Ultrafilter BOREAS DSM SD 1200-60 Specifications

I14 1001 0US
07.03
Operators Instruction
and
Maintenance Manual
BOREAS DSM
SD 1200-60 - SD 3000 W-60
SD 4000-60 - SD 5000 W-60

207.03
Type Code
BOREAS DSM
Model Type-No. Material-no.
SD 1200-60 457A L0457001000
SD 1400-60 458A L0458001000
SD 1600-60 459A L0459001000
SD 2000-60 460A L0460001000
SD 2400-60 461A L0461001000
SD 3000-60 462A L0462001000
SD 4000 W-60 593W L0593001000
SD 5000 W-60 594W L0594001000
SD 1200 W-60 457W L04570010005000
SD 1400 W-60 458W L04580010005000
SD 1600 W-60 459W L04590010005000
SD 2000 W-60 460W L04600010005000
SD 2400 W-60 461W L04610010005000
SD 3000 W-60 462W L04620010005000
SD 4000 A-60 593A L05930010006000
SD 5000 A-60 594A L05940010006000
Construction
Series
Type code
Version
aircooled
Version
watercooled
Version
watercooled
Version
aircooled

3
07.03
Type Code
Part 1 Important user infor-
mation
Part 2 Installation
Part 3 Description
Part 4 Operation
Part 5 Maintenance
Appendix
Page
2
1.1 General Notes 4
1.2 Safety regulations 5
1.3 Handling with refrigerant 6
1.4 First aid 7
1.5 Disposal 7
2.1 Transportation 8
2.2 Requirements on the place
of installation 8
2.3 Installation (Mounting) 8
2.4 Compressed air connection 9
2.5 Electric Connection 10
2.6 Connection condensate drain 10
2.7 Connection cooling water 10
3.1 Designation 11
3.2 Purpose 11
3.3 Unit layout 11
3.4 Nominal power of CA-dryer 12
3.5 Principle of operation 13
3.6 Mode of operation 13
3.7 SAB-processor 15
3.8 Condensate draining 17
4.1 Commissioning 18
4.2 Starting 18
4.3 Operation 18
4.4 Stopping 18
5.1 Maintenance 19
5.2 Trouble shooting 19
Technical data
Table of constancy
Wiring diagrams
Spare parts lists
Additional sheets for options
Table of contents
All safety notes in this operating instruction which may cause harm to personnel
or equipment, when ignored, are marked by the following symbols:
General danger symbol Electrical danger symbol
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407.03
Part 1 Important User Information
1.1 General notes • This refrigerated compressed air-dryer is referred to
below as CA-dryer.
• The Company does not accept responsibility if safety
regulations are not met during handling, operation,
maintenance and repair, even though these are not
strictly stated in these operating instructions.
• We recommend the notice of these operating instruc-
tions verified by the operating personnel in writing (per-
sonnel file).
• We recommend translation of these operating instruc-
tion into native language of foreign workers.
• The usability and the life cycle of the compressed air-
dryer as well as the avoidance of premature repairs
depends on proper operation, maintenance, care and
competent repair under consideration of these oper-
ating instructions.
• Hints to figures and locations are in brackets, e.g.
(Fig. 5/2)
• Due to our position as suppliers of components we do
not always know the final usage and total range of
products' applications.We constantly improve our prod-
ucts to the latest state of science and technology and
therefore, we assume that our products are free from
defects in the sense of product liability. However, it
cannot be excluded that during faulty operation in criti-
cal areas of application especially at danger to life and
limb of persons involved, additionally safety measures
may be necessary. Therefore, we request the user of
our components / units, to ensure in his own interest,
to inform us about the application of our products in
order to initiate additional safety measures, if neces-
sary.

