NANO NRC0020-0200 UL Operating instructions

Refrigerated air dryers
OPERATING AND MAINTENANCE MANUAL
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www.n-psi.com
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Original instructions
NRC0020-0200 UL

1
OPERATING AND MAINTENANCE MANUAL
- Contents
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C ONTENTS
C ONTENTS ......................................................................................................................................................................................... 1
Chapter 1
G ENERAL I NFORMATION .................................................................................................................................................................. 2
Chapter 2
S AFETY ............................................................................................................................................................................................... 4
2.1 General ..............................................................................................................................................................................................................4
2.2 General precautions...........................................................................................................................................................................................4
2.2.1 Type of compressed gases to be dried ................................................................................................................................................. 4
2.2.2 Precautions during lifting and transport ............................................................................................................................................ 4
2.2.3 Precautions to be adopted during installation and operation ............................................................................................................ 4
2.2.4 Precautions for maintenance and repair ............................................................................................................................................ 4
2.3 Refrigerant gases ...............................................................................................................................................................................................5
2.3.1 Characteristics of R134a refrigerant .................................................................................................................................................. 5
Chapter 3
T ECHNICAL DATA .............................................................................................................................................................................. 6
3.1 Data plate and meaning of abbreviations ..........................................................................................................................................................6
3.2 Performance data...............................................................................................................................................................................................6
3.2.1 Sound Level Measurements ................................................................................................................................................................. 6
Chapter 4
D ESCRIPTION ..................................................................................................................................................................................... 7
4.1 Operating principle............................................................................................................................................................................................7
4.2 Air and refrigerant circuits ................................................................................................................................................................................7
4.2.1 Air circuit ............................................................................................................................................................................................ 7
4.2.2 Refrigerant circuit ............................................................................................................................................................................... 7
Chapter 5
I NSTALLATION ................................................................................................................................................................................... 8
5.1 Location.............................................................................................................................................................................................................8
5.2Piping.................................................................................................................................................................................................................8
5.3 Electrical connections........................................................................................................................................................................................9
Chapter 6
S TART - UP ......................................................................................................................................................................................... 11
Chapter 7
I DRY E LECTRONIC C ONTROLLER ................................................................................................................................................ 12
7.1 User interface ....................................................................................................................................................................................................12
7.1.1 Display .............................................................................................................................................................................................. 12
7.1.2 Buttons ............................................................................................................................................................................................... 12
7.1.3 Icons .................................................................................................................................................................................................. 13
7.2 Main functions...................................................................................................................................................................................................13
7.2.1 Unit start-up ...................................................................................................................................................................................... 13
7.2.2 Unit shutdown ................................................................................................................................................................................... 13
7.2.3 Condensate drain test ........................................................................................................................................................................ 13
7.2.4 Dual set point management ............................................................................................................................................................... 13
7.2.5 Digital input ...................................................................................................................................................................................... 14
7.2.6 Compressor operating hours alarm .................................................................................................................................................. 14
7.3 Programming.....................................................................................................................................................................................................15
7.3.1 Editing parameters PR1 .................................................................................................................................................................... 15
7.3.2 Keypad lock/unlock function ............................................................................................................................................................. 15
7.4 Description of settings and parameters .............................................................................................................................................................15
7.5 Alarms ...............................................................................................................................................................................................................16
7.5.1 Alarm display .................................................................................................................................................................................... 16
7.5.2 High and low temperature alarm memorization ............................................................................................................................... 17
7.5.3 Serial line for monitoring systems ..................................................................................................................................................... 17
Chapter 8
S AFETY PRESSURE SWITCH / C ONDENSATE DRAIN ....................................................................................................................... 18
8.1 High pressure switch HP ...................................................................................................................................................................................18
8.2 condensate drain ................................................................................................................................................................................................18
8.2.1 Timed condensate drain .................................................................................................................................................................... 18
8.2.2 Capacitive condensate drain ............................................................................................................................................................. 19
Chapter 9
O PERATION AND M AINTENANCE ................................................................................................................................................... 20
9.1 General operation ..............................................................................................................................................................................................20
9.2 Maintenance ......................................................................................................................................................................................................20
9.2.1 Access to the dryer ............................................................................................................................................................................ 20
9.2.2 Special maintenance of electrical panel (Mod. from NRC0125÷0250 ) ........................................................................................... 20
9.3 Planning of checks and maintenance operations...............................................................................................................................................21
Chapter 10
T ROUBLESHOOTING ........................................................................................................................................................................ 22

2
OPERATING AND MAINTENANCE MANUAL
Chapter 1 - General Information
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 1
G ENERAL I NFORMATION
The units described in this manual are “dryers”.
