Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Refrigeration Dryer
(50Hz)
EN User manual
CRDU460
CRDU520
CRDU630
CRDU750
CRDU900
CRDU1200
CRDU1500
CRDU1800
English CRDii460-1800
1
English CRDH460-1800
2
3.4 Tips 4.2 Starting
For models C R D i i l 5 0 0 - 1 8 0 0 make sure to screw down the
stud bolts in the flanges before connecting the counterflanges To prevent damage to the internal parts of the dryer and air com- a) Start the dryer before the air compressor;
(see par. 8.6). pressor, avoid installations where the surrounding air contains
b) switch the power on by turning the MAIN SWITCH to
solid and/or gaseous pollutants (e.g. sulphur, ammonia, chlorine
For correct installation, follow the instructions given in par. "I ON": the P O W E R L E D (2) lights up turning yellow; The
and installations in marine environments).
8.2 and 8.3. The ducting of extracted air is not recommended for versions with crankcase heater will now start heating.
All dryers must be fitted with adequate pre-filtration near the axial fans.
dryer air inlet. Seller is excluded any obligation of compensation T H E CRANKCASE HEATER MUST BE
or refund for any direct or indirect damage caused by its absence. SWITCHED ON 12 H O U R S B E F O R E STARTING T H E
3.5 Electrical connection DRYER. Failure to comply with this rule may cause serious
Pre-filter element (for 3 micron filtration or better) must damage to the compressor.
Use approved cable in conformity with the local laws and regula-
be replaced at least once a year, or sooner as per manufacturer tions (for minimum cable section, see par. 8.3). O n c e the c r a n k c a s e i s preheated, p r e s s the O N b u t t o n o n
recommendations. Connect the 3 cable phases to terminals L 1 - L 2 - L 3 of the dis- t h e c o n t r o l panel.
connecting switch and the yellow/green earth wire to the special
3.2 O p e r a t i n g space terminal near the switch. Install a differential thermal magnetic c) press : the P O W E R LED (2) turns green and the com-
Leave a space of 1.5 m around the unit. circuit breaker with contact opening distance of 3 mm ahead of
pressor switches on; the dew point is displayed.
the system (IDn = 0.3A) (see the relevant current local regula-
Leave a space of 2 m above dryer models with vertical condensa-
tions). Scroll Compressor: if connected with the wrong phase se-
tion air expulsion.
The nominal current In of the magnetic circuit breaker must be quence it turns in the opposite direction, with the risk of being
equal to the FLA with an intervention curve type D.
3.3 Versions damaged (in this case it is very noisy); immediately invert the
phases.
A i r - c o o l e d v e r s i o n (Ac) 3.6 C o n d e n s a t e drain connection
Do not create cooling air recirculation situations. Do not obstruct Fans (Ac version): if connected with the wrong phase se-
the ventilation grilles. Make the connection to the draining system, avoiding con- quence they turn in the opposite direction, with the risk of being
W a t e r - c o o l e d v e r s i o n (Wc)
nection in a closed circuit shared by other pressurized discharge damaged (in this case the air exits the dryer cabinet from the con-
lines. Check the correct flow of condensate discharges. Dispose denser grilles instead from the fan grille - see par. 8.6 and 8.7 for
If not provided in the supply, fit a mesh filter on the condensation of all the condensate in conformity with current local environ-
water inlet. correct air flow); immediately invert two phases.
mental regulations. d) Wait 5 minutes, then slowly open the air inlet valve;
Inlet condensation water characteristics: e) slowly open the air outlet valve: the dryer is now drying.
NH < 1 ppm < 5 ppm d) with Wc version, open the cooling water circuit a few minutes
3
co 2
before starting the dryer.
CI -
< 5 0 ppm Al <0.2 ppm
4.4 Stop Name Description
5.2 Operation
Reference
a) stop the dryer 2 minutes after the air compressor stops or in Operation status
any case after interruption of the air flow; I ON = dryer powered;
1 MAIN SWITCH
b) make sure compressed air does not enter the dryer when the O O F F = dryer not powered. With the MAIN SWITCH turned to " I O N " (dryer pow-
dryer is disconnected or if an alarm occurs. Yellow = dryer powered. ered) three working conditions are possible:
2 POWER LED DRYER
Green = dryer operating. DISPLAY POWER LED (2)
c) Press : the P O W E R LED (2) turns yellow again; STATUS
E N E R G Y SAVING Lit = dryer in energy saving 1 OFF Off Yellow
3
d) Turn the MAIN SWITCH to "O O F F " to switch the LED condition.