5
07.03
!
Part 1 Important user Information
Attention!
The operator has to observe the national working-, op-
erating- and safety regulations.Also existing internal fac-
tory regulations must be met.
Maintenance and repair work must only be carried out
by specially trained personnel and, if necessary, under
supervision of a person qualified for this work.
• Protective or safety devices must not be removed,
modified or readjusted.
• During operation of the CA-dryer none of the protec-
tive of safety devices must be removed, modified or
readjusted temporarily or permanently.
• Use proper tools for maintenance and repair work only.
• Use original spare parts only.
• All maintenance and repair works must only be ex-
ecuted at stopped machine, disconnected power sup-
ply and pulled mains plug. Ensure that the CA-dryer
cannot be switched on by mistake.
• Prior to dismounting a part under pressure discon-
nect the CA-dryer from all pressure sources and de-
pressurize the CA-dryer.
• Do not use inflammable solvents for cleaning.
• Keep the environment absolutely clean during main-
tenance and repair works. Keep free of dirt by cover-
ing the parts and free openings with clean cloth, pa-
per or adhesive tape.
• Never weld at the pressure vessel or modify it in any
way.
• Ensure that no tools, loose parts or similar are left in
the system.
1.2 Safety regulations

607.03
• Wear eye protection and protective gloves
• Avoid contact of liquid refrigerants with your skin (frost-
bite).
• Do not inhale refrigerant vapours.
• To avoid higher concentrations, all work rooms must
be ventilated very well. The opening of windows and
doors may not be sufficient, so an exhausting system
must be used directly at the supply point or near the
floor.
• Do not smoke, because fire might decompose the
refrigerant. The resulting substances are toxic and
must not be inhaled.
• Do not have refrigerants escaped during filling or re-
pair work. Cover with tape.
• Leave the room immediately and only enter after the
room has been sufficiently ventilated when refrigerant
concentrations (e.g. pipe line leakages) appear sud-
denly.
• Execute welding and soldering works on refrigerating
systems in well ventilated rooms only. Refrigerants
will be decomposed in flames as well as in electrical
arcs.
• The resulting decomposition products are toxic.
• Before welding and soldering at refrigerating systems,
the refrigerant must be removed.
• A stinking smell points to decomposition of refrigerant
due to overheating:
- leave room immediately
- ventilate room very well.
Part 1 Important user Information
1.3 Handling with
refrigerant

7
07.03
!
Part 1 Important user Information
• Take victim immediately into the fresh air or into a
very well ventilated room.
• Splashes of refrigerant in the eyes must be blown out
with the mouth. Then rinse eyes with plenty of water.
Do not wipe with cloth!
• If the victim does not breathe, perform a mouth-to-
mouth resuscitation or use a respirator until the doc-
tors arrival.
•Call the doctor and inform him that accident has
been caused by refrigerants, for refrigerant type
see identification plate!
• Never leave the victim unattended!
• When disposing of used devices, pay attention to oil
and refrigerant in the hermetically sealed refrigerating
circuit of the CA-dryers. Therefore, before dismount-
ing, these operation media must be disposed by a
special company.
• The used materials are listed on the recycling label
inside the CA-dryer.
Attention!
Do not dispose waste oil into the environment. Do not
mix with household rubbish and do not burn in unauthor-
ized plants.
• The escape of refrigerant into the atmosphere must
be prevented by appropriate measures.
1.4 First aid
1.5 Disposal

807.03
2.1 Transportation
Fig. 1 Mounting of lifting
eyes (M20)
2.2 Requirements on
the place of in-
stallation
2.3 Installation (mount-
ing)
Part 2 Installation
The CA-dryer can be transported for a short time in an
inclined position of up to 45 °. For transportation or lifting
by means of a crane it is possible to use lifting eyes on
the upper side of the frame (fig. 1).
Attention!
When using lifting eyes the load limitations must be ob-
served!
The lifting eyes must only be loaded vertically (use
traverse)!
The CA-dryer may be transported by a fork lift truck or
stacker lift truck.
Transportation has to be carried out in the normal oper-
ating position of the CA-dryer.
At the site of installation, the CA-dryer can be installed
without anchorage or special foundation at the location
desired.
The CA-dryer is designed for an ambient temperature of
100 °F.
Attention!
At different ambient conditions pay attention to the lay-
out data!
To prevent the condensate from freezing the room tem-
perature must not drop below 35 °F.
Install the CA-dryer with access to the front panel to
reach the integrated switches and indicators. Further-
more leave space for service purpose on both sides of
the CA-dryer (fig. 2).
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!