They are designed to remove the moisture from a flow of “compressed gas”.
The dryers are equipped with a refrigerant circuit that is designed to cool the compressed air to a temperature designated “pressure dew point”.
Since, in the majority of applications, the gas to be dried is compressed air, hereinafter the term “compressed air” is used for the sake of
simplicity, even though the specific gas in an individual application may be different. Hereinafter the expression “pressure” is used to indicate
relative pressure.
The electrical cabinet is designed in compliance with standard UL508A (Industrial Control Panels), tested and approved to UL file no. E249753,
and bears the appropriate marking .
The following general symbols are to be found on the decals affixed to the unit and also in the dimensional drawings and refrigerant circuit
diagrams in this manual.
The meaning of each symbol is indicated hereinafter:
The following warning symbols are to be found on the decals affixed to the unit.
The meaning of each symbol is indicated below:
SYMBOL DESCRIPTION SYMBOL DESCRIPTION
Unit air inlet Unit air outlet
Condensate drain Flow of cooling air (air-cooled
models)
Direction of fan rotation (air-cooled
models) Direction of flow of refrigerant gas
Prohibition of using inserting lift
truck forks to handle the unit in the
point where the symbol appears
Indication of the axis to refer to in unit
lifting operations
WARNING SYMBOL DESCRIPTION WARNING SYMBOL DESCRIPTION
To maintain overcurrent,
short-circuit, and ground-
fault protection, the
manufacturer’s instructions
for selection of overload and
short circuit protection must
be followed to reduce the
risk of fire or electric shock.
If an overload or a fault
current interruption occurs,
circuits must be checked to
determine the cause of the
interruption.
If a fault condition exists, the
current-carrying components
should be examined and
replaced if damaged, and the
integral current sensors must
be replaced to reduce the risk
of fire or electric shock.
Hazardous voltage.
All doors must be closed
before energizing the panel.

3
OPERATING AND MAINTENANCE MANUAL
Chapter 1 - General Information
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
CAUTION
This manual, which is addressed to users, installers, and service personnel, supplies all the technical information required to install and work
with the dryer and to perform the routine maintenance operations required to ensure a long working life.
If spare parts are needed use exclusively genuine original components.
Requests for SPARE PARTS and any INFORMATION concerning the dryer must be made to the nearest dealer or service center, specifying the
SERIAL NUMBER shown on the unit's dataplate and on the first page of this manual.
Read and understand
operator’s manual before
using this machine.
Failure to follow operating
instructions could result in
death or serious injury.
Moving parts can crush and
cut.
Do not operate with guard
removed.
Follow lockout procedure
before servicing.
Hazardous voltage.
Disconnect power before
servicing or cleaning.
WARNING SYMBOL DESCRIPTION WARNING SYMBOL DESCRIPTION

4
OPERATING AND MAINTENANCE MANUAL
Chapter 2 - Safety
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 2
S AFETY
CAUTION
This unit is designed for safety in its intended use, provided it is installed, commissioned, and serviced in compliance with the instructions given
in the present manual.
The unit contains electrical components that operate at mains voltage and also moving parts such as fans, it must therefore normally be
disconnected from the electrical power supply before it is opened.
Operation, overhauls or repair of the unit or any maintenance operations that call for access to the unit must be executed by skilled or suitably
qualified personnel who are fully aware of all the necessary precautions, preferably under the guidance of a qualified supervisor.
