Fini RD 185-810, User Manual

Page 1: ...7425MUM041_EN_2008 06 EN USER S MAINTENANCE MANUAL RD RD RD RD 185 185 185 185 810 810 810 810 ISSUE 2008 Targhetta Dati REFRIGERATED AIR DRYER ...

Page 2: ...eid dat het hieronder beschreven product in overeenstemming is met de veiligheidsvoorschriften van de richtlijnen 98 37 EG 97 23 EG 73 23 EEG 89 336 EEG HU teljes felelısségének tudatában tanúsítja hogy az alábbiakban jellemzett termék a 98 37 ЕС 97 23 ЕС 73 23 ЕЭС és 89 336 ЕЭС sz irányelvek biztonsági követelményeinek megfelel N0 Erklærer under eget ansvar at produktet her beskrevet er i overens...

Page 3: ...e Max Inlet Air Temp Ambient Temp Refrigerant Type and qty Refrig Design Pres HP LP Electric Supply Electric Nominal Power Fuse Max Manufactured The data nameplate is located on the back of the dryer and shows all the primary data of the machine Upon installation fill in the table on the previous page with all the data shown on the data nameplate This data should always be referred to when calling...

Page 4: ... 810 AC Air Cooled 4 2 Technical Specifications RD 185 810 WC Water Cooled 5 TECHNICAL DESCRIPTION 5 1 Control panel 5 2 Operation 5 3 Flow Diagram Air Cooled 5 4 Flow Diagram Water Cooled 5 5 Refrigerating compressor 5 6 Condenser Air Cooled 5 7 Condenser Water Cooled 5 8 Condenser water regulating valve Water Cooled 5 9 Filter Drier 5 10 Capillary tube 5 11 Alu Dry Module 5 12 Hot gas by pass va...

Page 5: ... operate equipment with panels removed Maintenance or control operation to be performed by qualified personnel only 1 ARIA AIR LUFT AIR Compressed air inlet connection point ARIA AIR LUFT AIR Compressed air outlet connection point Condensate drain connection point Cooling water inlet connection point Water Cooled Cooling water outlet connection point Water Cooled Operations which can be worked out...

Page 6: ...damaged by accident modification misuse negligence or misapplication Unauthorized alterations will immediately void the warranty In case of fire use an approved fire extinguisher water is not an acceptable means in cases of electrical fire 1 3 PROPER USE OF THE DRYER This dryer has been designed manufactured and tested for the purpose of separating the humidity normally contained in compressed air...

Page 7: ...e pressure equipment 6 The maximum working pressure stated on the manufacturer s data nameplate must not be exceeded Prior to use the user must fit safety pressure relief devices 7 All documentation supplied with the equipment manual declaration of conformity etc must be kept for future reference 8 Do not apply weights or external loads on the vessel or its connecting piping Users of the equipment...

Page 8: ...failure and dryer failure due to the following compressor loss fan motor failure and electrical component failure Failures of this type will affect warranty considerations Do not install dryer in an environment of corrosive chemicals explosive gasses poisonous gasses steam heat areas of high ambient conditions or extreme dust and dirt In case of fire use an approved fire extinguisher water is not ...

Page 9: ... 3 3 or worse quality we recommend the additional installation of a pre filter 5 micron minimum to prevent a clogging of the heat exchanger Type A installation is suggested when the compressor operates at reduced intermittence and the total consumption equals the compressor flow rate Type B installation is suggested when the air consumption can consistently change with peak values highly exceeding...

Page 10: ...RD 185 has a nominal duty of 18500 l min What is the maximum allowable flow through the dryer under the following operating conditions Inlet air pressure 8 barg Ambient temperature 45 C Inlet air temperature 50 C Pressure DewPoint 10 C Each item of data has a corresponding numerical factor which multiplied by the design air flow is as follows The procedure here is to list the operating conditions ...

Page 11: ...up as shown in the following illustration Ø BPY0001 In realising the dryer particular measures have been taken in order to limit the vibration which could occur during the operation Therefore we recommend to use connecting pipes able to insulate the dryer from possible vibrations originating from the line flexible hoses vibration damping fittings etc CAUTION PIPING THE DRYER INLET OUTLET CONNECTIO...

Page 12: ...ryer comes with a flexible plastic drain tube The condensate drain occurs through a solenoid valve protected with a mechanical strainer The condensate coming from the separator is previously filtered then discharged The solenoid valve coil is operated by electronic instrument dryer controller If an electronic drainer is installed the intervention times are determined by the internal capacitive sen...

