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Sullair SR 10 AC, User Manual

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USER MANUAL 

REFRIGERATED AIR DRYER 

SR 10-480 AC 

 

 

 

 

WARRANTY NOTICE 

Failure to follow the instructions and 
procedures in this manual or, misuse of this 
equipment will VOID its warranty! 

MANUAL PART NUMBER: 

02250246-045 R02 

©SULLAIR LLC

 

SAFETY WARNING 

Users are required to read the entire User 
Manual before handling or using the product. 
Keep the User Manual in a safe place for 
future reference. 

 

Summary of Contents for SR 10 AC

Page 1: ...tions and procedures in this manual or misuse of this equipment will VOID its warranty MANUAL PART NUMBER 02250246 045 R02 SULLAIR LLC SAFETY WARNING Users are required to read the entire User Manual before handling or using the product Keep the User Manual in a safe place for future reference ...

Page 2: ...the SR 10 480 AC compressed air refrigeration dryer Please read these installation and operating instructions carefully before mounting and starting up the SR 10 480 AC and follow our directions Perfect functioning of the SR 10 480 AC and thus reliable compressed air drying can only be guaranteed when the provisions and notes stipulated here are strictly adhered to ...

Page 3: ...68 EU 13 6 Transport 15 7 Storage 15 8 Installation 15 8 1 Place of installation 15 8 2 Installation plan 16 8 4 Correction factors 17 8 5 Connection to the compressed air system 18 8 6 Electrical connections 19 8 7 Condensate drain 19 9 Start up 20 9 1 Preliminary stages 20 9 2 Initial start up 20 9 3 Shut down and restart 21 10 Technical data 23 10 1 Technical data SR 10 480 P 1 115 60 UL 23 10 ...

Page 4: ...u 33 11 13 Electronically level controlled Sullimax condensate drain 33 12 Maintenance troubleshooting spare parts and dismantling 34 12 1 Checks and maintenance 34 12 2 Troubleshooting 37 12 3 Recommended spare parts 41 12 3 1 SR 10 175 115V UL RAc spare parts 42 12 3 2 SR 220 480 230V UL RAc 43 12 4 Maintenance works at the refrigeration cycle 44 12 5 Dismantling the dryer 44 13 Appendices 46 13...

Page 5: ...125 220 AC 59 13 2 7 Exploded diagram SR 300 375 AC 60 13 2 8 Exploded diagram SR 480 AC 61 13 3 Electric diagrams 62 13 3 1 Electric diagrams list of components 62 13 3 2 Electric diagram SR 10 100 AC 63 13 3 3 Electric diagram SR 125 175 AC 64 13 3 4 Electric diagram SR 220 AC 65 13 3 5 Electric diagram SR 300 AC 66 13 3 6 Electric diagram SR 375 AC 67 13 3 7 Electric diagram SR 480 AC 68 Pos 1 ...

Page 6: ...by the fitter and the responsible operator certified skilled personnel prior to installation start up and maintenance The operating instructions must be accessible at all times at the place of application of the SR 10 480 AC compressed air refrigeration dryer In addition to these operating instructions local and national regulations need to be observed where required Ensure that operation of the S...

Page 7: ...echnische Dokumentation Sicherheit Gefahr Druckluft 0 mod_1184148143854_6 doc 5 Connection point compressed air inlet 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 of carrying out the required works and of identifying and avoiding any risks during the ma...

Page 8: ... hazard Consequences of non observance serious injury or death Warning 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 observanc...

Page 9: ...s applies accordingly when accessories are used Danger Compressed air Risk of serious injury or death through contact with quickly or suddenly escaping compressed air or through bursting and or unsecured plant components Compressed air is a highly dangerous energy source Never work on the dryer when the system is under pressure Never direct the compressed air outlet or condensate drain hoses at pe...

Page 10: ...fluorinated greenhouse gas refrigerant Installation repair and maintenance works at the refrigeration system must only be carried out by certified skilled personnel specialists A certification in accordance with EC regulation 303 2008 must be available The requirements of the EC 842 2006 directive must be met under all circumstances Please refer to the indications on the name plate as regards the ...

