Manual Secador de Aire Wh-40

7/25/2019 Manual Secador de Aire Wh-40

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7425MUM096_EN_2011-09

ENENENEN


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Technical data are subject to change without notice; errors not excluded.

Dear Customer,

thank you for choosing our product. In order to get the best performances out of this product, please readthis manual carefully.To avoid incorrect operation of the equipment and possible physical risk to the operator, please read andstrictly follow the instructions contained in this manual.

Note, these instructions are in addition to the safety rules that apply in the country where the dryer isinstalled.Before packing for shipment each PLHseries refrigerated air dryer undergoes a rigorous test to ensure theabsence of any manufacturing faults and to demonstrate that the device can perform all the functions forwhich it has been designed.Once the dryer has been properly installed according to the instructions in this manual, it will be ready foruse without any further adjustment. The operation is fully automatic, and the maintenance is limited to fewcontrols and some cleaning operations, as detailed in the following chapters.This manual must be maintained available in any moment for future references and it has to beintended as inherent part of the relevant dryer.Due to the continuous technical evolution, we reserve the right to introduce any necessary change withoutgiving previous notice.

Should you experience any trouble, or for further information, please do not hesitate to contact us.

IDENTIFICATION PLATE

The identification plate is located on the back of the dryer and shows all the primary data of the machine.This data should always be referred to when calling the manufacturer or distributor. The removal oralteration of the identification plate will void the warranty rights.

WARRANTY CONDITIONS

For 12 months from the installation date, but no longer than 14 months from the delivery date, the warrantycovers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel andrestaurant expenses of our engineer.The warranty doesnt cover any responsibility for direct or indirect damages to persons, animals orequipment caused by improper usage or maintenance, and its limited to manufacturing faults only.The right to warranty repairs is subordinated to the strict compliance with the installation, use andmaintenance instructions contained in this manual.The warranty will be immediately voided in case of even small changes or alterations to the dryer. Torequire repairs during the warranty period, the data reported on the identification plate must be notified


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1. SAFETY RULES

1.1 Definition of the conventional signs used in this manual1.2 Warnings1.3 Proper use of the dryer1.4 Instructions for the use of pressure equipment according to PED Directive 97/23/EC

2. INSTALLATION

2.1 Transport2.2 Storage2.3 Installation site2.4 Installation layout2.5 Correction factors2.6 Connection to the compressed air system2.7 Connection to the cooling water network (Water-Cooled)2.8 Electrical connections2.9 Condensate drain

3. START UP

3.1 Preliminary operation

3.2 First start-up3.3 Start-up and shut down

4. TECHNICAL SPECIFICATIONS

4.1 Technical specifications PLH 210-1000 /50Hz4.2 Technical specifications PLH 210-1000 /60Hz

5. TECHNICAL DESCRIPTION

5.1 Control panel5.2 Operation5.3 Flow diagram (Air-Cooled)5.4 Flow diagram (Water-Cooled)

5.5 Refrigerating compressor5.6 Condenser (Air-Cooled)5.7 Condenser (Water-Cooled)5.8 Condenser water regulating valve (Water-Cooled)5.9 Filter dryer5.10 Capillary tube5.11 Thermostatic expansion valve - TEX5.12 Air-to-air heat exchanger5.13 Air-to-refrigerant heat exchanger5.14 Condensate separator5.15 Hot gas by-pass valve5.16 Refrigerant pressure switches LPS HPS

5.17 Compressor crankcase heater5.18 DMC24 electronic device (Air Dryer Controller)5.19 Electronic level controlled condensate drain

6. MAINTENANCE, TROUBLESHOOTING, SPARES AND DISMANTLING

6.1 Controls and maintenance6.2 Troubleshooting6.3 Spare parts6.4 Maintenance operation on the refrigerating circuit6.5 Dismantling of the dryer

7. LIST OF ATTACHMENTS

7.1 Dryers dimensions7.2 Exploded view7.3 Electric diagrams


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1. SAFETY RULES

1.1 DEFINITION OF THE CONVENTIONAL SIGNS USED IN THIS MANUAL

Carefully read instruction manual before attempting any service or maintenance procedures on thedryer.

Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not

followed properly.

Electrical hazard. Warning message indicates practices or procedures that could result in personalinjury or fatality if not followed correctly.

Danger hazard. Part or system under pressure.

Danger hazard. High temperature conditions exist during operation of system. Avoid contact untilsystem or component has dissipated heat.

Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality mayresult if precautions are not followed.

Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptablemeans in cases of fire.

Danger hazard. Do not operate equipment with panels removed.

Maintenance or control operation to be performed by qualified personnel only 1.

ARIAAIR

LUFTAIR

Compressed air inlet connection point

ARIA

AIR

LUFTAIR

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 performed by the operator of the machine, if qualified 1.

NOTE: Text that specifies items of note to be taken into account does not involve safety precautions.

In designing this unit a lot of care has been devoted to environmental protection:CFC free refrigerantsCFC free insulation partsEnergy saving designLimited acoustic emission

Dryer and relevant packaging composed of recyclable materialsThis symbol requests that the user heed environmental considerations and abide with suggestionsannotated with this symbol.

1 Experienced and trained personnel familiar with national and local codes, capable to perform the needed activities, identify and avoid possibledangerous situations while handling, installing, using and servicing the machine. Ensuring compliance to all statutory regulations.


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1.2 WARNINGS

Compressed air is a highly hazardous energy source.Never work on the dryer with pressure in the system.Never point the compressed air or the condensate drain outlet hoses towards anybody.The user is responsible for the proper installation of the dryer. Failure to follow instructions given inthe Installation chapter will void the warranty. Improper installation can create dangeroussituations for personnel and/or damages to the machine could occur.

Only qualified personnel are authorized to service electrically powered devices. Before attemptingmaintenance, the following conditions must be satisfied:

Ensure that main power is off, machine is locked out, tagged for service and power cannot berestored during service operations.

Ensure that valves are shut and the air circuit is at atmospheric pressure. De-pressurize thedryer.

These refrigerating air dryers contain R134a or R407C HFC type refrigerant fluid. Refer to thespecific paragraph - maintenance operation on the refrigerating circuit.

Warranty does not apply to any unit damaged by accident, modification, misuse, negligence ormisapplication. Unauthorized alterations will immediately void the warranty.

In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases ofelectrical fire.

1.3 PROPER USE OF THE DRYER

This dryer has been designed, manufactured and tested for the purpose of separating the humidity normallycontained in compressed air. Any other use has to be considered improper.The Manufacturer will not be responsible for any problem arising from improper use; the user will bearresponsibility for any resulting damage.Moreover, the correct use requires the adherence to the installation instructions, specifically:

Voltage and frequency of the main power.

Pressure, temperature and flow-rate of the inlet air.Pressure, temperature and cooling water capacity (Water-Cooled).Ambient temperature.

This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to theplant in compliance with the instructions given in the following chapters.

The purpose of the machine is the separation of water and eventual oil particles present incompressed air.The dried air cannot be used for breathing purposes or for operations leading to direct contact withfoodstuff.This dryer is not suitable for the treatment of dirty air or of air containing solid particles.


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1.4 INSTRUCTIONS FOR THE USE OF PRESSURE EQUIPMENT ACCORDINGTO PED DIRECTIVE 97/23/EC

To ensure the safe operation of pressure equipments, the user must conform strictly to the above directiveand the following:

1. The equipment must only be operated within the temperature and pressure limits stated on themanufacturers data nameplate.

2. Welding on heat-exchanger is not recommended.3. The equipment must not be stored in badly ventilated spaces, near a heat source or inflammable

substances.4. Vibration must be eliminated from the equipment to prevent fatigue failure.5. Automatic condensate drains should be checked for operation every day to prevent a build up of

condensate in the pressure equipment.6. The maximum working pressure stated on the manufacturers 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.