Page 13: ... dryer temperature to stabilise at the pre set value Slowly open the air inlet valve Slowly open the air outlet valve Slowly close the central by pass valve of the system if installed Check the piping for air leakage Ensure the drain is regularly cycling wait for its first interventions Ensure that all the steps of the Installation chapter have been observed Ensure that the connection to the compr...

Page 14: ...ayed on electronic instrument DMC20 is correct and that the condensate is regularly drained Switch on the air compressor Shut down refer to paragraph 5 1 Control Panel DMC14 Electronic Instrument DMC20 Electronic Instrument Check that the DewPoint temperature indicated on the DMC14 is within range Switch OFF the air compressor After a few minutes switch OFF the dryer pressing the O OFF button of t...

Page 15: ...rg BSP F Ph V Hz W A W A dbA kg ACT MODEL Air flow rate at nominal condition 1 Pressure DewPoint at nominal condition 1 Nom ambient temperature max Min ambient temperature Nominal inlet air temperature max Nominal inlet air pressure Max inlet air pressure Air pressure drop p Inlet Outlet connections Refrigerant type Refrigerant quantity 3 Cooling air flow Cooling water flow at 15 C out 30 C Coolin...

Page 16: ...m 3 h m 3 h C barg BSP F Ph V Hz W A W A dbA kg RD MODEL Air flow rate at nominal condition 1 Pressure DewPoint at nominal condition 1 Nom ambient temperature max Min ambient temperature Nominal inlet air temperature max Nominal inlet air pressure Max inlet air pressure Air pressure drop p Inlet Outlet connections Refrigerant type Refrigerant quantity 3 Cooling air flow Cooling water flow at 15 C ...

Page 17: ...oval by the condensate drain The cool moisture free air then passes back through the air to air heat exchanger to be reheated to within 8 degrees of the incoming air temperature as it exits the dryer Refrigerant circuit Refrigerant gas is cycled through the compressor and exits at high pressure to a condenser where heat is removed causing the refrigerant to condense to a high pressure liquid state...

Page 18: ...obes T2 T8 DMC20 if installed c Condensate separator 13 Condensate drain service valve 2 Refrigerant Pressure Switches PB 14 Y shaped condensate drain strainer 3 Safety thermo switch Ts 15 Condensate drain solenoid valve 4 Refrigerant Pressure Switches PA 16 Coil for cond drain solenoid valve 5 Refrigerant pressure switch fan PV 17 EC Electronic control instrument PV1 PV2 RD 480 810 18 Condenser W...

Page 19: ...FREE FROM DUST AND OTHER IMPURITIES 5 7 CONDENSER Water Cooled The condenser is the element in which the gas coming from the compressor is cooled down and condensed becoming a liquid Basically it is a water refrigerating gas exchanger where the cooling water lowers the temperature of the refrigerating gas The temperature of the inlet water must not exceed the nominal values It must also guarantee ...

Page 20: ... exchanger module leads to low velocities and reduced power requirements The generous dimensions of the air to refrigerant heat exchanger plus the counter flow gas flow allows full and complete evaporation of the refrigerant preventing liquid return to the compressor The high efficiency condensate separator is located within the heat exchanger module No maintenance is required and the coalescing e...

Page 21: ...op 18 barg 41 C Tolerance 1 bar PV2 RD480 810 Fan control pressure switch located on the pushing side on the compressor It keeps the condensation temperature pressure constant within preset limits Air Cooled High Speed Calibrated pressure R 404 A Start 23 barg 51 C Stop 20 5 barg 46 C Tolerance 1 bar 5 14 SAFETY THERMO SWITCH TS 1 2 PQS0005 To protect the operating safety and the integrity of the ...

Page 22: ...en with dryer on and correct operating DewPoint contact is closed OPERATION After dryer starting the electronic controller displays current operating DewPoint it shows the measured temperature in Celsius degrees C C with a resolution of 0 5 C or in Fahrenheit F with a resolution of 1 F The condensate drain solenoid valve is activated for 2 seconds Ton LED on each minute ToF if standard setting To ...

Page 23: ...rmal functions When the dryer is in stand by condition the display shows Stand by and the crankcase oil heater and Stand by leds are ON If the remote command is in use the display shows Stand by Remote To switch ON the dryer keep the button 14 Dryer Start up pressed for at least 2 seconds NOTE DMC20 has an internal timer that cannot allow to restart the compressor before 4 minutes after the switch...

