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Instruction book

2987 2020 00

35

Summary of Contents for VDR 2600

Page 1: ...NANO Refrigerant dryers VDR 2600 VDR 3150 VDR 3700 VDR 4200 VDR 5050 Instruction book...

Page 2: ......

Page 3: ...f is prohibited This applies in particular to trademarks model denominations part numbers and drawings This instruction book is valid for CE non CE as well as UKCA labelled machines It meets the requi...

Page 4: ...8 1 6 Dismantling and disposal 9 2 General description 11 2 1 Introduction 11 2 2 Air system 15 2 3 Refrigeration system 18 2 4 Automatic regulation system 21 2 5 Condensate drain system 23 2 6 Elect...

Page 5: ...1 Dimension drawings 55 4 2 Installation proposal 59 4 3 Electric cable size and fuses 65 4 4 Pictographs 69 4 5 Cooling water requirements 70 5 Operating instructions 76 5 1 Warnings 76 5 2 Initial...

Page 6: ...8 Technical data 86 8 1 Object Missing 86 8 2 Limitations 86 8 3 Air dryer data 87 9 Pressure equipment directives 89 10 Documentation 90 Instruction book 4 2987 2020 00...

Page 7: ...icable legislation and standards 5 Before any maintenance repair work adjustment or any other non routine checks stop the dryer press the emergency stop button switch off the voltage and depressurize...

Page 8: ...mmable fumes vapors and particles e g paint solvents that can lead to internal fire or explosion 7 Arrange the air intake so that loose clothing worn by people cannot be sucked in 8 Ensure that the di...

Page 9: ...e or injury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation maintenance and repair even if not expressly stated will be...

Page 10: ...nsibility for any damage or injury resulting from neglecting these precautions or non observance of the normal caution and care required for installation operation maintenance and repair even if not e...

Page 11: ...damage materials of the air net e g polycarbonate bowls 20 The following safety precautions are stressed when handling refrigerant Never inhale refrigerant vapours Check that the working area is adequ...

Page 12: ...l and Electronic Equipment regulations 2013 with the crossed out wheelie bin symbol At the end of life time of the electric and electronic equipment EEE it must be taken to separate collection For mor...

Page 13: ...ncoming air temperature The electronic regulator keeps the pressure dew point stable by controlling the electronic valves On air cooled dryers the condenser has cooling fans controlled by a pressure s...

Page 14: ...Position of components Figure 3 Air cooled dryer Figure 4 Water cooled dryer 1 Cubicle 6 Non return valve 7 Electronic expansion valve 1 Instruction book 12 2987 2020 00...

Page 15: ...2 11 Heat exchanger 1 12 Heat exchanger 2 13 Sight glass 14 Refrigerant dryer filter 15 Condensor 16 Liquid separator 17 Fan 19 Compressor 20 Flow switch 21 Frequency convertor Connections Figure 5 R...

Page 16: ...essed air inlet 3 Cable gland electrical connection 4 Automatic drain hose 5 Automatic drain hose 6 Cooling water inlet Only on water cooled dryers 7 Cooling water outlet Only on water cooled dryers I...

Page 17: ...2 2 Air system Air flow diagram Figure 7 Air and refrigerant flow diagram for air cooled dryers Instruction book 2987 2020 00 15...

Page 18: ...and refrigerant flow diagram for water cooled dryers Reference Name 101a Air air heat exchanger 101b Air refrigerant heat exchanger 102 Condensate separator 201 Non return valve Instruction book 16 2...

Page 19: ...ressed air enters heat exchanger 101a and is cooled by the outgoing cold dried air Water in the incoming air starts to condense The air then flows through heat exchanger evaporator 101b where the refr...

Page 20: ...2 3 Refrigeration system Refrigerant flow diagram Figure 9 Air and refrigerant flow diagram for air cooled dryers Instruction book 18 2987 2020 00...

Page 21: ...ion Refrigerant compressor 209 delivers hot high pressure refrigerant gas which flows through condenser 202 where most of the refrigerant condenses The liquid flows through refrigerant dryer filter 20...

Page 22: ...erant flow in the line to be checked During normal operation the liquid flow must be clear In general vapor bubbles indicate a shortage of refrigerant Note that fluctuations in the load may cause bubb...

Page 23: ...2 4 Automatic regulation system Air and refrigerant flow diagram Figure 11 Air and refrigerant flow diagram for air cooled dryers Instruction book 2987 2020 00 21...

Page 24: ...system for explanation of the references in the flow diagram Description The condenser pressure must be kept as constant as possible to obtain stable operation therefore For air cooled versions The re...