9
07.03
The cooling air for the refrigerant condenser will be sucked
in at the front panel (fig. 2). This area must be kept free
and not be obstructed.
If necessary, the cooling air may be led to the CA-dryer
from outside through wall openings.
The cooling air outlet is positioned at the top of the unit
(fig. 2). Ensure a free air outlet and do not obstruct the
outlet of the cooling air.
If the CA-dryer is connected to an exhaust trunk, an
additional fan must be installed, depending on the di-
mensions of the trunk.
The connection must be executed acc. to marking at the
CA-dryer (fig. 2).
For service purposes the installation of a bypass line is
recommended (additional equipment).
Attention!
Before mounting the CA-dryer, welding residual, rust or
other pollution must be removed from the pipelines to be
connected. If pollution cannot be excluded, proper filter
system must be installed
The compressed air pipes must be installed stress-free.
Expansion joints are recommended in case of vibrations
and pulsations.
Part 2 Installation
2.3.1 Version air cooled
Fig. 2: Installation of the
CA-dryer (air cooled)
2.4 Compressed air con-
nection
min. 32 in
Direction of suc-
tion cooling air
min. 32 in
Outlet
cooling air
ö
ö
CA-outlet
CA-inlet
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10 07.03
!
The CA-dryers are completely equipped and wired.They
merely have to be connected to a power supply.The CA-
dryers are to be protected by slow-blow fuses as defined
in the wiring diagram.
Voltage: acc. to name plate or wiring diagram resp.
The power supply is provided in the switch cabinet.
Attention!
The proper phasing as given in the wiring diagram must
absolutely be fulfilled!
At correct direction of rotation the cooling air is sucked
through the condenser!
The CA-dryer separates water as well as oil from the
compressed air. The water/oil mixture must not be led
into the sewage. Water and oil must be separated by
suitable separators (additional equipment).
Attention!
Route outflow so that persons or objects will not be struck
by condensate (condensate escapes under operating
pressure)!
A minimum operation pressure of 30 psig is required for
safe operation. The condensate drain pipe (fig. 3.2) may
be fixed to the wall with a rising slope of maximum 15 ft.
Thereby the minimum operation pressure increases for
1/2 psi per ft.The collecting pipe (fig. 3/3) should be laid
throughout its whole length at least as the cross-section
of the condensate outlet.
A minimum cooling water differential pressure of 30 psig
is required.The cooling water pressure must not exceed
145 psig.
Attention!
It is essential to adhere to the limit values regarding
cooling water quality described in the appendix. In
case of deviating conditions please contact the
manufacturer. This note applies for all machines with
stainless steel plate condensers.
Part 2 Installation
2.5 Electric connection
2.6 Connection conden-
sate drain
Fig. 3 Connection conden-
sate drain
2.7 Connection cooling
water
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3
2
to treatment
1

11
07.03
3.1 Designation
3.2 Purpose
3.3 Unit Layout
Fig. 4: Complete system
Part 3 Description
Refrigerated compressed air-dryer (CA-dryer).
Version see type code (page 2)
Compressed air will be dehumidified by the CA-dryer.
Following components of the CA-dryer are accessible
from outside (fig. 4).
1 Compressed-air inlet
2 Compressed-air outlet
3 Switch cabinet with power supply (Fig. 5)
4 Cooling air inlet
5 Operating instructions
6 Condensate outlet
7 Cooling water inlet (water-cooled version)
8 Cooling water outlet (water-cooled version)
9 Access for service
3
4
5
6
7
8
9
2
1
9

