EKOM DK50 3x4VR/M User Manual Download

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COMPRESSOR

DK50 3x4VR/M

EKOM spol. s r. o.

Priemyselná 5031/18
SK-

921 01 Piešťany

Slovak Republic
tel.: +421 33 7967255
fax: +421 33 7967223

www.ekom.sk

email:

[email protected]

DATE OF LAST REVISION

06/2022

NP-DK50

3x4VR_M-AD-A-

EN-3_06-2022
112000554-0001

Summary of Contents for DK50 3x4VR/M

Page 1: ...DK50 3x4VR M User manual ...

Page 2: ......

Page 3: ...R M EKOM spol s r o Priemyselná 5031 18 SK 921 01 Piešťany Slovak Republic tel 421 33 7967255 fax 421 33 7967223 www ekom sk email ekom ekom sk DATE OF LAST REVISION 06 2022 NP DK50 3x4VR_M AD A EN 3_06 2022 112000554 0001 ...

Page 4: ...PRODUCT FUNCTION 10 TECHNICAL DATA 15 INSTALLATION 18 9 INSTALLATION CONDITIONS 18 10 COMPRESSOR ASSEMBLY 19 11 PNEUMATIC CONNECTION 22 12 ELECTRICAL CONNECTION 25 13 COMMISSIONING 29 14 PNEUMATIC DIAGRAM 30 OPERATION 32 15 SWITCHING ON THE COMPRESSOR 33 16 AD DRYER OPERATING MODES 34 17 SWITCHING OFF THE COMPRESSOR 39 PRODUCT MAINTENANCE 40 18 PRODUCT MAINTENANCE 40 19 LONG TERM SHUTDOWN 54 20 DI...

Page 5: ...ilable knowledge The Slovak version is to be used in the event of any uncertainties The user manual is original and the translation is performed with the best available knowledge 1 CONFORMITY WITH THE REQUIREMENTS OF THE EUROPEAN UNION This product conforms to the requirements of the European Union 2006 42 EC 2014 29 EU 2014 35 EU 2014 30 EU 2011 65 EU and is safe if used in compliance with the in...

Page 6: ...plosive or chemically unstable substances The compressor is intended for operation in clean and dry rooms 3 2 Incorrect use Contamination risk Air from the compressor is without additional treatment not suitable for breathing and direct contact with food Explosion risk The product is not intended for operation in rooms with explosion risk The compressor must not be used to compress aggressive gase...

Page 7: ...ply with the requirements of the specified intended use Taking this into account follow the product technical data Assessment of conformity shall be performed by the manufacturer supplier of the final product 4 3 Protection from dangerous voltage and pressure The equipment may only be connected to a properly installed socket connected to earth grounded Before the product is plugged in make sure th...

Page 8: ... for the product If it is necessary to return the product during the warranty period the manufacturer is not liable for damages caused by improper packaging The compressor is shipped in a vertical position and must be secured using transport straps Protect the compressor from humid and dirty environments and extreme temperatures during transport and storage Do not store near any volatile chemical ...

Page 9: ...pplied by the compressor is unsuitable for use with artificial lung ventilation devices without further filtration 7 ACCESSORIES Accessories that are not included in the standard order must be ordered separately Set of compressed air outlet filters The compressor may be equipped with a set of filters if specified The filter set may be equipped with an air pressure regulator Where a different level...

Page 10: ...mpressor mounter bracket DK50 3x4VR 603014136 000 Wall mounted bracket 603014120 000 8 PRODUCT FUNCTION 8 1 Compressor with adsorption dryer The compressor air pumps 1 draw air through the inlet filters 8 and compress it through non return valves 3 into a common manifold from which it is routed to the external adsorption dryer 9 through a connecting hose From the inlet to the dryer module the air ...

Page 11: ...ain switch 18 19 Outlet module 20 Connector 21 Red indicator 22 Logo CPU 23 Circuit breaker 24 Contactor 25 Motor circuit breaker 26 Power supply 27 Logo DM8 28 Logo text display 29 Pressure relief valve 30 Common air pump outlet manifold 31 Air tank non return valve 32 Adjustable foot 33 Regeneration solenoid valve 34 Regeneration solenoid valve 35 Inlet solenoid valve 36 Inlet solenoid valve 37 ...

