User manual - Air Compressors Direct
Contents
1. 11 12 ional drawing PRD50 PRD100 imensiona ln eer ei 2 gg 222 G96 pozz 08 de 095 S s i CU I A PM x ala DE T 8IT 9 01 m s DE E9e OR Cc tu H 86 Ge t e feiss ojo j Lv 9 8621 S26 1 t 801 e ITT JB DEE Re Sec nl aa g li L4 zg qe L pul E T x Se amp ad Es Seed Lor 021 a ilo 2 o rm STS 2c e Ts ies Ss T 2 x Ee m sol co ra 8 al S CIOS r3 Qi Qu m me a og CJ aus 9011 96 Et 612 Le SOS ar 96 8 7 Refrigerant circuit G amp b 6 TT Pv OY t 3 HT CED 13 8 8 Wiring diagram PRD10 PRD15 142. LIMIT OF EQUIPMENT Al Alarm Probe KA1 Alarm Contact TO 5 6 7 8 2 SOLO PER LA VERSIONE CON CONTATTI PULITI ONLY FOR FREE CONTACT VERSION A1 e STAR 115V 1Ph 50Hz L RI e PS cs LF 5 H H H I I N I SI she 1 1 QF lan 0 3A RECOMMENDED RACCOMANDATO e eje TE EX PE HT Ww 7 PV QS a 2 z z amp B x m lt KT KAI a si EN EN ul R1 51 DE a CN lt W I ul e Lu CO FAN CO OMP HIG FA TIME I SWITCH ELECTRONIC DRAIN POWER SUPPLY PRESSOR MOTOR MOTOR PRESSOR OVERLOAD PROTECTOR ING RELAY RESSOR START CAPACITOR TEMPERATURE SAFETY SWITCH PRESSURE SWITCH D RELAY ALARM SWITCH EL Wiring diagram PRD25 PRD100 115V 1Ph 60Hz 230V 1Ph 60Hz L 1 iU e li ze DL i d nals ie QF lan 0 3A RECOMMENDED RACCOMANDATO SIS KT a m LA as 2 PV ru m ca KT KAI lt S 3 Zx lt N Ec R S1 T 5 CN lz tox Ve KAl Alarm Probe KA1 Free Contact AG E 5 6 7 8 2 EV 512 i T0 e
3. 490 LL Dimensional drawing PRD10 PRD15 8 6 y 218 E 2691 0er z 2 91 02 als Cor G m 1 Zu ka Ww au per a Im 9 2 699 86 09 0 1 t Ge L V V eM 00 Ci Vvv ITT ES F e C m Gc af e IA eo G Ley Bes u Il uo x g m 2 ne ro Oho 8 co uso mio 021 J CIS eats Se a AG Y A gt m 3 CE 612 e mcd kesel as rei ibas 06 id TST drawing PRD25 PRD35 imensiona A p AS g ag LU t 1861 S0S amp 4961 wit 02 NE 00S G Silt i On 0 gs Irem e Br aile is H 81 688 86 DE Ice Go t V T ERU 00 Cle YV YV k _ 9 e L 2901 801 I ale 02 C72 82 si 1 CO c5 E Ve rT ez o ex CTS ul Eu M or m T D a BE 2 E Se 2 v RU we SD CD 8 CU af a J m Se m x als EE CES 96 yc8 612 Wat Chr 067 ER
4. 3 Preventive Maintenance Programme To guarantee lasting maximum dryer efficiency and reliability Maintenance Maintenance Interval Activity Description standard operating conditions Activity Weekly 4 Months 12 Months Check POWER ON indicator is lit Check control panel indicators gt Daily Check condensate drain Clean condenser fins Check electrical absorption AN Depressurize the dryer Complete drain maintenance d Depressurize the dryer Pa The following are available see par 8 4 a compressor kits b fan kits c automatic expansion valve kits d individual spare parts 6 4 Dismantling The refrigerant and the lubricating oil contained in the circuit must be recovered in conformity with current local environmen tal regulations RY Recycling amp Ai Disposal structural work steel epoxy polyester resins exchanger aluminium pipes aluminium copper drain polyamide exchanger insulation EPS sintered polystyrene pipe insulation synthetic rubber compressor steel copper aluminium oil condenser steel copper aluminium check Ba service Repalce pre and post filter ele refrigerant R154a ments valves brass electrical cables copper PVC 7 Troubleshooting Cooling air outlet mc trippe too high High SKPHT tripped dew point Ambient temper
5. 27 4 78 3G16A PRD35 0 50 C 5 50 C 65 C 16 bar SC 2 PRD50 584 265 881 025 8 31 NPT 55 PRD75 68 3 31 9 52 027 10 23 with adaptor PRD100 712 35 12 34 035 12 44 6 22 34 Calibration values Expansion automatic valve Fan pressure switch BS AEV D Pv 35 PSIg 1 5 0 PRD10 PRD15 ON 160 PSI 2 4 bar 0 gris O OFF 116 PSIg 32 PSIg 1 5 0 a par id 8 bar PRD25 PRD100 2 2 bar 0 1 0 84 T Spare parts list 8 5 PRD10 PRD15 PRD25 PRD35 PRD50 PRD75 PRD100 115V 1Ph 60Hz SP 147439 SP 147405 SP 147100 SP 147339 SP 147341 a Compressor kit 230V 1Ph 60Hz SP 147398 115V 1Ph 60Hz SP 381679 SP 381793 SP 381616 Mene 230V 1Ph 60Hz 9 SP 381794 c Automatic expansion valve kit 9 SP 473108 SP 473109 Refrigerant condenser Q SP 114800 SP 114801 SP 114802 SP 114803 SP 114754 Evaporator Separetor Air air heat exchanger SP 472157 SP 472158 SP 472159 Power cable SP 256347 Refrigerant filter SP 206214 d Dewpoint indicator D SP 354317 Fan pressure switch SP 354376 High temperature safety thermostat 3 SP 473399 Main power switch SP 255132 Cover 5 SP 137926 SP 137928 SP 137931 15 Exploded drawing S i o6 10 699 0 1 EL
