Hydrovane Refrig Dryer HV04!05!07 Англ.Яз 2005

COMPRESSED AIR DRYERS

MAINTENANCE AND OPERATING MANUAL

R10 for V4-7.5KW

COMPRESSED AIR DRYERS

1MAINTENANCE AND OPERATING MANUAL - Table of Contents

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TABLE OF CONTENTS

TABLE OF CONTENTS....................................................................................................................1

Chapter 1

GENERAL INFORMATIONS.............................................................................................................3

1.1 Summary of possible configurations ...........................................4Chapter 2

SAFETY...........................................................................................................................................5

2.1 General ........................................................................................52.2 General precautions ..................................................................... 5

2.2.1 Compressed gases to be dried ............................................................. 52.2.2 Precautions when using compressed air ............................................. 52.2.3 Lifting and transport precautions ........................................................ 62.2.4 Precautions during installation and operation .................................... 62.2.5 Maintenance and repair precautions ................................................... 6

2.3 Refrigerant gases ......................................................................... 72.3.1 R134a safety card ................................................................................ 8

Chapter 3

TECHNICAL DATA .......................................................................................................................11

3.1 Data plate and meaning of abbreviations ..................................113.2 Performances .............................................................................12

Chapter 4

DESCRIPTION...............................................................................................................................13

4.1 Operating principle.................................................................... 134.2 Air and refrigerant circuits ........................................................13

4.2.1 Compressed air circuit ....................................................................... 134.2.2 Refrigeration circuit .......................................................................... 14

Chapter 5

INSTALLATION.............................................................................................................................15

5.1 Positioning.................................................................................155.2 Piping.........................................................................................165.3 Electrical connections................................................................ 17

Chapter 6

START UP .....................................................................................................................................19

Chapter 7

ELECTRONIC CONTROL..............................................................................................................21

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7.1 Buttons and Leds....................................................................... 217.1.1 LED .................................................................................................... 217.1.2 Buttons ............................................................................................... 21

7.2 Temperature Probe .................................................................... 227.3 Starting the unit ......................................................................... 227.4 Thermostat function .................................................................. 237.5 Compressor delay...................................................................... 237.6 Condensate discharge................................................................ 237.7 Access to electronic board programming.................................. 247.8 Programming Procedures .......................................................... 25

7.8.1 PROG TON Procedure ...................................................................... 257.8.2 PROG RLE Procedure ...................................................................... 267.8.3 PROG HA1 Procedure ...................................................................... 27

7.9 Alarms ....................................................................................... 28Chapter 8

CONDENSATE DISCHARGE SYSTEM ............................................................................................29

8.1 Timed condensate discharger .................................................... 298.1.1 Filter cleaning ................................................................................... 298.1.2 Solenoid valve maintenance .............................................................. 30

8.2 Intelligent condensate drain ...................................................... 31Chapter 9

GENERAL OPERATING AND MAINTENANCE REGULATION ........................................................33

9.1 Operation................................................................................... 339.2 Maintenance .............................................................................. 33

9.2.1 Dryer access ...................................................................................... 339.2.2 Inspection and maintenance schedule ............................................... 34

Chapter 10

TROUBLE SHOOTING...................................................................................................................35

Chapter 11

LIST OF ATTACHMENTS ..............................................................................................................39

3MAINTENANCE AND OPERATING MANUALChapter 1 - General informations

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CHAPTER 1

GENERAL INFORMATIONS

The units described in this manual are called dryers.They are designed to dry a compressed gas flow.These dryers are equipped with a refrigeration circuit for cooling the compressed air to the temperature called dewpoint under pressure.In most applications the gas to be dried is the compressed air and this is why this term will be used even if the gas to be dried is different. Furthermore, the term pressure will be used to indicate the relative pressure.The following symbols are shown on the stickers on the unit as well as on the dimensional drawings and refrigeration circuits in this manual.Their meaning is the following:

SYMBOL DESCRIPTIONAir inlet in the unit

Air outlet from the unit

Condensate discharge

Cooling air flow (for air-cooled units)

Direction of fan rotation (for air cooled units)

Electric shock risk

Direction of the refrigerant gas flow

Table 1 SYMBOLS

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ATTENTIONThis manual gives the user, the installer and the maintenance technician all the technicalinformation required to install, commission and operate the dryer and carry out the routinemaintenance operations to ensure maximum service life.Use only original spare parts whencarrying out routine maintenance or repairs.For all INFORMATION or requests for SPARE PARTS concerning the dryer please contactyour distributor or the nearest service centre, providing the SERIAL NUMBER and TYPE ofthe unit shown on the data plate as well as on the first page of this manual.

1 . 1 S u m m a r y o f p o s s i b l e c o n f i g u r a t i o n sThe configuration of the unit to which this manual is attached was established in the quotation.The following table helps users to understand some of the descriptions contained in this manual ( Chapter 6, Chapter 9) wherever it is necessary to precisely establish the characteristics that differentiate a determined dryer from another.This table shows all the possible configurations for each model and must therefore be interpreted using both the quotation data and the drawings attached to this manual.For example, a dryer with a power input of both 50 and 60 Hz cannot exist.

Characteristic Alternative R10

Power supplySingle phase at 50 Hz xSingle phase at 60 Hz x

Electr. board units at 50 Hz Easycard x

Electr. board units at 60 Hz Easycard x

Condensate discharge

Timed discharge system xIntelligent discharge system x

Table 2 SUMMARY OF POSSIBLE CONFIGURATIONS

5MAINTENANCE AND OPERATING MANUALChapter 2 - Safety

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CHAPTER 2

SAFETY

ATTENTIONThis unit has been designed to be safe when used for the purpose for which it was intendedprovided it is installed, started up and serviced in accordance with the instructionscontained in this manual.The unit contains electrical components operating at mains voltageas well as moving parts, such as fans. It must therefore be disconnected from the mainssupply network before being opened.All maintenance operations which require the unit to beopened may only be carried out by expert or sufficiently trained people with a perfectknowledge of the necessary precautions and directed by a qualified supervisor, whereverpossible.

2 . 1 G e n e r a lThe user should make sure that all the personnel connected with operating and servicing the dryer and auxiliary equipment have read and understood all the warnings, cautions, prohibitions and notes indicated both in this manual and on the unit.If the user makes use of operating procedures, instruments or methods of working which are not specifically recommended, he must ensure that the dryer and auxiliary equipment will not be damaged or made unsafe and that there are no risks to people or property.

2 . 2 G e n e r a l p r e c a u t i o n s

2 . 2 . 1 Compressed gases to be driedCompressed gases to be dried should be compatible with the materials used to build the unit (carbon steel, cast iron, copper and its alloys) and may be air, nitrogen, argon and helium, for example.In any case they must not cause corrosion dangerous for the pressure vessels and fire in event of leakage.

2 . 2 . 2 Precautions when using compressed airIf using compressed air for cleaning purposes, make sure safety regulations are followed and appropriate clothing and eye protection is worn.Never direct compressed air towards your skin or other people.Never use compressed air to remove dirt from clothing.Before releasing compressed air through a hose make sure that the free end is held securely so that it cannot whip and cause injury.

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2 . 2 . 3 Lif t ing and transport precautionsMake sure that all chains, hooks, shackles and slings are in good condition and are of the correct capacity: they must be tested and approved according to local safety regulations.Cables, chains or ropes must never be applied directly to eyebolts.Arrange the lifting cables so that there are no sharp bends.Use a spreader bar to avoid side loads on hooks and eyebolts.While a load is being lifted, keep clear of the area beneath and around it.Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary.The units must be moved in accordance with the attached diagrams (please consult the final part of this manual).

ATTENTIONThe weights of the units are shown on their data plates and on the top side of the packaging.

2 . 2 . 4 Precautions during instal lat ion and operationFor connections to the mains power supply, please see Chapter 5 Installation. and the wiring diagrams.All piping must be painted or clearly marked in accordance with local safety regulations.Never remove or tamper with the safety devices, guards or insulation material fitted to the unit or auxiliary equipment.The unit and auxiliary equipment must be earthen and protected by fuses against short-circuits and overloading.When mains power is switched on, lethal voltages are present in the electrical circuits and the greatest of care must be taken whenever it is necessary to do any work on the electrical system.Do not open any electrical panels while voltage is applied unless this is necessary for measurements, tests or adjustments.This job should only be carried out by a qualified electrician equipped with the proper tools and wearing appropriate personal protection equipment against electrical hazards.