Page 25: ...oint the regulator opens the electronic hot gas by pass valve 208 to the evaporator circuit to prevent the evaporator temperature from dropping below 0 C 32 F 2 5 Condensate drain system Description F...

Page 26: ...ing compressed air When the controller registers a malfunction the red alarm LED on the control panel of the electronic water drain starts flashing a warning appears on the display of the regulator an...

Page 27: ...Check that a warning is generated on the display of the regulator Release the test button 2 6 Electrical system Electrical diagram Working with machinery controlled by a frequency converter requires s...

Page 28: ...Figure 17 Electrical diagram Instruction book 26 2987 2020 00...

Page 29: ...gure 18 Electrical diagram only for air cooled units Reference Description 1 Customer s installation 2 Condenser FAN motors 3 Main switch 4 Heater pad 5 Compressor motor Instruction book 2987 2020 00...

Page 30: ...use fans only for air cooled dryer F6 Circuit breaker Mk5 and expansion module F7 F15 Circuit breaker other components K1 Contactor dryer running Q1 Circuit breaker dryer motor Q2 Circuit breaker heat...

Page 31: ...plosive environments Avoid operation close to inadequately protected personal medical devices such as hearing aids and pacemakers Consult the manufacturers of the medical device to determine if it is...

Page 32: ...make accurate and immediate improvements when needed The results can be used for energy monitoring according to ISO50001 This product level is available as a free of charge 3 month trial Once an ICONS...

Page 33: ...omatically adjusting the cooling water flow only water cooled units The controller maintains a stable dew point during operation by automatically adjusting the cooling air flow only air cooled units A...

Page 34: ...warning condition disappears Service warning A number of service operations are grouped as a Service Plan Each Service Plan has a programmed time interval If the service timer exceeds a programmed va...

Page 35: ...arning sign Flashes in case of a shut down is lit in case of a warning condition 3 Service sign Is lit when service is needed 4 Operation sign Is lit when the unit is running in automatic operation 5...

Page 36: ...Data Status Inputs Outputs Counters Aux Equipment Parameters Converters Service Service Overview Service Plan Service History Service functions Clean Screen Week Timer Week Remaining Running Time Eve...

Page 37: ...ent Parameters Converter s Fan Internal SmartBox Auto Restart Controller Settings Network Settings Ethernet Settings CAN Settings Localisation Language Date Time Units User Password Help Information S...

Page 38: ...aded Wait Manual Stop Machine Control Mode Local Machine Control Mode Remote Machine Control Mode LAN Automatic Restart After Voltage Failure Week Timer Active System icons Icon Description Basic User...

Page 39: ...s indication Energy recovery Dryer Element Drain s Analogue Output Menu Reset Auto Restart Filter s Cooler Valve s Power Meter Input icons Icon Description Pressure Temperature Special Protection Open...

Page 40: ...e tapped to return to the main screen 2 Screen information On the main screen the screen information bar shows the serial number of the machine When scrolling through menus the name of the current men...

Page 41: ...he screen information bar Examples of inputs Ambient temp Outlet Dryer dewpoint Examples of counters Running hours Load relay Loaded hours 12 Menu button The menu button is always shown and can be tap...

Page 42: ...quality of the internal antenna can be monitored Each bar represents 25 reception strength If the four bars are filled the reception strength is 100 If only one bar is filled the reception strength is...

Page 43: ...s menu Auxiliary equipment parameters can also be changed The Auto restart function can be set through this menu This function is password protected 6 Controller settings Network settings Localisation...

Page 44: ...a icon Description Reference Designation 1 Status menu 2 Inputs menu 3 Outputs menu 4 Counters menu 5 Aux Equipment menu 6 Internal Data menu Status menu Tap the Status icon to enter the Status menu T...

Page 45: ...the Outputs icon to enter the Outputs menu This menu shows all the outputs of the controller Here information can be found about the expansion valves water valve fans and more Voltage free outputs may...

Page 46: ...ment menu This menu shows an overview of all auxiliary equipment fitted Internal Data menu Tap the Internal Data icon to enter the Internal Data menu This menu shows useful data like dryer dewpoint LA...

Page 47: ...remaining Running Hours and the remaining Real Time Hours until the next service The first row A shows the Running Hours when the first service is needed green the second row shows the Real Time Hours...

Page 48: ...with each up to 8 settings per day The week timers can be activated through this screen A Remaining Running Time can be set from 5 up to 240 minutes Procedure To enter the Week Timer menu screen 1 Ta...

Page 49: ...X 5 Add setting A selection screen pops up The user can change the setting by swiping up or down and confirm by tapping V or decline by tapping X 3 10 Event history menu Function This screen is used t...