12 07.03
Part 3 Description
3.3.1 Switch cabinet
Fig. 5 Switch cabinet
3.4 Nominal power of
CA-dryer
1 Main switch
2 Operation switch
3 Data input and output key
4 Measuring point indication
5 Temperature and working hour indication
The nominal power of the CA-dryer mentioned in the
technical data is related to a working pressure of 14 1/2
psig, a compressed air inlet temperature of 100°F as
well as an ambient temperature of 100 °F acc. CAGI.
Lower working pressure, higher compressed air inlet
temperature and/or higher ambient temperatures over-
load the compressor which causes to an increased pres-
sure dew point and the compressor can be stopped by
internal safety devices.
At an essentially modified operation mode as mentioned,
contact the deliverer of the CA-dryer for support.
3 4 5
2 1

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07.03
The CA-dryer includes a refrigerant system cooling the
compressed air flow. The steam saturation limit is low-
ered causing condensate to fall out, which is removed by
the condensate drain.
The higher the cooling temperature difference of the air,
the higher is the amount of condensate.
The lower the cooling temperature of air, the lower is the
moisture content.
The lower limit of air cooling results from the operating
principle of the CA-dryer based on the moisture separa-
tion in liquid form.Thus, the freezing point of water, i.e. a
temperature of 35 °F, is the lower limit. For reliability rea-
sons, a practical setting is used, which lies above this
theoretical limit of 35 °F.
The compressed air precooled in the aftercooler and
saturated with moisture enters into the CA-dryer and is
precooled in the first cooling stage, the air-to-air heat
exchanger without additional energy. Cooling is carried
out in counterflow to the already cooled air heated dur-
ing this process.
The cooling to the pressure dew point is performed in the
second cooling stage, the refrigerant-to-air heat ex-
changer cooled by the refrigerant system installed. Sub-
sequently, the cooled compressed air is reheated in the
air-to-air heat exchanger as already described.
The pressure dew point temperature is indicated on the
switch cabinet (fig. 5/5).
The refrigerant is injected into the refrigerant-to-air heat
exchanger where it evaporates, thereby cooling the com-
pressed air. A capacity control system at the refrigerant
side controls the capacity required by the compressed
air to ensure a constant pressure dew point temperature
in all capacity ranges.
The refrigerant compressed by the motor compressor is
condensed within the condenser and is available for the
evaporation again.
The CA-dryer can be operated under partial load, caused
by lower compressed air throughout or lower compressed
air inlet temperature, within the range of 0 to 100% ca-
pacity in continuous operation.
3.5 Principle of opera-
tion
3.6 Mode of operation
3.6.1 Compressed air side
3.6.2 Refrigerant side
3.6.3 Pressure dew point
control
Part 3 Description

14 07.03
3.6.4 Capacity levels
3.6.4.1 Types 593A, 593 W,
594A, 594 W
3.6.4.3 Siemens Logo
Part 3 Description
The CA dryer disposes of two parallel refrigerant
compressors. If the load is reduced to less than 50 %
one compressor is switched off depending on the
refrigerant pressure in order to reduce the power
consumption of the CA dryer. The values registered by
a pressure pick-up are transmitted to a Siemens Logo
which ensures the minimum runtimes of the
compressors.
The Siemens Logo has a fixed factory setting and must
not be changed by unauthorized persons.
If the load rises again to more than 50 % the second
compressor is switched on again via the same
components.
The values registered by a pressure pick-up are
transmitted to a Siemens Logo which ensures the
minimum runtimes of the compressors.
The Siemens Logo has a fixed factory setting and must
not be changed by unauthorized persons.