2.1 General
The user must ensure that all personnel involved in operating and servicing the dryer and the auxiliary equipment have read and
understood all the warnings, precautions, prohibitions and notes given in this manual and affixed to the unit.
If the user adopts operational procedures or uses tools or working procedures that are not specifically recommended, care must be taken to ensure
that the dryer and the auxiliary equipment are not damaged or made unsafe and that no risks emerge in relation to persons or property.
Any improper use of the machine will relieve the manufacturer from any liability for possible personal injury or property damage.
Arbitrary modifications made to the unit will automatically invalidate all forms of guarantee provided by the manufacturer.
2.2 General precautions
2.2.1 Type of compressed gases to be dried
The compressed gases that can be dried must be compatible with the unit's construction materials (carbon steel, cast iron, copper and copper
alloys) and can be, for example air, nitrogen, argon and helium.
CAUTION
The compressed gases must not give rise to phenomena of corrosion that could impair the condition of pressurised containers and they must not
be able to cause fire or explosions in the event of leakage or expulsion.
2.2.2 Precautions during lifting and transport
When a load is lifted from the ground keep well clear of the area beneath the load and the immediately surrounding area.
Keep accelerations and lifting speed well within safety limits and never leave a suspended load attached to a hoist any longer than strictly necessary.
Handling of dryers must be carried out in compliance with the diagrams given (see the final part of this manual).
The manufacturer does not supply bars, belts and lifting hooks with the unit.
CAUTION
The unit's weight is shown on the dataplate and on the label affixed to the crate.
2.2.3 Precautions to be adopted during installation and operation
For connection to the mains power supply follow the instructions given in Chapter 5 “Installation” and refer to the electrical diagrams.
Check the direction of rotation of the motors (in particular three-phase fans) when starting the unit for the first time after work has been
performed on the electrical connections or on the power supply sectioning device.
All piping must be painted and marked clearly in compliance with local safety prescriptions inforce inthe place of installation.
Do not remove or tamper with safety devices, protections, or the insulating materials installed in the unit or in the auxiliary equipment.
The dryer and its auxiliary equipment must be connected to earth and protected against short circuits and overloads.
When the unit is powered, the voltage in the electrical circuit assumes potentially lethal values so the maximum precautions must be adopted if
work is to be carried out on the electrical circuit.
Do not open the electrical equipment enclosure panels while the electrical system is powered unless this is strictly necessary for the execution of
tests, measurements or settings.
This work must be carried out exclusively by qualified personnel equipped with suitable tools and wearing all the relevant protective equipment
to safeguard against electrical hazards.
2.2.4 Precautions for maintenance and repair
If spare parts are required, use exclusively genuine original parts.
Keep a written record of all work carried out on the unit and the auxiliary equipment.
The frequency and nature of the work required in a certain period can reveal abnormal operating conditions that require correction.
Use exclusively the refrigerant specified on the machine dataplate.
Make sure that all the instructions concerning operation and maintenance are followed scrupulously and that the entire unit and all the
accessories and safety devices are maintained in proper working order.
Always keep the unit clean.
Protect components and exposed openings, plugging them, for example with clean rags during maintenance and repair work.
Precautions must be taken when before welding or performing repair operations that may generate heat, flames or sparks.
Components in the vicinity must be protected with non-inflammable material.
Do not weld or perform work that generates heat close to a system that contains oil.

5
OPERATING AND MAINTENANCE MANUAL
Chapter 2 - Safety
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
Systems that may contain oil must be completely drained and flushed, for example, with steam, before performing any operation.
Do not weld or modify a container that may be subject to pressurisation.
To prevent an increase in working temperature and pressure values check and clean the heat exchange surfaces (e.g. the fins of condensers) regularly.
For all dryers establish a convenient time interval for cleaning procedures.
Never use an open flame as a light source to inspect parts of the dryer.
Before dismantling parts of a unit ensure that all mobile and heavy parts are securely fixed, and ensure electrical power has been disconnected.