2 ON Dew point Green
power off. Off = no signal. 3 REMOTE OFF r.OF Yellow
4 WARNING LED
Wc version, close the water circuit with the dryer stopped. Flashing = alarm or warning.
5 DRAIN LED Lit = drain open.
To switch from O F F to ON (and vice versa) press
5 Control In O F F status the unit remains powered until the MAIN
Keypad mode STANDARD | MENU* |
5.1 Control p a n e l SWITCH is turned to "O OFF"!
English CRDii460-1800
3
English CRDii460-1800
4
c) EXTERNAL - if there is an external drain. List of p a r a m e t e r s
Energy saving function To change operation mode, use the parameter d3 (see par. 5.3 in Al Sets the unit of measure for dew point in ° C or ° F.
List of parameters). Total hours of dryer operation = A 3 x l 0 0 0 + A 2
In ON mode, operating conditions permitting, the dryer reduces A2/A3
(display only).
energy consumption by temporarily switching off the refrigera- Only set the E X T E R N A L mode in absence of the solenoid
tion compressor; the E N E R G Y SAVING L E D (3) comes on (see Like A2/A3 but for hours of refrigeration compressor opera-
valve. Otherwise the relative coil could become damaged. A4/A5
Control Panel). tion.
Sets Hd Warning intervention temperature (see par. 5.4 in
A l a r m log A6
List of alarm/warnings).
Scheduled m a i n t e n a n c e Contains the descriptions of the last alarms (max. 8).
A7 Inhibits remote O F F command.
When the DISPLAY alternatively shows the Sr warn- Press for 5 seconds: the keypad now operates in A l a r m bl Sets the dryer address for serial communications.
ing code and dew point, contact authorized assistance personnel b2 Sets the serial communication speed.
MENU mode and the events can be scrolled with-
for carrying out scheduled maintenance indicated in par. 6.3 and b3 Not available
for resetting the warning code (see par. 5.4 in List of alarm/warn-
and b5 Refrigerant evaporation temperature.
ings).
b7 Not available
Every event is displayed with "ALx" (x = 1 - 8).
b8 Compressor discharge (delivery) temperature.
Press to cancel the warning for 24 hours. AL1 = most recent event.
b9 Not available
Condensate drain If there are no events " " appears.
bll Auxiliary refrigerant evaporation temperature.
There are three operation modes: Dryer model:
a) INTEGRATED - draining controlled by the level sensor; To view the details of the event, press :
C5 - 0 models C R D i i l 2 0 - 3 5 0
b) TIMED - check that the automatic condensate drainage sys- ALx - 1 models C R D i i 4 6 0 - 1 8 0 0
tem is working properly.
1 Alarm code Sets compressor operation mode:
Use manual drainage to check that condensate is not retained
2 Thousands of hours C7 - CYC = CYCLING (energy saving enabled).
as this is symptomatic of poor drainage. 3 Hours - C O N = C O N T I N U O U S (energy saving disabled).
This check of the timed drain opening (parameter d l ) . 4 Dew point
Settings depends upon the operating conditions of the dryer Operating logic of the alarm/machine status relay.
5 Evaporation temperature
and varies the amount of condensate to be removed. 6 Compressor discharge temperature 0 = relay energised when dryer is running, d e - e n e r g i s e d if
For standard dryer operating conditions, see the following 7 Auxiliary evaporation temperature in warning/alarm status.
table of recommended settings: C36 1 = relay d e - e n e r g i s e d when dryer is running, energised if
in warning/alarm status.
Model Parameter dl Scroll with and 2 = relay de - energised when dryer is not running, energised
when running.
CRDii460-750 10 5.3 Parameters C37 % energy saving.
Accessing p a r a m e t e r s Sets the seconds of condensate drain opening (if set in TI-
CRDii900-1800 20 dl
M E D mode).
d2 Like d l , but for seconds closed.
P a r a m e t e r d l : time open in seconds for every 2 minutes of Press and at the same time : the keypad now operates
Sets condensate drain operation mode:
operation. in P a r a m e t e r s M E N U mode and the parameters can be scrolled - CAP = I N T E G R A T E D
d3
- tIM = TIMED
with and - Con = E X T E R N A L (24VAC)
List of a l a r m s / w a r n i n g s
Changing parameters
HP High Pressure Alarm
6 Maintenance
a) The machine is designed and built to guarantee continuous
After displaying the parameter, press , change with CP Compressor Thermal Protection Alarm
operation; however, the life of its components depends on the
LP Low Pressure Alarm maintenance performed.
and , then press to confirm. Ld Low Dew Point Alarm b) When requesting assistance or spare parts, identify the ma-
Lt Low Evaporation Temperature Alarm chine (model and serial number) by reading the dataplate lo-
cated on the unit.
