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FRIULAIR ACT VC 3000 - 6000, Manual

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FRIULAIR ACT VC 3000 - 6000 Manual Download Page 49

Maintenance operation on the refrigeration circuit 

ACT VS 3000 - 6000

 

 

EN - 49 

13  Maintenance operation on the refrigeration circuit 

 

Caution! 

Refrigerant! 

Maintenance and repair works at refrigeration systems must only be carried out by  certified refrigerating 
engineers only in accordance with the local provisions. 

The total amount of refrigerant in the system must be collected for recycling purposes, resource recovery 
or disposal. 

The refrigerant must not be discharged into the environment. 

When delivered, the dryer is ready to operate and filled with a refrigerant of the R407C type. 

 

Should  you  detect  a  refrigerant  leak,  please  contact  a  certified  refrigerating  engineer.  Prior  to  any 
intervention, the room needs to be ventilated. 

When the refrigeration cycle needs to be refilled, please also contact a certified refrigerating engineer. 

You will find the refrigerant type and amount on the name plate of the dryer. 

 

Characteristics of refrigerants used: 

 

Refrigerant 

Chemical formula 

TLV 

GWP 

R407C - HFC 

R32/125/134a (23/25/52) 

CHF2CF3/CH2F2/CH2FCF3 

1000 ppm 

1773.85 

 

13.1  Dismantling of the dryer 

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

 

 

Part 

Material 

Refrigerant fluid 

R407C, Oil 

Canopy and Supports 

Carbon steel, Epoxy paint 

Refrigerating compressor 

Steel, Copper, Aluminium, Oil 

Alu-Dry Module 

Aluminium 

Condenser Unit 

Aluminium, Copper, Carbon steel 

Pipe 

Copper 

Fan 

Aluminium, Copper, Steel 

Valve 

Brass, Steel 

Electronic Level Drain 

PVC, Aluminium, Steel 

Insulation Material  

Synthetic rubber without CFC, Polystyrene, Polyurethane 

Electric cable 

Copper, PVC 

Electric Parts 

PVC, Copper, Brass 

 

We recommend to comply with the safety rules in force for the disposal of each type of material. 

Refrigerant contains droplets of lubrication oil released by the refrigerating compressor. 

Do not dispose this fluid in the environment. Is has to be discharged from the dryer with a suitable device 
and then delivered to a collection centre where it will be processed to make it reusable. 

  

Summary of Contents for ACT VC 3000 - 6000

Page 1: ...Refrigerating air dryer Air water cooled EN User s maintenance and spare parts manual 74MD0008A8 EN_00 ...

Page 2: ...facturing faults and to demonstrate that the device can perform all the functions for which it has been designed Once the dryer has been properly installed according to the instructions in this manual it will be ready for use without any further adjustment The operation is fully automatic and the maintenance is limited to few controls and some cleaning operations as detailed in the following chapt...

Page 3: ...Condenser water regulating valve Water Cooled 23 11 9 Filter dryer 23 11 10 Electronic Expansion Valve EEV 24 11 11 Alu Dry module 24 11 12 Refrigerant pressure switches LPS HPS 24 11 13 Compressor crankcase heater 24 11 14 Electrical panel fan 24 11 15 DMC50 electronic control unit 25 11 15 1 Starting the dryer ON mode 25 11 15 2 Stopping the dryer STANDBY mode 25 11 15 3 Performing the condensat...

Page 4: ...of components 50 14 1 Dryers dimension 51 14 1 1 ACT VS 3000 3750 51 14 1 2 ACT VS 4000 5000 51 14 1 3 ACT VS 6000 Air Cooled 51 14 1 4 ACT VS 6000 Water Cooled 51 14 2 Exploded views 51 14 2 1 ACT VS 3000 3750 Air Cooled 51 14 2 2 ACT VS 3000 3750 Water Cooled 51 14 2 3 ACT VS 4000 5000 Air Cooled 51 14 2 4 ACT VS 4000 5000 Water Cooled 51 14 2 5 ACT VS 6000 Air Cooled 51 14 2 6 ACT VS 6000 Water...

Page 5: ...ructions local and national regulations need to be observed where required Ensure that operation of the compressed air refrigeration dryer only takes place within the permissible limit values indicated on the name plate Any deviation from these limit values involves a risk for persons and for the material and may result in malfunction or a breakdown After installing the device correctly and in acc...