Page 50: ...Machine settings menu Function This screen is used to display the following submenus Alarms Regulation Extra Aux Equipment parameters Auto Restart These submenus can be entered by tapping the icons P...

Page 51: ...to enter the Regulation menu Dryer modes can be changed and alarms can be modified through this menu Flow Switch Mode can be set to active in the menu If this mode is active the dryer will go in stand...

Page 52: ...ws an overview of all the auxiliary equipment fitted Through this menu the parameters of the auxiliary equipment can be changed Modify a setting When tapping a list item a selection screen pops up The...

Page 53: ...tapping V or decline by tapping X Modify a setting When clicking a list item a selection screen pops up The user can modify the setting by tapping or and can confirm by tapping V or decline by tapping...

Page 54: ...ned off the settings can be modified Modify a setting When tapping a list item a selection screen pops up The user can modify the setting by tapping or and can confirm by tapping V or decline by tappi...

Page 55: ...User Password icon to enter the User Password menu The user password can be activated or deactivated through this menu Enter and confirm a user password to activate repeat to deactivate Enter a passw...

Page 56: ...Level button at the upper right corner of the screen Description Reference Designation Function 1 User A basic set of parameters is visualized no password required 2 Service This access level is only...

Page 57: ...4 Installation 4 1 Dimension drawings Dimension drawing of water cooled dryer metric units Instruction book 2987 2020 00 55...

Page 58: ...Dimension drawing of water cooled dryer imperial units Instruction book 56 2987 2020 00...

Page 59: ...Dimension drawing of air cooled dryer metric units Instruction book 2987 2020 00 57...

Page 60: ...Dimension drawing of air cooled dryer imperial units Reference Description 1 Front view 2 Side view 3 Rear view 4 Top view 5 Compressed air inlet Instruction book 58 2987 2020 00...

Page 61: ...0 Automatic drain 11 Electrical connection 12 Water connections water cooled dryer 13 ANSI flange X 126 mm X 4 96 in 14 DIN flange X 92 mm X 3 62 in 4 2 Installation proposal Example Working with mach...

Page 62: ...Figure 22 Air cooled dryer Instruction book 60 2987 2020 00...

Page 63: ...e water install an oil water separator Consult Nano Reference Description 1 Dryer unit The unit should be installed on a level floor capable of taking the weight of the dryer Distances between units a...

Page 64: ...llows p L x 450 x Qc d x p L length of pipe m p pressure drop recommended maximum 0 1 bar 1 5 psi d inner diameter of pipe mm p absolute pressure at dryer outlet bar a Qc Free air delivery of the comp...

Page 65: ...allowable pressure drop in ducting after the dryer 30 Pa The air velocity to the grid s has to be limited to 5 m s The direction of the cooling flows may never be inverted 6 Alternative 1 7 Alternati...

Page 66: ...Anchor pads and ducting connections Figure 24 Anchor pads and ducting connections in mm Instruction book 64 2987 2020 00...

Page 67: ...ble 52 C11 with installation method E Grouping distance between cables is equal to the cable diameter For IEC dryers the settings of the main fuses below are according to Directive 2014 35 EU low volt...

Page 68: ...le VDR 5050 380 3x63 gG 1 x 3x 25mm 16mm VDR 5050 400 3x63 gG 1 x 3x 25mm 16mm VDR 5050 460 3x60 Type RK1 KTS R type J JKS type T JJS Bussman 1 x 3x AWG4 AWG4 TT TN IEC air cooled dryers with an ambie...

Page 69: ...water cooled dryers with an ambient temperature of 46 C 114 8 F Dryer type Supply voltage V Fuse A Fuse type Supply cable VDR 2600 380 3x50 gG 1 x 3x 16mm 16mm VDR 2600 400 3x50 gG 1 x 3x 16mm 16mm VD...

Page 70: ...y voltage V Fuse A Fuse type Supply cable VDR 5050 460 3x60 Type RK1 KTS R type J JKS type T JJS Bussman 1 x 3x AWG4 AWG4 TT TN cULus air cooled dryers with an ambient temperature of 46 C 114 8 F Drye...

Page 71: ...460 3x50 Type RK1 KTS R type J JKS type T JJS Bussman 1 x 3x AWG 4 AWG 4 VDR4200 460 3x60 Type RK1 KTS R type J JKS type T JJS Bussman 1 x 3x AWG 4 AWG 4 VDR5050 460 3x60 Type RK1 KTS R type J JKS ty...

Page 72: ...s are a general guide line for acceptable coolant quality However where strict limits apply a statement is made in the specification The water requirements refer to untreated water When water is treat...