Press to return to STANDARD mode. High Compressor Discharge Temperature Alarm = T>
Ht c) Circuits containing 6 kg or more of refrigerant fluid are
120 °C.
checked to identify leaks at least once a year.
5.4 A l a r m s a n d Warnings LtA Alarm low auxiliary evaporation temperature.
Circuits containing 30 kg or more of refrigerant fluid are
Refrigerant Temperature Sensor Warning checked to identify leaks at least once every six months.
A l a r m s cause the dryer to switch off. rSE
Switches to C O N T I N U O U S mode. (CE842/2006 art. 3.2.a, 3 2 b ) .
W a r n i n g s only cause a signal.
Condensate Drain Warning
d) For machines containing 3 kg or more of refrigerant fluid, the
In the case of Alarm or Dew Point Sensor Warning (dSE), drE operator must keep a record stating the quantity and type of
Condensate drainage switches to T I M E D mode. refrigerant used, an quantities added and that recovered dur-
displays the alarm code. In the case of a Warning, alterna- Dew Point Sensor Warning ing maintenance operations, repairs and final disposal
dSE The measured temperature must return within its normal (CE842/2006 art. 3.6).
tively displays the fault code and the dew point and WARNING
range.
L E D comes on.
High Dew Point Warning
Hd
If an alarm occurs: Automatic reset when the dew point = A6 - 4 ° F (2°C).
1) Identify and eliminate the cause; HSE Discharge temperature sensor Warning
ASE Auxiliary refrigerant temperature sensor Warning
2) press to reset the alarm; Scheduled Maintenance Warning
Sr
See par. 5.2 and 6.3
3) press to restart the dryer.
English CRDii460-1800 5
English CRDii460-1800
6
6.1 General instructions 6.3 Preventive M a i n t e n a n c e P r o g r a m m e The following are available (see par. 8.4):
a) 3 y e a r preventive m a i n t e n a n c e kits;
To guarantee lasting maximum dryer efficiency and reliability:
Before any maintenance, make sure: b) service kits
• the pneumatic circuit is no longer pressurized; Maintenance Maintenance Interval 1. compressor kits;
Activity Description (standard operating conditions) 2. fan kits;
• the dryer is no longer powered.
3. hot gas valve kits;
Always use the Manufacturer's original spare parts: other- 4. water condenser kits;
12 Months
36 Months
4 Months
wise the Manufacturer is relieved of all liability regarding ma- Activity c) individual spare parts.
Weekly
chine malfunctioning.
Daily
For models CRDii460 to 1200, in case of maintenance to the 6.4 Dismantling
flanged air connections, replace the seals using only the spare
parts indicated in par. 8.4. Check P O W E R ON indicator is lit. The refrigerant and the lubricating oil contained in the circuit
must be recovered in conformity with current local environmen-
In case of refrigerant leakage, contact qualified and author- Check control panel indicators. tal regulations.
ized personnel. The refrigerant fluid is recovered before final scrapping of the
Check condensate drain. equipment (CE 842/2006 art.4.4).
The Schrader valve must only be used in case of machine
Recycling
malfunction: otherwise any damage caused by incorrect refriger- Clean condenser fins.
Disposal
ant charging will not be covered by the warranty.