2 . 2 . 5 Maintenance and repair precautionsWhen disposing of parts and waste material of any kind take care not to pollute drains or water-course.Do not burn any waste which could cause air pollution.Protect the environment by using approved storage methods.If replacement parts are needed always use original spares.Keep a written record of all maintenance and repair work carried out on the unit and auxiliary equipment.The frequency and the nature of the work required over a certain period may give rise to adverse operating conditions which should be corrected.Use only refrigerant gas specified on the data plate of the unit.Make sure that all operating and maintenance instructions are strictly followed and that the complete unit, with all accessories and safety devices, is kept in good working order.


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Regularly check the accuracy of pressure and temperature gauges.Replace them when acceptable tolerances are exceeded.Keep the machine clean at all times.During maintenance and repair work, protect components and exposed openings by covering them with clean cloths.Precautions must be taken when carrying out welding or other repair operations which generate heat, flames or sparks.Always protect nearby components with non-flammable material.Never carry out welding or other repair operations which generate heat close to a component containing oil.Before carrying out these operations the systems must first be thoroughly purged and cleaned, preferably by steam cleaning.Never weld or otherwise modify a pressure vessel.To prevent increases in working temperatures and pressures, inspect and clean the heat transfer surfaces (e.g. condenser cooler fins) at regular intervals.Prepare a suitable cleaning schedule for each unit.Never use a light source such as a naked flame to inspect the inside of the unit.Before dismantling any part of the unit ensure that all heavy movable parts are secured.After completing a repair, make sure no tools, loose parts or rags are left inside the machine.Check the direction of rotation of electric motors when starting up the unit for the first time and after any work on the electrical connections or switch gear.Put back all guards after carrying out repair or maintenance work.Do not use flammable liquid to clean components while the unit is working.If non-flammable chlorinated hydrocarbon fluids are used for cleaning, safety precautions must be taken against the release of toxic vapours.Before removing any panels or dismantling any part of the unit, carry out the following operations:

Disconnect the power cable of the unit from the mains electricity supply. Attach a warning label reading: WORK IN PROGRESS - DO NOT SWITCH

ON. Do not switch on the mains electricity supply or attempt to start the unit if a

warning label is attached.

2 . 3 R e f r i g e r a n t g a s e sOnly R134a is used as refrigerant in these dryers.The manufacturer's instructions and local safety regulations should always be observed when handling and storing refrigerant gas cylinders.

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2 . 3 . 1 R134a safety card

PHYSICAL AND CHEMICAL PROPERTIESName: R134a (1,1,1,2 - tetrafluoroethane)Colour: ColourlessOdour: Similar to etherBoiling point: -26.5C / -15.7F at atmospheric pressureFlammability: Non-flammableRelative density: 1.21 kg/l at 25C / 77FWater solubility: 0.15% in weight at 25 C / 77F and atmospheric pressure

STABILITY AND REACTIVITYStability: No reactivity if used in compliance with the instructionsSubstances to be avoided: Alkaline metals, alkaline-earth metals, granulated metal salts,

Al, Zn, Be, etc. in powder formDangerous decomposed products:

Halogens acids, carbonyl halide traces

TOXICOLOGICAL INFORMATIONAcute toxicity: ALC/inhalation/4 hours/ on rat = 567 ml/lLocal effects: Concentrations higher than 1000 ppm v/v may cause narcotic

effects. Inhalation of a high concentration of decomposing products may cause respiratory problems (pulmonary oedema)

Long-term toxicity: No carcinogenic, teratogenic or mutagenic effects shown during tests on animals

Specific effects: A rapid evaporation of the liquid may cause iceECOLOGICAL INFORMATION

Potential global heating HGWP (R11=1):

0.28

Potential ozone impoverishment ODP (R11=1):

0

Disposal considerations: Can be re-used after reprocessingHAZARD INDICATIONS

Main hazards: AsphyxiaSpecific hazards: Unknown

FIRST-AID PRECAUTIONSInhalation: Take the patient outdoors. If necessary give oxygen or

artificial respiration. Never give adrenaline or similar substances

Contact with eyes: Rinse the eye thoroughly with water for at least 15 minutes. Seek medical attention

Contact with skin: Wash immediately with water. Remove contaminated clothingFIRE PRECAUTIONS

Means of extinction: Any oneSpecific hazards: Pressure increaseSpecific methods: Cool the containers by spraying water

Table 3 R134A SAFETY CARD


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PRECAUTIONS IN CASE OF ACCIDENTAL LEAKAGEIndividual precautions: Evacuate personnel to safety areas. Proper ventilation is

required. Use personal protection equipmentEnvironmental precautions: EvaporateCleaning methods: Evaporate

HANDLING AND STORAGEHandling: Technical precautions: only use in ventilated areas.Safety

recommendations: leakage test. Do not carry out pressure tests using an air/R134A mixture. When mixed with air it can become a combustible at a higher than atmospheric pressure when the volume ratio is higher than 60%

Storage: Technical precautions/storage method: close carefully and keep in a fresh, dry and well ventilated place

INDIVIDUAL EXPOSURE/PERSONAL PROTECTIONControl parameters: 1000 ppm v/v or ml/m3 as the weighted average over 8 hoursRespiratory protection: For rescue operations and when carrying out maintenance

work on vessels suitable for R134A use an independent breathing apparatus. Vapours are heavier than the air, and they therefore could cause suffocation by reducing the oxygen available for breathing

Protection for eyes: Safety gogglesProtection for hands: Rubber glovesHygiene protection: Do not smoke

Table 3 R134A SAFETY CARD

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11MAINTENANCE AND OPERATING MANUALChapter 3 - Technical Data

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CHAPTER 3

TECHNICAL DATA

3 . 1 D a t a p l a t e a n d m e a n i n g o f a b b r e v i a t i o n s

The main technical data of the dryer are indicated on the data plate:

MODEL and CODE The model number and the code identify the size of the unit and the type of construction.

MANUAL Code number of this manual.SERIAL NUMBER Serial or construction number of the unit.YEAR OR CONSTRUCTION Year in which final testing of the unit took place.VOLTAGE/PHASE/FREQUENCY Power supply characteristics.MAX. CONSUMPTION (I max) Current absorbed by the unit at limit working conditions

(refrigerant condensing temperature 70C = 158F; refrigerant evaporating temperature 10C = 50F).

INSTALLED POWER (P max) Power absorbed by the unit at limit working conditions (refrigerant condensing temperature 70C = 158F; refrigerant evaporating temperature 10C = 50F).

PROTECTION DEGREE As defined by EN 60529 European standard.REFRIGERANT Type of refrigerant in the unit.QUANTITY OF REFRIGERANT Quantity of refrigerant contained in the unit.MAX. COOLING PRESSURE Rated pressure of refrigeration circuit.MAX. COOLING TEMPERATURE Rated temperature of refrigeration circuit.USER CIRCUIT FLUID Fluid cooled by the unit.MAX. WORKING PRESSURE Maximum rated pressure of user circuit.MAX. TEMPERATURE Rated temperature of user circuit; this should not be

confused with the maximum working temperature which is defined in the quotation.

CONDENSER COOLING FLUID Fluid used by the unit to cool the condenser (this data is not present if the unit condenser is air cooled).

MAX. COOLING PRESSURE Maximum rated pressure of the condenser cooling circuit (this data is not present if the unit condenser is air cooled).

MAX. TEMPERATURE Max. rated temperature of the condenser cooling circuit (this data is not present if the unit condenser is air cooled).

SOUND PRESSURE LEVEL Free field sound pressure level in hemispherical irradiation conditions (open field) at a distance of 1 m from the unit, condenser side, and 1.2 m from the ground.

AMBIENT TEMPERATURE Min. and max. temperature of cooling air.WEIGHT Approximate weight of the unit before packing.