Page 12: ...PRODUCT DESCRIPTION NP DK50 3x4VR_M AD A EN 3_06 2022 12 06 2022 Fig 1 DK50 3x4VR M Compressor with adsorption dryer ...

Page 13: ...PRODUCT DESCRIPTION 06 2022 13 NP DK50 3x4VR_M AD A EN 3_06 2022 Fig 2 Adsorption dryer ...

Page 14: ...PRODUCT DESCRIPTION NP DK50 3x4VR_M AD A EN 3_06 2022 14 06 2022 Fig 3 Switchboard ...

Page 15: ...kW 3x2 2 Air tank volume l 290 Maximum operating pressure of safety valve bar 10 0 Noise level at 5 bar LpA dB 80 Operating mode S1 100 PDP drying performance at 7 bar d C 20 Time to fill air tank from 0 to 7 bar s 230 Required cooling air changes in space m3 h 1850 Dimensions net w x d x h mm 2520x800x1025 Dimensions compressor w x d x h mm 1780x800x1025 Dimensions AD750E dryer w x d x h mm 530x3...

Page 16: ... at 5 bar LpA dB 80 Operating mode S1 100 PDP drying performance at 7 bar d C 40 Time to fill air tank from 0 to 7 bar s 230 Required cooling air changes in space m3 h 1850 Dimensions net w x d x h mm 2520x800x1025 Dimensions compressor w x d x h mm 1780x800x1025 Dimensions AD750E dryer w x d x h mm 530x350x965 Net weight c kg 327 Net weight compressor c kg 283 Net weight dryer c kg 44 a Specify t...

Page 17: ...rm of FAD Free Air Delivery applies to the following conditions Altitude 0 m n m Temperature 20 C Atmospheric pressure 101325 Pa Relative humidity 0 To calculate FAD compressor capacity in dependence on altitude it is necessary to apply correction factor according to the following table Altitude m n m 0 1500 1501 2500 2501 3500 3501 4500 FAD correction factor 1 0 8 0 71 0 60 ...

Page 18: ... see the Technical Data chapter The compressor on the operator s side must be at least 70 cm from the wall to allow air flow for cooling purposes and to ensure the safety of the operator and maintenance personnel Approximately 70 of the electrical energy used by the compressor aggregates is converted to heat and therefore the rooms in which a compressor assembly is installed must have additional v...

Page 19: ...ompressor and dryer module to the pallet Use a fork lift truck or similar hoisting equipment to handle and position the product Position the compressor module at the site of installation Fig 5 Remove the transport beams 1 Position and level the compressor assembly at its final location Cooling air inlet Recommended flow of cooling air DK50 3x4VRT M 1850 m3 h Applies for continuous operation and co...

Page 20: ...bilisers from the air pumps 6 mounts Fig 6 Prior to installation ensure that the compressor is free of all transport packaging and stabilizers to avoid any risk of damage to the product Remove all devices used to secure the aggregates once the compressor is installed and levelled at the site of final installation ...

Page 21: ...om the packaging Install the dryer in its operating position Fig 7 Manipulation At least two persons are needed to handle the equipment Integrated handles are installed on the lower brackets on the product Each person must grasp the equipment with one hand on a handle and the other behind the dryer chamber when moving the equipment ...

Page 22: ...mpressor Connect the compressor assembly using the connecting hoses included with delivery Connecting hose A is routed from the compressor outlet 1 to the dryer inlet 2 and is routed together with hose B using double clips 3 Connecting hose B is routed from the dryer outlet 4 to the air tank inlet 5 and is connected to the dryer 6 using clips ...

Page 23: ...INSTALLATION 06 2022 23 NP DK50 3x4VR_M AD A EN 3_06 2022 Fig 8 Connecting the dryer to the compressor IN OUT ...

Page 24: ... the provided hoses 2800 mm Fig 9 Air inlet to the dryer Burn or fire hazard Caution Hot surface When installing connecting hose Fig 8 at the air inlet to the dryer please note the hose and the manifold on the compressor may be hot and reach hazardous temperatures that may harm materials or operating staff AD dryer compressed air outlet Connect the outlet from the dryer 1 to the air inlet on the c...