TAMPERING, MODIFICATION AND IMPROPER USE OF THE PRESSURE EQUIPMENT ARE

FORBIDDEN. Users of the equipment must comply with all local and national pressureequipment legislation in the country of installation.

2. INSTALLATION

2.1 TRANSPORT

Check for visible loss or damage, if no visible damage is found place the unit near to the installation pointand unpack the contents.

Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid onits side or if placed upside down.

Store machine in a clean, dry environment, do not expose to severe weather environments.

Handle with care. Heavy blows could cause irreparable damage.

2.2 STORAGE

SCC

0001

Even when packaged, keep the machineprotected from severity of the weather.

Keep the dryer in vertical position, also whenstored. Turning it upside down some parts couldbe irreparably damaged.

If not in use, the dryer can be stored in itspackaging in a dust free and protected site at amaximum temperature of 50 C, and a specific

humidity not exceeding 90%. Should the stockingtime exceed 12 months, please contact themanufacturer.

The packaging materials are recyclable. Dispose of material in compliance with the rules

and regulations in force in the destination country.


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2.3 INSTALLATION SITE

Failure to install dryer in the proper ambient conditions will affect the dryers ability to condenserefrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency andperformance, overheated condenser fan motors, electrical component failure and dryer failure dueto the following: compressor loss, fan motor failure and electrical component failure. Failures ofthis 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, wateris not an acceptable means in cases offire.

Minimum installation requirements:

Select a clean dry area, free from dust, and protected from atmospheric disturbances.

The supporting area must be smooth, horizontal and able to hold the weight of the dryer.

Minimum ambient temperature +1C.

Maximum ambient temperature +50C.Ensure a proper cooling air replacement.

Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitate maintenanceoperations.

The dryer does not require attachment to the floor surface.

Do not block, even partially, ventilation grid.Avoid any possible re-circulation of the exhaust cooling air.Protect the dryer from air drafts or forced cooling air conditions.

2.4 INSTALLATION LAYOUT

2

2

1

7

- A -

- B -

1

7

5

6

IN OUT

9

9

8

9

8

5

6

IN OUT

99

3 4

99

3 4

9

1 Air compressor

2 Aftercooler

3 Condensate separator

4 Pre-Filter (min. 5 micron)

5 By-pass group

6 Dryer

7 Compressed air tank

8 Final filter

9 Condensate drain

In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommendthe additional installation of a pre-filter (5 micron minimum) to prevent a clogging of theheat exchanger.

Type A installation is suggested when the compressor operates at reduced intermittence and the totalconsumption equals the compressor flow rate.

Type Binstallation is suggested when the air consumption can consistently change with peak values highly

exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensateeventual instantaneous demanding conditions (peak air consumption).


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2.5 CORRECTION FACTORS

Correction factor for operating pressure changes:Inlet air pressure barg 15 20 25 30 35 40 45

Factor (F1) 0.57 0.70 0.80 0.88 0.94 1.00 1.05

Correction factor for ambient temperature changes (Air-Cooled):

Ambient temperature C 25 30 35 40 45 50

Factor (F2) 1.00 0.96 0.90 0.82 0.72 0.60

Correction factor for inlet air temperature changes:Air temperature C 25 30 35 40 45 50 55 60 65

Factor (F3) 1.20 1.12 1.00 0.83 0.69 0.59 0.50 0.44 0.39

Correction factor for DewPoint changes:

DewPoint C 3 5 7 10

Factor (F4) 1.00 1.09 1.19 1.37

How to find the air flow capacity:

Air flow capacity = Nominal duty x Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)

Example:

An PLH 380has a nominal duty of 2280 m/h. What is the maximum allowable flow through the dryerunder the following operating conditions:

Inlet air pressure = 35 bargAmbient temperature = 35CInlet air temperature = 45CPressure DewPoint = 10C

Factor (F1) = 0.94Factor (F2) = 0.90Factor (F3) = 0.69Factor (F4) = 1.37

Each item of data has a corresponding numerical factor which multiplied by the design air flow is as

follows:Air flow capacity = 2280 x 0.94 x 0.90 x 0.69 x 1.37 = 1823 m/h

1823 m/hThis is the maximum flow rate that the dryer can accept under these operating conditions.

How to select a suitable dryer for a given duty:

Minimum std. air flow rate =Design air flow

Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)

Example:

With the following operating parameters:

Design air flow = 1100 m3

/hInlet air pressure = 35 bargAmbient temperature = 35CInlet air temperature = 45CPressure DewPoint = 10C

Factor (F1) = 0.94Factor (F2) = 0.90Factor (F3) = 0.69Factor (F4) = 1.37

In order to select the correct dryer model the required flow rate is to be divided by the correction factorsrelating to above mentioned parameters:

Minimum std. air flow rate =1100

= 1375 m/h0.94 x 0.90 x 0.69 x 1.37

Therefore the model suitable for the conditions above is PLH 270 (1620 m/h- nominal duty).


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2.6 CONNECTION TO THE COMPRESSED AIR SYSTEM

Operations to be performed by qualified personnel only.Never work on compressed air system under pressure.The user is responsible to ensure that the dryer will never be operated with pressure exceedingthe maximum pressure rating on the unit data tag.Over-pressurizing the dryer could be dangerous for both the operator and the unit.

The air temperature and the flow entering the dryer must comply within the limits stated on the datanameplate. The system connecting piping must be kept free from dust, rust, chips and other impurities,and must be consistent with the flow-rate of the dryer. In case of treatment of air at particularly hightemperature, the installation of a final refrigerator could result necessary. In order to perform maintenanceoperations, it is recommended to install a dryer by-pass system.

In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommendthe additional installation of a pre-filter (5 micron minimum) to prevent a clogging of theheat exchanger.

Pulsations and vibrations must be eliminated from the compressed air and IN/OUT pipingto avoid possible fatigue failure.Do not use the dryer to treat air containing corrosive substances for copper and its alloys.

CAUTION:PIPING THE DRYER, INLET/OUTLET CONNECTIONS MUST BE SUPPORTED ASSHOW IN THE DIAGRAM.FAILING WILL RESULT IN DAMAGE.

2.7 CONNECTION TO THE COOLING WATER NETWORK (WATER-COOLED)

Operations to be performed by qualified personnel.Never operate with plants under pressure.The user is responsible to ensure that the dryer will never be operated with pressure exceedingthe nominal values.Eventual over-pressure could be dangerous both for the operator and the machine.

The temperature and the amount of cooling water must comply with the limits indicated on the technicalcharacteristics chart. The cross section of the connection pipes, preferably flexible, must be free from rust,chips and other impurities. We recommend to use connecting pipes able to insulate the dryer from possiblevibrations originating from the line (flexible hoses, vibration damping fittings, etc.).

We recommend the installation of a 500 micron filter to prevent a clogging of the heat exchanger.

Minimum cooling water requirements:

Temperature 15 30C (1) HCO 3 / SO4 >1.0 mg/l or ppm

Pressure 310 barg (2) NH3 3 bar (2) (3) Cl- 50 mg/l or ppm

Total hardness 6.015 Cl2

0.5 mg/l or ppm

PH 7.59.0 H2S


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2.8 ELECTRICAL CONNECTIONS

Qualified personnel should carry out connecting unit to the main power.Be sure to check the local codes in your area.

Before connecting the unit to the electrical supply, verify the data nameplate for the proper electrical information.Voltage tolerance is +/- 10%. The installer is responsible for supplying and installing the power cable. Be sure toprovide the proper fuses or breakers based on the data information located on the nameplate.

PLH 210-380 PLH 400-1000

The mains socket must be provided with a mainsmagneto-thermal differential breaker (In=0.03A),adjusted on the basis of the consumption of the dryer

(see the nominal values on the data plate of thedryer). The cross section of the power supply cablesmust comply with the consumption of the dryer, whilekeeping into account also the ambient temperature,the conditions of the mains installation, the length ofthe cables, and the requirements enforced by the localPower Provider.