Table 4 DATA PLATE AND MEANING OF ABBREVIATIONS

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The following abbreviations are present on the data plate and wiring diagram:

3 . 2 P e r f o r m a n c e s

ATTENTIONThe performance of the dryer (dew-point, electrical power consumption, pressure drops,etc.) mainly depends on the flow rate and pressure of the compressed gas to be dried and onthe temperature of the ambient air to cool the condenser.These dryers are matched to the following air compressors and should not be used withany other type or model:R10: Hydrovane HV04, HV05, HV07 and HV07RS.Refer to the relevant CompAir technical data sheet for further information.

IMAX max. current;PMAX max. power;ILR current with rotor stopped;In rated current;Icn rated failure current.

13MAINTENANCE AND OPERATING MANUALChapter 4 - Description

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CHAPTER 4

DESCRIPTION

4 . 1 O p e r a t i n g p r i n c i p l eA refrigeration circuit reduces the temperature of a patented thermal mass through which the humid compressed air to be dried is passed.As the air is cooled its water vapour condenses and is then separated and drained.The temperature of the thermal mass is controlled by an electronic board which stops the compressor when it reaches the fixed set point.

4 . 2 A i r a n d r e f r i g e r a n t c i r c u i t s(See attached refrigerant drawings)

4 . 2 . 1 Compressed air circuitThe warm, wet compressed air enters the dryer and passes through the air-to-air heat exchanger section of the thermal mass.Here it is pre-cooled by the cold, dry compressed air leaving the air-to-refrigerant heat exchanger section or the evaporator of the thermal mass.The pre-cooled air then enters the evaporator section of the thermal mass where it is cooled (in most applications to a temperature of approximately 3C / 37.4F) exchanging heat with the evaporator refrigerant fluid and the silica thermal mass.The heat is exchanged by conduction through the aluminium fins connecting the copper tubes, inside which the compressed air flows, to the copper tubes, inside which the refrigerant fluid evaporates.The aluminium fins also exchange heat with the silica thermal mass keeping it at a temperature of approximately 0C (32 F).At this stage, the compressed air is in a saturated state and entrains the condensed moisture produced during cooling.It then passes into the high efficiency condensate separator (demister type with stainless steel mesh) where the entrained moisture is precipitated out of the air and collects at the bottom of the separator.A timed or intelligent condensate discharger (depending on the unit configuration) opens at intervals to force the condensate from the dryer with compressed air.The cold, dry air leaving the separator then flows for a second time through the air-to-air heat exchanger section of the thermal mass where it is reheated while pre-cooling the warm wet air entering the dryer.Not only does this air-to-air heat exchanger reduce the energy consumption required to dry a given quantity of compressed air, but it also prevents condensation from forming on the dryer outlet.

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4 . 2 . 2 Refrigeration circuitThe compressed refrigerant gas flows to the condenser.Here the cooling action causes the refrigerant gas to condense to a liquid.The condenser is a finned coil heat exchanger cooled by a flow of air provided by one or two electrically driven fan, according to the model,.The condenser is generously sized in order to be partially used as a liquid receiver.The cooling air enters the side grills, passing through the air filters (which can be removed) and exits from the front side of the dryer.After the condenser, the liquid refrigerant then passes through a filter-dryer to a capillary tube which reduces its pressure in order to lower its boiling point.The refrigerant then enters the evaporator tubes in the thermal mass and cools both the thermal mass and the compressed air.The refrigerant leaving the evaporator is now a cold vapour and returns to the compressor to repeat the cycle.Since the heat of the compressed air available to evaporate the refrigerant varies considerably due to fluctuations in the air flow rate and inlet temperature, the dryer features an electronic system which controls the temperature of the thermal mass temperature, thereby achieving 3 important objectives:to ensure that the dew-point under pressure is maintained at a constant value of approximately +3C (+37.4F);to prevent the compressed air temperature from falling below 0C (32F), a temperature at which the condensed moisture could start to freeze;to ensure that all the refrigerant leaving the evaporator is in the form of a vapour so that no liquid refrigerant returns to the compressor.When there is little or no load, the temperature in the thermal mass tends to fall.At 0C (32F), the electronic board switches off the refrigerant compressor.The compressed air that continues to flow in the evaporator is cooled by the cold energy stored in the silica.When the temperature of the latter eventually starts to increase, the refrigerant compressor is automatically switched back on to cool it down again.This system has the advantage of reducing the average energy consumption of the dryer roughly in proportion to the demand.

15MAINTENANCE AND OPERATING MANUALChapter 5 - Installation

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CHAPTER 5

INSTALLATION

DANGERBefore installing or operating these dryers, make sure that all personnel have read andunderstood Chapter 2 Safety of this manual.

5 . 1 P o s i t i o n i n g1. Install the compressor and dryer in a well ventilated area where the ambient air is

clean and free from flammable gas or solvents.

2. Take care when installing the compressor and dryer in areas subject to low ambienttemperatures.Take steps to prevent any discharged condensate from freezing in the drainagesystem.The minimum operating ambient temperature of the dryer is shown on the datatable applied on the unit.

3. The dryer may be placed on any sufficiently strong and level surface.Allow the clearances shown in the installation drawings around the unit forservicing access and to ensure an unrestricted flow of cool air through therefrigeration condenser. Position the dryer so that cooling air cannot recirculate in the ventilation inletgrilles. Make sure that the dryer is not subject to warm air flows from the air compressor,after-coolers or other pieces of equipment.

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5 . 2 P i p i n g(see installation diagram)The dryer is normally supplied already fitted to the air compressor, in which case proceed as follows:

1. Air outlet connections are clearly marked (see Chapter 1 General informations).Pipes and connections must be of the correct size and suitable for workingpressure.Do not forget to remove blanking plugs from the pipe connections but take care toprevent swarf, metal filings, pieces of tape or other solid particles from enteringthe dryer during installation as these may block the filter or the discharge valve.

2. All piping must be properly supported. Flexible connections are recommendedin order to prevent pipe stress or the transmission of vibrations.

3. Connect the condensate discharge pipe to a suitable point.The dryer discharge must not be connected to those from any other compressed airequipment; ideally it should discharge into a open funnel.Condensate drainage must never be piped into a common sewer drain as it maycontain oil.Oil/water separators should be used to collect discharged oil.Make sure that the drainage system complies with local regulations.

If the dryer is not supplied already fitted to the air compressor, proceed as follows:1. Air inlet and outlet connections are clearly marked (see Chapter 1 General

informations).Pipes and connections must be of the correct size and suitable for workingpressure.Do not forget to remove blanking plugs from the pipe connections but take care toprevent swarf, metal filings, pieces of tape or other solid particles from enteringthe dryer during installation as these may block the filter or the discharge valve.

2. All piping must be properly supported. Flexible connections are recommendedin order to prevent pipe stress or the transmission of vibrations.

3. Connect the condensate discharge pipe to a suitable point.The dryer discharge must not be connected to those from any other compressed airequipment; ideally it should discharge into a open funnel.Condensate drainage must never be piped into a common sewer drain as it maycontain oil.Oil/water separators should be used to collect discharged oil.Make sure that the drainage system complies with local regulations.

4. Connect the air supply from the compressor to the dryer using the flexibleconnector and condensate separator kit provided by CompAir.

17MAINTENANCE AND OPERATING MANUALChapter 5 - Installation

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5 . 3 E l e c t r i c a l c o n n e c t i o n s

ATTENTIONIn order to prevent the possible damages at the fuse-holder and at the fuse, they wereuninstalled and they were placed into the paper-holder, to protect them from anyaccidental hit.Before to connect the unit to the main power supply, it is necessary to reassemble thefuse into the fuse-holder, and reinstall it.

The machine must be connected to the mains power supply in accordance with the laws and regulations in force in the country of installation.Voltage, frequency and the number of phases must comply with the values indicated on the machine data plate.Input voltage must always remain within the tolerances indicated in the electrical diagram.Unless otherwise indicated, frequency tolerance is equal to +/-1% of its rated value (+/-2% for short periods).The voltage must be supplied between the phase and neutral and the latter conductor must be earthed in its own transformation cabin (TN system according to IEC 364) or by the electricity provider (TT system according to IEC 364).The phase and earth conductors must not be exchanged.