When a repair has been completed make sure that no tools, detached parts or rags are left in the dryer.
Check the direction of rotation of the electrical motors (in particular three-phase fans) when starting the unit for the first time after work has been
performed on the electrical connections or on the power supply sectioning device.
All the protections must be refitted following maintenance or repair work.
Do not use inflammable liquids to clean components while the dryer is running.
If non-inflammable hydrocarbons containing chlorine are used all the relevant safety precautions must be adopted to protect against the toxic
fumes that may be given off.
Before removing any panels or dismantling any parts of the unit perform the following steps:
• Isolate the unit from the electrical power supply by disconnecting the supply upstream of the power feeding line.
• Lock out the breaker (if present) in the “OFF” position by fitting a padlock.
• If an 0/1 switch is present, i.e. not a sectioning device, ensure the breaker upline from the unit has been locked out in the “OFF”
position by means of a padlock. The breaker must be sized in compliance with the indications of the electrical diagram.
• Attach a warning label to the main switch (if present) reading: "WORK IN PROGRESS - DO NOT SWITCH ON".
• Do not set the electrical power switch to ON or attempt to start the unit if the warning label is attached.
Colored tracers can be used in service-maintenance operations.
Inspect all refrigerant circuit joints including connectors, flanges, and more generally all critical points (open joints) in order to prevent possible
leakage of refrigerant gas.
2.3 Refrigerant gases
The units can be charged only with R134a.
The use and storage of cylinders containing refrigerants must be in compliance with the prescriptions of the manufacturers of the cylinders and in
compliance with the applicable safety laws and prescriptions in force in the place of installation.
2.3.1 Characteristics of R134a refrigerant
At normal temperature and pressure conditions, this is a class A1 colourless gas (classification EN 378-1).
Concentrations significantly above 1000 ppm v/v can cause narcotic effects.
In the event of leakages provide adequate ventilation of the room before entering.

6
OPERATING AND MAINTENANCE MANUAL
Chapter 3 - Technical data
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 3
T ECHNICAL DATA
3.1 Data plate and meaning of abbreviations
The main technical data of the unit are indicated on the data plate::
The following abbreviations are present on the data plate and wiring diagram:
3.2 Performance data
CAUTION
The performance of the dryer (dew point, power consumption, pressure drops, etc.) depends mainly on the flow rate and pressure of the
compressed gas to be dried and on the condenser cooling fluid temperature (ambient temperature).
These data, which are usually defined at the time of the offer, constitute the basic point of reference in relation to dryer performance.
3.2.1 Sound Level Measurements
The noise emission values measured are below 70 dB(A).
MODEL and CODE Identify the size of the unit and its type of construction.
MANUAL Code number of the present manual.
SERIAL NUMBER Unit serial number or manufacturing number.
YEAR OF CONSTRUCTION Year of unit's final testing.
VOLTAGE/PHASES/FREQUENCY Power supply characteristics.
SHORT CIRCUIT CURRENT Short circuit current.
HIGHEST MOTOR FULL LOAD
AMPERAGE
Maximum current input.
MAX CURRENT DRAW (I max) Sum of FLA of all loads.
INSTALLED POWER (P max) Sum of the maximum power input of all loads.
PROTECTION RATING According to European standard UL508A and EN60529.
ELECTRICAL DIAGRAM Identifies the electrical diagram number.
REFRIGERANT Type of refrigerant charge with which the unit is filled.
REFRIGERANT CHARGE Quantity of refrigerant supplied to circuit.
MAX. REFRIGERANT PRESS. Refrigerant circuit design pressure.
MAX REFRIGERANT TEMP. Refrigerant circuit design temperature.
USER CIRC. FLUID Fluid cooled by the machine.
MAX. WORKING PRESSURE User circuit maximum design pressure.
MAX TEMPERATURE User circuit maximum design temperature - not to be confused with the maximum working
temperature, which is specified at the time of the offer.
