Gardner Denver RCD1000 Instruction Manual Download

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REFRIGERATED

TYPE

COMPRESSED

AIR DRYERS

SERVICE DEPARTMENT: (724) 746-1100

INSTRUCTION MANUAL

Models: RCD800, RCD1000, RCD1200

8610.483.16

Rev. A

4/05

#18-2-710 1st Edition

Internal Use Only

5031b/050414

CONTENTS

INTRODUCTION ...........................................................

SAFETY ........................................................................

SAFETY INSTRUCTIONS ............................................

RECEIVING AND INSPECTION ...................................

INSTALLATION .............................................................

HOW IT WORKS ..........................................................

ENERGY MANAGEMENT CONTROLLER (EMC) ........

EMC MEMBRANE PANEL ............................................

AUTOMATIC DRAIN VALVES (ADVs) ..........................

START-UP .....................................................................

SHUTDOWN .................................................................

MAINTENANCE ............................................................

FIELD SERVICE GUIDE ...............................................

DIMENSIONS AND WEIGHTS .....................................

ENGINEERING DATA ...................................................

REPLACEMENT PARTS ...............................................

ELECTRICAL SCHEMATICS ........................................

OPERATOR’S LOG ......................................................

WARRANTY ..................................................................

Summary of Contents for RCD1000

Page 1: ... 050414 CONTENTS INTRODUCTION 2 SAFETY 2 SAFETY INSTRUCTIONS 3 RECEIVING AND INSPECTION 3 INSTALLATION 3 HOW IT WORKS 5 ENERGY MANAGEMENT CONTROLLER EMC 7 EMC MEMBRANE PANEL 8 AUTOMATIC DRAIN VALVES ADVs 11 START UP 11 SHUTDOWN 12 MAINTENANCE 12 FIELD SERVICE GUIDE 14 DIMENSIONS AND WEIGHTS 16 ENGINEERING DATA 17 REPLACEMENT PARTS 18 ELECTRICAL SCHEMATICS 22 OPERATOR S LOG 26 WARRANTY 28 ...

Page 2: ...nder pressure within the dryer can cause severe injury or death 4 High voltage in the motor and control box is danger ous The dryer must be installed in accordance with recognized electrical codes Before working on the electrical system disconnect power from the dryer with a manual disconnect switch Install a circuit breaker or fused safety switch in the electrical supply line leading to the dryer...

Page 3: ...im filing and processing is your responsibility Handling The dryer is mounted on a base to facilitate moving the dryer with a forklift Forks should extend all the way through the forklift channels provided to reduce stress on the dryer frame If slings are used to move the dryer use spreader bars to prevent damage to the sides of the dryer Returns to Manufacturer If the dryer or a component of the ...

Page 4: ... cause a rise in dew point unless the dryer inlet air flow is reduced The refrigerant discharge pressure control will shut down the refrigerant compressor if cooling water is inadequate Table 2 COOLING WATER REQUIREMENTSa R E Y R D L E D O M N N O C S E Z I S s e h c n i T P N b T A E H N O I T C E J E R r h U T B D E R I U Q E R R E T A W G N I L O O C m p g W O L F c F 0 7 F 0 8 F 5 8 F 0 9 W 0 ...

Page 5: ...des CAUTION Operation of dryers with improper line voltage con stitutes abuse and could affect the dryer warranty Standard dryer enclosures and controls are designed to meet NEMA Type 1 electrical standards All wiring is com plete Connect power leads as indicated in electrical sche matic and marked in the electrical enclosure Ground the frame Install a branch circuit disconnect in accordance with ...