For mains power input:1. Connect the machine (PE terminal in the electrical panel) to the earth system of the

building;

2. Fit an automatic interruption in the event of insulation faults (protection againstindirect contact according to IEC 364) by means of a residual current circuitbreaker (normally with a rated cut-in current of 0.03 A);

3. Provide protection against direct contact of at least IP2X or IPXXB upline fromthe power cable;

4. Fit a device protecting the power cable or the cable supplied with the machinefrom overcurrent (short-circuit) (see indication in the electrical diagram) uplinefrom the power cable;

5. Use conductors which can carry the maximum current required at the maximumambient operating temperature, according to the type of installation chosen (IEC364-5-523) (see indication in the electrical diagram).

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Indications in the electrical diagram:A Maximum permitted size of gG fuse.

Generally speaking, the fuses can be replaced with an automatic switchadjusted to the maximum current absorbed by the machine (contact themanufacture if necessary);

B Cross-section and type of power cable (unless already supplied): installation: insulated conductors, ducted multi-pole cable, overhead or

attached to the wall (type C according to IEC 364-5-523 1983) or not in contact with any other cable;

operating temperature: maximum ambient operating temperature of the unit; type of cable: copper conductors, PVC insulation to 70C / 158F (unless

specified) or EPR insulation to 90C / 194F.

19MAINTENANCE AND OPERATING MANUALChapter 6 - Start up

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CHAPTER 6

START UP

ATTENTIONBefore starting up or operating these dryers be sure that all personnel have read andunderstood the Chapter 2 Safetyof this manual.

1. If the unit is equipped with an intelligent condensate discharge system, checkthat it is correctly installed.

2. Check that the ambient temperature is within the range indicated on the data plateof the unit.

3. Check that the main switch on the dryer panel is in the O position.

4. Power the dryer by means of the line protection device.

5. Turn the main switch of the dryer to the I position.

6. When the unit is powered, one of the LEDs on the electronic board lights up (seeChapter 7 Electronic Control).

7. After switching on the electronic board and the pre-set delay, the refrigerantcompressor starts working for several minutes.

8. The fan starts immediately together with the compressor.

9. Check that the compressor stops when the thermal mass reaches the settemperature.

10.Switch on the air compressor.

The dryer is now ready for normal operation (see Chapter 9 General operating and maintenance regulation).

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21MAINTENANCE AND OPERATING MANUALChapter 7 - Electronic Control

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CHAPTER 7

ELECTRONIC CONTROL

7 . 1 B u t t o n s a n d L e d s

7 . 1 . 1 LED

7 . 1 . 2 Buttons

During programming operations (see paragraph 7.7 Access to electronic board programming ), the above LEDs and button have different functions.

The unit starts working if it is connected to the main power supply and if the main switch IG is closed (I).In these conditions, if no alarm signal is present and if the unit is not in the parameter programming mode (see paragraph 7.7 Access to electronic board programming ), the LEDs and the buttons will have the following functions:

L1 L GREEN Power on LED, lights up when the electronic board is powered;L2 N GREEN Energy saving LED, lights up when the refrigerant compressor is

off;

L3 J RED Alarm LED, flashes when the dew-point is too high or when there is a fault in the electronic board.

Table 5 LED

P1 Button for activating the condensate discharge solenoid valve (if the condensate discharge is of timed type); or programming button.

Table 6 BUTTONS

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7 . 2 T e m p e r a t u r e P r o b eThe electronic board features a temperature probe which is inserted into the thermal mass to measure the dew-point temperature in order to control the thermostat (see paragraph 7.4 Thermostat function ).The probe is protected to IP67 (including the cable) and features an NTC sensor with an operating temperature range of -10 / +65C (+14 / +149F).The resistance-temperature ratio must correspond to that described by the resistance values (rated), expressed in k, indicated in the Table 7.

In the event of damage, only replace with original CompAir probes.

7 . 3 S t a r t i n g t h e u n i tAfter making electrical connections, close (I) the main switch IG to start the unit.

LED L1 L, indicating that the board is powered, and LED L2 N, indicating that the refrigerant compressor is off, both light up.The unit starts working automatically according to the temperature measured by the probe, respecting the thermostat function logic (see paragraph 7.4 Thermostat function ).Please note: when the temperature measured by the probe reaches the value at which the refrigerant compressor should start, it will only do so provided that the delay time set by electronic control (see paragraph 7.5 Compressor delay ) has elapsed.

The compressor starting will be confirmed by LED L2 N switching off.At unit starting, if it had been stopped for an extended period and if HA1 alarm (see

paragraph 7.8.3 PROG HA1 Procedure ) is enabled, LED L3 J (high dew point alarm) could light up.This could happen when the temperature measured by the probe at the beginning is balanced with the ambient temperature, then it is 1C (1.8F) higher than HA1 high dew point alarm threshold (see paragraph 7.8.3 PROG HA1 Procedure ).The alarm signal should stop after a few minutes from refrigerant compressor starting (LED

L2 N off) when the temperature will decrease under HA1 threshold and LED L3 J will go out.If there is a power supply failure when the machine is working, the unit restart automatically after power is restored following the process described above.

Temperature B1 probe resistance values

0 C / + 32 F 27.28 k+10 C / +50F 17.96 k+20 C / +68 F 12.09 k+25 C / 77 F 10.00 k+ 30 C / + 86 F 8.31 k

Table 7 PROBE FEATURES


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7 . 4 T h e r m o s t a t f u n c t i o nThe thermostat function starts and stops the refrigerant compressor by comparing the value measured by the probe with the SET (0C / 32.0F) and DIF (4C / 7.2F) values on the electronic board.The following graph illustrates the thermostat function operating logic.When the compressor is enabled, it always starts after a timed delay set by the electronic control (see paragraph 7.5 Compressor delay ).The SET and DIF values of the thermostat function are fixed so they cannot be modified.

The SET and DIF values of the thermostat function are fixed so they cannot be modified.

7 . 5 C o m p r e s s o r d e l a yThe refrigerant compressor always starts with a delay of 120 seconds.Therefore, even if the temperature measured by the probe is higher than SET+DIF and the compressor start is called for, it cannot start until the delay time has elapsed, in the following cases:

when the machine is switched on; from when the compressor last stopped; when the machine is powered again after an interruption while it was working.

ATTENTIONThe compressor starting delay time (120 seconds) cannot be modified.

7 . 6 C o n d e n s a t e d i s c h a r g e

ATTENTIONThe unit is furnished without a condensate discharge system.The control board is set to use timed relay.

The electronic board is fitted with a relay for controlling condensate discharge.It controls opening and closing of the solenoid valve.Electronic board manages the condensate discharge relay in two different ways depending on how the RLE parameter is set (see paragraph 7.8.2 PROG RLE Procedure ):

1. Relay permanently energised (if the condensate discharger is of intelligenttype):The relay contact remains permanently closed (relay energised) and the P1 button has no function apart from programming.

Temperature measuredby the probe

COMPR.ON

COMPR.OFF

SET SET+DIF

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2. Timed relay (if the condensate discharger is of timed type):The relay is energised every 120 seconds (TOFF) for a time equal to TON seconds.When the machine is switched on, the cycle will always start with the energisingphase.The following diagram illustrates the operating logic.

TOFF (120 seconds) is fixed while TON is programmable.For information on settings, please see paragraph 7.8.1 PROG TON Procedure .With timed management of the condensate discharge relay, the solenoid valve maybe manually controlled during unit operation by pressing button P1 .P1 energises the solenoid valve relay for as long as it is held down.The manual control does not modify the current ON - OFF cycle.

7 . 7 A c c e s s t o e l e c t r o n i c b o a r d p r o g r a m m i n g

The Table 8 indicates information relative to the programmable control parameters.The electronic board must be switched off before the programming mode can be accessed.The machine remains inactive during the programming phase.To programme a parameter (see Table 8):Press the button indicated in the BUTTON/S column against the chosen parameter, power the electronic board (turn on the main switch IG) and keep the button pressed down for the time indicated in the HOLD TIME column.The LED corresponding to the chosen parameter, indicated in the LED column of the Table 8, starts flashing to confirm the programming mode has been accessed.

STATUS OF THE CONDENSATEDISCHARGE RELAY

Energised De-energised

T=0 electronic board switching ON

Energised

TIME

TON TONTOFF

PAR

AM

ETER

DE

SCR

IPT

ION

BUT

TON

/S

HO

LD T

IME

LED

PRO

GR

AM

MIN

G P

RO

CE

DU

RE

TON opening time of condensate discharge solenoid valve

P1 between 0 and 5 sec.