Page 25: ... provided collection vessel A noise silencer is recommended when connecting directly to drain piping Fig 12 Codensate drain Risk of damage to pneumatic components Air hoses must not be broken 12 ELECTRICAL CONNECTION The product is delivered without a power cord Connect the compressor module to the dryer module using the W22 cable Fig 13 The connecting cable must be protected with a suitable cable...

Page 26: ...AD A EN 3_06 2022 26 06 2022 Fig 13 Connecting the W22 connection cable Fig 14 Connecting the control signal 1 Connector Harting Risk of fire and electric shock Electrical cable must not be in contact with hot compressor components ...

Page 27: ...0 100 M network via the controller as follows Use the RJ 45 connector on the switchboard door to connect a cable to the Ethernet network Fig 16 Configuration of the IP address to connect to the local network The default IP address of the BM module is 192 168 0 3 TDE 192 168 0 2 sub mask 255 255 255 0 The user shall request the configuration of IP addresses specific or requested from the manufactur...

Page 28: ...oogle Chrome etc The process for logging into the Web Server function once the compressor is connected to an Ethernet network is as follows Open the web browser on a PC smartphone or tablet and enter the IP address of the controller basic module 192 168 0 3 Enter the password LOGO and click on the LOG on button After logging in the browser displays the first screen showing the system information f...

Page 29: ...or keys the same as on the real display 13 COMMISSIONING Make sure all transport stabilizers were removed Check that all compressed air connections are correct see chap 11 Check correct connection to the mains see chap 12 Check to ensure the connection cable is properly connected on the dryer Fig 13 Check to ensure the outlet valve is in the OFF position The compressor is not equipped with a backu...

Page 30: ...INSTALLATION NP DK50 3x4VR_M AD A EN 3_06 2022 30 06 2022 14 PNEUMATIC DIAGRAM DK50 3x4VR M ...

Page 31: ... Non return valve 7 Pressure valve 8 Condensate separator 9 Condensate collection vessel 10 Pressure sensor 11 Pressure gauge 12 Cooler 13 Cooler fan 14 Air tank 15 Condensate drain valve 16 Outlet valve 17 Dryer solenoid valve 18 Chamber inlet filter 19 Adsorbent 20 Chamber outlet filter 21 Regeneration jet 22 Outlet filter 23 Chamber left 24 Chamber right ...

Page 32: ...re switch s lower limit level The compressor automatically switches off after reaching the pressure switch s upper limit level Potential for damage to pneumatic components The working pressure settings for the pressure switch set by the manufacturer cannot be changed Compressor operation at a working pressure below the switching pressure indicates high air usage see the Troubleshooting chapter Ris...

Page 33: ...troller depending on compressed air usage The compressors sequentially turn off once the switching pressure is reached The pressure sensor monitors the pressure in the air tank The pressure value is shown on the display Check all air line connections and check for compressed air leaks Remedy all leaks that are identified Slowly open the outlet valve to the ON position The compressor assembly start...

Page 34: ...he mains The green P1 indicator should turn off 16 AD DRYER OPERATING MODES RUN mode The dryer is in RUN mode when the control signal from the compressor is active The cooler fans are activated and the chambers are cyclically switched by the solenoid valves based on the following time diagram T This is the chamber switching period and dT represents the pressure balancing time in the chambers prior...

Page 35: ...e display is backlit in white The home screen is followed by the RUN MODE and STAND BY MODE screens based on the compressor control signal RUN MODE screen TOTAL HRS total time the dryer has been energised RUN HRS total dryer cycling time TME to MT time until the service interval expires STAND BY MODE screen TOTAL HRS total time the dryer has been energised RUN HRS total dryer cycling time This scr...

Page 36: ...monitors operating pressure and operating hours These values alarms and service interval information are shown on the display The control panel on the controller has four cursor buttons ESC and OK buttons and four function buttons F1 F4 which trigger the following F1 display backlight F2 information on operating hours and maintenance intervals F3 statistics on the number of motor circuit breaker t...

