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Pneumatech AD 1250, Instruction Book, Page: 1 / 45

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PNEUMATECH 

AD 750, AD 1000, AD 1250 

Instruction book  

Summary of Contents for AD 1250

Page 1: ...PNEUMATECH AD 750 AD 1000 AD 1250 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 as well as non CE labelled machines It meets the requirements for instructions specified by the applicable European directives as identified in the Declaration of Conformity 2017 06 No 9828 0931 61 www pneumatech com ...

Page 4: ...l description 10 2 1 INTRODUCTION 10 2 2 AIR SYSTEM 13 2 3 REFRIGERATION SYSTEM 14 2 4 AUTOMATIC REGULATION SYSTEM 15 2 5 ELECTRICAL SYSTEM 16 3 Installation 17 3 1 DIMENSION DRAWINGS 17 3 2 INSTALLATION PROPOSAL 18 3 3 ELECTRIC CABLE SIZE AND SETTING OF MOTOR CIRCUIT BREAKER 22 3 4 PICTOGRAPHS 23 4 Operating instructions 25 4 1 CONTROL PANEL 25 4 2 STARTING 31 4 3 DURING OPERATION 32 4 4 STOPPING...

Page 5: ... 5 1 MAINTENANCE INSTRUCTIONS 35 5 2 DISPOSAL OF USED MATERIAL 36 6 Settings 37 6 1 DEVICE SETTINGS 37 7 Problem solving 38 7 1 PROBLEM SOLVING 38 8 Technical data 41 8 1 REFERENCE CONDITIONS AND LIMITATIONS 41 8 2 AIR DRYER DATA 42 ...

Page 6: ...ergency stop button Switch off the voltage Depressurize the machine Lock Out Tag Out LOTO Open the power isolating switch and lock it with a personal lock Tag the power isolating switch with the name of the service technician On units powered by a frequency converter wait 10 minutes before starting any electrical repair Never rely on indicator lamps or electrical door locks before maintenance work...

Page 7: ... control is installed the machine must bear a clear sign stating DANGER This machine is remotely controlled and may start without warning The operator has to make sure that the machine is stopped and that the isolating switch is open and locked before any maintenance or repair As a further safeguard persons switching on remotely controlled machines shall take adequate precautions to ensure that th...

Page 8: ...or rooms where the sound pressure level reaches or exceeds 80 dB A shall wear ear protectors 8 Periodically check that All guards are in place and securely fastened All hoses and or pipes inside the machine are in good condition secure and not rubbing There are no leaks All fasteners are tight All electrical leads are secure and in good order Safety valves and other pressure relief devices are not...

Page 9: ...s to avoid the risk of spontaneous ignition of the oil vapour when air is admitted 14 Never use a light source with open flame for inspecting the interior of a machine pressure vessel etc 15 Make sure that no tools loose parts or rags are left in or on the machine 16 All regulating and safety devices shall be maintained with due care to ensure that they function properly They may not be put out of...

Page 10: ...ction General view AD 750 up to AD 1250 Introduction The AD air dryers remove moisture from compressed air by cooling the air near to the freezing point This causes water to condense The condensate is automatically drained The air is warmed up before leaving the dryer ...

Page 11: ...Instruction book 9828 0931 61 11 Safety devices Safety devices Reference Name 1 Fan protection grid 2 Grounding 3 Safety pressure switch ...

Page 12: ...whole machine Refer to images added on the next page for the location of danger zone Danger Zones Reference Danger signal Description of danger signal 1 Dangerous electric voltage 2 Air not fit for breathing 3 High pressure 4 Fan rotating not shown in image 5 Hot parts ...

Page 13: ...igh pressure shut down switch 14 Liquid separator 15 Automatic condensate drain Description Compressed air enters heat exchanger 10 and is pre cooled by the outgoing cold dried air Water in the incoming compressed air starts to condense The air then flows through heat exchanger evaporator 4 where the refrigerant evaporates causing the air to be cooled further to close to the evaporating temperatur...

Page 14: ...d by the digital controller 11 2 3 Refrigeration system Refrigerant flow diagram Text on figure 1 Air inlet 2 Air outlet 3 Condensate drain Reference Name 1 Refrigerant compressor 2 Condenser 3 Motor and fan 4 Evaporator 5 Condensate separator 6 Impurity trap 7 Expansion capillary tube 8 Refrigerant filter 9 Hot gas by pass valve 10 Air air heat exchanger 11 Digital controller 12 Fan control switc...

Page 15: ...pressed air by further evaporation at constant pressure The heated refrigerant leaves the evaporator and is sucked in by the compressor 1 2 4 Automatic regulation system Air flow diagram Text on figure 1 Air inlet 2 Air outlet 3 Condensate drain Reference Name 1 Refrigerant compressor 2 Condenser 3 Motor and fan 4 Evaporator 5 Condensate separator 6 Impurity trap 7 Expansion capillary tube 8 Refri...