L2 N see paragraph 7.8.1 PROG TON Procedure

RLE condensate discharge relay mode

P1 between 5 and 30 sec.

L1 L see paragraph 7.8.2 PROG RLE Procedure

Table 8 TABLE OF PARAMETERS


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DANGERThe above parameters must only be adjusted by qualified personnel and only in specialcases.

7 . 8 P r o g r a m m i n g P r o c e d u r e sThe tables in the following paragraphs indicate the possible programmable parameter settings for each of the programming procedures of the electronic board.Please note: the unit is normally supplied with all the control parameters pre-set for correct operation (Please see the "FACTORY SETTINGS" attachment in the final part of this manual).

7 . 8 . 1 PROG TON ProcedureThis procedure is only used if the unit has a timed condensate discharger.It is used to set the solenoid valve ON time which manages the timed condensate discharge (see paragraph 7.6 Condensate discharge ).

1. If the dryer is already switched on, it is necessary to switch off the electronicboard: operate on IG main switch putting it in open position (O);

2. While holding P1 button pressed, simultaneously switch on the electronicboard by putting IG main switch in closed position (I);

3. Keep P1 button pressed;4. LED L2 N starts flashing, indicating correct access to TON programming

procedure: release P1 button;5. Modify the parameter always using P1 button.

The parameter can be modified within 5 seconds from programming procedureaccess, otherwise the electronic board microprocessor automatically exits from theprogramming phase.The parameter value is shown by means of a combination of LED L1, L2 and L3illumination.With the first press of P1 button (within 5 seconds) the parameter value beforethis procedure has been accessed is shown (see Table 9).By pressing the P1 button as follows (within 5 seconds) the value shown canbe set (see Table 9).

HA1 high temperature alarm threshold

P1 over 30 sec. L3 J see paragraph 7.8.3 PROG HA1 Procedure

PAR

AM

ETER

DE

SCR

IPT

ION

BU

TTO

N/S

HO

LD T

IME

LE

D

PRO

GR

AM

MIN

G P

RO

CED

UR

E

Table 8 TABLE OF PARAMETERS

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6. If the parameter value has been modified, it will be automatically stored 5 secondsafter P1 button has been released.

7. After storing the new parameter value, the electronic board microprocessorautomatically exits from the programming phase.The unit will return to normal operation.

The association between the LEDs and solenoid valve time ON is shown in the following table:

See the "FACTORY SETTINGS" attachment in the final part of this manual.

7 . 8 . 2 PROG RLE ProcedureIt is used to set the operating modality of the condensate discharge relay (see paragraph 7.6 Condensate discharge ).If the dryer is factory-fitted with intelligent condensate drain, this function will have been pre-set, but follow these instructions in order to check it.


2. While holding P1 button pressed simultaneously switch on the electronicboard by putting IG main switch in closed position (I);

3. Keep P1 button pressed for more than 5 seconds;4. LED L2 N starts flashing, indicating access to TON programming procedure

(already described): continue to keep P1 button pressed;5. LED L2 N goes out and LED L1 L starts flashing, indicating correct access to

RLE programming procedure: release P1 button;6. Modify the parameter always using P1 button.

The parameter can be modified within 5 seconds from programming procedureaccess, otherwise the electronic board microprocessor automatically exits from theprogramming phase.The parameter value is shown by means of a combination of LED L1, L2 and L3illumination.With the first press of P1 button (within 5 seconds) the parameter value beforethis procedure has been accessed is shown (see Table 10).With the following pressures of P1 button (within 5 seconds) the followingvalue can be set (see Table 10).



LED status Value

L1 L L2 N L3 JOFF OFF ON 3 secondsOFF ON OFF 6 secondsOFF ON OFF 12 seconds

Table 9 PROG TON


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The association between the LEDs and solenoid valve relay mode is shown in the following table:

ATTENTIONIf Relay always energised mode is selected, TON programming (see paragraph 7.8.1PROG TON Procedure ) is however possible but this parameters will not affect theoperation of the intelligent discharge system.

7 . 8 . 3 PROG HA1 ProcedureIt is used to set the high temperature alarm threshold:


2. While holding P1 button pressed, simultaneously switch on the electronicboard by putting IG main switch in closed position (I);

3. Keep P1 button pressed for more than 30 seconds;4. LED L2 N starts flashing, indicating access to TON programming procedure

(already desribed): continue to keep P1 button pressed;5. LED L2 N goes out and LED L1 L starts flashing, indicating access to RLE

programming procedure (already described): continue to keep P1 buttonpressed;

6. LED L1 L goes out and LED L3 J starts flashing, indicating correct access toHA1 programming procedure: release P1 button;

7. Modify the parameter always using P1 button.The parameter can be modified within 5 seconds from programming procedureaccess, otherwise the electronic board microprocessor automatically exits from theprogramming phase.The parameter value is shown by means of a combination of LED L1, L2 and L3illumination.With the first press of P1 button (within 5 seconds) the parameter value beforethis procedure has been accessed is shown (see Table 11).With the following pressures of P1 button (within 5 seconds) the followingvalue can be set (see Table 11).



LED status Value

L1 L L2 N L3 JOFF OFF ON Timed relay (timed condensate

discharger)OFF ON OFF Permanently energised relay

(intelligent condensate discharger)

Table 10 PROG RLE

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The association between the LEDs and the high temperature alarm threshold is shown in the following table:

See the "FACTORY SETTINGS" attachment in the final part of this manual.

7 . 9 A l a r m sThe electronic board manages the alarms listed in the following table:

LED status Value

L1 L L2 N L3 JOFF OFF ON 10 C / 50FOFF ON OFF 15 C / 59 FOFF ON OFF Disabled

Table 11 PROG HA1A

LAR

M

LED

AC

TIV

ATI

ON

TIM

E

EFFE

CT

RE

SET

NO

TES

High dew-point temperature

L3 Jflashing

Instantaneous

warning only automatic The alarm trips if the temperature measured is greater than or equal to the value of parameter HA1+1C (HA1+1.8F); it will reset if the temperature measured returns under the value of parameter HA1 (see paragraph 7.8.3 PROG HA1 Procedure ).

Temperature probe damaged or faulty

L3 Jon Instantaneous

refrigerant compressor stops

automatic A probe measuring a temperature outside the -10/+65 C (+14 / +149F) range may be considered as faulty.

Fault in the electronic board microprocessor

L3 J on Instantaneous

refrigerant compressor stops

automatic If the alarm reappears after the machine has been turned on and off (using the main switch IG), replace the electronic board.

Table 12 EASYCARD ALARMS

29MAINTENANCE AND OPERATING MANUALChapter 8 - Condensate discharge system

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CHAPTER 8

CONDENSATE DISCHARGE SYSTEM

ATTENTIONThe unit is furnished without a condensate discharge system.The control board is set to use timed relay.

Each unit is fitted with either a timed or intelligent condensate discharge assembly depending on which option is ordered.The timed condensate drain is automatically controlled by the electronic board with which it is possible to set the condensate discharge intervals (see Chapter 7 Electronic Control).The intelligent condensate drain features an electronic condensate level control system with a capacitive sensor.The electronic board of the drain continuously reads the signal sent to it by the capacitive sensor.When the level of condensate increases above the sensor, the solenoid valve is energised after a delay time of 23 seconds in order to allow the discharge of condensate.When the level of condensate falls again below the sensor, the solenoid valve is de-energised and stops the condensate discharge.

8 . 1 T i m e d c o n d e n s a t e d i s c h a r g e rThe timed condensate drain must be carefully checked and serviced in order to prevent the separated condensate from being entrained with the flow of compressed air into the distribution system.

8 . 1 . 1 Fil ter cleaningWhen a dryer is installed for the first time, it is common for particles of rust, pipe scale, metal filings etc. to find their way into the separator and then into the filter.It should therefore be cleaned about a month after installation.Thereafter it should be cleaned once every 3 months.In some installations, even more frequent cleaning may be required.A Filterstop valve with incorporated strainer (see adjacent figure) is installed.

