NANO NED 4L User manual

NANO
Condensate treatment
NED 4L, NED 6LC, NED 8LC, NED 16LC, NED 40LC, NED 160LC,
NED 350L
Instruction book

NANO
Condensate treatment
NED 4L, NED 6LC, NED 8LC, NED 16LC, NED 40LC,
NED 160LC, NED 350L
Instruction book
Original instructions
Copyright notice
Any unauthorized use or copying of the contents or any part thereof is prohibited.
This applies in particular to trademarks, model denominations, part numbers and
drawings.
This instruction book is valid for CE, non-CE as well as UKCA labelled machines. It
meets the requirements for instructions specified by the applicable European directives
or UK statutory instruments as identified in the Declaration of Conformity.
January 2023
No. 2920 7213 30
www.n-psi.com

Table of contents
1 Safety precautions..........................................................................................................4
1.1 Safety icons................................................................................................................................4
1.2 General safety precautions.................................................................................................... 4
1.3 Safety precautions during installation................................................................................ 5
1.4 Safety precautions during operation.................................................................................... 6
1.5 Safety precautions during maintenance or repair.............................................................. 6
1.6 Dismantling and disposal..........................................................................................................7
2 General description........................................................................................................9
2.1 Functional description............................................................................................................. 9
3 Control panel.................................................................................................................11
3.1 Description................................................................................................................................11
3.2 Operation logic........................................................................................................................12
3.3 Flow chart................................................................................................................................ 16
4 Installation.....................................................................................................................18
4.1 Installation proposal............................................................................................................. 18
4.2 Dimension drawings................................................................................................................. 21
4.3 Electrical connections.......................................................................................................... 27
5 Operating instructions................................................................................................. 31
5.1 Commissioning...........................................................................................................................31
5.2 Shutting down.......................................................................................................................... 31
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6 Maintenance..................................................................................................................32
6.1 Maintenance activities.............................................................................................................32
6.2 Service kits............................................................................................................................... 34
7 Problem solving............................................................................................................35
7.1 General causes........................................................................................................................ 35
7.2 Faults and remedies................................................................................................................ 35
8 Optional equipment...................................................................................................... 38
8.1 Precautions for optional equipment....................................................................................38
8.2 Heater........................................................................................................................................38
9 Technical data............................................................................................................... 42
9.1 Reference conditions and limitations.................................................................................. 42
9.2 Electronic water drain data................................................................................................. 42
10 Pressure equipment directives................................................................................... 45
11 Declaration of conformity............................................................................................ 46
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1 Safety precautions
1.1 Safety icons
Danger: Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
Warning: Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
Notice: Indicates a potential situation which, if not avoided, might result in property damage
or in an undesirable result or state.
Note: Indicates important information.
1.2 General safety precautions
Danger: The condensate drain is under pressure. Suddenly escaping compressed air may
result in serious injuries. Do not carry out mechanical or electrical work on the condensate
drain as long as the condensate drain is under pressure.
Danger: Touching live parts might result in serious injury or death.
Danger: There is a risk of leakage of condensate into the environment. Water spots on the
floor may be very slippery and result in serious fall injury. Water spots should be properly
removed from the floor immediately.
Danger: Exceeding the maximum allowable operating conditions may result in serious injury
or death. It is the duty of the operator to ensure that the operating pressure and temperature
fall within the values provided by the condensate drain; these values are indicated on the
identification plate.
Danger: Damages of the condensate drain may lead to unpredictable hazardous situations.
Operating a damaged condensate drain may result in serious injury or death. Never start or
operate a damaged condensate drain.
Danger: The condensate drain components are not designed to withstand any external
overloads; the condensate drain may burst due to additional pressure. Any bursts of
pressurized components may cause serious injuries and/or death. Transmission of loads or
stress into the connections of the condensate drain is not permissible.
Warning: All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for installation,
operation, maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
• Read the instruction book carefully.
• The operator must employ safe working practices and observe all related local work safety
requirements and regulations.
• If any of the following statements does not comply with local legislation, the stricter of the two
shall apply.
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• Installation, operation, maintenance and repair work must only be performed by authorised,
trained, specialised personnel.
• Before carrying out any maintenance, repair work, adjustment or any other non-routine checks,
stop the device. In addition, the power isolating switch must be opened and locked.