6. User manual Refrigeration Dryer PRDIO PRDIS PRD25 PRD35 PRD50 PRD75 PRD100 DATE 2012 06 20 Rev 2 CODE 272889 Index 1 Safety 2 Introduction 3 Installation 4 Commissioning 5 Control 6 Maintenance 7 Troubleshooting 8 Appendix M There are symbols whose meaning is given in the paragraph 8 1 8 1 Legend 8 2 Installation diagram 8 3 Technical data 8 4 Spare parts list 8 5 Exploded drawings 8 6 Dimensional drawings 8 7 Refrigerant circuits 8 8 Wiring diagram 1 Safety 11 Importance of the manual Keep it for the entire life of the machine Read it before any operation tis subject to changes for updated information see the ver sion on the unit 12 Warning signals AN Instruction for avoiding danger to persons Instruction for avoiding damage to the equipment Sy The presence of a skilled or authorized technician is required There are symbols whose meaning is given in the para 8 LU 13 Safety instructions A Always disconnect the dryer from the main power sup ply before starting maintenance work A The manual is intended for the end user only for opera tions performable with closed panels operations requiring open ing with tools must be carried out by skilled and qualified person nel TE Do not exceed the design limits given on the dataplate A gt It is the user s responsibility to avoid loads different from the internal stati
7. ature over 122 F 50f C Reduce temperature Excessive thermal load compressor head too hot Reduce compressed air quantity or air temperature Insufficient refri gerant repair any leaks and recharge the circuit CAUSE Excessive current consumption Compressor noisy Fan does not work Compressor components perished Compressor winding insulation partially perished compressor too hot Repair or replace com pressor REMEDY High pressure drop on air side Heat exchanger fouled with debris Clean heat exchanger blow to operating air flow Fit renew prefilter compressed air in opposite direction Ice formation on evaporator low evapora tion pressure By pass air flow keeping air inlet open Open con densate drain valve manually Restart appliance checking setting of expansion valve High refriger ant discharge pressure Fan pressure switch PV calibration error or damaged Condenser dirty Clean condenser Replace pressure switch Replace fan Seek external assistance 8 Appendix 8 1 Legend Meaning Meaning DMC Compressor 2 Pv Fan pressure switch Refrigerant condenser HT High temperature safety thermostat EV Fan motor Qs Main power switch D Evaporator Cover Separator CN Elec
8. c pressure The unit must be appropriately protected whenever risks of seismic phenomena exist A The safety deviceson the compressed air circuit must be pro vided for by the user Only use the unit for professional work and for its intended pur pose The user is responsible for analysing the application aspects for product installation and following all the applicable industrial and safety standards and regulations contained in the product instruction manual or other documentation supplied with the unit Tampering or replacement of any parts by unauthorised person nel and or improper machine use exonerate the manufacturer from all responsibility and invalidate the warranty The manufacturer declines and present or future liability for damage to persons things and the machine due to negligence of the operators non compliance with all the instructions given in this manual and non application of current regulations regard ing safety of the system The manufacturer declines any liability for damage due to alter ations and or changes to the packing Itisthe responsibility ofthe user to ensure that the specifications provided for the selection of the unit or components and or options are fully comprehensive for the correct or foreseeable use of the machine itself or its components A IMPORTANT The manufacturerreserves the right to modi fy this manual at any time For the most comprehensive and updated information the user is advi