The timed condensate discharger is fitted with a Filterstop valve: just close the valve.

Press the manual condensate discharge button P1 to check that the filter is not pressurised.

Open the IG main switch to disconnect the power supply to the dryer. Carefully unscrew the filter cap [1] retaining the sealing gasket [2] and remove

the strainer mesh [3]. Once cleaned, reinsert the mesh making sure it is home and square and tighten

cap [1]. Replace the sealing gasket if it is damaged.

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After re-opening the Filterstop valve, switch on IG again and re-start the unit.

8 . 1 . 2 Solenoid valve maintenanceThe solenoid valve must always be protected by an appropriate filter to prevent solid particles preventing it from opening and closing correctly.However, if these particles manage to cross the filter and cause the valve to malfunction, all its internal components must be cleaned.To access to the solenoid valve follow the same indications described for the strainer (see paragraph 8.1.1 Filter cleaning ).

Proceed as follows: isolate and depressurise the dryer; open the main switch IG to turn off power to the dryer; unscrew the nut fixing the cap for the valve power supply; lift up and remove the cap;

Filterstop valve

1. Filter cap

2. Sealing gasket

3. Strainer

31MAINTENANCE AND OPERATING MANUALChapter 8 - Condensate discharge system

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DANGERDo not tighten the nut [1] excessively as this could cause the valve to open and closeincorrectly.

8 . 2 I n t e l l i g e n t c o n d e n s a t e d r a i nThe intelligent condensate drain is normally supplied already wired and connected to the dryer power unit and is therefore ready to work.It can also be retro-fitted using the appropriate CompAir kit.The operating and maintenance instructions for the intelligent condensate drain are contained inside the dedicated instruction manual of the drain itself.

remove the solenoid valve from the pipe and tightly clamp the body in a vice;

unscrew the nut [1] fixing the solenoid valve [2] and remove it from the tie-rod [3];

unscrew the tie-rod from the valve seat; check the condition of the O-ring seal [4] and of all other components and clean them carefully;

re-assemble the components by reversing the above procedures;

make sure that the valve is re-installed with the arrow pointing in the right direction.

Condensate discharge solenoid valve

1. Fixing Nut

2. Solenoid

3. Rod

4. O-ring

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33MAINTENANCE AND OPERATING MANUALChapter 9 - General operating and maintenance regulation

R10

CHAPTER 9

GENERAL OPERATING AND MAINTENANCE REGULATION

9 . 1 O p e r a t i o nDo not switch off the dryer if there is no compressed air flow.The dryer switches on and off automatically.The number of starts and stops depends on the flow of compressed air, its temperature and ambient temperature.As explained in the Chapter 5 Installation, the control board automatically switches off the refrigerant compressor when there is no air flow.In this case, the refrigerant compressor will run occasionally and for brief periods to compensate for the dispersion of heat between the thermal mass and the surrounding ambient air.The dryer is therefore ready to dry compressed air as soon as the flow is restarted.However, it is perfectly safe to switch off the dryer at night or at weekends when the air compressor is not running.In this case, remember to start the dryer at least 10-15 minutes before the air compressor.

9 . 2 M a i n t e n a n c e

ATTENTIONBefore starting up or operating these dryers be sure that all personnel have read andunderstood Chapter 2 Safety of this manual.

These dryers will give many years of trouble-free service if they are properly maintained and serviced.

9 . 2 . 1 Dryer accessConsult the Air Compressor manual for details of access to the dryer.

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9 . 2 . 2 Inspection and maintenance schedule

ATTENTIONThe above maintenance schedule is based on average operating conditions. In some cases itmay be necessary to increase maintenance frequency.

OPERATION

1 da

y

1 m

onth

6 m

onth

s

annu

al

Check there are no alarm signals. If the dryer is fitted with a timed condensate discharge system, find out if there is an excessive production of condensate and, if so, increase the opening (ON) time of the valve.Make sure the solenoid valve opens correctly observing the times set with the electronic board.

Check that the compressed air inlet temperature is lower than the limit for which dryer was selected (normally 35-40C 95-104F).

With the compressor running, check the top part is not too hot (over 50C / 122F approx.).Check current consumption of dryer lies within data plate values.

Remove, clean and put back the condensate discharge system filter.If the filter is always clogged with material it may be necessary to dismantle and clean the whole condensate discharge system.

Make a visual inspection of the refrigerant circuit to make sure the piping has not deteriorated and that there are no traces of oil which may indicate a leak of refrigerant.

Check the condition and safety of piping connections. Check the tightness, condition and safety of the wiring and electrical connections.

Check that the ambient air temperature is lower than the limit used to select the dryer (normally 25-30C / 77-86F). Check the area is well ventilated.

Check that the fan-motor assembly is switched on automatically and check for any unusual noises.

If cooling air filters fitted, check condition of the cooling air filters and clean if necessary.

If cooling air filters fitted, clean the cooling air filters or replace if necessary.

If cooling air filters fitted, replace the cooling air filters.

Table 13 INSPECTION AND MAINTENANCE SCHEDULE

35MAINTENANCE AND OPERATING MANUALChapter 10 - Trouble shooting

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CHAPTER 10

TROUBLE SHOOTING

PROBLEM CAUSE SYMPTOM REMEDYA Dew-point

higher than expected.

A1 Compressed air inlet temperature too high.

A1.1 Dew-point and compressed air

inlet temperatures higher than expected;

the alarm signal relative to the problem is displayed on the electronic board panel(see paragraph 7.9 Alarms );

Reduce the compressed air inlet temperature to within rated limits.

A2 Compressed air pressure too low. Increase the compressed air operating pressure to within rated limits.

A3 ambient temperature too high. If the unit is installed indoors, reduce the ambient temperature to within rated limits (e.g. install fans to extract the air).

A4 cooling air filters dirty or clogged. Clean or replace air filters.

A5 obstruction of dryer cooling airflow intakes or discharge.

Remove obstruction.

A6 Shortage of refrigerant fluid in circuit.If you suspect that the dryer is short of refrigerant, measure the suction temperature (equivalent suction pressure) of the refrigerant compressor by using the relative Schraeder valve. Slowly vary the air flow through the dryer until a temperature value of 3C (+37.4F) is displayed; the suction temperature (shown on the temperature scale of the refrigerant fluid used) will vary from -3C (26.6F) to 0C (32F) approx.; if the temperature is lower, the dryer is probably short of refrigerant.

A6.1 Compressor doesn't stop even if

there is a little or no air flow; the head of the refrigerant

compressor is very hot; frosting on the evaporator

capillary inlet; power absorption lower than

expected; see also A1.1.

Call in a qualified refrigeration engineer to check for leaks and fill circuit with refrigerant.

B Excessive compressed air pressure drop.

B1 See A2. B1.1 Possible increase in dew-point (see also A1.1);pressure downline from the dryer lower than expected.

Increase the compressed air pressure and flow to within rated limits.

B2 There is an increase in pressure drop and the dryer ices up.

B2.1 See point C. See point C.

B3 Heat exchanger tubes blocked by impurities conveyed by the compressed air.

B3.1 Pressure downline from the dryer lower than expected.

Clean the exchanger tubes with a mild detergent suitable for steel and copper. Install a prefilter.

C Dryer blocked and no airflow.

C1 Incorrect position of temperature probe and as a result the thermal mass temperature reduced to below 0C (32F) with consequent freezing inside exchanger tubes.(The temperature probe may have been dislodged from its position during maintenance work carried out inside the dryer)

C1.1 The value measured by the probe remains higher than 0C (32F) even if the compressor operates for long periods (e.g. more than 10-15 minutes) without compressed air flowing.

Adjust the position of the probe in the collector by pushing it in up to the relative indicator marked on the probe.

C2 A calibration error or malfunction in the electronic board cause ice to form.

C2.1 The compressor doesnt stop even if the dew-point is near to 0C (32F).

Replace the control board.

C3 Incorrect calibration of temperature probe. C3.1 Everything seems to work properly but the air doesnt flow.

Use a tester to check the ohmic resistance of the probe at 20C / 68F as indicated in Chapter 7 Electronic Control.If necessary, replace the probe.

D Presence of condensate downline from dryer.

