫度 ℃ 35
Dew point of outlet air
出口空氣露點 ℃ -17 at atmosphere 大氣壓下 17
Ambient temperature
環境溫度 ℃ 32
Allowable conditions
使用範圍
Maximum inlet air temperature
最高使用溫度 ℃ 10 ～ 50
Ambient temperature
環境溫度 ℃ 2 ～ 40
Maximum air pressure
最高使用壓力 MPa 0.2 ～ 0.98
External dimensions
本體外形尺寸
Height
高度 mm 478 542 705 705 966 1166 1220 1260
Depth
深度 mm 490 423 423 440 490 490 984 1022
Width
寬度 mm 377 722 797 797 944 944 696 792
Net weight
淨重 kg 22 34 42 42 70 88 105/95 180
Air pipe connection
空氣配管尺寸 B R 1/2 R 1 R 1-1/2 R 2 R 2-1/2
Electric rating
電氣規格
Power source
使用電源 1ø220V 50/60Hz 單相 220V 50/60Hz 3ø220V50/60Hz 三相 220V50/60Hz
Power consumption
消耗電力 kW 0.25/0.3 0.4/0.5 0.6/0.7 0.8/0.9 1.6/1.7 1.6/1.7 2.2/1.7 3.4/4.1
Electric current
電流 A 1.3/1.5 2.0/2.3 2.7/3.3 4.1/4.5 6.0/6.7 6.3/7.5 8.0/6.8 12.0/12.5
Equipment details
裝置細目
Evaporator
熱交換器 Cross - wave fin type (Shell : SUS304) 交錯氣流鰭片 (外殼材質:SUS304)
Condenser
冷凝器 Fin and tube, forced air cooling 鰭管式，強迫通風 Parallel flow condenser ,forced air cooling 平行流風扇強制通風 Fin and tube
鰭管式
Fan motor for condenser
冷凝器用風扇馬達 φ/W 120/40 230/40 250/40 300/40 350/100 400/250 500/400
Refrigerant controller
冷媒控制 Capillary tube system 毛細管
Capacity controller
容量控制 Capacity control valve 容量控制閥
Refrigerant
冷媒 R134a R407C
Auto drain trap
自動排水器 Float type 浮球式 Discus type 碟式
Protecting devices
保護裝置
Over current relay
過電流保護繼電器
─ Opposite phase relay
反相繼電器
Compressor
壓縮機 ─ Thermostat 過熱繼電器
Fan motor for condenser
冷凝器用風扇馬達 ─
Fan motor over temp. switch
風扇馬達過熱保護開關
Refrigerant circuit
冷媒回路 ─ High pressure switch 高壓壓力開關
Cooling fan control switch
風扇控制壓力開關