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07.03
Part 3 Description
3.7 SAB-Processor
3.7.1 Display
Fig. 6 Display
3.7.2 Temperature mea-
suring
3.7.3 Plausibility and
average value
3.7.4 Limit values
Fig. 7: Limit values
The SAB-Processor measures, shows and stores tem-
peratures, working hours and failures.
The display consists of a 2-digit measuring point indica-
tion (fig. 6/2) and a 3-digit indication for the correspond-
ing values (fig. 6/3).The data to be requested can be get
by short operation of the data input/output key (fig. 6/1).
The SAB-Processor has 4 temperature inputs:
1. Pressure dew point
2. Refrigerant suction gas temperature
3. Compressed air inlet temperature
4. Ambient temperature
Incoming measured values will be compared and the
resulting average values will be processed. Rapid changes
of the incoming measured values on steady higher or
lower value resp. will be checked. If the value changes
are too high it is recognized as measuring failure.
2 limit values are provided for each temperature between
which the temperatures must be during normal operation.
After starting the CA-dryer all errors will be suppressed
for 15 minutes.
1 Data input/output key
2 Measuring point indication
3 Temperature and working
hour indication
Temperature rising
upper error limit value
upper alarm limit value
lower alarm limit value
lower error limit value
Temperature falling
unallowed oper. cond.
critical oper. cond.
normal operation
condions
critical oper. cond.
unallowed oper. cond

16 07.03
Part 3 Description
3.7.5 Pressure dew
point report
Fig. 8: Limit value setting
3.7.6 Temperature - His-
tory
3.7.7 Operating status -
normal operation
The customer of these CA-dryers has the possibility to
adapt the upper error value of the pressure dew point to
the company´s needs, if necessary.
The actual status of the DIP-switches is read during the
program start only, i.e., after each change of the switch
position, a power disconnection must be executed
Switches 1 and 2 are used for the upper switching point
of the pressure dew point , switches 3 serves for chang-
ing between °C and °F . Switch 4 must not be changed in
its position.
All 10 minutes the temperatures are read into and up-
dated in a memory.
Additionally date and time of all values are stored, too.
So the temperatures of the last 24 hours can be followed
up.
During normal operation the display indicates the dew
point temperature.Following values can be recalled con-
secutively when the data input and output keys are
pressed:
1. Pressure dew point (compressed air)
2. Suction gas temperature (refrigerant compressor)
3. Inlet temperature (compressed air)
4. Ambient temperature
OP Operating hours (indicated value x 100)
If key (fig. 6) is not operated, the display shows again the
pressure dew point after about 45 seconds .
Switch position 1 2 3 4
no alarm off off on on
64 °F on off on on
59 °F off on on on
54 °F on on on on
no alarm off off off on
18 °C on off off on
15 °C off on off on
12 °C on on off on
on
1 2 3 4
Factory setting

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07.03
Corresponding to the set limit values, at critical opera-
tion phases an alarm, and at prohibited operation condi-
tions a failure report is triggered by the processor´s
monitoring system (see 5.2.2).
The SAB-service unit permits changes of limit values,
simple data input and output as well as the recording of
all data for service purposes and documentation.
All data can be printed via the SAB-service unit by means
of a printer.
The condensate drain automatically drains the conden-
sate. A minimum pressure of 30 psig is required for safe
operation.
Once the container has filled with condensate, so that
the capacitive level sensor emits a signal, the internal
solenoid valve opens and the condensate is forced by
the working pressure into the discharge pipe.
The condensate drain electronic system ensures the clos-
ing of the outlet opening before any compressed air can
escape.
1 Condensate drain is ready for operation (LED lights)
2 Manual draining (operate button for max. 30 sek.)
3 Failure (LED blinks, see 5.2.3)
At standstill or very small volume flow of the CA-dryer, a
time-controlled solenoid valve avoids the collection of
condensate in the inlet pipe to the water separator.
Furthermore the solenoid valve controls the desludging
of the heat exchanger.
The solenoid valve is accessible after removing the right
side plate (fig. 4/9).
Part 3 Description
3.7.8 Operating status -
alarm / failure
3.7.9 SAB-service unit
(additional equip-
ment)
3.8 Condensate draining
3.8.1 Condensate drain
Fig. 9: Condensate drain indi-
cations
3.8.2 Drain valve
Power
Alarm
Test
Power
Alarm
Test
Power
Alarm
Test
1 2 3