Page 6: ...ressed air inlet ARIA AIR LUFT AIR Connection point compressed air outlet Connection point condensate drain Connection point cooling water inlet water cooled Connection point cooling water outlet water cooled 1 Certified skilled personnel are persons who are authorised by the manufacturer with experience and technical training who are well grounded in the respective provisions and laws and capable...

Page 7: ...g Potential hazard Consequences of non observance possible serious injury or death Caution Imminent hazard Consequences of non observance possible injury or property damage Notice Potential hazard Consequences of non observance possible injury or property damage Important Additional advice info hints Consequences of non observance disadvantages during operation and maintenance no danger 2 Certifie...

Page 8: ... or the device Pos 5 Beko Technische Dokumentati on Sicherheit M aßnahmen Dr uckl uft BM 0 mod_1184148284291_6 doc 5812 Pos 6 Beko Technische Dokumentati on Sicherheit Gefahr N etzspannung 0 mod_1184148186948_6 doc 5794 Danger Supply voltage Contact with non insulated parts carrying supply voltage involves the risk of an electric shock resulting in injuries and death Only qualified and skilled per...

Page 9: ...se use an approved fire extinguisher Water is not a suitable agent to extinguish an electrical fire This must only be carried out by persons who are trained and informed about the hazards emanating from the product Caution Unauthorised intervention Unauthorised interventions may endanger persons and plants and lead to malfunction Unauthorised interventions modification and abuse of the pressure de...

Page 10: ...d air cannot be used for breathing air purposes and is not suitable for the direct contact with food This dryer is not suitable for the treatment of contaminated air or of air containing solids 5 Instructions for the use of pressure equipment according to PED directive 2014 68 EU To ensure the safe operation of pressure equipments the user must conform strictly to the above directive and the follo...

Page 11: ...ith care Heavy blows could cause irreparable damage 7 Storage SCC0001 Even when packaged keep the machine protected from severity of the weather Keep the dryer in vertical position also when stored Turning it upside down some parts could be irreparably damaged If not in use the dryer can be stored in its packaging in a dust free and protected site at a temperature of 1 C 50 C 34 F 122 F and a spec...

Page 12: ...chemicals with a corrosive effect explosive gases toxic gases evaporation heat high ambient temperatures or extreme dust and dirt can be found Minimum installation requirements Choose an area which is clean and dry free from dust and protected against atmospheric disturbances The load bearing zone must be even horizontal and able to bear the weight of the dryer Minimum ambient temperature 1 C 34 F...

Page 13: ...mpressors capacity varies suddenly and frequently after the dryer if the air consumption variation is very wide frequent and sudden or both to have the best load variation dampness Compressed air tanks can be installed as capacity dampers installed before the dryer Type A if the compressor capacity varies suddenly and often after the dryer Type B if the change in air consumption is very large freq...

Page 14: ...re 120 psig 8 barg Ambient temperature 115 F 45 C Inlet air temperature 122 F 50 C Pressure DewPoint 50 F 10 C Factor F1 1 07 Factor F2 0 78 Factor F3 0 68 Factor F4 1 36 Each item of data has a corresponding numerical factor which multiplied by the design air flow is as follows Air flow capacity 3000 x 1 07 x 0 78 x 0 68 x 1 36 2316 scfm 3935 m h 2316 scfm 3935 m h This is the maximum flow rate t...

Page 15: ...t rust chips and other impurities and must be consistent with the flow rate of the dryer In case of treatment of air at particularly high temperature the installation of a final refrigerator could result necessary In order to perform maintenance operations it is recommended to install a dryer by pass system In realising the dryer particular measures have been taken in order to limit the vibration ...

Page 16: ... local Power Provider CAUTION Please observe the direction of rotation of the fix speed compressors In this system the direction of rotation of the fix speed compressors is supervised by a reverse phase protector RPP When this guard is triggered the DMC50 goes into alarm mode the status bar flashes red and shows alarm n 5 Compressor Protection In the event that the compressor does not run the dire...

Page 17: ...H Cl2 0 5 mg l or ppm PH 7 5 9 0 H2S 0 05 mg l or ppm Conductivity 10 500 μS cm or μmho cm CO2 5 mg l or ppm Residual solid particles 30 mg l or ppm NO3 100 mg l or ppm Saturation Index SI 0 2 0 0 2 Fe 0 2 mg l or ppm HCO3 70 300 mg l or ppm Al 0 2 mg l or ppm SO4 2 70 mg l or ppm Mn 0 1 mg l or ppm Note 1 Other temperature on request Check the data shown on the identification plate 2 Other pressu...