Page 6: ...E CUT OUT SWITCH AMBIENT AIRFLOW CONDENSER DISCHARGE COMPRESSOR SUCTION SERVICE ACCESS VALVE HPS GLYCOL TANK GLYCOL MIXTURE SEPARATOR DRAIN SUCTION COMPRESSOR DISCHARGE CONDENSER WATER OUT WATER IN WATER REGULATING VALVE HIGH PRESSURE CUT OUT SWITCH SERVICE ACCESS VALVE FILTER DRYER HIGH SIDE PROCESS PORT CAPILLARY TUBES DISTRIBUTOR LOW SIDE PROCESS PORT AIRFLOW ASSEMBLY OUTLET AIR INLET AIR GLYCO...

Page 7: ...a l e D r e y r D e t u n i m 1 o t 0 s d n o c e s 0 6 s e t u n i m 0 6 o t 1 y a l e d o N s t r a t s e r r e y r d y l e t a i d e m m i s r u o h 4 o t 1 s r u o h 4 o t 1 p u m r a w l l i w r e y r d e m i t f o t n u o m a e m a s e h t r o f f f o s a w r e w o p s r u o h 4 n a h t e r o M s r u o h 4 The display will show the minutes remaining in the warmup period Power off for more th...

Page 8: ...the dryer i e the Dryer On LED is off Up and Down Buttons Used to change the display for the right hand column of LEDs when the DISPLAY SELECT button is pressed These buttons are also used to select the temperature display units see Fahrenheit and Celsius LED descriptions when the display is showing the Process Control Temperature DISPLAY SELECT Button Used to select the function which is on the d...

Page 9: ...n setting the drain open times Drain Closed LED Indicates when the automatic drain valve is closed See Set Auto Drain Off Time Min for information on setting the drain closed times Fahrenheit LED Indicates the temperature is displayed in F To change the display temperature setting Make sure the process control temperature is displayed and the Process Control Temperature LED is on Press the UP or D...

Page 10: ...off time Press the DISPLAY SELECT button until the Set Auto Drain Off Time Min LED is lit The display will show the current drain off time setting in minutes Press the up or down button to increase or decrease the drain off time The Set Auto Drain Off Time Min LED will blink This setting has a minimum value of 0 5 and a maxi mum value of 30 The up and down buttons will auto repeat from 0 5 to 30 i...

Page 11: ...urn on at the proper time refer to the Maintenance section of this manual If the dryer is under warranty call your local distributor for authorization before servicing To minimize air losses set the timer so that only air dis charges at the end of the open period Recommended ini tial settings are a 3 second drain on time and a 4 minute drain off time If air discharges for more than one second set ...

Page 12: ...require little maintenance for satisfactory operation Good dryer performance can be ex pected if the following routine maintenance steps are taken DANGER Dismantling or working on any component of the compressed air system under pressure may cause equipment failure and serious personal injury Be fore dismantling any part of the dryer or com pressed air system completely vent the internal pressure ...

Page 13: ... or blow out debris with compressed air from an OSHA approved air nozzle that limits its discharge pressure to 30 psig 12 Check that small port in diaphragm assembly is clear and solenoid coil moves freely in housing Viton seals are compatible with commonly used synthetic lubri cants CAUTION Do not disassemble timer or attempt to repair elec trical parts Replace timer if defective To reassemble th...

Page 14: ...f I e g r a h e r d n a r i a p e r k a e l e t a c o L y r o t c a f t l u s n o c d e c a l p e r n o i t c u s t n a r e g i r f e R n a h t r e h g i h e r u t a r e p m e t l a m r o n F 0 2 1 n a h t r e h g i h e r u t a r e p m e t r i a t e l n I o t e r u t a r e p m e t e g r a h c s i d r e l o o c r e t f a e c u d e R x a m 0 3 1 s n o i t i d n o c n g i s e d E e v i s s e c x w o ...

Page 15: ...Type Valve Aids in Disconnecting Compressor from the System PRESSURE GUAGE THERMOMETER DRIP LEG MANOMETER DIFFERENTIAL PRESSURE INDICATOR AUTOMATIC DRAIN VALVE FALSE LOADER Blows Off Air Outside of Compressor Room SYSTEMS INSTRUMENTATION INCLUDES Nepholometer Hygrometer Pressure Temperature VENTILATION Motorized louvers Exhaust Fans AFTERCOOLER SEPARATOR ISOLATION VALVE UNION STRAINER AND TRAP NOT...