SOUND PRESSURE LEVEL Free field sound pressure level in hemispherical radiation conditions (open field) at a distance of 1m
(39.37in) from the condenser side of the unit and a height of 1.6m (63.0in) from the ground.
AMBIENT TEMPERATURE Cooling air minimum and maximum temperature values.
WEIGHT Approximate weight of the unit without packaging.
CONDENSER COOLING FLUID Fluid used by the machine to cool the condenser (this information is not given if the machine
condenser is air-cooled).
MAX. WORKING PRESSURE Condenser cooling circuit maximum design pressure (this information is not given if the machine
condenser is air-cooled).
MAX TEMPERATURE Condenser cooling circuit maximum design temperature (this information is not given if the machine
condenser is air-cooled).
FLA full load amperage;
PMAX maximum power;
ILR locked rotor current;

7
OPERATING AND MAINTENANCE MANUAL
Chapter 4 - Description
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 4
D ESCRIPTION
4.1 Operating principle
A refrigerant circuit cools a patented “thermal mass” through which the humid compressed air to be dried flows.
The air cools, resulting in condensation of the water vapor it contains, which is subsequently separated and discharged.
The temperature of the thermal mass is regulated by an electronic controller, which stops the refrigerant compressor when the programmed set-
point is reached.
4.2 Air and refrigerant circuits
(See attached refrigerant circuit diagrams)
4.2.1 Air circuit
The warm and humid compressed air entering the dryer flows through the air/air exchanger section of the thermal mass.
Here the air is precooled by the cold and dry compressed air leaving the air/refrigerant or evaporator section of the thermal mass.
The precooled air then enters the evaporator section of the thermal mass where it is cooled (in most applications to a temperature of
approximately 3°C/37.4 °F) exchanging heat with the refrigerant fluid and the silica thermal mass.
Heat is exchanged by a process of conduction through the aluminium fins that join the copper tubes through which the compressed air flows, to
the copper tubes in which the refrigerant fluid evaporates.
The aluminium fins exchange heat also with the silica thermal mass keeping it at a temperature of approximately 0°C (32°F).
At this point the compressed air is saturated and conveys with it the condensation produced during the cooling process.
The precooled air then enters a high efficiency condensate separator (demister type with stainless steel mesh) where the condensate is
precipitated and collected on the bottom of the enclosure.
A condensate drain either of the timer controlled or capacitive type, depending on the unit's configuration, opens periodically and drains the
condensate which is expelled by compressed air pressure.
The dry cold air at the outlet of the separator flows for the second time through the air/air section of the thermal mass, where it absorbs the heat
of the warm and humid compressed air entering the dryer and thereby cools the inlet flow.
This air/air exchanger both reduces the amount of energy required to dry a given flow of air and also has the benefit of reducing the relative
humidity thereby avoiding the risk of the formation of condensate at the dryer outlet.
4.2.2 Refrigerant circuit
The high pressure compressed refrigerant gas flows into the condenser.
In the condenser the refrigerant changes from the gaseous to the liquid phase.
• The condenser is a heat exchanger of the finned core type and it is cooled by an air flow provided by fan.
The condenser is generously sized in such a way that it can function partially also as a liquid receiver.
Downstream from the condenser the refrigerant enters a filter drier and a capillary tube where refrigerant pressure is reduced to lower its boiling
pressure.
The refrigerant then enters the tubes of the evaporator section of the thermal mass, cooling both the compressed air and the thermal mass itself.
The refrigerant at the dryer outlet is now in the form of a cold vapor, which is returned to the compressor to repeat the cycle.
Since the heat provided by the compressed air to cause the refrigerant to evaporate varies significantly because of fluctuations in the compressed
air temperature and flow rate, the dryer is equipped with an electronic system to control the temperature of the thermal mass. This system fulfils
3 important roles:
• it ensures an almost constant pressurised dew point (approx. +3°C (+37.4°F));
• it prevents the compressed air temperature from falling below 0°C (32°F) with consequent freezing of the condensate;
• it ensures that all the refrigerant is evaporated in the evaporator, thus avoiding the risk of any liquid entering the compressor
suction side.