Page 18: ...ed and connected to a collection system or container Ensure that the by pass system if installed is closed and the dryer is isolated Ensure that the manual valve of the condensate drain circuit is open Remove any packaging and other material which could obstruct the area around the dryer Activate the mains switch Turn on the main switch pos 1 on the control panel Wait about 45 seconds the initiali...

Page 19: ...isplay of electronic controller shows STANDBY Keep pressed the button at least 3 seconds the dryer starts and the display shows ON If the temperature shown on the display is sufficiently high verify that the refrigerating compressor starts within a few minutes NOTE With low temperatures the refrigerating compressor will remain OFF Wait few minutes verify that the DewPoint temperature displayed on ...

Page 20: ...5 1 29 8 34 3 38 0 41 6 Max noise level at 1 m dbA Weight lb kg 1850 840 2090 950 2350 1065 2670 1210 3660 1660 Refrigerant type Refrigerant quantity 2 oz kg 332 9 40 430 12 20 448 12 70 617 17 50 776 22 00 Max cooling water inlet temp 3 F C Min Max cooling water inlet pressure psig barg Cooling water flow at 30 C US gpm m3 h 12 5 2 84 15 5 3 51 17 4 3 95 19 5 4 42 25 6 5 82 Heat Rejection btu hr ...

Page 21: ... evaporating pressure above the freezing point Expired the first 3 minutes DMC50 will adjust VS compressor s speed in order to keep the evaporating pressure almost constant allowing a constant DewPoint even with dryer thermal load variation Having an higher load to the dryer the capacity of the VS compressor to its maximum speed is insufficient the evaporation pressure tends to increase beyond the...

Page 22: ...ectronic drainer 2 Refrigerant pressure switch LPS 25 Compressor crankcase heater 4 Refrigerant pressure switch HPS 34 Liquid sight glass 6f Compressor FIX 35 Electronic Expansion Valve EEV 6v Compressor VS 36 Liquid separator 8 Condenser Air Cooled 37 Refrigerant pressure transducer BHP 9 Condenser fan Air Cooled 39 Refrigerant pressure transducer BLP 10 Filter dryer 43 Oil separator 12 1 T1 Temp...

Page 23: ...the ambient air temperature does not exceed the nominal values It is also important to keep the condenser unit free from dust and other impurities 11 7 Condenser Water Cooled The condenser is the component in which the gas coming from the compressor is cooled down and condensed becoming a liquid Basically it is a water refrigerating gas exchanger where the cooling water lowers the temperature of t...

Page 24: ...t pressure switches LPS HPS As operation safety and protection of the dryer a series of pressure switches are installed in the gas circuit LPS Low pressure protection device on the suction side of the compressor trips if the pressure drops below the pre set value The values are automatically reset when the nominal conditions are restored Calibrated pressure R407C Stop 1 7 barg 24 7 psig Restart 2 ...

Page 25: ...nd display ON NOTE During the warm up phase which lasts about 3 minutes the compressor works at a set speed to enable the lubricating oil to circulate correctly in the compressor at the beginning This phase is illustrated with a bar symbol under the compressor icon which gradually becomes blue and shows the time that has lapsed since the dryer started Once the dryer has warmed up the bar symbol di...

Page 26: ...ssure balancing solenoid valve active powered Pressure balancing solenoid valve not active not powered 3 Hold the button to perform the condensation drain test Release the button to finish the condensation drain test 4 Press the button to display the log file process values expressed graphically or numerically for the last 60 minutes of dryer operation The default graph includes traces for all 8 p...

Page 27: ...vice warning is shown 2 Confirm the service warning is to be reset with OK or exit without resetting with Cancel NOTE After resetting service warnings the operator maintenance technician must verify solve the problem that caused the service warning Service warnings never reset automatically with the exception of service warning no 19 malfunction of electronic condensation drainer which is factory ...

Page 28: ...vents the dryer starting up in the presence of an alarm and displays the alarm status by changing the colour of the status bar red Resetting an alarm 1 Touch the screen on the status bar where the alarm is shown to display the list of stored alarms 2 Touch the screen on the alarm to be reset 3 Confirm the alarm is to be reset with OK or exit without resetting with Cancel 4 Touch the screen on the ...

Page 29: ...seconds T1 0 C 32 F 7 Probe Fault LP LP pressure transducer fault Flag immediately Restore transducer 8 Probe Fault HP HP pressure transducer fault Flag immediately Restore transducer 9 Probe Fault T1 T1 temperature probe fault Flag immediately Restore probe 10 Probe Fault T4 T4 temperature probe fault Flag immediately Restore probe 11 Low Differential Pressure Low differential pressure between th...