Page 16: ...2 7 2 1 7 0 1 4 6 5 1 2 2 2 3 5 9 7 0 1 2 0 0 2 1 3 7 8 1 5 7 3 7 0 1 8 1 5 2 1 7 8 7 9 5 8 3 5 7 7 1 9 8 9 6 2 7 2 1 7 0 1 8 5 5 6 9 1 2 6 0 0 1 3 2 2 2 NOTE Dimensions and weights are for reference only Request certified drawings for construction purposes DIMENSIONS AND WEIGHTS LEFT SIDE REAR FRONT RIGHT SIDE TOP 3 NPT OUTLET 3 NPT INLET AIRFLOW AIRFLOW ELECTRICAL 1 2 KNOCKOUTS CUSTOMER ELECTRIC...

Page 17: ...Voltage 460 3 60 Max Min voltage 506 414 Rated Load Amps 7 69 9 62 9 94 Locked Rotor Amps 42 67 80 Minimum Circuit Ampacity 11 69 14 21 14 82 Branch Circuit Fuse Size amps 17 5 20 20 Watts 35 F Evaporator 100 F Ambient 4 486 5 424 5 674 Resistance ohms 3 8 2 41 1 9 NominalVoltage 208 230 3 60 Max Min Voltage 253 187 Rated Load Amps 23 08 29 49 Locked Rotor Amps 114 143 Minimum Circuit Ampacity 32 ...

Page 18: ...18 REPLACEMENT PARTS Air Cooled Models 800 1200 scfm 1 6 7D 7C 9 3 4 5 7A 7B 6 8 2 7A 7B REAR VIEW TOP VIEW FRONT VIEW LEFT SIDE VIEW ...

Page 19: ... G 4 0 5 9 9 0 3 G 0 8 5 8 6 0 3 G r o t i c a p a C n u R r o t o M n a F 1 9 0 1 5 0 3 G 1 9 0 1 5 0 3 G 8 5 9 2 6 0 3 G 6 0 6 3 0 6 4 r o s s e r p m o C 0 5 2 6 3 1 3 G 0 4 6 0 1 1 3 G 9 7 1 9 9 0 3 G r o t c a t n o C r o s s e r p m o C 9 2 6 6 3 1 3 G 9 2 6 6 3 1 3 G 9 2 6 6 3 1 3 G t i K r e m r o f s n a r T 4 9 3 4 9 0 3 G G 0 8 2 5 6 0 3 9 8 9 0 1 1 3 G y l b m e s s A w o l F r i A A 7...

Page 20: ...20 REPLACEMENT PARTS Water Cooled Models 800 1200 scfm FRONT VIEW TOP VIEW LEFT SIDE VIEW REAR VIEW 3 1 2 9 5 8 6 4 7D 7C 7A 7B 7A 7B ...

Page 21: ...0 3 G r o t c a t n o C r o s s e r p m o C 9 2 6 6 3 1 3 G 9 2 6 6 3 1 3 G 9 2 6 6 3 1 3 G t i K r e m r o f s n a r T 4 9 3 4 9 0 3 G G 0 8 2 5 6 0 3 9 8 9 0 1 1 3 G y l b m e s s A w o l F r i A A 7 d l o f i n a M t e l n I 2 7 0 5 9 0 3 G 2 7 0 5 9 0 3 G 8 3 1 6 3 1 3 G B 7 d l o f i n a M t e l t u O 2 9 1 6 8 0 3 G 2 9 1 6 8 0 3 G 9 0 7 9 1 1 3 G C 7 l i o C y l b m e s s A w o l f r i A 6 ...