1.3 Safety precautions during installation
• The use of personal protection equipment (P.P.E.) during installation and maintenance
operations is recommended.
• Install the equipment where the ambient air is cool and as clean as possible. Consult section
Reference conditions and limitations.
• During installation or any other intervention on the equipment or one of the connected
machines, the machines must be stopped, de-energized and the isolating switch opened and
locked before any maintenance or repair. As a further safeguard, persons switching on remotely
controlled machines shall take adequate precautions to ensure that there is no one checking or
working on the machine. To this end, a suitable notice shall be affixed to the start equipment.
• Install the equipment in an area free of flammable fumes, vapours and particles, e.g. paint
solvents, that can lead to internal fire or explosion.
• The electrical connections must correspond to the applicable codes. The equipment must be
earthed and protected against short circuits by fuses in all phases. A lockable power isolating
switch must be installed near the equipment.
• For machines controlled by a central control system, a sign stating "This machine may start
without warning" must be affixed near the instrument panel.
• In multiple compressor systems, manual valves must be installed to isolate each compressor.
Non-return valves (check valves) must not be relied upon for isolating pressure systems.
• Never remove or tamper with the safety devices.
• If the maximum pressure of the compressor is higher than the design pressure of the connected
equipment (e.g. a nitrogen generator or an oxygen generator), a full flow safety valve must be
installed between the compressor and the connected equipment, in order to be able to blow off
the excessive pressure.
• Only use pressure-proof installation material. The feed line must be firmly fixed. The discharge
line should be a short pressure hose or a pressure-proof pipe. Ensure that the condensate
cannot squirt onto persons or objects.
• Avoid excessive tightening of the connectors on the inlet and outlet. When tightening the
connectors, two keys have to be used: one to hold the valve, the other to tighten the nut.
• In areas where freezing temperatures are expected, the device should be provided with
thermostatically controlled heating (optional equipment).
• During electric installation, all regulations in force need to be adhered to (e.g. VDE 0100 / IEC
60364).
Note: Also consult following safety precautions: Safety precautions during operation and
Safety precautions during maintenance or repair.
Note: The precautions apply to electrical devices.
Note: For precautions applying to the connected equipment, consult the relevant instruction
book.
Note: Some precautions are general and cover several machine types and equipment;
hence some statements may not apply to your device.
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1.4 Safety precautions during operation
Warning: All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for installation,
operation, maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
• Persons switching on remotely controlled machines shall take adequate precautions to ensure
that there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the remote start equipment.
• Never operate the device in the presence of flammable or toxic fumes, vapours or particles.
• Never operate the device below or in excess of its limit ratings.
• Keep all bodywork doors and panels closed during operation. The doors may be opened for
short periods only, e.g. to carry out routine checks.
• People staying in environments or rooms where the equipment is operated shall wear adequate
personal protective measures, such as ear protection, safety goggles, etc.
• Periodically check that:
• All guards and fasteners are in place and tight.
• All hoses and/or pipes are in good condition, secure and not rubbing.
• There are no leaks.
• All external electrical leads are secure and in good order.
• Never remove or tamper with the safety devices.
• The electronic drain valve will only function when voltage is being supplied to the device.
• Do not use the test button for continuous draining.
• Do not use the electronic drain valve in hazardous areas (with potentially explosive
atmospheres).
Note: Also consult following safety precautions: Safety precautions during installation and
Safety precautions during maintenance or repair.
Note: The precautions apply to electrical devices.
Note: For precautions applying to the connected equipment, consult the relevant instruction
book.
Note: Some precautions are general and cover several machine types and equipment;
hence some statements may not apply to your device.
1.5 Safety precautions during maintenance or repair
Warning: All responsibility for any damage or injury resulting from neglecting these
precautions, or non-observance of the normal caution and care required for installation,
operation, maintenance and repair, even if not expressly stated, will be disclaimed by the
manufacturer.
• The use of personal protection equipment (P.P.E.) during installation and maintenance
operations is recommended.
• Use only the correct tools for maintenance and repair work.
• Use only genuine spare parts.
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• A warning sign bearing a legend such as "Work in progress - do not start" shall be attached to
the starting equipment, including all remote start equipment.
• Persons switching on remotely controlled machines shall take adequate precautions to ensure
that there is no one checking or working on the machine. To this end, a suitable notice shall be
affixed to the remote start equipment.