Page 30: ... the screen on the alarm just reset to display the dryer process values for the 60 minutes of operation immediately preceding the occurrence of the alarm in question 5 Scroll through the stored process values using the buttons 6 Press the button to return to the previous screen 7 Use the button to download process values in txt format for possible analysis diagnostics See the detailed procedure fo...

Page 31: ...es are to be downloaded with OK or exit the operation with Cancel 3 Confirm the download operation was successful with OK 4 Press the button to return to the previous screens Final steps Switch OFF the dryer by means of the main switch Open the control panel door with the special key provided with the dryer Remove the USB stick Close the control panel door carefully Switch ON the dryer 11 15 9 Dis...

Page 32: ...ed 2g The total hours of 2nd fixed speed compressor operation if installed 2h The hours remaining till the next service 2i The partial hours of dryer operation starting from the last time the counter was zeroed NOTE Only qualified skilled personnel should perform following operations 3 With dryer stopped STANDBY mode press the Reset button to reset the count of the hours remaining before the next ...

Page 33: ...en in REMOTE mode However it is possible to carry out all other operations such as the condensation drain test the management of alarms service warnings and access functions menus Only a clean contact free from electric potential and suitable for low voltage must be used Ensure there is adequate insulation on potentially hazardous live parts 11 15 12 How the alarm service warning flagging contact ...

Page 34: ...r to be changed requires a numerical value set the new value using the numerical keypad within the max and min limits shown 5 Confirm the setting or numerical value entered using the button or press the button to return to the parameter list without making any changes Repeat operations 3 4 5 for all parameters to be changed 6 Press the button to return to the previous screen at any time 7 Press th...

Page 35: ...8 0 x1000 hours SCL Scale Sets the temperature pressure units of measurement C Temperature in C and pressure in bar F Temperature in F and pressure in psi C F C AS Auto Restart Enables disables automatic dryer restart after restoring the electricity supply Yes the dryer restarts automatically after restoring the electricity supply if it had been started No The dryer must be restarted using the but...

Page 36: ...the current date and time 5 Confirm using the button or press the button to return to the parameter list without making any changes 6 Press the button to return to the previous screen at any time 11 15 16 Changing the user interface language 1 With the dryer stopped STANDBY or operating ON mode press the button to access the dryer s menu of functions 2 Press the button to display the list of avail...

Page 37: ...aintenance easily At dryer start up verify that this valve is open Control panel Power Service Led green ON ready to work supplied Blinking maintenance required Alarm Led red Blinking alarm condition Power Alarm Led ON circuit board defect TEST Button Discharge test keep pushed for 2 seconds Troubleshooting Only qualified personnel should perform troubleshooting and or maintenance operations Prior...

Page 38: ...antling chapters leads to the expiration of the guarantee Improper maintenance may result in dangerous situations for the personnel and or the device Danger Supply voltage Contact with non insulated parts carrying supply voltage involves the risk of an electric shock resulting in injuries and death Only qualified and skilled personnel are authorised to run electrically operated devices Prior to un...

Page 39: ...ponsible for the adherence to these provisions The respective directives in force apply to the qualification and expertise of the certified skilled personnel For safe operation the device must only be installed and operated in accordance with the indications in the operating instructions In addition the national and operational statutory provisions and safety regulations as well as the accident pr...

Page 40: ...mes higher Verify the electric wiring Electronic controller DMC50 in alarm condition see the corresponding point If the fan still doesn t work replace it and or its variable speed drive Condensing pressure measured with DMC50 and BHP pressure transducer is not correct Contact a refrigeration engineer to verify and compare the correct condensing pressure value If required replace BHP pressure trans...

Page 41: ...y drains condensate Electronic drainer is dirty see section 10 16 Water within the line Verify that the air inlet and outlet connections are correctly connected to the compressed air system not reversed connection The dryer doesn t start see specific point If installed Untreated air flows through the by pass unit close the by pass The dryer doesn t drain the condensate see specific point DewPoint ...

Page 42: ...enser even with fan off protect dryer against wind or external air flows not caused by dryer s fan Air Cooled 3 The temperature of the cooling water is too low restore nominal conditions Water Cooled 4 The cooling water flow adjusting valve requires re adjusting contact a specialized technician to restore nominal setting Water Cooled 5 Failure refrigerant pressure transducer BHP verify condensing ...