Page 16: ...orator pressure from dropping any further 2 5 Electrical system Description The fan control switch starts the fan motor as soon as the condenser pressure reaches the upper set point of the switch and will stop the fan motor when the condenser pressure decreases to its lower set point The high pressure shut down switch stops the compressor motor when the pressure in the refrigerant circuit reaches ...

Page 17: ...Instruction book 9828 0931 61 17 3 Installation 3 1 Dimension drawings AD 1000 1250 connection details AD 750 connection details Dimension drawing ...

Page 18: ...tting the metal strapping is a dangerous operation Do not cut pieces in the environment After removing the packing ensure that no damage has occurred to the machine during transportation If you are in doubt do not use the machine Call your distributor s service department or dealer The packing material plastic bags polystyrene foam nails screws wood metal strapping and so on must not be left withi...

Page 19: ... use a forklift truck Do not use metal cables for lifting Move the dryer gently Ensure that the operator can see the whole machine from the control panel and check the presence of any unauthorized persons in the vicinity of the machine Compressor room example ...

Page 20: ...n the inlet grids and ventilation fan should be installed in such way that any recirculation of cooling air to the dryer is avoided The maximum air velocity to the grids has to be limited to 5 m s The maximum allowable pressure drop over the cooling air ducts is 30 Pa When 30 Pa is exceeded a ventilation fan is needed at the outlet of the cooling air ducts Ensure appropriate composition of the air...

Page 21: ...e compressed air network 1 Fit a manual ball valve 1 between the machine and the compressed air network to isolate the dryer during maintenance operations see above figure 2 Drainage of automatic condensate 2 are led outside the machine with a flexible pipe Inspect drain pipes Drainage must comply with the local regulations in force All damages due to failure to comply with these indications canno...

Page 22: ...size mm2 Maximum cable length 10m 32 8ft 6 6 6 Electrical data 60 Hz dryers IEC AD 750 AD 1000 AD 1250 Voltage V 380 380 380 Maximum current A at Tamb 46 C Tin 60 C 11 7 12 3 15 6 Disconnector switch Fuses Type aM 14x51 20 25 32 Maximum cable size mm2 Maximum cable length 10m 32 8ft 10 10 10 AD 750 AD 1000 AD 1250 Voltage V 460 460 460 Maximum current A at Tamb 46 C Tin 60 C 9 7 10 2 12 9 Setting ...

Page 23: ...ictographs Danger signals Reference Name 1 Warning dangerous electric voltage 2 Warning air not fit for breathing 3 Warning high pressure 4 Warning rotating fan 5 Warning hot surface 6 Switch off the voltage and depressurize the dryer before maintenance or repair ...

Page 24: ...ates fitted on the compressor unit are part of the machine they have been applied for safety purposes and must not be removed or spoiled for any reason Position of the data plates Reference Name 1 Spare plate Code 1079 9903 48 2 IN 3 OUT 4 Identification plate ...

Page 25: ... Control panel Description Reference Name 1 Dryer on off switch 2 Green indicator for voltage on dryer running and blocked door 3 Red indicator for alarm for condensate drain 4 Red indicator for alarm for high pressure or fan motor protection 5 Digital controller ...

Page 26: ...utton 10 DOWN buttom 8 9 Back to previous screen 8 10 Menu Icons Icon Name Mode Function Alarm Off No active alarms On Probe failure alarm High temperature or low temperature alarm Service alarm Refrigerant compressor On Dryer on Flashing SE Maintenance warning Flashing L2 Dewpoint too low Dryer is stopped Flashing H3 Too high discharge temperature of the refrigerant compressor see further Dryer i...

Page 27: ... opens in case of an alarm Free contact location Fault messages Flashing fault message Description Remedy Dewpoint temperature probe failure Replace the probe Refrigerant compressor discharge temperature probe failure Replace the probe Pressure dewpoint too high Refer to the fault and remedies section Pressure dewpoint too low Refer to the fault and remedies section ...

Page 28: ...oller Maintenance required Perform the maintenance and reset the alarm Resetting the maintenance warning Front panel of the controller To reset the maintenance warning follow steps 1 to 12 1 The display is flashing between standard view dewpoint and maintenance required SE alarm 2 Push and hold buttons SET 8 and DOWN 10 to enter the menu 3 Message SE appears on display 4 Push and release the UP bu...

Page 29: ... interval To set the service interval follow steps 1 to 9 1 PDP is showing standard view 2 Push and hold buttons SET 8 and DOWN 10 to enter the menu 3 Message SE appears on display 4 Push and release SET 8 to enter the SE menu 5 Current service interval is displayed 60 or any other value between 0 and 99 6 Select desired service interval using the UP and DOWN button 40 4000h 55 5500h 80 8000h 7 Pu...