• Never use flammable solvents or carbon tetrachloride for cleaning parts. Take safety
precautions against toxic vapors of cleaning liquids.
• Scrupulously observe cleanliness during maintenance and repair. Keep dirt away by covering
the parts and exposed openings with a clean cloth, paper or tape.
• Never use a light source with open flame for inspecting the interior of the device.
• All regulating and safety devices shall be maintained with due care to ensure that they function
properly. They may not be put out of action.
• Before clearing the device for use after maintenance or repair, check that operating pressures,
temperatures and time settings are correct. Check that all control and shutdown devices are
fitted and that they function correctly.
• Make sure that no tools, loose parts or rags are left in or on the device.
• Never use caustic solvents which can damage materials of the device.
• Do not exceed the maximum operating pressure. Maintenance work may only be carried out
when the device is not under pressure.
• All maintenance work must only be undertaken when the device is in a de-energized condition.
• Before removing any pressurized components, effectively isolate the device from all sources of
pressure and relieve the system of pressure.
Note: Also consult following safety precautions: Safety precautions during installation and
Safety precautions during operation.
Note: The precautions apply to electrical devices.
Note: For precautions applying to the connected equipment, consult the relevant instruction
book.
Note: Some precautions are general and cover several machine types and equipment;
hence some statements may not apply to your device.
1.6 Dismantling and disposal
The device must be disposed according to local regulations. The product is not designed for
refurbishing after finished lifecycle.
Dismantling
Once the end of life of the machine is reached, please follow next steps:
1. Stop the machine.
2. Check all safety precautions mentioned in the previous chapters to secure safe handling (e.g.
LOTO, cool-down, depressurize, discharge, etc.).
3. Have trained personnel dismantle the installation.
4. Separate the harmful from the safe components (e.g. drain oil from parts containing oil).
5. Refer to the disposal topic below.
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Disposal of electrical and electronic appliances (WEEE)
This equipment falls under the provisions of the European Directive 2012/19/EU on waste electrical
and electronic appliances (WEEE) and may not be disposed as unsorted waste.
The equipment is labelled in accordance with the European Directive 2012/19/EU with the crossed-
out wheelie bin symbol.
At the end of life-time of the electric and electronic equipment (EEE) it must be taken to separate
collection.
For more information check with your local waste authority, customer center or distributor.
Disposal of other used material
Used filters or any other used material (e.g. filter bags, filter media, desiccant, lubricants, cleaning
rags, machine parts, etc.) must be disposed of in an environmentally friendly and safe manner, and
in line with the local recommendations and environmental legislation.
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2 General description
2.1 Functional description
General
These condensate drains have been engineered to solve the problem of discharging condensed
water from production plants and compressed air distribution systems. The specific applied
technology permits a controlled drainage of condensate without any waste of compressed air.
The condensate drain is equipped with a built-in storage tank, inside which a level sensor has been
mounted and is controlled by an intelligent electronic circuit based on a microprocessor logic. All
condensate drain functions are displayed on the control panel that is moreover equipped with a test
push button for manual drainage.
The condensate drain starts working as soon as the sensor detects water at the maximum level and
activates the opening of the solenoid valve to take the water level back down to a minimum value,
leaving a small residual quantity to prevent the system from discharging compressed air.
In the event of any fault, the control circuit activates the unclogging of possibly clogged drain pipes
by carrying out a series of forced opening/closing cycles of the solenoid valve. If this is not
sufficient, the fault is reported externally by means of a potential- free contact alarm that can be
used to draw the attention of maintenance staff in order to instruct the plant system’s control logic.
The drain may also be installed on applications that produce very aggressive condensates, such as
oil-free compressors. The presence of a built-in, easy to clean filter cup prevents the solenoid valve
from clogging.
Main characteristics
• Zero loss drain system.
• Logic based on an 8-bit microprocessor which records events on an integral flash memory.
• Revolving “Easy-Lock” connection.
• Integrated filter for the collection of impurities for easy maintenance.
• Fluoroelastomer (FKM) diaphragm.
• Remote alarm connection for warning.
• Tank in aluminium with a treatment for operating with aggressive condensation.
• Secondary condensate input that is ideal for low attachment points. (Not for NED 4L and NED
6LC.)
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Operation
Figure 1: Condensate drain, standby mode and discharge mode
The drain is connected to the point where the elimination of the condensate is required (tank, filter,
dryer, etc.), by means of the connection supplied (1).