Page 24: ...o longer in effect the dryer will run correctly otherwise the alarm message will appear again When the Automatic Start Up and Reset Autom functions are activated customer selected setting yes any alarm which has caused the stop of the dryer and any anomaly with one or more probes Probe Fault is automatically reset once nominal conditions return and the dryer will run again automatically Any alarm ...

Page 25: ...10 minutes a goes off as soon as the DewPoint goes below 10ºC Stop High DP Selecting YES it is possible to enable the high DewPoint alarm to switch OFF the dryer otherwise a simple alarm signal is displayed Condensation Setting of the activation threshold for the condensing temperature too high Condens Diff This is the differentialtemperature to deactivate the high condensing temperature alarm Con...

Page 26: ...alarm 1 0 10 0 ºK 5 ºK High DP Delay Delay time for the too high DewPoint alarm 0 5 30 min 20 min High DP Stop STOP enabled in case the DewPoint of the dryer is too high YES NO NO Condensation Temp of intervention for the too high condensation temperature alarm 50 0 70 0 ºC 60 0 ºC Condens Diff Differential temp for the too high condensation temperature alarm 1 0 10 0 ºK 5 ºK Condens Delay Delay t...

Page 27: ...y see spare parts list to convert the RS232 PC signal into an RS485 DMS20 signal The RS485 line is made of a two wire cable and can be up to max 2000 meters long for long distance exceeding 100m it is advisable to use a shielded twisted pair polyethylene cable For good data transmission it is imperative that at the cable end of the RS485 line a 120 ohm watt resistor is placed as shown in figure K ...

Page 28: ...h DP Diff Differential temperature for the too high DewPoint alarm Signed Integer 0214 R W High DP Delay Delay time for the too high DewPoint alarm Signed Integer 0215 R W Condensation Temperature of intervention for the too high DewPoint alarm Signed Integer 0216 R W Condens Diff Differential temperature for the too high DewPoint alarm Signed Integer 0217 R W Condens Delay Delay time for the too ...

Page 29: ...tenance or service be sure that no part of the machine is powered and that it cannot be connected to the mains supply no part of the machine is under pressure and that it cannot be connected to the compressed air system Maintenance personnel have read and understand the safety and operation instructions in this manual SYMPTOM POSSIBLE CAUSE SUGGESTED ACTION No led lighting up Verify that the syste...

Page 30: ...Y Verify that the DewPoint displayed on the electronic instrument is correct Check the proper operation of the condensate drain systems Verify the condenser for cleanliness EVERY 200 HOURS OR MONTHLY With an air jet max 2 bar 30 psig blowing from inside towards outside clean the condenser repeat this operation blowing in the opposite way be careful not to damage the aluminium fins of the cooling p...

Page 31: ...o switch TS has been activated see specific point DMC14 The alarm led is ON see specific point DMC20 Internal delay device wait at least 4 min from last shut off DMC20 The alarm in progress led is ON see specific point If the compressor still doesn t work replace it The fan of the condenser doesn t work Air Cooled Verify the electric wiring RD 185 410 PV pressure switch is faulty contact a refrige...

Page 32: ... leak in the refrigerating fluid circuit contact a refrigeration engineer Reset the thermo switch by pressing the button on the thermo switch itself verify the correct operation of the dryer The TS thermo switch is faulty replace it The PA high pressure switch has been activated Check which of the following has caused the activation 1 The ambient temperature is too high or the room aeration is ins...

Page 33: ...oint 9 HIGH DewPoint The DewPoint is too high see specific point 10 Probe Fault one of the probes is faulty see specific point DMC20 The condensing temperature is too high Check which of the following has caused the alarm 1 The ambient temperature is too high or the room aeration is insufficient provide proper ventilation Air Cooled 2 The condenser is dirty clean it Air Cooled 3 The condenser fan ...

Page 34: ...R134a HFC CH2FCF3 1000 ppm 1300 R404A HFC CH2FCF3 C2HF5 C2H3F3 1000 ppm 3784 6 4 DISMANTLING OF THE DRYER If the dryer is to be dismantled it has to be split into homogeneous groups of materials Parte Materiale Refrigerant fluid R404A R134a Oil Canopy and Supports Carbon steel Epoxy paint Refrigerating compressor Steel Copper Aluminium Oil Alu Dry Module Aluminium Condenser Unit Aluminium Copper C...