When the load is low or zero, the temperature of the thermal mass tends to fall.
When it reaches 0°C (32°F) the electronic controller stops the compressor.
The compressed air that continues to flow in the evaporator is cooled by the cooling energy stored in the silica.
When the silica temperature starts to rise, the refrigerant compressor is started automatically so that it can cool it down again.
This system offers the benefit of reducing average energy consumption of the dryer in such a way as to make it approximately proportional to
demands.

8
OPERATING AND MAINTENANCE MANUAL
Chapter 5 - Installation
NRC0020-0200 UL
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 5
I NSTALLATION
DANGER
Before installing or operating these dryers, ensure that all personnel involved have read and understood Chapter 2 “Safety” in this manual.
5.1 Location
1. Install the dryer in a well-ventilated place, where the ambient air is clean and free from flammable gases or solvent vapors.
2. Avoid installing the dryer in excessively cold places; this could cause the discharged condensate to freeze in the drainage systems.
The minimum ambient temperature for installation of these dryers is shown in the dataplate affixed to the unit.
3. The dryer can be positioned on any flat surface that is sufficiently solid to support its weight.
Leave free space around the dryer as indicated in the installation drawings to allow unimpeded access during servicing operations
and to avoid obstructing or disturbing the condenser cooling air flow.
Position the dryer in such a way that the cooling air can not recirculate to the intake grilles.
Ensure that the dryer is not subject to hot air flows deriving from systems for cooling, for example, the air compressor, the
refrigerant compressor, or any other equipment in the vicinity.
4. The position of the dryer in the compressed air distribution system depends on the methods of use of the compressed air (see
installation drawing).
A The dryer must be installed downstream of the tank when the air compressor runs intermittently and the maximum compressed
air working flow rate is no higher than the flow rate delivered by the compressor (this is the most common type of installation).
B The dryer should be installed upline from the tank when it is sized in order to allow wide fluctuations of the air flow rate utilised
with peak values that are significantly higher than the maximum flow rate of the compressor.
5.2 Piping
(see installation drawing)
1. The inlet and outlet connections are clearly marked(see Chapter 1 “General Information”). The piping and connections must be
correctly sized and suitable for the working pressure of the application. Remember to remove the protective caps from the
connections. Make sure to use the NPT adaptor fittings for the dryers that require them. Ensure that no debris or other material enters
the connections during installation procedures. Any foreign material that enters the connections can result in clogging of the filter or
jamming of the condensate drain valve.
2. All pipingmust be equipped with suitable supports. Flexible couplings should be installed to prevent the transmission of
vibration.
3. Connect the condensate drain hose to a suitable drain point. The drain line of the dryer should not be connected to the drain lines of
other equipment; ideally the line should end in an open funnel type drain. Do not route the condensate to a common drain header
because of the possibility of oil contents. Oil/water separators should be installed to separate any oil out of the condensate. Make
sure that the drainage system complies with local regulations and bylaws.
4. It is advisable to install a prefilter up-line of the dryer and, if necessary, a coalescent deoiler filter down-line of the dryer.
Install shut-off valves on the compressed air inlet and outlet connections so that the dryer can be isolated if necessary.
Fit as suitably sized pressure relief valve upline from the shut-off valves.
Contact nano - purification solutions for information on prefilters and afterfilters, www.n-psi.com
5. Install a bypass line with shut-off valves so that dryer maintenance operations can be carried out without interfering with the
compressed air supply.
6. Pipingand other parts whose temperature may exceed 60°C (140°F) and that may be accidentally touched by personnel must be
protected or insulated.
7. In order to discharge the compressed air from the dryer so that the unit can be depressurised prior to maintenance operations, fit a
venting valve in the pipe between the dryer and one of the shut-off valves.
1. Compressed air compressor
2. Final refrigerant
3. Condensate separator
4. Compressed air tank
5. Prefilter
6. Dryer
7. By-pass