Page 22: ...ASIC TMR 1 2 3 POWER 21 J5 22 20 J4 NO ALARM CONTACTS NO NC GND EMERGENCY STOP SWITCH COMPRESSOR FAN1 1 2 3 HIGH PRESSURE CUT OUT WITH MANUAL RESET HPS M 32 RC DRAIN VALVE RATING 5A 115 VAC 5A 24 VDC 1SOL UNPOWERED NC COM CHASSIS GROUND SEE NOTE 13 SEE NOTE 6 FIELD SERVICE SEE NOTE 13 1TS 3 GND 7 L3 L2 L1 3 2 1 X1 X2 H3 H1 H2 T H4 21 FU FB 3 HTR 2 2 8 2 1M 1M 1M 6 4 1MTR 1 2 3 4 6 7 8 9 10 11 12 1...

Page 23: ...LER 2 1 IDP DIP SWITCHES 1 2 3 SEE NOTE 14 6 5 8 7 COMPRESSOR 1 1 2 CUTOUT SW J8 2 DRAIN VALVE J7 1 2 3 4 1 2 3 J6 ALARM J5 C OPTION DRAIN VALVE 1 TMR 20 20 3TS 21 2SOL POWER J4 CHASSIS GROUND 5A 24 VDC RATING 5A 115 VAC WITH MANUAL RESET HIGH PRESSURE CUT OUT ALARM CONTACTS NO NC 25 HPS GND 29 30 28 27 26 DRAIN VALVE 1SOL 24 NC 22 23 COM NO 2TS SEE NOTE 13 UNPOWERED 20 21 21 6 5 4 SEE NOTE 13 GND...

Page 24: ...C 2 2 1 1 2 CONTROLLER 2 1 IDP DIP SWITCHES 1 2 3 SEE NOTE 14 6 5 8 7 COMPRESSOR 1 1 2 CUTOUT SW J8 2 DRAIN VALVE J7 1 2 3 4 1 2 3 J6 ALARM J5 DRAIN VALVE 1 TMR 20 20 3TS 21 2SOL POWER J4 CHASSIS GROUND 5A 24 VDC RATING 5A 115 VAC WITH MANUAL RESET HIGH PRESSURE CUT OUT ALARM CONTACTS NO NC 25 HPS GND 29 30 28 27 26 DRAIN VALVE 1SOL 24 NC 22 23 COM NO 2TS SEE NOTE 13 UNPOWERED 20 21 21 6 5 4 GND 3...

Page 25: ...71 2 4 1 5 3 1 2 4 1 12 12 12 12 6 6 6 4 ENCLOSURE COVER 3091860 8 1 13 T 16 15 14 16 15 14 13 11 17 18 19 20 6 21 21 6 5 9 21 9 11 16 15 14 13 8 2FU2FB 3TS 16 15 14 13 17 18 19 20 6 21 9 23 24 0020244 3093383 3088358 3066660 12 2 1 6 24 23 22 21 BRACKET TM E6X BRACKET INSERT CONDUIT SEALING RING 1 2 POP RIVET 3 16 31 LABEL MAKE FIELD CONNECTIONS HERE LABEL DANGER SHOCK HAZARD 3138598 3074098 25 2...

Page 26: ... y a l p s i D e t a D e m i T y B n i a r D o t u A e v l a V l i O p m o C l e v e L n O r e w o P h g i H e r u t a r e p m e T m r a l A w o L e r u t a r e p m e T m r a l A s s e c o r P s l o r t n o C p m e T F t n e c r e P s g n i v a S ...

Page 27: ...27 NOTES ...

Page 28: ...SSLY IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WAR RANTY OF FITNESS FOR A PARTICULAR PURPOSE THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAM AGE BY REASON OF STRICT LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN MANUFACTURE OR INSPECTION OF THE EQUIPMENT OR ITS FAILURE TO DISCOVER REPORT REPAIR OR MODIFY LATENT DEFECTS INHERENT THEREIN THE MAN...

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