L G T 0 0 2 8

L1 L2 L3 PE

QS

CAUTION:ATTENTION SHOULD BE PAID ON THE ROTATING DIRECTION OF THE COMPRESSOR !The rotating direction of the compressor in this machine is cheched out by a Reverse PhaseProtector (RPP).

When this protection trips, the DMC24 is engaged (the alarm led flashes and the DMC24

display shows and ). If the compressor does not run, the rotating direction must bechanged by swapping two phases. These changes have to be done only by a qualified electrician.DO NOT BY PASS RPP PROTECTION: BY OPERATING THE MACHINE IN WRONGROTATING DIRECTION, THE COMPRESSOR WILL FAIL IMMEDIATELY AND THEWARRANTY WILL BE VOIDED.

Important: ensure that the dryer is earthed.Do not use any socket adapters at the mains plug.If the mains plug needs to be replaced, this must only be done by a qualified electrician.


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2.9 CONDENSATE DRAIN

The condensate is discharge at the system pressure.Drain line should be secured.

Never point the condensate drain line towards anybody.

The dryer comes already fitted with an electronic condensate drainer.

Connect and properly fasten the condensate drain to a collecting plant or container.The drain cannot be connected to pressurized systems.

Dont dispose the condensate in the environment.The condensate collected in the dryer contains oil particles released in the air by the compressor.Dispose the condensate in compliance with the local rules.We recommend to install a water-oil separator where to convey all the condensate drain comingfrom compressors, dryers, tanks, filters, etc.

3. START UP

3.1 PRELIMINARY OPERATION

Verify that the operating parameters match with the nominal values stated on the data nameplateof the dryer (voltage, frequency, air pressure, air temperature, ambient temperature, etc.).

This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unitcould be damaged during transportation, check the integrity of the dryer during first start-up and monitoroperation during the first hours of operation.

Qualified personnel must perform the first start-up.When installing and operating this equipment, comply with all National Electrical Code and anyapplicable federal, state and local codes.Who is operating the unit is responsible for the proper and safe operation of the dryer.Never operate equipment with panels removed.


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3.2 FIRST START-UP

This procedure should be followed on first start-up, after periods of extended shutdown orfollowing maintenance procedures.Qualified personnel must perform the start-up.

Sequence of operations (refer to paragraph 5.1 Control Panel).

Ensure that all the steps of the Installation chapter have been observed.

Ensure that the connection to the compressed air system is correct and that the piping is suitably fixedand supported.

Ensure that the condensate drain pipe is properly fastened and connected to a collection system orcontainer.

Ensure that the by-pass system (if installed) is closed and the dryer is isolated.

Ensure that the manual valve of the condensate drain circuit is open.

Remove any packaging and other material which could obstruct the area around the dryer.

Activate the mains switch.

Turn on the main switch - pos. 1 on the control panel.

Display DMC24 shows .If the alarm led flashes and display DMC24 shows and the electrical power phases

are not correctly connected. Change two of the three phases on the main power supply (seeparagraph 2.8)

Wait at least two hours before starting the dryer (compressor crankcase heater must heat the oil of thecompressor).

Ensure the cooling water flow and temperature is adequate (Water-Cooled).

Press key for at least 2 seconds to start the dryer: if the compressor has been shut down for enoughtime, it will start up immediately; otherwise the display will show the countdown of the seconds before the

compressor starts up again, and the led flashes (max delay 5 minutes).

Ensure the consumption matches with the values of the data plate.

Check that the rotation direction of the fan corresponds with the arrows on the condenser (Air-Cooled).

Allow the 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.

CAUTION:ATTENTION SHOULD BE PAID ON THE ROTATING DIRECTION OF THE COMPRESSOR!The rotating direction of the compressor in this machine is cheched out by a Reverse PhaseProtector (RPP).

When this protection trips, the DMC24 is engaged (the alarm led flashes and the DMC24

display shows and ). If the compressor does not run, the rotating direction must bechanged by swapping two phases. These changes have to be done only by a qualified electricianDO NOT BY PASS RPP PROTECTION: BY OPERATING THE MACHINE IN WRONGROTATING DIRECTION, THE COMPRESSOR WILL FAIL IMMEDIATELY AND THEWARRANTY WILL BE VOIDED.


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3.3 START-UP AND SHUT DOWN

For short periods of inactivity, (max 2-3 days) we recommend that power is maintained tothe dryer and the control panel. Otherwise, before re-starting the dryer, it is necessary towait at least 2 hours for the compressor crankcase heater to heat the oil of the compressor.

Start-up (refer to paragraph 5.1 Control Panel)

Check the condenser for cleanliness (Air-Cooled).

Ensure the cooling water flow and temperature is adequate (Water-Cooled).

Display DMC24 shows .

Press for at least 2 seconds to start the dryer: if the compressor has been shut down for enough time,it will start up immediately; otherwise the display will show the countdown of the seconds before the


Wait a few minutes; verify that the DewPoint temperature displayed on electronic instrument DMC24 iscorrect and that the condensate is regularly drained.

Switch on the air compressor.

Shut down (refer to paragraph 5.1 Control Panel)

Check that the DewPoint temperature indicated on the DMC24 is within range.

Shut down the air compressor.

After a few minutes, shut down the dryer keeping the button on DMC24 pressed for at least 2

seconds. The display shows .

Dryer remote control ON-OFF :

See instructions on para 5.18.7.

Use dry contacts only (potential free) suitable for low voltage. Assure an adequateisolation of potentially dangerous powered parts.

CAUTION:AUTO-RESTART / REMOTE ON-OFFTHE DRYER MAY POWER UP WITHOUT BEING ACTED UPON.THE USER WILL BE RESPONSIBLE FOR THE INSTALLATION OF PROPER PROTECTIONSFOR POSSIBLE SUDDEN POWER RESTORATION TO THE DRYER.

NOTE: A DewPoint within 0C and +10C displayed on Air D ryer Controller is correct according to thepossible working conditions (flow-rate, temperature of the incoming air, ambient temperature, etc.).

During the operation, the refrigerating compressor will run continuously. The dryer must remain on duringthe full usage period of the compressed air, even if the air compressor works intermittently.

The number of starts must be no more than 6 per hour.The dryer must stop running for at least 5 minutes before being started up again.The user is responsible for compliance with these rules. Frequent starts may cause irreparabledamage.The DMC24 is fitted with internal protections to prevent the dryer from starting up too frequently.


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4. TECHNICAL SPECIFICATIONS

4.1 TECHNICAL SPECIFICATIONS PLH 210-1000 50Hz


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4.2 TECHNICAL SPECIFICATIONS PLH 210-1000 60Hz


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5. TECHNICAL DESCRIPTION

5.1 CONTROL PANEL

The control panel illustrated below is the only dryer-operator interface.

PQS

0060

T3T4

K

T1

T2

3

ESCset

info

log

reset

1 Main switch2 Electronic control instrument DMC24

3 Air and refrigerant flow diagram

5.2 OPERATION

Operating principle- The dryer models described in this manual operate all on the same principle. The hotmoisture laden air enters an air to air heat exchanger. The air then goes through the evaporator, alsoknown as the air to refrigerant heat exchanger. The temperature of the air is reduced to approximately 2C,causing water vapor to condense to liquid. The liquid is continuously coalesced and collected in theseparator for removal by the condensate drain. The cool moisture free air then passes back through the airto 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 acondenser where heat is removed causing the refrigerant to condense to a high-pressure liquid state. Theliquid is forced through a capillary tube where the resulting pressure drop allows the refrigerant to boil off ata predetermined temperature. Low-pressure liquid refrigerant enters the heat exchanger where heat fromthe incoming air is transferred causing the refrigerant to boil; the resulting phase change produces a lowpressure, low temperature gas. The low-pressure gas is returned to the compressor, where it is re-compressed and begins the cycle again. During those periods when the compressed air load is reducedthe excess refrigerant is by-passed automatically back to the compressor via the hot gas by-pass valvecircuit.