Page 11: ...tainers and plants which are filled with refrigerant can burst violently in the event of fire The refrigerants themselves are incombustible but they are degraded to very toxic products at high temperatures Remove the container plant from the fire zone as there is the risk of bursting Cool down containers and bottles via a directed water jet from a safe position In the event of fire please use an a...

Page 12: ...entation Sicherheit Vorsicht Fehlfunktion 0 mod_1214378096290_6 doc 9359 Note Ambient conditions In the event that the dryer is not installed under suitable ambient conditions the ability of the device to condense refrigerant gas is impaired This can result in a higher load of the refrigerating compressor and in a loss of efficiency and performance of the dryer This in turn leads to overheated con...

Page 13: ...dryer contains pressure equipment in the sense of the 2014 68 EC Pressure Equipment Directive Therefore the entire plant needs to be registered with the supervisory authority if required in accordance with the local regulations For the examination prior to the start up and for periodic inspections the national regulations need to be observed such as the industrial safety regulation in the Federal ...

Page 14: ...ever must be installed at or placed on the SR 10 480 AC compressed air refrigeration dryer and the connecting lines Installation of the plant in frost free places only Operation of the plant is only permissible with fully closed and intact housing and cover panels Operation of the plant with damaged housing cover panels is prohibited ...

Page 15: ...in the country of destination 8 Installation 8 1 Place of installation Note Ambient conditions In the event that the dryer is not installed under suitable ambient conditions the ability of the device to condense refrigerant gas is impaired This can result in a higher load of the refrigerating compressor and in a loss of efficiency and performance of the dryer This in turn leads to overheated conde...

Page 16: ...with peak values which considerably exceed the throughput rate of the compressor The storage capacity of the tank must be dimensioned in such a way that a possible short term high air demand peak air consumption can be compensated Do not obstruct the ventilation grille not even partially Prevent any recirculation of the outgoing cooling air Protect the dryer against draughts Note Contaminated inta...

Page 17: ... 110 122 130 ºC 32 38 43 50 55 Factor F3 1 11 1 00 0 80 0 65 0 53 Correction factor for DewPoint modifications DewPoint ºF 38 41 45 50 ºC 3 5 7 10 Factor F4 0 92 1 00 1 07 1 25 Calculation of the actual air throughput Actual air throughput air throughput acc to planning x factor F1 x factor F2 x factor F3 x factor F4 Example The SR 75 has a planned nominal capacity of 75 scfm 127 m h The highest a...

Page 18: ... capacity of 125 scfm 212 m h 8 5 Connection to the compressed air system Danger Compressed air All works must only be carried out by qualified skilled personnel Never work on compressed air systems which are under pressure The operator or the user must ensure that the dryer is never operated with a pressure exceeding the maximum pressure value indicated on the name plate Exceeding the maximum ope...

Page 19: ... the cable laying conditions the length of the cables and the requirements of the local electricity supplier need to be considered Danger Supply voltage and missing earth connection Important ensure that the plant is connected to earth Do not use plug adapters at the power plug Possible replacement of the power plug must only be carried out by a qualified electrician 8 7 Condensate drain Danger Co...

Page 20: ...e user is responsible for the compliance with these provisions Irreparable damage can be caused by starting up the device too often The method below should be applied during the first start up after longer downtimes or subsequent to maintenance works The start up must be carried out by certified skilled personnel Processing sequence see Section 11 1 Control panel Ensure that all steps of the Insta...

Page 21: ...e indicated on the electronic control unit is stable Interrupt the compressed air supply After a few minutes stop the dryer by switching off the main switch on the control panel pos 1 Restart see Section 11 1 Control panel Make sure that the condenser is clean Check whether or not voltage is applied at the dryer Start the dryer by switching on the main switch on the control panel pos 1 Ensure that...

Page 22: ...80 AC 02250246 045 R02 22 Subject to EAR ECCN EAR99 and related export control restrictions The user is responsible for the compliance with these provisions Irreparable damage can be caused when starting up the device too often ...

Page 23: ...User Manual US EN SR 10 480 AC 02250246 045 R02 23 Subject to EAR ECCN EAR99 and related export control restrictions 10 Technical data 10 1 Technical data SR 10 480 P 1 115 60 UL ...

Page 24: ...User Manual US EN SR 10 480 AC 02250246 045 R02 24 Subject to EAR ECCN EAR99 and related export control restrictions 10 2 Technical data SR 125 480 NA E 1 230 60 UL ...