The accumulation tank (2) collects the condensation and the diaphragm (3) keeps the drainage
hole closed thanks to the pressure exerted on its surface.
As the liquid level rises the float (4) rises and, as soon as it has reached the maximum filling level,
the solenoid (5) is triggered by means of the logic control circuit, to open the pilot valve (6).
As compensation is lacking, the diaphragm is lifted allowing the discharge of water to bring the level
in the tank back to a minimum (3), to then close the passage of the discharge without letting air
escape.
The product is also equipped with two components that are very useful for ensuring functionality
and reliability.
An integrated filter cup (7) and a flow regulator (8) inserted into the hose holder (9). The first is used
to retain the impurities contained in the condensate, to ensure a perfect operation of the valve even
in the most critical applications. The second, instead, is used to control the discharge flow, slowing
the purging to avoid an additional oil emulsion that, in most cases, is present in the condensate
water.
By pressing the test button it is also possible to manually actuate the discharge in order to control
the functionality; it can be also useful for unblocking in the event of faulty operation.
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3 Control panel
3.1 Description
NED 4L
The control panel on top of the drain includes a multifunction button and two state display LEDs.
•Green LED
This LED is on when the drain is powered and during its normal function.
•Blue LED
This LED is on when the drain is in timer mode. Timer mode is active when the cleaning routine
has not solved an anomaly.
•Multifunction button
• If pressed during normal operation, manual drainage starts.
• If pressed for 5 seconds, it resets the logic of the microprocessor.
NED 6LC - NED 350L
It is possible to monitor the operation of the condensate drain at any time thanks to a control panel,
which includes two status display LEDs, and a multifunctional button.
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Reference Description
L1 Green LED
Power status indicator
L2 Red LED
Alarm indicator
P1 Multifunctional test button
3.2 Operation logic
NED 4L
Power on
The CPU of the drain starts-up and loads the internal data.
Green LED Blinks 3 times.
Blue LED Blinks 2 times.
Purge valve -
Standby
The drain is ready to operate: activation through floater movement. Every 30 minutes a routine to
keep the drain clean from oil/ condensate residuals starts.
Green LED On
Blue LED -
Purge valve 1. On for 2 seconds.
2. Off for 30 seconds.
Automatic discharge
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The drain is ready to operate: activation through floater movement. Every 30 minutes a routine to
keep the drain clean from oil/ condensate residuals starts.
Green LED On
Blue LED -
Purge valve On until the condensate chamber is almost empty.
Cleaning routine
If the floater is stuck at the top, after 10 sec the drain starts a cleaning operation. When the floater
moves down, that routine stops immediately and the drain goes to standby.
Green LED On
Blue LED -
Purge valve
1. On for 2 seconds, off for 2 seconds. (This is repeated 30 times.)
2. Paused for 1 minute.
3. On for 2 seconds, off for 2 seconds. (This is repeated 30 times.)
Timer routine
If the floater is still stuck after the cleaning routine has been completed, the drain switches to the
timer routine. When the floater moves down, that routine stops immediately and the drain goes to
standby.
Green LED -
Blue LED On
Purge valve 1. On for 1 second.
2. Off for 60 seconds.
Manual discharge
Press the test button to discharge manually. The drain discharges condensate for 1 second, even if
test button remains pressed. To discharge for more than 1 second, you need to press test button
repeatedly.
Green LED On
Blue LED -
Purge valve On until the test button is pushed.
Reset
Press the test button for 5 seconds to reset the drain.
Green LED 1. Both LEDs are off for 2 seconds.
2. The green LED blinks 3 times.
3. The blue LED blinks 2 times.
Blue LED
Purge valve -
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NED 6LC - NED 350L
Power on
The condensate drain is powered on.
L1 The green and red LED flash one after the other for 5 seconds.
L2
P1 -
Valve -
Alarm -
Normal operation
The condensate drain is operating normally.
L1 On
L2 -
P1 -
Valve -
Alarm -
Supply voltage missing
The condensate drain is disconnected from the power supply. The operating functions are
deactivated. An alarm signal is remotely transmitted.
L1 -
L2 -
P1 -
Valve -
Alarm On
Standby
There is no condensate. The supply voltage is applied and the condensate drain is ready to
operate. If no condensate is discharged for 3 hours, the software performs a brief forced discharge.