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5.5 REFRIGERATING COMPRESSOR

The refrigerating compressor is the pump in the system, gas coming from the evaporator (low pressureside) is compressed up to the condensation pressure (high pressure side). The compressors utilized aremanufactured by leading manufacturers and are designed for applications where high compression ratiosand wide temperature changes are present.The hermetically sealed construction is perfectly gas tight, ensuring high-energy efficiency and long, usefullife. Dumping springs support the pumping unit in order to reduce the acoustic emission and the vibration

diffusion. The aspirated refrigerant gas, flowing through the coils before reaching the compression cylinderscools the electric motor. The thermal protection protects the compressor from over heating and overcurrents. The protection is automatically restored as soon as the nominal temperature conditions arereached.

5.6 CONDENSER (AIR-COOLED)

The condenser is the component in which the gas coming from the compressor is cooled down andcondensed becoming a liquid. Mechanically, a serpentine copper tubing circuit (with the gas flowing inside)is encapsulated in an aluminum fin package.The cooling operation occurs via a high efficiency fan, creating airflow within the dryer, moving air throughthe fin package. Its mandatory that the ambient air temperature does not exceed the nominal values. It isalso important to keep the condenser unit free from dust and other impurities.

5.7 CONDENSER (WATER-COOLED)

The condenser is the component in which the gas coming from the compressor is cooled down andcondensed becoming a liquid. Basically it is a water/refrigerating gas exchanger where the cooling waterlowers the temperature of the refrigerating gas.The temperature of the inlet water must not exceed the nominal values. It must also guarantee an adequateflow and that the water entering the exchanger is free from dust and other impurities.

5.8 CONDENSER WATER REGULATING VALVE (WATER-COOLED)

The condenser water regulating valve is used to keep the condensing pressure/temperature constant whenthe Water-Cooled is being used. Thanks to the capillary tube, the valve detects the pressure in thecondenser and consequently adjusts the water flow. When the dryer stops the valve automatically closes

the cooling water flow.The condenser water regulating valve is an operating control device.The closure of the water circuit from the pressure condenser water regulating valve cannot be usedas a safety closure during service operations on the system.

ADJUSTMENTThe condenser water regulating valve is adjusted during the testing phase to a pre-set value thatcovers 90% of the applications. However, sometimes the extreme operating conditions of the dryermay require a more accurate calibration.During start-up, a qualified technician should check the condensing pressure/temperature and ifnecessary adjust the valve by using the screws on the valve itself.To increase the condensing temperature, turn the adjusting screws counter-clockwise; to lower it

turn the screws clock-wise.

Water valve setting : R407C pressure 16 barg (+0.5 / -0 bar)

5.9 FILTER DRIER

Traces of humidity and slag can accumulate inside the refrigeran circuit. Long periods of use can alsoproduce sludge. This can limit the lubrication efficiency of the compressor and clog the expansion valve orcapillary tube. The function of the filter drier, located before the capillary tubing, is to eliminate anyimpurities from circulating through the system.

5.10 CAPILLARY TUBE

It consists of a piece of reduced cross section copper tubing located between the condenser and the

evaporator, acting as a metering device to reduce the pressure of the refrigerant. Reduction of pressure is adesign function to achieve optimum temperature reached within the evaporator: the smaller the capillarytube outlet pressure, the lower the evaporation temperature.The length and interior diameter of the capillary tubing is accurately sized to establish the performance ofthe dryer; no maintenance or adjustment is necessary.


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5.11 THERMOSTATIC EXPANSION VALVE - TEX

The purpose of this valve is to regulate the refrigerant flow across the dryer relative to the heat load. Itsoperation is to maintain a constant condition in the evaporator, regardless of load variations, to provide thecorrect dew point and prevent liquid refrigerant returning to the compressor.

5.12 AIR-TO-AIR HEAT EXCHANGER

The purpose of this exchanger is to drop the heat of the incoming compressed air onto the outgoing cold

air. The benefits of this solution are essentially two: the incoming air is already partially cooled so therefrigerating circuit can be sized as to assure a limited thermal heat, with a 4050% energy saving.Secondly no cold air is allowed into the compressed air line, thus preventing the systems pipes sweating.

5.13 AIR-TO-REFRIGERANT HEAT EXCHANGER

Also called evaporator. The liquid formed in the condenser is evaporated in this part of the circuit. In theevaporation phase the refrigerant tends to absorb the heat from the compressed air present in the otherside of the exchanger.Refrigerant and air are in counter flow, thus contributing to limit pressure drop and to provide efficientthermal exchange.

5.14 CONDENSATE SEPARATOR

The cold air exiting the evaporator goes through the hi-efficiency condensate separator featuring a stainlesssteel mesh. As the condensate transported by the air gets in contact with the mesh net it is separated andexpelled by means of the draining device. The resulting cold and dry air is then conveyed into the air-to-airheat exchanger.The mesh type mist separator offers the benefit to be highly efficient even with variable flow rates.

5.15 HOT GAS BY-PASS VALVE

This valve injects part of the hot gas (taken from the discharge side of the compressor) in the pipe betweenthe evaporator and the suction side of the compressor, keeping the evaporation temperature/pressureconstant at approx. +2 C. This injection prevents the formation of ice inside the dryer evaporator at everyload condition.

ADJUSTMENT

The hot gas by-pass valve is adjusted during the manufacturing testing phase. As a rule noadjustment is required; anyway if it is necessary the operation must be carried out by anexperienced refrigerating engineer.

WARNINGthe use of Schrader service valves must be justified by a real malfunction of the refrigeratingsystem. Each time a pressure gauge is connected, a part of refrigerant is exhausted.Without compressed air flow through the dryer, rotate the adjusting screw (position A on thedrawing) until the following value is reached:

Hot gas setting : R407C pressure 4.5 barg (+0.1 / -0 bar)

PLH 210-380

2 x

A

4 mm5/32 in.

+

-

VL

Y0001

PLH 400-1000

A8 mm

5/16 in.

-

+

VLY0003


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5.16 REFRIGERANT PRESSURE SWITCHES LPS HPS

As operation safety and protection of the dryer a series of pressure switches are installed in the gas circuit.

LPS : Low-pressure controller device on the suction side of the compressor, is enabled only if thepressure drops below the pre-set value. The values are automatically reset when the nominalconditions are restored.Calibrated pressure : R 407 C Stop 1.7 barg - Restart 2.7 barg

HPS : This high-pressure controller device, located on the discharge side on the compressor, is activatedwhen the pressure exceeds the pre-set value. It features a manual-resetting button mounted on thecontroller itself.

Calibrated pressure : R 407 C Stop 30 barg - Manual reset (P


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5.18.1 HOW TO SWITCH ON THE DRYER

When the unit is powered the display shows .

The condensate drain test is always active through button ESC .

Press for at least 2 seconds to start the dryer: if the compressor has been shut down for enough time, itwill start up immediately; otherwise the display will show the countdown of the seconds before the


5.18.2 HOW TO SWITCH OFF THE DRYERFrom any menu press for at least 2 seconds. The display shows .

5.18.3 HOW TO DISPLAY THE OPERATING PARAMETERS - INFO MENU

The info menu shows the dynamic operating parameters of the dryer.

With the dryer ON and not in other menus, press info for at least 1 second to enter the info menu.

Access to the info menu is confirmed by message on the display (first parameter of the menu). Use

the arrows and to move to the following/previous. Press info to show the value of the selected

parameter. Press info again to return to the list of displayable parameters.

Press ESC to exit info menu (if no button is pressed after 2 minutes the menu is exited automatically).

Info Description

T1 - Temperature probe T1 DewPoint

T2 Temperature probe T2 Air IN

T3 Temperature probe T3 compressor suction

T4 Temperature probe T4 compressor discharge

HP condensing pressure HP

HrS total hours of operation

SrV hours until next service

Note : The temperatures are displayed in C or F (led or is lighted).