Page 35: ...3 HP Refrigerant gauge high pressure 4 Refrigerant pressure switch PA 24 LP Refrigerant gauge low pressure 5 Refrigerant Fan pressure switch PV 25 Compressor crankcase heater PV1 PV2 RD 480 810 6 Compressor 51 Front panel 7 Hot gas by pass valve 52 Back panel 8 Condenser Air Cooled 53 Right lateral panel 9 Condenser fan 54 Left lateral panel 10 Filter Drier 55 Cover 11 Capillary tube 56 Base plate...

Page 36: ...yers RD 480 810 Electronic Instrument DMC20 POWER 7 3 11 Electrical Diagram of Dryers RD 480 810 Electronic Instrument DMC20 AUXILIARY 7 3 12 Electrical Diagram of Dryers RD 480 810 Electronic Instrument DMC20 CONNECTIONS Electrical Diagram table of components IG Main switch K Refrigerating compressor KT Compressor thermal protection V Condenser fan TV Fan thermal protection DMC14 DMC14 Electronic...

Page 37: ...40069 Zola Predosa BO ITALY info finicompressors it 7 1 1 RD 185 350 AC 7 1 2 RD 410 AC 7 1 3 RD 480 620 AC ...

Page 38: ...40069 Zola Predosa BO ITALY info finicompressors it 7 1 4 RD 810 AC 7 1 5 RD 185 350 WC 7 1 6 RD 410 WC ...

Page 39: ...40069 Zola Predosa BO ITALY info finicompressors it 7 1 7 RD 480 620 WC 7 1 8 RD 810 WC ...

Page 40: ...40069 Zola Predosa BO ITALY info finicompressors it 7 2 1 RD 185 410 ...

Page 41: ...40069 Zola Predosa BO ITALY info finicompressors it 7 2 2 RD 480 810 ...

Page 42: ...a BO ITALY info finicompressors it 7 3 1 RD 185 410 DMC14 SEZ 0 1 3 COMPRESSOR U W M V 2 2 K 2 6 2 1 6 4 3 5 V 2 7 2 3 Q1 Q2 min 4G2 5 SUPPLY Unless specified 1x1rd A TF Q3 4A R 2 6 K 12 11 A 50 60Hz B FAN 3 TV M U V W ...

Page 43: ... 8 2 4 1 3 1 3 K A2 A1 A 2 9 0 5 9 22 21 2 4 12 6 5 11 1 3 1 4 N U 1 4 1 4 A1 A2 V P N X L PV ON CP 1 Wh X2 X1 B P 13 K 13 14 2 1 14 Rd 4 12 2 1 2 7 4 1 8 5 12 9 13 14 A P 1 5 Q2 13 14 PB P PA 1 3 Q1 14 13 TV TS P T1 POWER 2 DEW POINT ALARM max 230V 1 1 A 4 5 8 9 DEW POINT PROBE 11 12 DMC14 Air Dryer Controller 3 ON CP ...

Page 44: ... finicompressors it 7 3 3 RD 185 410 DMC14 T1 T1 11 12 10 9 7 6 5 4 3 2 1 TERMINAL 8 PV MOUNTING PLATE R red UKK 5 TERMINAL 14 12 WIRE 15 12 26 23 22 TYPE white 32 12 14 Q3 5 6 1 2 3 4 11 12 7 8 9 10 Q1 Q2 SEZ T1 TF K V A TV TS PA PB ...

Page 45: ...a BO ITALY info finicompressors it 7 3 4 RD 185 410 DMC20 SEZ 0 1 3 COMPRESSOR U W M V 2 2 K 2 6 2 1 6 4 3 5 V 2 7 2 3 Q1 Q2 min 4G2 5 SUPPLY Unless specified 1x1rd A TF Q3 6A R 2 6 K 12 11 B A 50 60Hz FAN 3 TV M U V W ...

Page 46: ... 185 410 DMC20 1 4 N U 1 4 1 4 PV P Q1 A 1 3 1 C T1 4 3 2 T2 T3 T4 1 8 11 12 11 12 OPTIONAL N L Q2 14 1 5 14 ON OFF REMOTE B T7 6 5 13 13 T5 T6 7 T8 K V 5 6 1 3 2 4 1 3 1 3 1 3 A2 5 1 3 6 2 4 A2 A1 A1 3 1 13 12 K 11 B DMC20RI 14 15 E 6 5 16 S 7 TV TS P P PB P PA ...