18 07.03
Part 4 Operation
4.1 Commissioning
4.2 Starting
4.3 Operation
4.4 Stopping
After installion, the CA-dryer can be switched on with the
main switch (fig. 5/1).
So the refrigerating compressor heating and the SAB-
Processor is supplied with power.
Before operating the operation switch (fig. 5/2), a waiting
period of at least 6 hours is necessary, to enable a pre-
heating of the refrigeration compressor.
The CA-dryer is switched on via the operation switch (fig.
5/2). After approx. 5 minutes the compressed air admis-
sion is possible by connecting the compressed air com-
pressor.
Attention!
A period of 5 minutes must be kept between switching
off and switching on the CA-dryer to achieve a pressure
compensation within the refrigeraion system.
After some hours of operation under load, it should be
controlled that condensate is generated and drained.
The CA-dryer is designed for continuous operation and
may remain switched on during periods of no load, as it
adapts to the required performance automatically.
Operation is indicated by the luminous operation switch
(fig. 5/2).
The temperature display at the switch cabinet (fig. 5/5)
indicates the pressure dew point reached by the CA-
dryer.
During normal operation, the lamp „Power“ (fig. 9/1) lights
permanently .
At standstill periods, the CA-dryer is switched off with
the operation switch, the main switch remains switched
on.
For longer standstill periods or during service resp. the
CA-dryer is switched off with the main switch (see 4.1).
At restarting proceed as mentioned in item 4.2.
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07.03
5.1 Maintenance
5.1.1 Daily maintenance
5.1.2 Weekly mainte-
nance
5.2 Troubleshooting
5.2.1 Function:
Cause
No function
Attention!
Prior to any maintenance works all safety regulations for
electrical systems and units must be observed.
Maintenance intervals highly depend on the mode of
operation and the ambient conditions on site, the inter-
vals below are only to be understood as general recom-
mendations.
a) Check function of condensate drain.
Condensate drain:
Operate “Test ”-button (fig. 9/2),
check, if water is drained.
b) Monitoring of all temperatures.
Inspection and cleaning of condensate draining system
if necessary.
Attention!
Maintenance work must be performed at the depressu-
rized condensate drain only. For this purpose, the instal-
lation of a bypass line is recommended (additional equip-
ment).
Remedy
- Check and ensure power supply.
- If power supply is o.k., call for service.
Part 5 Maintenance
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20 07.03
Part 5 Maintenance
5.2.2 Reports of the
SAB-processor:
5.2.2.1 Alarm indications
A1 Pressure dew point
in critical range
A2 Suction gas tempera-
ture in critical range
A 3 Inlet temperature in
critical range
A 4 Ambient tempera-
ture in critical range
5.2.2.2 Failure indications
H 1 Pressure dew point
too high
H 2 Suction gas tem-
perature too high
H 3 Inlet temperature too
high
H 4 Ambient tempera-
ture too high
L 1 Pressure dew point
too low
L 2 Suction gas tem-
perature too low
L 3 Inlet tempera-
ture too low
L 4 Ambient tempera-
ture too low
5.2.2.3 Failure reports with
stopping the refriger-
ant compressor
FF Pressure dew point too
low
FH Refrigerant overpres-
sure
FL Refrigerant underpres-
sure
FI Overcurrent
5.2.2.4 Failure acknowledge-
ment
Check load conditions of CA-dryer
Check control (call for service)
Check aftercooler of CA-dryer
Lower machine room temperature
Check load conditions of CA-dryer
Check control (call for service)
Check aftercooler of CA-dryer
Lower machine room temperature
Check control (call for service)
Check control (call for service)
Increase compressed air inlet temperature
Increase machine room temperature
After 45 seconds, the indication always goes back to the
failure appeared first, which was also stored and counted
particularly. If a failure disasppears again, the correspond-
ing indication disappears, too.
Note: At determined operation conditions, the fans can
run on.
Check control (call for service)
Check fans or cooling water control valve (water-cooled
version) resp., clean condenser,
lower machine room temperature
Increase machine room temperature
Lack of refrigerant - check cooling circuit for leakage,
Check control (call for service)
Check current consumption of refrigerant compressor
and replace if necessary (call for service)
FH: operate reset button at pressure limiter
FH, FI: Acknowledgement by switching the operation
switch on and off