Pressure is displayed in barg or psig (led or is lighted).The total hours of operation and the hours until the next service are shown in the field 0999hours and in thousands of hours from 01.0 hours on (example : if the display shows number 35 itmeans 35 hours; if the display shows number 3.5 it means 3500 hours).


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5.18.4 HOW A SERVICE WARNING IS DISPLAYED

A service warning is an unusual event that must recall the attention of operators/maintenance technicians.Generally it does not stop the dryer (except for a high DewPoint parameter that can be set to stop thedryer).

When the service warning is active the led flashes. If the service warning is memorized (it tripped but

then it switched off by itself) led is lighted.In both cases the display shows the DewPoint temperature and the service warnings that are active or notactive but that have not yet been reset.

Service warnings are not automatically reset (except for that can be set in auto-reset).

To RESET the service warning press the buttons logreset

simultaneously for 3 seconds. Only thememorized service warning will be reset, whereas the service warning are still engaged will remain

displayed and the led flashes.

NOTE: the operator/maintenance technician must inspect the dryer and verify/solve the problem thatgenerated the service warning.

Service Warning Description

PF1 - Probe 1 Failure : failure temperature probe 1



HdP - High DewPoint: DewPoint too high, higher than the HdA value set.

LdP - Low DewPoint : DewPoint too lowSet T1< -1C (30F) delay 5 minutes / Reset T1> 0C (32F)

drn - Drainer : condensate drainer failure (opening of contact DRN if electronic leveldrainer is installed see electric diagram)

SrV - Service : maintenance service time expired SrV

dt - Discharge Temperature : compressor discharge temperature (probe T4) beyondnormal values, but within safety limitsSet T4> 90C (194F) delay 3 minutes / Reset T4< 85 C (185F)

HCP - High Condensing Pressure : condensing pressure (transducer HP) beyondnormal values, but within safety limitsSet HP> 28barg (406psig) delay 3 minutes / Reset HP< 25barg (363psig)

NOTE: with dryer ON, but without compressed air pressure, the drainer failure notice mayappear.


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5.18.5 HOW AN ALARM IS DISPLAYED

The alarm is an unusual event that always causes the dryer to switch OFF for the safety of the machine andthe operators.

When the alarm is active the led flashes. If the alarm is memorized (it tripped but then it switched off by

itself) led is lighted (dryer stay OFF in any case).

When the led flashes the message and the active alarm/s appear in sequence on the display.

When the led is lighted, the message and the alarm/s that tripped and require to be reset appearin sequence on the display.

The alarms are not automatically reset. To RESETthe alarm the led must be lighted and the buttonslog

reset

must be pressed simultaneously for at least 3 seconds.The dryer does not start up automatically after the alarms have been reset.

NOTE: the operator/maintenance technician must inspect the dryer and verify/solve the problem thatgenerated the service warning.

Alarm Description

HP - High Pressure : the refrigerant high pressure safety pressure switch HPS tripped (note :the pressure switch has a reset button)

LP - Low Pressure : the refrigerant low pressure safety pressure switch LPS tripped

COn - Compressor : the compressors protections and/or the reverse phase protector RPPtripped

FAn - Fan : the fan protections tripped

Hdt - High Discharge Temperature : compressor discharge temperature beyond the safetylimit

Set T4> 100C (212F) delay 1 minute / Reset T4< 90 C (194F)

ICE - ICE / freezing : temperature inside the exchanger (probe T1) is too low and causes thecondensate to freeze.Set T1< -3C (27F) delay 1 minute / Reset T1> 0C (32F)

LCP - Low Condensing Pressure : condensing pressure too low

PF4 - Probe 4 Failure : failure probe 4

PFP - Probe Pressure Failure : failure condensing pressure trasducer BHP


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5.18.6 HOW TO SHOW THE ALARM MEMORY - LOG MENU

The log menu is the list of the last 10 alarms (only alarms, not service warning). They appear inchronological order (LIFO logic).

With dryer ON or OFF and not in other menus, press log for at least 1 second to enter the log menu.

Access to the log menu is confirmed by message (L01) on the display (first parameter of menu). Use

the arrows and to move to following/previous (L01 L10). Press log to show the selected logvalue. Alternatively the parameter that generated the alarm and the hours of operation of the machine when

the alarm tripped are shown. Press log again to return to the log list.

Press ESC to exit log menu (if no button is pressed after 2 minutes the menu is exited automatically).

NOTE: an empty position in the log list is displayed by the message .

5.18.7 HOW TO CONTROL DRYER WITH REMOTE CONTROL

The DMC24 can be easily controlled using 2 digital inputs connected to terminals 1, 2 and 3 (see electricdiagram).

Close the contact between the terminals 2 and 3 to enable the remote control, the led turns on andit is no longer possible to switch the dryer ON or OFF from local panel (the condensate drain test is possibleand access to info and log menus).Having contact between terminals 2 and 3 closed, close the second contact between the terminals 1 and 2

to switch ON the dryer. Open the contact between the terminals 1 and 2 to switch oFF the dryer.

Use dry contacts only (potential free) suitable for low voltage. Assure an adequateisolation of potentially dangerous powered parts.

CAUTION:AUTO-RESTART / REMOTE ON-OFFTHE DRYER MAY POWER UP WITHOUT BEING ACTED UPON.THE USER WILL BE RESPONSIBLE FOR THE INSTALLATION OF PROPER PROTECTIONSFOR POSSIBLE SUDDEN POWER RESTORATION TO THE DRYER.

5.18.8 OPERATION OF THE FAILURE/ALARM DRY CONTACT (POTENTIAL FREE)

The DMC24 is equipped with a dry contact (potential free) to display failure and/or alarm conditions.

54 6 Dryer powered and no service warning or alarm (active and not yet reset) displayed.

654 Dryer not powered or service warning or alarm (active and not yet reset) displayed.

5.18.9 CONNECTION TO SERIAL LINE

The DMC24 can be connected to a supervision serial line, remote control or download of log file (memory)of alarms.Contact your distributor or service centre for more information.


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5.18.10 HOW TO CHANGE OPERATING PARAMETERS SETUP MENU

The setup menu can be used to change the dryers operating parameters.

Only qualified personnel must be allowed to access to the setup menu. The manufactureris not responsible for malfunctioning or failure due to modification to the operatingparameters.

With dryer ON or OFF and not in other menus, simultaneously press buttonsinfo

set for at least 5 seconds

to enter the setup menu.Access to the info menu is confirmed by message on the display (first parameter of menu). Use

arrows and to move to following/previous one.

Keep info pressed to display the value of the selected parameter and use arrows and to change

the value. Release the button info to confirm the value and skip to following parameter.

Press ESC to exit setup menu (if no button is pressed after 2 minutes the menu is exited automatically).

ID Description Limits ResolutionStandard

setup

Ton drain time ON : time ON condensate drain valve00 = level electronic drainer installed

00 20 sec 1 sec 03

ToF - drain time OFF : pause time for condensatedrain valve

1 20 min 1 min 1

HdA - High DewPoint Alarm : Alarm threshold for ahigh DewPoint (the alarm disappears when thetemperature drop 1C / 2F below alarm point)

0.025.0 Cor

32 77 F

0.5 Cor

1 F

20or68

Hdd - High DewPoint Delay : high DewPoint alarmenable delay

01 20minutes

1 min 15

HdS - High DewPoint alarm STOP : select if highDewPoint alarm stops dryer (YES) or does not stopdryer (nO)

YES nO - nO

SrV - Service Setting: setting of service warning timer.00 = service warning timer disabled.