9. ch The dewpoint indicator can show one of three conditions blue dewpoint too low green dewpoint ideal red dewpoint too high 6 Maintenance a The machine is designed and built to guarantee continuous operation however the life of its components depends on the maintenance performed b when requesting assistance or spare parts identify the ma chine model and serial number by reading the dataplate lo cated on the unit 6 1 General instructions A Before any maintenance make sure the pneumatic circuit is no longer pressurized the dryer is disconnected from the main power supply LS Always use the Manufacturer s original spare parts other wise the Manufacturer is relieved of all liability regarding ma chine malfunctioning EF Incase of refrigerant leakage contact qualified and author ized personnel EF The Schrader valve must only be used in case of machine malfunction otherwise any damage caused by incorrect refriger ant charging will not be covered by the warranty 6 2 Refrigerant Charging any damage caused by incorrect refrigerant replace ment carried out by unauthorized personnel will not be covered by the warranty gt At normal temperature and pressure the R134a refrigerant is a colourless gas classified in SAFETY GROUP Al EN378 group 2 fluid according to Directive PED 97 23 EC GWP Global Warming Potential 1300 A In case of refrigerant leakage ventilate the room 6
10. eplaced at least once a year or sooner as per manufacturer recommendations LS Do not invert the compressed air inlet and outlet connec tions and observe the maximum tightening torque N x m as spe cified in par 8 3 3 2 Operating space EF Leave a space of 60 inches 1 5 m around the unit 3 3 Tips To prevent damage to the internal parts of the dryer and air com pressor avoid installations where the surrounding air contains solid and or gaseous pollutants e g sulphur ammonia chlorine and installations in marine environments The ducting of extracted air is not recommended for versions with axial fans 3 4 Electrical connection Use approved cable in conformity with the local laws and regula tions for minimum cable section see par 8 3 Install a differential thermal magnetic circuit breaker with contact opening distance gt 0 12 inches 3 mm ahead of the sys tem IDn 0 3A see the relevant current local regulations The nominal current In of the magnetic circuit breaker must be equal to the FLA with an intervention curve type D 3 5 Condensate drain connection The dryer is supplied either with a float drain a timed drain or an electronic level sensing drain If a timed or electronic unloader is installed use terminals CN R1 S1 see par 8 8 For timed and electronic drains refer to separate manual sup plied with the dryer for specific details concerning the condensate drain gt Make the connecti
11. ig 1 SOLO PER VERSIONE CON CONTATTI PULI ONLY FOR FREE CONTACT VERSION QS MAIN SWITCH CN ELECTRONIC DRAIN POWER SUPPLY MC COMPRESSOR MOTOR EV FAN MOTOR PV FAN PRESSURE SWITCH SK COMPRESSOR OVERLOAD PROTECTOR KA STARTING RELAY C STARTING CAPACITOR HT HIGH TEMPERATURE SAFETY SWITCH KT TIMED RELAY KA1 ALARM SWITCH 2012 Parker Hannifin Corporation Product names are trademarks or registered trademarks of their respective companies Parker Hannifin Corporation Finite Airtek Filtration Division 4087 Walden Avenue Lancaster NY 14086 phone 716 686 6400 www parker com faf
12. ntroduction This manual refers to refrigeration dryers designed to guarantee high quality in the treatment of compressed air 2 1 Transport The packed unit must a remain upright b be protected against atmospheric agents c be protected against impacts 2 2 Handling Useafork lifttruck suitable for the weight to be lifted avoiding any type of impact ensure conductor cross sectional areas and the sup ply line protection system conform to applicable regula tions 2 3 Inspection a Allunits are assembled wired filled with coolant and oil and tested under standard operating conditions in the factory b on receiving the machine check its condition immediately notify the transport company in case of any damage c unpack the unit as close as possible to the place of installa tion 2 4 Storage If several units have to stacked follow the notes given on the packing Keep the unit packed in a clean place protected from damp and bad weather 3 Installation 3 1 Procedures Install the dryer inside in a clean area protected from direct at mospheric agents including sunlight Comply with the instructions given in par 8 2 and 8 3 All dryers must be fitted with adequate pre filtration near the dryer air inlet Seller is excluded any obbligation of compensation or refund for any direct or indirect damage caused by its absence EF Pre filter element for 3 micron filtration or better must be r