D1 The piping of the distribution line is located in a cold environment (temperature lower than the pressure dew-point of the compressed air) and is not insulated.In this case, condensation forms on the internal surfaces of the piping.

D1.1 Dryer runs normally.Problems are caused by external factors.

Insulate the piping exposed to low ambient temperatures.

Table 14 TROUBLE SHOOTING

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E Presence of condensate downline from the dryer.

E1 Condensate discharge system fault. E1.1 The condensate and/or compressed air are not discharged when the manual check button is pressed.

Refer to the Instruction Manual for the level sensing drain.Repair or replace the condensate discharge system.

F Compressor protection trips.

F1 Ambient and compressed air inlet temperatures too high.

F1.1 The head and the body of the

compressor are very hot; the compressor stops and tries

to restart after a short time (even a few seconds).

Stop the unit and reduce the air flow and temperature to within rated limits.Wait a few minutes before starting the unit again.Before replacing the fuse, check the conditions of all the safety devices (built-in or external motor circuit breakers) positioned downline from the fuse or automatic switch. In case of doubt, replace all the devices.

F2 Compressed air temperature too high combined with a shortage of refrigerant(see also A6).

Call in a qualified refrigeration engineer to check for leaks and fill up the circuit with refrigerant.Before replacing the fuse, check the conditions of all the safety devices (built-in or external motor circuit breakers) positioned downline from the fuse or automatic switch. In case of doubt, replace all the devices.

G All LEDs off although the main switch IG is on (I).

G1 Control board circuit breaker trips.Power supply fluctuations or 'spikes'.

G1.1 Despite the presence of power at the input terminals, the digital display and all LEDs remain unlit.

Provide cleaner power supply to the dryer.

G2 Abnormal power consumption by one or more of the control board components.

If the circuit breaker continues to trip, replace the control board.

H Temperature probe fault alarm (see paragraph 7.9 Alarms ).

H1 Probes in open circuit or in short circuit. H1.1 Refrigerant compressor stops;

Check that the temperature probe is correctly connected to the control board terminals and that the cable is undamaged. If necessary replace the temperature probe.

I Alarm relative to the microprocessor or its Eprom memory (see paragraph 7.9 Alarms ).

I1 Control board microprocessor initialising error or microprocessor mistake in reading data.

I1.1 The alarm signal relative to the problem is displayed on the electronic board (see paragraph 7.9 Alarms ) and the unit is blocked.

Turn the unit off and on.If this doesnt solve the problem, contact the nearest service centre.

PROBLEM CAUSE SYMPTOM REMEDY


37MAINTENANCE AND OPERATING MANUALChapter 10 - Trouble shooting

R10

J Fuses fitted on the unit trip(see wiring diagram).

J1 Compressor motor or compressor supply line short-circuited.

J1.1 The compressor doesnt start even if the thermostat function requires it to.

Use a tester to check the motor windings and supply line.Replace the compressor or the cable if necessary.Before replacing the fuse, check the conditions of all the safety devices (built-in or external motor circuit breakers) positioned downline from the fuse or automatic switch. In case of doubt, replace all the devices.

J2 Short-circuit of solenoid valve, fan and electronic board supply lines.

J2.1 Apparent power supply failure.

Use a tester to check the components and cables.Replace the damaged component or cable.Before replacing the fuse, check the conditions of all the safety devices (built-in or external motor circuit breakers) positioned downline from the fuse or automatic switch. In case of doubt, replace all the devices.

J3 Short circuit in the fan or in the fan and transformer auxiliary power lines.

Use a tester to check the components and cables.Replace the damaged component or cable.Before replacing the fuse, check the conditions of all the safety devices (built-in or external motor circuit breakers) positioned downline from the fuse or automatic switch. In case of doubt, replace all the devices.

PROBLEM CAUSE SYMPTOM REMEDY


38

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39MAINTENANCE AND OPERATING MANUALChapter 11 - List of attachments

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CHAPTER 11

LIST OF ATTACHMENTS

FACTORY SETTINGS LIFTING AND TRANSPORT DIAGRAMS EXPLODED VIEW OVERALL DIAGRAMS REFRIGERANT CIRCUIT DIAGRAM ELECTRICAL DIAGRAMS

40

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1ALLEGATI ATTACHMENTS ANLAGEN ANNEXES ANEXOS BILAGOR BIJLAGEN BILAG LIITTEET

R10 3817

SETTAGGI DI FABBRICAFACTORY SETTINGSWERKSEITIGE EINSTELLUNGENRGLAGES DUSINEAJUSTES DE FBRICAFABRIKSINSTLLNINGARFABRIEKSINSTELLINGENFABRIKSINDSTILLINGERTEHDASASETUKSET

Le tabelle di questo capitolo contengono i valori dei settaggi di fabbrica con i quali la macchina stata collaudata. La dotazione di un determinato tipo di centralina elettronica e la presenza dei pressostati, del termostato di sicurezza dello scaricatore di condensa temporizzato o di quello intelligente, dipendono dalla configurazione della macchina ( PROSPETTO RIASSUNTIVO DELLE CONFIGURAZIONI POSSIBILI).Nel caso fosse necessario verificare le impostazioni di fabbrica della centralina elettronica, del o dei pressostati e del termostato di sicurezza fare riferimento ai relativi capitoli di questo manuale.

The tables in this chapter contains the factory setting values used for testing the unit.The type of electronic board, the presence of pressure switches, safety thermostat, timed or intelligent condensate discharger depend on the unit configuration ( THE LIST OF CONFIGURATIONS)If it is necessary to check the factory settings of electronic board, of pressure switch(es) and of safety thermostat make reference to the appropriate chapters of this manual.

Die Tabellen in diesem Kapitel enthalten die Werte der werkseitigen Einstellungen, mit denen die Maschine geprft worden ist.Das Vorhandensein einer bestimmten elektronischen Steuereinheit und der Druckschalter, des Sicherheitsthermostats des Kondensatablassers mit Zeitgebung oder des intelligenten Kondensatablassers hngen von der Gestaltung der Maschine ab ( ZUSAMMENFASSENDE TABELLE DER MGLICHEN GESTALTUNGEN ).Falls eine berprfung der werkseitigen Einstellungen der elektronischen Steuereinheit, des oder der Druckschalter und des Sicherheitsthermostats notwendig sein sollte, wird auf die jeweiligen Kapitel in dieser Anleitung verwiesen.

Les tableaux de ce chapitre contiennent les valeurs de rglage dusine avec lesquels la machine a t essaye.Lattribution dun certain type dunit de commande lectronique et la prsence des pressostats, du thermostat de scurit du purgeur de condensat temporis ou intelligent, dpendent de la configuration de la machine. ( RSUM DES CONFIGURATIONS POSSIBLES).En cas de ncessit de vrifier les prrglages dusine de lunit de commande lectronique, du ou des pressostats de scurit, voir les chapitres correspondants de ce manuel.

Las tablas de este captulo contienen los valores de los ajustes de fbrica con los que la mquina ha sido probada.El equipamiento de un determinado tipo de cuadro electrnico y la presencia de los presstatos, termstato de seguridad del dispositivo de desage del lquido de condensacin temporizado o inteligente, dependen de la configuracin de la mquina ( RESUMEN DE LAS CONFIGURACIONES POSIBLES).Si fuera necesario comprobar las configuraciones de fbrica del cuadro electrnico, del o de los presstatos y del termstato de seguridad, refirase a los captulos correspondientes de este manual.

Tabellerna i detta avsnitt innehller vrdena fr maskinens fabriksinstllningar.De elektroniska styrenheternas utfrande, med tryckvakter, skerhetstermostat fr tidsinstlld eller intelligent kondenstmningsenhet, beror p maskinens konfiguration ( SAMMANSTLLNING AV MJLIGA KONFIGURATIONER).Kontrollera, om det r ndvndigt, fabriksinstllningarna fr den elektroniska styrenheten, lysdioderna eller tryckvakterna och skerhetstermostaten. Se aktuellt kapitel i denna bruksanvisning.