0.0 9.0(x 1000)

hours

0.5(x1000)hours

3.0

SCL - Scale: display scale of temperatures andpressure.(Note : setting C = temperature in C and pressure in bar;setting F = temperature in F and pressure in psi)

C F - C

AS - Auto Restart : automatic re-start at power supply.YES = at power supply dryer starts up againautomatically (if it was ON)

nO = at power supply dryer is always OFF

YES nO - nO

Ard - Auto Reset service drain : automatic reset ofservice drainYES = automatic reset at normal conditionsnO = manual reset required

YES nO - YES

IPA - IP Address : selection of IP address to use inserial connection line

1 255 1 1

AS = YES - CAUTION -THE DRYER MAY POWER UP WITHOUT BEING ACTED UPON.THE USER WILL BE RESPONSIBLE FOR THE INSTALLATION OF PROPER PROTECTIONS

FOR POSSIBLE SUDDEN POWER RESTORATION TO THE DRYER.


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5.19 ELECTRONIC LEVEL CONTROLLED CONDENSATE DRAIN

Instead of the usual drain system (a solenoid valve controlled by means of electronic instrument); anelectronic level controlled drain is installed. This drain consists of a condensate accumulator where acapacitive sensor continuously checks the level of the liquid: as soon as the accumulator is filled, the sensorpasses a signal to the electronic control and a diaphragm solenoid valve will open to discharge thecondensate. For a complete condensate discharge the valve opening time will be adjusted exactly for eachsingle drain operation to avoid wasting air. No Y-shaped filter is installed and no adjusting is required. A

service valve is installed before the electronic drain in order to make check and maintenance operationeasy.

AT DRYER START-UP VERIFY THAT THIS VALVE IS OPEN.

CONTROL PANEL

Power Led On - drain ready to work / supplied

Valve Led On - membrane solenoid valve open / discharging

Alarm Led On - drain in alarm condition

TEST Button Discharge test (keep pushed for 2 seconds)

TROUBLESHOOTING

Only qualified personnel should perform troubleshooting and or maintenanceoperations.Prior to performing any maintenance or service, be sure that:

no part of the machine is powered and that it cannot be connected to the mainssupply.

no part of the machine is under pressure and that it cannot be connected to thecompressed air system.

Maintenance personnel have read and understand the safety and operationinstructions in this manual.

SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION

No led lighting up. Verify that the system is powered.Verify the electric wiring (internal and/or external).Check internal printed circuit board for possible damage.

Pressing of Test button, butno condensate discharge.

The service valve located before the drain is closed - open it.The dryer is not under pressure - restore nominal condition.Solenoid valve defective - replace the drain.The internal printed circuit board is damaged - replace the drain.

Condensate discharge onlywhen Test button ispressed.

The capacitive sensor is too dirty - open the drain and clean the sensorplastic tube.

Drain keeps blowing off air. The diaphragm valve is dirty - open the drain and clean it.The capacitive sensor is too dirty - open the drain and clean the sensor

plastic tube.

Drain in alarm condition. The capacitive sensor is too dirty - open the drain and clean the sensorplastic tube.

The service valve located before the drain is closed - open it.The dryer is not under pressure - restore nominal condition.Solenoid valve defective - replace the drain.

NOTE : When the drain is in alarm condition, the diaphragm solenoid valve will open 7.5 sec every 4min.


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6. MAINTENANCE, TROUBLESHOOTING, SPARES AND DISMANTLING

6.1 CONTROLS AND MAINTENANCE


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.


Before attempting any maintenance operation on the dryer, shut it down and wait at least 30minutes.

Some components can reach high temperature during operation. Avoid contact until system orcomponent has dissipated heat.

DAILY

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 outsideclean the condenser; repeat this operation blowing in the opposite way; becareful not to damage the aluminum fins of the cooling package.

Close the manual condensate drain valve, unscrew the strainer (if installed) and clean it with

compressed air and brush. Reinstall the strainer properly tight, and then open the manual valve.At the end, check the operation of the machine.

EVERY 1000 HOURS OR YEARLY

Verify for tightness all the screws of the electric system and that all the Disconnects-Tabs typeconnections are in their proper position inspect unit for broken, cracked or bare wires.

Inspect refrigerating circuit for signs of oil and refrigerant leakage.Measure and record amperage. Verify that readings are within acceptable parameters as listed

in specification table.Inspect flexible hoses, and replace if necessary.At the end, check the operation of the machine.


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6.2 TROUBLESHOOTING


no part of the machine is powered and that it cannot be connected to the mainssupply.

no part of the machine is under pressure and that it cannot be connected to thecompressed air system.


Before attempting any maintenance operation on the dryer, shut it down and wait at least 30minutes.

Some components can reach high temperature during operation. Avoid contact until system orcomponent has dissipated heat

SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION

The dryer doesn't

start.

Verify that the system is powered. Verify the electric wiring. Blow of fuse (see FU1/FU2/FU4 on the electric diagram) of the auxiliary circuit -

replace it and check the proper operation of the dryer.

DMC24 - The led is lighted - see specific point.

The compressordoesnt work.

Activation of the compressor internal thermal protection - wait for 30 minutes,then retry.

Verify the electric wiring. DMC24 - Internal delay device the display shows the seconds before start-up.

DMC24 - The led is lighted - see specific point. If the compressor still doesnt work, replace it.

Condensers fandoesnt work(Air-Cooled).

Verify the electric wiring. Fan power contactor (see KV1/KV2 on the electric diagram) is faulty - replace it.

DMC24 - The led is lighted - see specific point. There is a leak in the refrigerant circuit - contact a refrigeration engineer. If the fan still doesn't work, replace it.

DewPoint toohigh.

The dryer doesn't start - see specific point. The T1 DewPoint probe doesnt correctly detect the temperature - ensure the

sensor is pushed into the bottom of probe well. The compressor doesnt work - see specific point. The ambient temperature is too high or the room aeration is insufficient -

provide proper ventilation (Air-Cooled). The inlet air is too hot - restore the nominal conditions. The inlet air pressure is too low - restore the nominal conditions. The inlet air flow rate is higher than the rate of the dryer - reduce the flow rate -

restore the normal conditions. The condenser is dirty - clean it. The condenser fan doesnt work - see specific point (Air-Cooled). The cooling water is too hot - restore the nominal condition (Water-Cooled). The cooling water flow is insufficient - restore the nominal condition

(Water-Cooled). The dryer doesnt drain the condensate - see specific point. The hot gas by-pass valve is out of setting - contact a refrigeration engineer to

restore the nominal setting. There is a leak in the refrigerant circuit - contact a refrigeration engineer.


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DewPoint too low. The fan is always on verify the correct operation of the fan power contactor(see KV1/KV2 on the electric diagram) and/or of pressure transducer (see BHPon the electric diagram) (Air-Cooled).

Ambient temperature is too low - restore de nominal condition. The hot gas by-pass valve is out of setting - contact a refrigeration engineer to

restore the nominal setting.

Excessivepressure drop

within the dryer.

The dryer doesnt drain the condensate - see specific point. The DewPoint is too low - the condensate is frost and blocks the air - seespecific point.

Check for throttling the flexible connection hoses.

The dryer doesntdrain thecondensate

Inlet compressed air pressure is too low and condensate is not drained restore nominal conditions.

The condensate drain service valve is closed - open it. Condensate strainer is clogged remove and clean it. The drain solenoid valve is jammed remove and clean it. The coil of the drain solenoid valve is failed replace. Verify the electric wiring. The DewPoint is too low - the condensate is frost and blocks the air - see

specific point. Drainer is not operating correctly (see paragraph 5.19).

The dryercontinuouslydrainscondensate.

The drain solenoid valve is jammed remove and clean it. Try to remove the electric connector on the solenoid valve if drain stops verify

the electric wiring or the electronic instrument is faulty replace it. Drainer is dirty (see paragraph 5.19).

Water within theline.

The dryer doesn't start - see specific point. If installed- Untreated air flows through the by-pass unit - close the by-pass. The dryer doesnt drain the condensate - see specific point. DewPoint too high - see specific point.

HPS highpressure switchhas beenactivated.

Check which of the following has caused the activation :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 .3. The condenser fan doesnt work - see specific point (Air-Cooled).4. The cooling water is too hot - restore the nominal condition (Water-Cooled).5. The cooling water flow is insufficient - restore the nominal condition (Water-

Cooled). Reset the pressure switch pressing the button on the controller itself - verify the

dryer for correct operation. HPS pressure switch is faulty - contact a refrigeration engineer to replace it.