Check electrical absorption. structural work steel/epoxy- polyester resins
check service
7 Troubleshooting
FAULT CAUSE REMEDY
CP High Ht
compressor Lt Low evaporation temperature alarm LP Low High HP
Compressor thermal protec- pressure dew point high pressure
noisy warning temperature
tion alarm Ld Low dew point alarm. alarm alarm alarm
no no no no
Fan Replace
always pressure switch Decrease
working Excessive thermal load yes compressed yes Excessive
(PV pressure (air flow, inlet temperature) air quantity thermal load
switch fault) temperature (inlet air flow,
temperature)
no no
no
no
Hot gas Calibrate
yes
valve valve
not calibrated Fan Replace ' Condenser yes Clean yes Condenser
yes pressure switch
pressure switch dirty or condenser dirty or
(PV) not set obstructed obstructed
no
no no no
Compressor Condenser yes Clean
components dirty or condenser
deteriorated obstructed No Fan
Liquid line Low refrigerant. Low Replace yes
yes yes pressure switch does not turn
solenoid valve current Recharge current
no yes closed absorption (PV pressure
no yes absorption
switch fault)
no no no
Replace no
Repair or Compressor
replace ves the coil
winding
compressor with partial
loss of Replace fan yes Fan
insulation fault
no
Request external assistance
no
English CRDU460-1800
7
CRDii460-1800
8 Appendix
8.1 Legend (Sheet 1 of 7)
ENGLISH
Weight
Ambient temperature
Amb
After installation
In
Max
(0)
EN/DE/FR/NL
Condensate drain
Calibration values
Lifting holes
General alarm
CRDii460-1800 9
CRDii460-1800 10
Legend (Sheet 3 of 7)
ENGLISH
Limit of equipment
Optional
Compressor
Refrigerant condenser
Fan motor
EV1-3
Evaporator
Separator
Expansion capillary
Refrigerant filter
H o t gas valve
HGV
A i r - a i r heat-exchanger
Legend (Sheet 4 of 7)
ENGLISH
Liquid separator
Pressure point
Valve
Seals
CRDii460-1800 11
CRDii460-1800 12
Legend (Sheet 5 of 7)
ENGLISH
Control Card
Al
Compressor protection
PI1
Digital Inputs
ID
Digital Outputs
UD
Analog Inputs
Al
v
Remote Off
RO
Legend (Sheet 6 of 7)
ENGLISH
Fuses
FU1-4
FU11-21
Compressor contactor
KM1
Fan contactor
KM2
Noise filter
RC1-2
Capacitor
C1
Cranckase heater
EH1
CRDii460-1800 13
CRDii460-1800 14
Legend (Sheet 7 of 7)
ENGLISH
Auxiliary transformer
TCI
Terminal blocks
X1-X5
Serial card
A2
Serial line
SL
Panels
A/B/C/D/
E/F/G
(#)
8.2 Installation d i a g r a m (Sheet 1 of 2)
1 2 3 4
Air compressor Dryer B y - p a s s unit Filter (3 micron filtration or better) near dryer air inlet
5 6 7 8
Tank in position A or in B Outlet filter O i l - w a t e r separator Condensate drain Suitable dampers if the system undergoes pulsations.
CRDii460-1800
15
8.3 Technical data
M I N . - MAX. Ambient
Weight Refrigerant Minimum Connections
temperature
Compressed Air-side section Sound
F.LA. [A]
Amb air inlet max. working validated cable pressure
400V±10%/3Ph/50Hz
R407C (kg) temperature pressure for eletrical level
During transport After connection Compressed Compressed Condensate
and stockage installation air inlet/outlet water inlet/outlet drain
Calibration values Hot gas valve Fan pressure switch High pressure switch Low pressure switch Water pressostatic valve
HGV PV HP LP WPV
ON: 18 bar
CRDH460-1800 4.6 - 4.8 bar 28 bar 1.5 - 2.5 bar 16 bar
OFF: 14 bar
CRDii460-1800 17
CRDii460-1800
18
8.4 Spare parts list (Sheet 1 of 2)
(See paragraph. 8.5 / 8.8) CRDU460 CRDii520 CRDii630 CRDH750 CRDii900 CRDiil200 CRDiilSOO CRDiil800