De tabellen van dit hoofdstuk bevatten de fabrieksafregelwaarden waarmee de machine getest is.De uitrusting met een bepaald soort elektronische regeleenheid en de aanwezigheid van drukschakelaars, van de veiligheidsthermostaat van de condensafvoer met tijdschakelaar of van de intelligente condensafvoer zijn afhankelijk van de machineconfiguratie ( OVERZICHT MOGELIJKE CONFIGURATIES ).Raadpleeg de desbetreffende hoofdstukken van deze handleiding indien de fabrieksinstellingen van de elektronische regeleenheid, de drukschakelaars of veiligheidsthermostaat gecontroleerd moeten worden.

Tabellerne i dette kapitel indeholder de fabriksindstillede vrdier, de vrdier som maskinen er blevet prvekrt med.Den ene eller den anden type elektronisk centralenhed trykreler, sikkerhedstermostat med timer eller "intelligent" kondensataflb, afhnger af maskinens konfiguration ( SAMMENFATTENDE PROSPEKT AF DE MULIGE KONFIGURATIONER).Om ndvendigt kontrolleres fabriksindstillingerne p den elektroniske centralenhed, trykreler og sikkerhedstermostaten under de relative kapitler i denne manual.

Tmn luvun taulukoista lytyvt tehdasasetusten arvot, joilla kone on koekytetty.Varustus mrtyn tyyppisell elektronisella yksikll ja painekatkaisimilla ja lauhdeveden ajastetun tai lypoistolaitteen turvatermostaatilla riippuvat koneen kokoonpanosta ( TIIVISTELM MAHDOLLISISTA KOKOONPANOISTA).Jos elektronisen yksikn, painekatkaisimen/mien ja turvatermostaatin tehdasasetuksia joudutaan tarkistamaan, ks. ohjekirjan aihekohtaisia lukuja.

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IMPOSTAZIONI UNITA' SCHEDA EASYCARDSETTINGS FOR UNITS WITH EASYCARD CONTROL BOARDEINSTELLUNGEN DER STEUEREINHEIT MIT EASYCARDPRRGLAGES UNITAVEC CARTE EASYCARDCONFIGURACIONES DE LA UNIDAD TARJETA EASYCARDINSTLLNING AV ENHET MED STYRENHETEN EASYCARDINSTELLINGEN EENHEID MET EASYCARDINDSTILLINGER TIL ENHEDER MED KORTET EASYCARDEASYCARD-KORTILLA VARUSTETUN YKSIKN ASETUKSET

PARAMETROPARAMETERPARAMETERPARAMTREPARMETROPARAMETERPARAMETERPARAMETERPARAMETRI

SETSETSETSETSETSETINGESTELDSETSET

VALORE DEL SETSET VALUESOLLWERTVALEUR DU SETVALOR DEL SETBRVRDESET-WAARDESETVRDIERSET-ARVO

L1L L2 N L3 JTON OFF OFF ON 3 sec. / sec. / Sek. / sec. / seg.

/ sek. / sec. / s.

RLE

(unit provvista di scaricatore temporizzato / unit with timed condensate discharger / Einheit mit Kondensatablasser mit Zeitgebung / unit munie de purgeur temporis / unidad equipada con dispositivo de desage temporizado / enhet frsedd med tidsinstlld tmningsenhet / eenheid met condensafvoer met tijdschakelaar / enhed med timeraflb / ajastetulla poistolaitteella varustettu yksikk)

OFF OFF ON

gestione temporizzata / timed management / Betrieb mit Zeitgebung / gestion temporise / gestin temporizada / tidsinstlld styrning / aansturing met tijdklok / drift med timer / ajastettu ohjaus

(unit provvista di scaricatore intelligente / unit with intelligent condensate discharger / Einheit mit intelligentem Kondensatablasser / unit munie de purgeur intelligent / unidad equipada con dispositivo de desage inteligente / enhet frsedd med intelligent tmningsenhet / eenheid met intelligente condensafvoer / enhed med "intalligent"aflb / lypoistolaitteella varustettu yksikk)

OFF ON OFF

rel sempre eccitato / relay always energised / Relais immer erregt / Relais toujours excit / rel siempre excitado / permanent aktivt rel / permanent ingeschakeld relais / rel altid pvirkelig / rele aina aktivoitu

HA1 OFF ON OFF 15 C / 59F


R10 3817

MOVIMENTAZIONE DELLA MACCHINA / LIFTING AND TRANSPORT DIAGRAMS / ZEICHNUNGEN FR DIE VERSCHIEBUNG DES GERTS / DESSINS DE MANUTENTION DE LA MACHINE / DIBUJOS DE DESPLAZAMIENTO DE LA MQUINA / SKISSER VER FRFLYTTNING AV MASKINEN / MACHINEVERPLAATSINGSTEKENINGEN / TEGNINGER OVER MASKINENS BEVGELSER / KONEEN LIIKUTUSPIIRROKSET

L min(mm)

D min(mm)

500 350

PESO LORDO (kg)GROSS WEIGHT (kg)BRUTTOGEWICHT (kg)POIDS BRUT (kg)PESO BRUTO (kg)BRUTTOVIKT (kg)BRUTOGEWICHT (kg)BRUTTOVGT (kg)BRUTTOPAINO (kg)

44

43817 R10


R10 3817

ESPLOSO COMPONENTI / EXPLODED VIEW / DETAILZEICHNUNG DER KOMPONENTEN / VUE CLATE DES COMPOSANTS / DIBUJO DE DESPIECE DE LOS COMPONENTES / SPRNGSKISSER OPENGEWERKTE TEKENING / EKSPLOSIONSTEGNING OVER KOMPONENTER / KOMPONENTTIEN HAJOTUSKUVA

63817 R10

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7ALLEGATI ATTACHMENTS ANLAGEN ANNEXES ANEXOS BILAGOR BIJLAGEN BILAG LIITTEETLista parti di ricambio-Spare parts list

R10 3817

LISTA PARTI DI RICAMBIO-SPARE PARTS LIST

RIF.REF.

(I) Descrizione(GB) Description(F) Description(D) Beschreibung(S) Descripcin

(I) Codice(GB) Code(F) Code(D) Kode(S) Cdice

(I) Quantit impiegata sulla macchina(GB) Quantity used in the machine(F) Quantit utilise dans la machine(D) Quantitt benutztet in der Maschine(S) Cantidad utilizada en las mquinas

-- Interruttore bianco 22x30White switch 22x30Interrupteur Blanc 22x30weier Schalter 22x30interruptor blanco 22x30

3652452 1

11 Scheda Elettronica+sondaElectr. Board + Probecarte lectronique+sondeelektr. Platte +SondeTarjeta electrnica+ Sonda

365013602 1

2 Ventilatore MA-VIB V02-C041.02+EL5.230.31.AAFan MA-VIB V02-C041.02+EL5.230.31.AAVentilateur MA-VIB V02-C041.02+EL5.230.31.AAVentilator MA-VIB V02-C041.02+EL5.230.31.AAVentilador MA-VIB V02-C041.02+EL5.230.31.AA

351062440 1

1 Compressore Danfoss SC15GXCompressor Danfoss SC15GXCompresseur Danfoss SC15GXKompressor Danfoss SC15GXcompresor Danfoss SC15GX

345055000 1

-- Coperchio protezione per compressore SC15/SC21protective cap for Compressor SC15/SC21couvercle de protection pour le compresseur SC15/SC21Schutzdeckel fr der Kompressor SC15/SC21tapa de proteccin para el compresor SC15/SC21

345131830 1

-- Pallet Pallet Pallet Pallet Pallet

380004855 1

-- Imballo cartoneCardboard PackingEmballage en cartonKartonverpackungEmbalaje en cartn

380035200 1

-- Fusibile 6A gG 10,3x38 500VFuse 6A gG 10,3x38 500VFusible 6A gG 10,3x38 500VSicherung 6A gG 10,3x38 500VFusible 6A gG 10,3x38 500V

36526802002 --

4 Filtro + CapillareFilter + CapillaryFiltre + CapillaireFilter + KapillareFiltro + Tubo capilar

352260100 --

-- Attacco carica 1/4 SAE+tubo rameCharge connection 1/4 SAE + copper tubeConnexion de charge 1/4 SAE + tube de cuivreFllungsverbindung 1/4 SAE + KupferrohrConexin de carga 1/4 SAE + tubo de cobre

3727594 --

83817 R10

Documents

Hydrovane Refrig Dryer HV04!05!07 Англ.Яз 2005