Page 43: ...l display shows 15 30 and push OK button The latest alarms are logged and displayed with their alarm code The total alarm logged are 10 starting with number 0 to 9 Alarm code and description 2 Fault in condenser fan drive replace the driver 4 Mains phase loss Missing phase on supply side or too high voltage imbalance Check supply voltage 7 DC over voltage Intermediate circuit voltage exceeds limit...

Page 44: ...e electric diagram reset restart and check the perfect functioning of the dryer If RPP triggered power phases are not connected properly Change two of three phases at the supply main 6 Ice The temperature inside the exchanger probe BT1 is too low the dew point is too low see the specific point Note is the only alarm which is displayed and automatically resets with the dryer stopped STANDBY 7 Probe...

Page 45: ...r than nominal check proper compressor motor functioning 169010 DC under Volt FC 101 fault number 8 Intermediate circuit voltage drops below voltage warning low limit Check and correct missing phase in input power supply blown fuse undervoltage on mains 169011 DC over Volt FC 101 fault number 7 Intermediate circuit voltage exceeds the limit Check static or transient overvoltages in the input power...

Page 46: ... too low see the corresponding paragraph 24 High Condensing Pressure The condensing pressure is too high see the corresponding paragraph 169201 169318 Variable speed drive INV1 in warning condition For complete information refer to the manual of the refrigerant compressor driver Compressor variable speed drive warning disappear when abnormal condition is removed 169201 Pwr Card Temp FC 101 fault n...

Page 47: ...r replace the transducer A44 Fault in controller replace the DRV controller E1 Fault in controller replace the DRV controller A11 Fault in controller replace the DRV controller E19 Fault in controller replace the DRV controller E25 Fault in controller replace the DRV controller As soon as the problem is solved the four led on the left of the display will be OFF not blinking Verify that the actual ...

Page 48: ... transducer 1 1 1 1 1 39 BLP Pressure transducer 1 1 1 1 1 44 Suction strainer 1 1 1 1 1 67 Electrical panel filter 1 1 1 1 1 82 CHV Check valve 2 2 2 2 3 85 Pressure balancing solenoid valve 1 1 1 1 1 85 1 Coil for pressure balancing solenoid valve 1 1 1 1 1 86 BSn EEV temperature probe 3 3 4 4 6 87 BPn EEV pressure transducer 3 3 4 4 6 QS Main switch 1 1 1 1 1 A1 DMC50 power module 1 1 1 1 1 DMC...

Page 49: ... the dryer Characteristics of refrigerants used Refrigerant Chemical formula TLV GWP R407C HFC R32 125 134a 23 25 52 CHF2CF3 CH2F2 CH2FCF3 1000 ppm 1773 85 13 1 Dismantling of the dryer If the dryer is to be dismantled it has to be split into homogeneous groups of materials Part Material Refrigerant fluid R407C Oil Canopy and Supports Carbon steel Epoxy paint Refrigerating compressor Steel Copper ...

Page 50: ...nt service valve H P side 36 Liquid separator 84 Refrigerant service valve L P side 37 Refrigerant pressure transducer BHP 85 Pressure balancing solenoid valve EVB 39 Refrigerant pressure transducer BLP 86 EEV temperature sensor BS 40 Compressor variable speed drive INV1 87 EEV pressure transducer BP Electric diagrams List of components MC1 MC3 Compressor LPS Low pressure switch RC Compressor cran...

Page 51: ...S 6000 Water Cooled 14 2 Exploded views 14 2 1 ACT VS 3000 3750 Air Cooled 14 2 2 ACT VS 3000 3750 Water Cooled 14 2 3 ACT VS 4000 5000 Air Cooled 14 2 4 ACT VS 4000 5000 Water Cooled 14 2 5 ACT VS 6000 Air Cooled 14 2 6 ACT VS 6000 Water Cooled 14 3 Electric diagrams 14 3 1 ACT VS 3000 3750 14 3 2 ACT VS 4000 14 3 3 ACT VS 5000 14 3 4 ACT VS 6000 ...

Page 52: ...Attachments 52 EN ACT VS 3000 6000 ...

Page 53: ...Attachments ACT VS 3000 6000 EN 53 ...

Page 54: ...Km 21 Fraz Strassoldo www friulair com Istruzioni originali in ITALIANO Con riserva di modifiche ed errori Original instructions are in ITALIAN Subject to technical changes without prior notice errors not excluded EN Subject to technical changes without prior notice errors not excluded Translation of original instructions ...

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