Page 37: ...osition after remedying the malfunction Pressing F4 F4 is only active if the maintenance screen appears once 2000 hours of operation have been passed see the maintenance alarm Press and hold F4 for at least 5 seconds to set a new interval The screen switches back to normal operating mode once the new interval is set Note Only service personnel are authorised to configure a new service interval usi...

Page 38: ...d Any maintenance or service work must be recorded in the compressor s service log Low pressure alarm during compressor start up PRESSURE current pressure in the system HOURS RUN operating hours The information on the display automatically disappears once air pressure is above 5 bar The compressor supplies air to the compressed air system as needed and without restriction Medium priority alarm con...

Page 39: ...rity over maintenance interval signals As such the light will indicate an alarm from any of the air pumps 17 SWITCHING OFF THE COMPRESSOR Use the main switch Q10 to switch off the compressor for maintenance or other reasons the switch also functions as a central stop button The compressor is disconnected from the mains with the exception of the mains terminal block X0 Attention Power terminals X0 ...

Page 40: ...be performed by the operator s trained personnel Only use manufacturer approved replacement parts and accessories Danger of injury or equipment damage Prior to commencing compressor maintenance it is necessary to check if it is possible to disconnect the compressor from the appliance in order to avoid any risk of injury to the person using the appliance or other material damage turn off the compre...

Page 41: ...rd When the compressor is running or shortly thereafter certain portions of the air pump and parts of the dryer may be hot do not touch these components The removed grounding conductor during service must be connected back to the original position after completing the service ...

Page 42: ...ours x x x x x x 6000 hours x x x x x 4000 hours x x x x x x 2000 hours x x x x x Once every 2 years Once a year Once a week Once a day x x 50 Hz Check of product operation Pour the trapped condensate out of the container Check of pneumatic connections leakage and device inspection Inspection of electrical connections Check of non return vaves function Check the function of pressure sensor B1 Chec...

Page 43: ...x x x x x x 8000 hour s x x x x 6000 hoou rs x x 4000 hour x x x x 2000 hours Once every 2 years Once a year x x Once a week Once a day 50 Hz Check of safety valve Check operation of solenoid valves Replacement of pump inlet filter Replacement of the dryer s internal filters Check of pneumatic connections for leaks Check of cooler and fan dryer Replacement of cassettes with adsorbent media AD750 E...

Page 44: ... Check filters condition filters must be undamaged and sufficiently clean Check condition of the pump itself check if there is no dirt inside the crankcase or clearance in the crankshaft Check the functionality of the automatic condensate drain Replace any defective parts as needed Check the solenoid valves in the valve module the valves should cyclically cycle between the chambers based on the de...

Page 45: ...ET UP function for a new service interval is only functional if the dryer indicates an upcoming service interval or that a service interval has expired Once complete the MAINT counter increases number of completed service operations by one See the screen Counters Information screens version AD750 E Information screens are activated by simultaneously pressing and holding down the ESC key and cursor...

Page 46: ...ing to the next service interval SERV INTER value of the defined service interval ESC press and hold for 10 seconds to configure a new service interval once a service operation is complete see above Configuration of a new service interval 18 5 Condensate drain A wet floor resulting from overflow from the vessel poses a slip hazard Condensate is automatically drained into a vessel to collect conden...

Page 47: ...r Let the safety valve vent for a few seconds Turn the screw fully to the right the valve must be closed now Fig 19 Check of safety valve Damage to the safety valve could cause pressure to rise to hazardous levels Never use the safety valve to release the air pressure in the air tank This could damage the safety valve The valve is set to the maximum permitted pressure by the manufacturer Never adj...

Page 48: ...l the motors 18 11 Check the function of pressure sensor B1 Functionality is checked visually using the TDE screen which shows the compressed air value Changes in air usage must be reflected in pressure changes on the display 18 12 Cleaning and disinfection of the exterior surfaces of the product Clean and disinfect the exterior surfaces with neutral cleaning products Use of aggressive detergents ...