Ac Bl B2 B3 KM2 473001
3 year preventive
a) maintenance kits
Wc B l B2 B3 473269
b) 1. compressor kits Ac/Wc KM1 473010 473011 473012 473013 473014 473015 473016 473017
W a t e r - a i r exchanger / Separator /
Ac/Wc 473068
A i r - a i r exchanger
(See paragraph. 8.5 / 8.8) CRDH460 CRDii520 CRDU630 CRDH750 CRDH900 CRDiil200 CRDH1500 CRDU1800
c)
Condensate level sensor Ac/Wc cs 275752
Ac/Wc TCI
- 255904
Auxiliary transformer
Ac/Wc FU1-2-3-4 473070
Fuses
Ac/Wc FU11-21 254694
-
Compressor contactor Ac/Wc KM1 256248 256325 256376
Ac/Wc A 137385
Ac 137374 137394
B 137792
Wc 137374 137394
Ac 137374 137394
C 137791
Wc 137374 137394
Ac 137386
D 137795
Panels Wc 137811
CRDii460-1800
19
CRDii460-1800
20
8.5 E x p l o d e d drawing C R D i i 4 6 0 - 5 2 0 (Ac)
Exploded drawing C R D i i 6 3 0 - 900 (Ac)
CRDii460-1800
21
CRDii460-1800
22
Exploded drawing CRDU1200 (Ac)
Exploded drawing C R D i i l 5 0 0 - 1 8 0 0 (Ac)
CRDii460-1800
23
CRDii460-1800 24
Exploded drawing C R D i i 4 6 0 - 630 (Wc)
Exploded drawing C R D i i 7 5 0 - 1 2 0 0 (Wc)
CRDii460-1800
25
CRDii460-1800 26
Exploded drawing C R D i i l 5 0 0 - 1 8 0 0 (Wc)
8.6 D i m e n s i o n a l drawing C R D i i 4 6 0 - 5 2 0 (Ac)
CRDii460-1800
27
CRDii460-1800 28
D i m e n s i o n a l drawing C R D i i 6 3 0 - 900 (Ac)
D i m e n s i o n a l drawing C R D i i l 2 0 0 (Ac)
CRDM60-1800 29
CRDii460-1800
30
D i m e n s i o n a l drawing C R D i i l 5 0 0 - 1 8 0 0 (Ac)
D i m e n s i o n a l drawing C R D H 4 6 0 - 6 3 0 (Wc)
CRDii460-1800
31
CRDii460-1800
32
D i m e n s i o n a l drawing C R D i i 7 5 0 - 1 2 0 0 (Wc)
D i m e n s i o n a l drawing C R D i i l 5 0 0 - 1 8 0 0 (Wc)
CRDii460-1800
33
CRDii460-1800
34
8.7 Refrigerant circuit
CRDii460-1200(Ac) C R D i i l 5 0 0 - 1 8 0 0 (Ac)
Refrigerant circuit
C R D i i 4 6 0 - 1 2 0 0 (Wc) C R D i i l 5 0 0 - 1 8 0 0 (Wc)
CRDii460-1800
35
CRDii460-1800
36
8.8 Wiring d i a g r a m C R D i i 4 6 0 - 5 2 0 (Ac) Sheet 1 of 5)
Wiring d i a g r a m C R D i i 4 6 0 - 5 2 0 (Ac) Sheet 2 of 5)
CRDii460-1800
37
CRDii460-1800
38
Wiring d i a g r a m C R D i i 4 6 0 - 5 2 0 (Ac) Sheet 3 of 5)
Wiring diagram CRDii460-520 (Ac) Sheet 4 of 5)
CRDii460-1800
39
CRDii460-1800
40
Wiring d i a g r a m CRDhii460-520 (Ac) Sheet 5 of 5)
Wiring d i a g r a m C R D i i 6 3 0 - 1 8 0 0 (Ac) Sheet 1 of 5)
CRDii460-1800
41
CRDii460-1800
42
Wiring d i a g r a m C R D H 6 3 0 - 1 8 0 0 (Ac) Sheet 2 of 5)
Wiring diagram CRDii630-1800 (Ac)
Sheet 3 of 3)
CRDii460-1800
43
CRDii460-1800
44
Wiring diagram CRDii630-1800 (Ac) Sheet 4 of 5)
Wiring d i a g r a m C R D i i 6 3 0 - 1 8 0 0 (Ac) Sheet 5 of 5)
CRDii460-1800
45
CRDii460-1800
46
Wiring d i a g r a m C R D i i 4 6 0 - 5 2 0 (Wc) Sheet 1 of 5)
f
Wiring d i a g r a m C R D i i 4 6 0 - 5 2 0 (Wc) Sheet 2 of 5)
CRDii460-1800 47
CRDii460-1800 48
Wiring d i a g r a m C R D i i 4 6 0 - 5 2 0 (Wc) Sheet 3 of 5)
Wiring d i a g r a m C R D H 4 6 0 - 5 2 0 (Wc) Sheet 4 of 5)
CRDii460-1800
49
CRDii460-1800 50
Wiring d i a g r a m C R D i i 4 6 0 - 5 2 0 (Wc) Sheet 5 of 5)
Wiring d i a g r a m C R D i i 6 3 0 - 1 8 0 0 (Wc) Sheet 1 of 5)
CRDii460-1800
51
CRDii460-1800 52
Wiring d i a g r a m C R D i i 6 3 0 - 1 8 0 0 (Wc) Sheet 2 of 5)
Wiring d i a g r a m C R D i i 6 3 0 - 1 8 0 0 (Wc) Sheet 3 of 5)
CRDii460-1800
53
CRDii460-1800
CRDii460-1800 55