LPS low pressureswitch has beenactivated.

There is a leak in the refrigerating fluid circuit - contact a refrigeration engineer. The pressure switch reset automatically when normal conditions are restored -

check the proper operation of the dryer.


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DMC24 - ledis lighted.

With led flashing : one or more alarms are active and the display shows

and the active alarms. With led lighted : one or more alarms are waiting to be

reset and the display shows and the alarms that are no longer active but notyet reset.

The alarms are displayed with the following messages :1. : pressure switch HPS tripped (refrigerant high pressure) for condensing

pressure too high - see specific paragraph (NOTE : when problem is solved pressreset key on HPS pressure switch).

2. : LPS pressure switch tripped (low pressure) due to refrigerant pressure too low- see specific paragraph.

3. : Con during first startup power phases of compressor are not connectedproperly (see RPP on the electric diagram) Change rotating direction swappingtwo phases of the power supply of dryer. These changes have to be done only by aqualified electrician. DO NOT BY PASS RPP PROTECTION: BY OPERATINGTHE MACHINE IN WRONG ROTATING DIRECTION, THE COMPRESSOR WILLFAIL IMMEDIATELY AND THE WARRANTY WILL BE VOIDED.

4. : Con one phase of power supply of dryer is missing (see RPP on the electricdiagram) restore the missing phase.

5. : Con Reverse Phase Protector (RPP) is faulty replace it.6. : Con electric protection of compressor tripped (see Q1/QC1 on the electric

diagram) reset and verify the dryers proper operation.7. : FAn - electric protection of fan tripped (see QV1 on the electric diagram) -

reset and verify the dryers proper operation (Air-Cooled).8. : FAn thermal protection inside the fan/s tripped (see MF on wiring diagram

wait 30 minutes and try again 30 (Air-Cooled).9. : Hdt compressor discharge temperature protection tripped due to very high

temperature (probe T4) see specific paragraph.10. : ICE temperature inside exchanger (probe T1) too low DewPoint is too low

- see specific paragraph.11. : LCP - condensing pressure too low see specific paragraph.

12. : PF4 failure temperature probe T4 (compressor discharge) verify electricwiring and/or replace probe.13. : PFP failure pressure transducer BHP (condensing pressure) verify

electric wiring and/or replace transducer.

NOTE: after solving the problem, the alarms must be reset (press the keyslog

reset

simultaneously for 3 seconds).

DMC24 - ledis lighted.

With led flashing: one or more service warnings are active. With ledlighted: one or more service warnings are waiting to be reset. The display showsthe DewPoint temperature and the active or not reset service warning.

The service warnings are displayed with the following messages:1. : PF1 temperature probe failure T1 (DewPoint) verify electric wiring and/or

replace probe.2. : PF2 - temperature probe failure T2 (air IN) verify electric wiring and/orreplace probe.

3. : PF3 - temperature probe failure T3 (compressor suction) verify electricwiring and/or replace probe.

4. : Hdp DewPoint too high (higher than set HdA value) see specificparagraph.

5. : Ldp - DewPoint too low - see specific paragraph.6. : drn the condensate drainer does not work properly (DRN contact open- if

electronic drainer is installed) - see specific paragraph.7. : SrV - Service maintenance notice time expired (parameter SrV) carry out

planned maintenance and reset hour counter.8. : dt compressor supply temperature too high (probe T4) see specific

paragraph.9. : HCP condensing temperature too high see specific paragraph.NOTE: after solving the problem, the services must be reset (press the keys

log

reset

simultaneously for at least 3 seconds).


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Compressordischargetemperaturetoo high.

Verify what caused the failure :1. Excessive thermal load restore nominal conditions.2. Inlet air is too hot - restore nominal conditions.3. Ambient temperature is too high or the room aeration is insufficient - provide

proper ventilation.4. The condenser is dirty clean it.5. Fan does not work see specific paragraph.

6. Fan is always on verify proper operation of fan power contactor (see KV1/KV2on electric diagram) and/or of pressure transducer (see BHP on electricdiagram) (Air-Cooled).

7. The hot gas by-pass valve requires re-adjusting contact a specializedtechnician to reset the rated calibration.

8. The temperature of the cooling water is too low reset rated conditions (Water-Cooled).

9. The cooling water flow adjusting valve requires re-adjusting - contact aspecialized technician to reset the rated calibration (Water-Cooled).

10. Refrigerant gas leak - contact a refrigeration engineer.

Condensing

pressure too high.

Verify what caused the failure :

1. Ambient temperature is too high or there is not enough air change in area arrange for proper ventilation (Air-Cooled).

2. The condenser filter is dirty clean it or replace it (Air-Cooled).3. Fan does not work see specific paragraph (Air-Cooled).4. The cooling water is too hot reset rated conditions (Water-Cooled).5. Cooling water flow is not sufficient - reset rated conditions (Water-Cooled).

Condensingpressure too low.

Verify what caused the failure :1. Fan is always on verify proper operation of fan power contactor (see KV1/KV2

on electric diagram) and/or of pressure transducer (see BHP on electricdiagram).

2. Ambient temperature is too low - restore nominal conditions.

3. Air flows through the condenser even with fan off protect dryer against wind orexternal air flows (not caused by dryers fan).4. The cooling water temperature is too low restore nominal conditions (Water-

Cooled).5. The cooling water flow adjusting valve requires re-adjusting - contact a

refrigeration engineer to restore the nominal calibration (Water-Cooled).6. Refrigerant gas leak contact a refrigeration engineer.7. Compressor does not work see specific point


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6.3 SPARE PARTS

The suggested spare parts list will enable you to promptly intervene in case of abnormal operation, soavoiding to wait for the spares delivery. In case of failure of other parts, for example inside the refrigeratingcircuit, the replacement must be worked out by a refrigerating systems specialist or in our factory.NOTE: To order the suggested spare parts or any other part, its necessary to quote the datareported on the identification plate.

Suggested spare part


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6.4 MAINTENANCE OPERATION ON THE REFRIGERATING CIRCUIT

Maintenance and service on refrigerating systems must be carried out only by certifiedrefrigerating engineers only, according to local rules.All the refrigerant of the system must be recovered for its recycling, reclamation or destruction.Do not dispose the refrigerant fluid in the environment.

This dryer comes ready to operate and filled with R134a or R407C type refrigerant fluid.

In case of refrigerant leak contact a certified refrigerating engineer. Room is to be aired before anyintervention.If is required to re-fill the refrigerating circuit, contact a certified refrigerating engineers.Refer to the dryer nameplate for refrigerant type and quantity.

Characteristics of refrigerants used:

Refrigerant Chemical formula TLV GWP

R134a - HFC CH2FCF3 1000 ppm 1300

R407C - HFCR32/125/134a (23/25/52)

CHF2CF3/CH2F2/CH2FCF31000 ppm 1653

6.5 DISMANTLING OF THE DRYER

If the dryer is to be dismantled, it has to be split into homogeneous groups of materials.

Part Material

Refrigerant fluid R407C, R134a, Oil

Canopy and Supports Carbon steel, Epoxy paint

Refrigerating compressor Steel, Copper, Aluminium, Oil

Heat exchanger Stainless steel, Copper

Condensate separator Stainless steel

Condenser Unit Aluminium, Copper, Carbon steel

Pipe Copper

Fan Aluminium, Copper, Steel

Valve Brass, Steel

Electronic Level Drain PVC, Aluminium, Steel

Insulation Material Synthetic rubber without CFC, Polystyrene, Polyurethane

Electric cable Copper, PVC

Electric Parts PVC, Copper, Brass

We recommend to comply with the safety rules in force for the disposal of each type of material.Refrigerant contains droplets of lubrication oil released by the refrigerating compressor.Do not dispose this fluid in the environment. Is has to be discharged from the dryer with a suitabledevice and then delivered to a collection centre where it will be processed to make it reusable.