The green LED is continuously on and the condensate drain activates the same routine until there
is a normal discharge that brings the sensor back to the minimum level.
L1 On
L2 -
P1 -
Valve 1. Off for 3 hours.
2. On for 2 seconds.
Alarm -
Automatic condensate discharge
The maximum level is reached. The valve opens (with a delay of 10 seconds) and the condensate
is discharged. The valve closes as soon as the minimum level is reached.
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L1 Flashing slowly
L2 -
P1 -
Valve On for a maximum of 20 seconds.
Alarm -
Cleaning routine 1
Even if the valve is opened, the minimum level is not reached within 20 seconds. The condensate
drain tries with repeated on/off cycles to unblock the situation probably caused by clogging.
L1 -
L2 Flashing slowly
P1 -
Valve
1. On for 2 seconds.
2. Off for 2 seconds.
3. Repeated 30 times.
Alarm -
Cleaning routine 2
After cleaning routine 1, the minimum level has not been reached. The condensate drain continues
to operate as a timer, continuing with the on/off sequence and continues with alarm modalities.
L1 -
L2 Flashing quickly
P1 -
Valve 1. On for 3 seconds.
2. Off for 60 seconds.
Alarm On
Irreversible error
A fault has occurred in the system. Try with the reset function. If the problem reoccurs, a technical
intervention is required.
L1 -
L2 On
P1 -
Valve 1. On for 3 seconds.
2. Off for 60 seconds.
Alarm On
Manual condensate draining
When the test button is pressed, the condensate is discharged manually.
L1 Flashing quickly
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L2 -
P1 On for a maximum of 3 seconds.
Valve On for a maximum of 3 seconds.
Alarm -
Reset
When a reset in an alarm state is required. If the problem persists, the alarm state will be
reactivated after a short period.
L1 Green and red LED sequence and then the green LED is on.
L2
P1 On for more than 5 seconds.
Valve -
Alarm -
3.3 Flow chart
1. Drain powered.
Red and green LED alternating on/off for 6 seconds.
2. Is the water level increasing?
Option Description
Yes Solenoid energized with 10s delay, continue with step 3
No After 3 hours, valve open for 2 seconds, continue with step 4.
3. Is the drain draining water?
Option Description
Yes Drain works
No The level of the water is high and the drain does not drain
water. An attempt to open the valve is made for 20 seconds.
Continue with step 5.
4. Is water discharging?
Option Description
Yes Drain works
No Go to step 2, No: in loop for 5 times then LED stays in green.
5. Is water discharging?
Option Description
Yes Drain works
No Start cleaning routine 1: Drain attempts to open and close the
valve according to following scheme:
30 cycles
• 2 sec: open
• 2 sec: closed
Total routine time: 2 min
Continue with step 6.
6. Is water discharging?
Option Description
Yes Drain works
No Start cleaning routine 2: Drain attempts to open and close the
valve according to following scheme:
Unit drain restarts discharging
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Option Description
• 3 sec: open
• 60 sec: closed
Total routine time: infinite
External free contact opens.
Continue with step 7.
7. Is water discharging?
Option Description
Yes Drain works
No Drain remains in cleaning routine 2 until drain ejects water or is
serviced/repaired.
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4 Installation
4.1 Installation proposal
Danger: Installation or maintenance work can only be carried out by trained and qualified
staff who must follow the procedures of this manual and use proper safety and protection
equipment.
Danger: Disconnect the electrical power supply as well as the air plant system before any
installation or maintenance works.
Danger: Do not use the condensate drain in hazardous areas with potentially explosive
indoor or outdoor atmospheres. The condensate drain has not been engineered in
accordance with the ATEX standard.
Danger: Only use pressure-proof installation materials! The feed line must be firmly fixed.
Outlet line: short pressure hose to pressure-proof pipe. Ensure that condensate cannot squirt
onto persons or objects.
Note: Do not discharge the condensate into the environment: the condensate water may
contain pollutants. Comply with local regulations and legislation.
Procedure
1. Connect the inlet fitting of the condensate drain to the condensate collection point required,
using the compliant equipment.
Do not use the condensate drain as a lever.
In order to facilitate the installation, the drain is supplied with the revolving Easy-Lock
connection with an O-ring.
2. Connect the outlet hose fittings of the condensate drain to the condensate collection point,
using a rubber hose with a diameter of 10 to 12 mm.
Remarks
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