Page 30: ...e is higher than 2 C 30 second are passed from the refrigerant compressor stop minimum balancing pressure stop time A countdown is available if the reset is made before the minimum stop time Silent alarm function To snooze the alarm press button 7 Refrigerant compressor discharge temperature visualization function To see the discharge refrigerant compressor temperature follow steps 1 to 5 1 PDP is...

Page 31: ...allow pressure equalization To keep the compressed air net free of condensate start the dryer before starting the compressor and stop the compressor before stopping the dryer Procedure Step Action 1 If installed close the dryer by pass valve See Installation proposal 2 Switch the on off switch to On 3 Open dryer air inlet valve customer s installation 4 Approx 5 minutes later open dryer air outlet...

Page 32: ...arged via condensate outlet The amount depends on the operating conditions 4 4 Stopping Attention To ensure optimum operational efficiency do not use dryer on off switch 1 repeatedly within a short time period Wait at least 5 minutes to start the dryer again after stopping to allow pressure equalization To keep the compressed air net free of condensate start the dryer before starting the compresso...

Page 33: ...Instruction book 9828 0931 61 33 Procedure Step Action 1 Close the dryer inlet and outlet valve customer s installation 2 Switch off the dryer 3 If provided open the dryer by pass valve ...

Page 34: ...pressing the condensate drain TEST pushbutton located on the steam trap 3 4 Switch off the machine Turn the switch to STOP 4 5 Turn on the supply automatic differential switch 5 6 Close the panel 2 4 6 Dismantling Description Before dismantling the responsible operating department must de commission the system and ensure that it is de pressurized Dismantle the product according to local legislatio...

Page 35: ...ntact 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 safety glasses must hence be worn Refrigerant R410A is poisonous Do not inhale refrigerant vapors Check that the working area is adequately ventilated When removing the side panels of the dryer be aware that internal elements such as the pipes can re...

Page 36: ...iccant lubricants cleaning rags machine parts etc must be disposed of in an environmentally friendly and safe manner and in line with the local recommendations and environmental legislation Refer to local regulations for directions on how to dispose of electronic components in an environmentally friendly manner ...

Page 37: ...828 0931 61 37 6 Settings 6 1 Device settings Regulating and safety devices The regulating and safety devices are factory adjusted to obtain optimum performance of the dryer Do not alter the setting of any of the devices ...

Page 38: ...ing out any maintenance or repair work on the dryer Close air inlet and outlet valve of the dryer Press the test button on the electronic condensate drain Move dryer on off switch to position 0 Switch off the voltage See section Stopping Open the isolating switch to prevent an accidental start The air inlet and outlet valve can be locked during maintenance or repair work as follows Close the valve...

Page 39: ...Ambient temperature too high Check and correct if necessary draw cooling air via a duct from a cooler room or relocate the dryer Condenser externally clogged Clean condenser 3 Compressor stops or does not start and PDP is ON Thermal protection of refrigerant compressor motor tripped Wait for reset of thermostatic protection Overload fan motor protection tripped Reset the overload motor protection ...

Page 40: ...5 Evaporator pressure is too high or too low at unload Hot gas by pass valve incorrectly set or out of order Have hot gas by pass valve adjusted Condenser pressure too high or too low See 2 Shortage of refrigerant Have circuit checked for leaks and recharged ...

Page 41: ...s C 38 60 Hz dryers F 100 Ambient temperature 50 Hz dryers C 25 50 Hz dryers F 77 60 Hz dryers C 38 60 Hz dryers F 100 Pressure dewpoint 50 Hz dryers C 3 50 Hz dryers F 37 4 60 Hz dryers C 4 60 Hz dryers F 39 Limits Unit Maximum compressed air inlet pressure bar e 14 Maximum compressed air inlet pressure psig 203 Min max ambient air temperature C 1 46 Min max ambient air temperature F 39 115 Max c...

Page 42: ...C kW 5 65 6 07 7 63 Nominal electric power input Ambient temperature 100 4 F Inlet temperature 100 4 F hp 7 68 8 25 10 37 Maximum electric power input Ambient temperature 46 C Inlet temperature 60 C kW 6 86 7 1 8 91 Maximum electric power input Ambient temperature 114 8 F Inlet temperature 140 F hp 9 33 9 66 12 12 Weight of the unit kg 358 368 383 Weight of the unit lb 789 811 844 460 V Air dryer ...

Page 43: ...88 Amount of refrigerant gas and tonnes of CO2 equivalent for 50 Hz dryers Dryer Amount kg Amount lbs CO2 equivalent AD 750 3 6 7 94 7 52 AD 1000 3 8 8 38 7 93 AD 1250 4 5 9 92 9 40 Amount of refrigerant gas and tonnes of CO2 equivalent for 60 Hz dryers Dryer Amount kg Amount lbs CO2 equivalent AD 750 3 7 8 16 7 73 AD 1000 4 3 9 48 8 98 AD 1250 4 5 9 92 9 40 ...

Page 44: ...Instruction book 44 9828 0931 61 ...

Page 45: ...www pneumatech com ...

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