Page 73: ...F Recirculating 65 C 149 F Closed System 65 C 149 F Closed System 95 C 203 F 1 pH 6 8 9 3 6 8 9 3 6 8 9 3 7 5 9 3 7 5 9 3 2 Conductivity S cm 1500 600 4000 1500 50 600 3 Total Dissolved Solids mg L TD...

Page 74: ...or RSI 7 5 10 Sulphates Rejection 2000 ppm To be measured for calculating RSI 11 Chemical Corrosion Index Index Chlorides Sulphates Nitrates M Alkalinity all expressed in meq l 15 Ammonium limit not...

Page 75: ...control and descaling operation necessary Not recommended for plate heat exchangers Not applicable 5 6 RSI 6 2 350 ppm Slight scale formation Water treatment not necessary Occasional inspection recomm...

Page 76: ...6 RSI 6 2 350 ppm Slight scale formation Water treatment not necessary Occasional inspection recommended 6 3 RSI 6 8 500 ppm Neutral water Water treatment not necessary Occasional inspection recommend...

Page 77: ...inspection recommended 6 9 RSI 7 5 350 ppm Slight corrosion Water treatment not necessary Occasional inspection recommended 7 6 RSI 9 0 200 ppm Strong corrosion Regular control necessary Use of corro...

Page 78: ...if operating above 1000 m 3281 ft 5 2 Initial start Control panel Description Step Action 1 At least 10 minutes before starting the main supply to the dryer must be switched on to initialize the cont...

Page 79: ...f installed For water cooled versions Open the water inlet and outlet valves customer s installation Press start button 7 Open the dryer air inlet valve customer s installation Approx 5 minutes later...

Page 80: ...Close dryer inlet and outlet valves customer s installation 2 Press stop button 6 The electronic valves will go to 0 opening and then the dryer stops Voltage on sign 5 remains lit Leave the voltage on...

Page 81: ...there is contact with the skin the skin should be rinsed with water On no account may clothing be removed Fluid refrigerant will also cause freezing of the eyes therefore safety glasses must be worn R...

Page 82: ...an authorized control body The installation should be checked once a year by an authorized control body Warranty and product liability Use only authorized genuine parts Any damage or malfunction cause...

Page 83: ...downtime and reduce the total life cycle costs General The following remarks should be kept in mind Keep the dryer clean Brush or blow off the finned surface of the condenser regularly On water cooled...

Page 84: ...collector air cooled Figure 29 Valve on the outlet collector water cooled Attention Use only authorized parts Any damage or malfunction caused by the use of unauthorized parts is not covered by Warran...

Page 85: ...recharged Refrigerant compressor does not run See below Evaporator pressure too high See below Condenser pressure too high See below Automatic drain system clogged Have the system cleaned Condenser pr...

Page 86: ...Condition Fault Remedy Drain alarm No pressure in the air net Error disappears when the pressure in the air net is restored Drain was not able to drain all the water Push drain button manually When t...

Page 87: ...ition Fault Remedy Superheat refrigerant temperature too low Incorrect working of electronic expansion valve steering Check electrical connection of valve or contact Nano Instruction book 2987 2020 00...

Page 88: ...inlet temperature C 0 Minimum cooling water inlet temperature F 32 Maximum cooling water inlet temperature C 40 Maximum cooling water inlet temperature F 104 Minimum cooling water inlet pressure bar...

Page 89: ...0 kg 800 Weight VDR 2600 lb 1764 Weight VDR 3150 kg 815 Weight VDR 3150 lb 1797 Weight VDR 3700 kg 855 Weight VDR 3700 lb 1885 Weight VDR 4200 kg 865 Weight VDR 4200 lb 1907 Weight VDR 5050 kg 870 Wei...

Page 90: ...8 2 VDR 4200 13 5 29 8 28 2 Table 11 Amount of refrigerant gas and tonnes of CO2 equivalent for 60 Hz air cooled dryers and an ambient temperature of 46 C 115 F Dryer Amount kg Amount lbs CO2 equivale...

Page 91: ...s of category I according to 2014 68 EU are integrated into the machine and fall under the exclusion of article 1 2 f i Parts subject to the Simple Pressure Vessel Directive 2014 29 EU are excluded fr...

Page 92: ...10 Documentation Declaration of conformity Typical example of a Declaration of Conformity document Figure 30 1 Manufacturer 2 Applicable directives Instruction book 90 2987 2020 00...

Page 93: ...ufacturer On the Declaration of Conformity the harmonized and or other standards that have been used for the design are shown and or referred to The Declaration of Conformity is part of the documentat...

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Page 96: ...No 2987 2020 00 October 2022 Atlas Copco Airpower N V Experience Customer Service www n psi com...

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