13. on to the draining system avoiding con nection in a closed circuit shared by other pressurized discharge lines Check the correct flow of condensate discharges Dispose of all the condensate in conformity with current local environ mental regulations 4 Commissioning 41 Preliminary checks Before commissioning the dryer make sure a installation was carried out according that given in the section 3 b the air inlet valves are closed and that there is no air flow through the dryer c the power supply is correct 42 Starting a Start the dryer before the air compressor by means of the main power switch Q2 the power lamp will illuminate green b after at least 5 minutes slowly open the air inlet valve and subsequently open the air outlet valve the dryer is now performing its air drying function 4 3 Operation a Leave the dryer on during the entire period the air compres sor is working b thedryeroperates in automatic mode therefore field settings are not required 2 c inthe event of unforeseen excess air flows by pass to avoid overloading the dryer 4 4 Stop a Stop the dryer 2 minutes after the air compressor stops or in any case after interruption of the air flow b do not allow compressed air to flow through the dryer when the latter is not running c switch off at the main power switch The power light goes out and the compressor stops 5 Control AD Dewpoint indicator Main power swit
14. sed to consult the manual supplied with the unit 14 Residual risks The installation start up stopping and maintenance of the ma chine must be performed in accordance with the information and instructions given in the technical documentation supplied and always in such a way to avoid the creation of a hazardous situa tion The risks that it has not been possible to eliminate in the design stage are listed in the following table part affected residual risk manner of exposure precautions heat exchanger coil small cuts contact avoid contact wear protective gloves fan grille and fan lesions insertion of poin ted objects through the grille while the fan is in operation do not poke objects of any type through the fan grille or place any objects on the grille inside the unit compressor and discharge pipe contact avoid contact wear protective gloves inside the unit metal parts and electrical wires intoxication electrical shock serious burns defects in the insu lation of the power supply lines up stream of the elec trical panel live metal parts adequate electrical protection of the power supply line ensure metal parts are properly con nected to earth outside the unit area surroun ding the unit intoxication serious burns fire due to short circuit or overhea ting of the supply line upstream of the unit s electrical panel 2 I
15. tronic condensate drain power supply Power cable SK Overload protector AEV Expansion automatic valve KA Starting relay Refrigerant filter C Compressor starting capacitor Air air exchanger QF Residual current automatic circuit breaker Dewpoint indicator 8 2 Installation diagram 7 Air compressor 2 Dryer 3 By pass unit i 3 i E Safety valves for not exceeding dryer design pressure 4 Filter 3 micron filtration or better near dryer air inlet A gt 5 Tank in position A or in B A gt Hoses for air connections if the system undergoes vibrations 6 Outlet filter A CS Suitable dampers if the system undergoes pulsations 7 Oil Water separator 8 Condensate drain 8 3 Technical data MIN MAX geg Compressed Connections Weight Refrigerant Ambient temperature nn air inlet outlet Tightening torque Compressed Air side Amb air inlet max working F L A A Kee Pu o amp R134a Kg temperature pressure for eletrical G e During transport After ti e and stockage installation CE 115V 10 230V 10 z w kg c2 AG lt J Max Iph amp OHz mam 9 NPT INxm ME pa PRD10 41 8 19 5 99 0 17 3 74 NPT 50 PRD15 compatible PRD25 32 122 F 41 122 F 149 F 232 PSIg 1 2 51 8 23 5 9 52 0
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