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7. LIST OF ATTACHMENTS

7.1 DRYERS DIMENSIONS

7.1.1 PLH 210-380 Dryers dimensions

7.1.2 PLH 210-380 FL Dryers dimensions

7.1.3 PLH 400-1000 Dryers dimensions

7.2 EXPLODED VIEW

7.2.1 Exploded view of dryers PLH 210-380 /AC

7.2.2 Exploded view of dryers PLH 210-380 FL /AC

7.2.3 Exploded view of dryers PLH 210-380 /WC

7.2.4 Exploded view of dryers PLH 210-380 FL /WC

7.2.5 Exploded view of dryers PLH 400-830 /AC

7.2.6 Exploded view of dryers PLH 400-830 /WC

7.2.7 Exploded view of dryers PLH 1000 /WC

Exploded view table of components

1 Heat exchanger group 20 Refrigerant accumulator

.1 Insulation material 21 Electronic drainer

a Air- to-air heat exchanger 22 Main switch

b Air-to-refrigerant heat exchanger 35 Thermostatic expansion valve

c Condensate separator 37 Refrigerant pressure transducer

2 Refrigerant pressure-switch LPS 38Drain solenoid valve electric filter(PLH 600-1000)

4 Refrigerant pressure-switch HPS 51 Front panel

6 Compressor 52 Back panel

7 Hot gas by-pass valve 53 Right lateral panel

8 Condenser (Air-Cooled) 54 Left lateral panel

9 Condenser fan 55 Cover

10 Filter drier 56 Base plate

11 Capillary tube 57 Upper plate

12 T1 Temperature probe (DewPoint) 58 Support beam

13 Condensate drain isolation valve 59 Support bracket

14 Condensate drain strainer 60 Control panel

15 Condensate drain solenoid valve 65 Condenser filter

16 Coil for condensate drain solenoid valve 66 QE door

17 Air Dryer Controller 81 Flow diagram sticker

18 Condenser (Water-Cooled) 83 Refrigerant service valve - High pressure side

19 Condenser water regulating valve (Water-Cooled) 84 Refrigerant service valve - Low pressure side


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---- ----ENENENEN----

7.3 ELECTRIC DIAGRAMS

7.3.1 Electrical diagram of dryers PLH 210-380

7.3.2 Electrical diagram of dryers PLH 400-1000

Electrical diagram table of components

MC : Compressor

MV : Condenser fan

DMC24RU : DMC24 Display Module - Air Dryer Controller

DMC24MA : DMC24 Main Module - Air Dryer Controller

BT1 : T1 Temperature probe DewPoint

BT2 : T2 Temperature probe Air IN

BT3 : T3 Temperature probe Compressor suction

BT4 : T4 Temperature probe Compressor discharge

BHP : Refrigerant pressure transducerHPS : Pressure switch - Compressor discharge side (HIGH pressure)

LPS : Pressure switch - Compressor suction side (LOW pressure)

ELD : Electronic drainer

EVD : Timed drainer (not used)

QS : Main switch with door block

RC : Compressor crankcase heater

NT1 : Air Cooled only

NT2 : Verify transformer connection according to power supply voltage

NT3 : Jump if not installed

NT4 : Provided and wired by customer

NT5 : Limit of equipment

NT6 : Timed drain output (not used)

NT7 : Water Cooled only

BN = BROWN OR = ORANGE

BU = BLUE RD = RED

BK = BLACK WH = WHITE

YG = YELLOW/GREEN WH/BK = WHITE/BLACK


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----ATATATAT---- ----

7.1.1 PLH 210-380 Dryers Dimensions


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----ATATATAT----

7.1.2 PLH 210-380 FL Dryers Dimensions


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----ATATATAT---- ----

7.1.3 PLH 400-1000 Dryers Dimensions


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----ATATATAT----

7.2.1 Exploded view of Dryers PLH 210-380 /AC


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----ATATATAT---- ----

7.2.2 Exploded view of Dryers PLH 210-380 FL /AC


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----ATATATAT----

7.2.3 Exploded view of Dryers PLH 210-380 /WC


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----ATATATAT---- ----

7.2.4 Exploded view of Dryers PLH 210-380 FL /WC


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----ATATATAT----

7.2.5 Exploded view of Dryers PLH 400-830 /AC


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----ATATATAT---- ----

7.2.6 Exploded view of Dryers PLH 400-830 /WC


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----ATATATAT----

7.2.7 Exploded view of Dryers PLH 1000 /WC


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----ATATATAT---- ----

7.3.1 Electrical Diagram of Dryers PLH 210-380

0

1

3

2

4

5

6

7

8

9

Rev.

Note:

Sheet

03

of

Drawingno

.:

03

01

WIRE

TERMI N

AL

TYP

E

TERMINA

L

UKK5 RC COMPRESSORCRANKCASEHEATER

HIGHPRESSURESWITCHHPS

MV1

LPS

9024

024

CDI

12

CDI

DI2

DI4

2

1

5

4

3

6

UKK5

13

11

10

12

14

RC100

10 RC2

00

DR1

DR2

CDI

DI5

LOWPRESSURESWITCH

FANTHERMALPROTECTION

8

7

00

UDT

NOTINSTALLEDIFELECTRONICDRAINERISUSED

CONDENSATEDRAINSOLENOIDVALVE

ELD

AIRCOOLEDONLY-JUMPIFNOTINSTALLED

ELECTRONICLEVELDRAINER

FR

PLH5478QCD

001

PE

L1

L3

L2

Technicalmodificatio

nsaresubjecttochange

withoutnotice;errorsnot

excluded.

OPTION-JUMP13-14IFNOTINSTALLED


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----ATATATAT----


0

1

3

2

4

5

6

7

8

9

Rev.

Note:

Sheet

03of

Drawingno.:

04

01

BA

11

14

22

24

[2-8]

KDR

[2-5]

KDR [2

-5]

2.3

0.2

0.8

0.1

2.2

0.7

0.0

[2-8]

ELD

FRPLH54

78QCD002

Tech

nica

lmodificationsaresubjec

ttochangewithoutnotice

;errorsnotexcluded.


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----ATATATAT---- ----


0

1

3

2

4

5

6

7

8

9

Rev

.

Note:

Sheet

04

of

Draw

ingno.:

04

01

LOWPRESSURESWITCH

HIGHPRESSURESWITCH

LPS

HP

S

MV1

COMPRESSORCRANKCASEHEATERRC

00

DI2

CDI

12

024

WIRE

TERMINAL

TERMINAL

TYPE

UKK5

DI4

024

00

35

UDT

31

10

00 RC1

RC2

UKK5

024 17

32CDI

16

15

33

00

20

18

19

9

1

5

3

2

4

7

6

8

10

11

12

13

14

MV2

21

22

DI5

34

E

LD

FRPLH5478Q

CD002





ELECTRONICLEVELDRAINER

L3

L1L2

PE

Technicalmodi f

icationsaresubjecttoch

angewithoutnotice

;error s

notexcluded.

OPTION-JUMP15-16IFNOTINSTALLED

CONDENSATEDRAINSOLENOIDVALVENOTINSTALLEDIFELECTRONICDRAINERISUSED


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COSTRUTTORE / MANUFACTURER :

FRIULAIR S.r.l.

Sede Legale:

34077 - Ronchi dei Legionari (GO) ITALYVia Joze Srebernic, 10

Cap.Soc. 12.480 i.v.P.IVA 00430110312Export MGO001913COD.ID.CEE IT 00430110312R.E.A.GO n.51691Cod.Fisc.e Reg.Impr. 00430110312

Sede Operativa:

33050 - Cervignano del Friuli (UD) ITALYVia Cisis, 36 - S.S.352 Km 21 Fraz. Strassoldo

www.friulair.com

Manual Secador de Aire Wh-40

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Transcript of Manual Secador de Aire Wh-40