Page 47: ...1 18 42 29 20 red T6 T2 T1 T2 T1 T3 T3 T4 T4 T5 T5 white white white white white red red red red red T7 T6 T7 T8 T8 white white white red red T6 Q1 13 14 11 12 7 8 9 10 1 2 3 4 5 6 15 16 T2 T1 T4 T3 T5 DMC20RI T8 T7 Q3 TF K V Q2 SEZ 17 18 12 16 12 13 TV TERMINAL R 3 4 1 2 TYPE WIRE TERMINAL 39 12 UKK 5 18 12 PA PB 6 5 20 21 7 22 TS ...

Page 48: ...Y info finicompressors it 7 3 7 RD 480 810 DMC14 SEZ 0 1 3 COMPRESSOR U W M V 2 1 6 4 3 5 2 9 Q2 min 4G4 SUPPLY Unless specified 1x1 rd R 2 1 K 12 11 A K 2 1 A Q3 6A 50 60Hz TF V2 2 3 V1 2 2 Q1 2 9 B W1 V1 U1 W2 FAN M 3 U2 V2 TV ...

Page 49: ...1 2 4 12 6 5 11 1 3 N U A1 A2 V1 N X L ON CP 1 Wh X2 X1 B P 13 K 13 14 2 1 14 Rd 4 12 2 1 2 7 4 1 8 5 12 9 13 14 A P 1 5 Q2 13 14 PB P PA 1 2 Q1 14 13 TV A1 A2 5 11 1 3 V2 P 6 1 6 12 1 6 1 6 2 4 PV2 N U PV1 P 1 2 1 2 1 5 1 5 1 5 SD 9 5 P TS POWER 2 4 3 5 8 ON CP Air Dryer Controller max 230V 1 1 A DEW POINT ALARM DEW POINT PROBE 12 T1 9 11 DMC14 ...

Page 50: ...AL 12 WIRE 15 12 31 26 TYPE 8 27 DEW POINT PROBE T1 T1 red white CONDENSATE DRAIN VALVE NOT INSTALLED IF OPTIONAL ELECTRONIC DRAINER IS USED 23 5 FAN CONTROL PRESS SWITCH HIGH SPEED NOT INSTALLED FOR WATER COOLED PV2 9 10 11 12 22 23 FAN DOOR INTERLOCK SAFETY SWITCH BRIDGE IF NOT INSTALLED SD 12 OPTIONAL ELECTRONIC LEVEL DRAINER 18 REMOTE ALARM ON INDICATION TF Q3 230V max 1A 19 20 MOUNTING PLATE ...

Page 51: ... info finicompressors it 7 3 10 RD 480 810 DMC20 SEZ 0 1 3 COMPRESSOR U W M V 2 1 6 4 3 5 2 3 Q2 min 4G4 SUPPLY Unless specified 1x1 rd R 2 5 K 12 11 A K 2 5 A Q3 6A B 50 60Hz TF V2 2 7 W2 U2 FAN V2 U1 3 M V1 W1 Q1 2 2 TV V1 2 8 ...

Page 52: ...4 11 12 OPTIONAL N L Q2 14 14 ON OFF REMOTE B T7 6 5 13 13 T5 T6 7 T8 K 5 6 1 3 2 4 A2 A1 3 1 13 12 K 11 B DMC20RI 14 15 E 6 5 16 S 7 TV 12 11 P V2 5 1 3 6 4 2 A2 A1 On CP 1 2 1 2 1 2 1 9 2 2 1 6 1 6 1 6 1 5 1 3 P 2 8 12 V1 11 V2 2 7 12 11 PV1 PV2 12 11 2 1 V1 5 1 3 6 4 2 A2 A1 1 5 1 5 1 5 SD TS P PB P P PA ...

Page 53: ...16 17 18 19 20 DMC20RI Q2 Q3 V1 V2 SEZ K Q1 MOUNTING PLATE 24 23 23 24 TS NOT INSTALLED IF OPTIONAL ELECTRONIC DRAINER IS USED FAN DOOR INTERLOCK SAFETY SWITCH CONDENSATE DRAIN VALVE T5 COMPRESSOR DISCHARGE HIGH SIDE T4 COMPRESSOR SUCTION LOW SIDE COMPRESSOR CRANKCASE HEATER TYPE WIRE TERMINAL TERMINAL T6 CONDENSING BRIDGE IF NOT INSTALLED WATER COOLED ONLY T7 AMBIENT T8 WATER IN SD R T3 AIR OUT T...

Page 54: ...40069 Zola Predosa BO ITALY info finicompressors it The access code to the 2 level is 20 EN ...