Page 49: ...pment Fig 21 Fig 21 Venting pressure from the dryer chambers Disconnect the hose 2 from the lower part of the condensate separator 3 Fig 22 Fig 22 Venting pressure from the cooler and condensate separator The process of manually venting pressure from the equipment is complete after approximately 2 minutes 18 14 Replacement of the dryer s internal filters Working with pressurised pneumatic componen...

Page 50: ...Check for any dryer leaks Fig 23 Replacement of internal filters 18 15 Replacement off cassettes with adsorbent media In normal operation the replacement of the cassettes with adsorbent media must be performed at the defined interval Turn off the compressor Check the pressure in the dryer If the dryer chambers are under pressure proceed in accordance with Chapter 18 13 Unscrew the 8 screws 1 Remov...

Page 51: ...nozzles 5 and clean as necessary Reverse the procedure to reassemble Check for leaks and the operation of the logic valve and nozzles check for the cyclical switching of the chambers Fig 25 Replacement of the logic valve ball 18 17 Replacement of the dryer s silencer Working with pressurised pneumatic components poses a risk of injury Operating the equipment without silencers generates high levels...

Page 52: ...o before working on the equipment In normal operation the solenoid valves in the bottom of the dryer must be replaced at the defined interval Turn off the compressor Check the pressure in the dryer If the dryer chambers are under pressure proceed in accordance with Chapter 18 13 Unscrew the 1 screw from the valve connector 1 Disconnect the valve connector 2 Unscrew the 4 screws 3 Remove the soleno...

Page 53: ... replaced Mount the valve coil 4 5 onto the valve body 4 4 and secure with the nut 4 6 Insert the valve membrane spring 4 3 into the membrane 4 2 and the insert into the assembled valve coil and body assembly Then mount the valve seal 4 1 onto the dryer body Fig 28 Solenoid valve assembly 18 20 Pressure relief valve The pressure relief valve automatically begins to vent air from the system if the ...

Page 54: ...nufacturer is required before any adjustment is made to the relief valve The outlet openings on the relief valve may not be blocked and the egress of compressed air through them may not be restricted 1 Compressor pressure relief valve 2 Dryer pressure reief valve Fig 29 Pressure relief valve 19 LONG TERM SHUTDOWN If the compressor is not going to be used for long period it is recommended to drain ...

Page 55: ...the mains Release the air pressure in the pressure tank by opening the drain valve 7 Fig 1 release the air pressure from the dryer chambers Fig 21 Dispose of the equipment following all applicable regulations Entrust a specialised company to sort and dispose of waste Worn out components have no negative environmental impact ...

Page 56: ...ing failure damaged thermal protection Replace motor or windings Capacitor failure Replace capacitor Seized piston or other rotating part Replace damaged components Pressure switch does not switch Check function of pressure switch Controller malfunction Check controller operation check to ensure software is present replace if damaged or upload the correct program RUN STOP indicator is not green Lo...

Page 57: ... switch off in vertical stacks overheating Lack of ventilation in compressor room Secure suitable ambient conditions Cooling fans for aggregates cooler and enclosure do not work Defective fans replace Defective temperature switch replace Degraded drying performance high pressure dew point condensed water in the air Low operating pressure Reduce the demand for air check the output from the compress...

Page 58: ... or replace dirty filters Once a dryer fault is cleared and after its reassembly the dryer should quickly be regenerated best when using continuous compressor operation at a pressure of around 1 bar for a period of at least 1 hour then check the dryness of the compressed air Check the moisture content of the air exiting the air tank see the Technical data chapter to prevent damage to connected dow...

Page 59: ...nel alarms operation in alarm conditions Y N N Installation connection to equipment Y Product maintenance maintenance intervals maintenance procedure service intervals operating activities Y N N Functional test Y Safety measures warnings their meaning and compliance Y N N Notes 7 Operator instructed on safety measures operations and maintenance Name Signature Name Signature Name Signature 8 Instal...

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Page 64: ...DK50 3x4VR M EKOM spol s r o Priemyselná 5031 18 921 01 PIEŠŤANY Slovak Republic tel 421 33 7967255 fax 421 33 7967223 e mail ekom ekom sk www ekom sk NP DK50 3x4VR_M AD A EN 3_06 2022 112000554 0001 ...

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