Page 25: ...hrough an evaporator which is also known as an air refrigerant heat exchanger The air temperature is reduced to approximately 36 F 2 C so that water vapour condenses to liquid The continuously accumulating condensate is collected in the separator to be discharged via the condensate drain Subsequently the cold and dry air is led through the air air heat exchanger so that it is reheated to up to 46 ...

Page 26: ...refrigerant which is under low pressure is led into the heat exchanger where it expands The cold resulting from the expansion serves to cool down the compressed air in the heat exchanger During this process the refrigerant evaporates The low pressure gas is resupplied to the compressor where it is compressed again It then re enters the cycle In phases of a reduced compressed air load the excess re...

Page 27: ...rigerant pressure switch LPS SR 480 12 2 Temperature probe T2 Fan control SR 10 100 3 Safety temperature switch TS SR 220 480 13 Condensate drain shut off valve 4 Refrig pressure switch HPS SR 300 480 14 Condensate drain strainer 5 Refrigerant fan pressure switch PV SR 125 480 15 Condensate drain solenoid valve 6 Refrigerating compressor 16 Coil for condensate drain solenoid valve 7 Hot gas bypass...

Page 28: ...he pressure of the refrigerant The pressure reduction serves to reach an optimum temperature inside of the evaporator The lower the outlet pressure at the capillary tube the lower the evaporation temperature The length and the inner diameter of the capillary tube are exactly dimensioned to ensure the performance of the dryer Settings or maintenance works are not required 11 8 Aluminium heat exchan...

Page 29: ... experienced refrigerating engineer WARNING the use of Schrader service valves must be justified by a real malfunction of the refrigerating system Each time a pressure gauge is connected a part of refrigerant is exhausted Without compressed air flow through the dryer rotate the adjusting screw position A on the drawing until the following value is reached Hot gas setting R134 a pressure 29 0 psig ...

Page 30: ...si P 23 bar PV Fan control pressure switch which is installed on the discharge side of the compressor It keeps the condensation temperature and pressure constantly in the range of the preadjusted limit values Calibrated pressure R 134 a Start 160 psig 7 25 0 psi 11 barg 0 5 0 bar Stop 116 psig 0 7 25 psi 8 barg 0 0 5 bar R 407 C Start 261 psig 7 25 0 psi 18 barg 0 5 0 bar Stop 203 psig 0 7 25 psi ...

Page 31: ...nlet air temperature high ambient temperature etc Compressed air treatment may be improper Led shows that condensate drain solenoid valve is ON Led shows that condenser fan is ON SR 10 100 The condensate drain test is always active using the button 11 12 2 Switching the dryer off Switch the device off via the ON OFF switch pos 1 Section 11 1 11 12 3 Indication of a service warning service alarm A ...

Page 32: ...250246 045 R02 32 Subject to EAR ECCN EAR99 and related export control restrictions NOTE fan is forced always ON Display 10th right led is flashing DewPoint too high Display 1st left led is flashing DewPoint too low lower than 1 C 30 F ...

Page 33: ... pressed and use arrows to change the value Release the button to confirm the value Press shortly to skip to following parameter Press to exit setup menu if no button is pressed after 2 minutes the menu is exited automatically Display Description Limits Resolution Standard setup Synchronous flashing led led SR 10 100 FANon condenser fan activation ON temperature 31 40 C or 88 104 F 1 C or 2 F 35 o...

Page 34: ...nal statutory provisions and safety regulations as well as the accident prevention regulations required for the respective case of application need to be observed during employment This applies accordingly when accessories are used Danger Compressed air Risk of serious injury or death through contact with quickly or suddenly escaping compressed air or through bursting and or unsecured plant compon...

Page 35: ...enance measures Please also ensure that the power supply cannot be re established during the works Prior to carrying out maintenance works at the dryer switch it off and wait for at least 30 minutes Caution Hot surfaces During operation several components can reach surface temperatures of more than 140 F 60 C There is the risk of burns All components concerned are installed inside of the closed ho...

Page 36: ...ge Finally verify the operation of the device EVERY 1 000 HOURS OR ANNUALLY Verify all screws clamps and connections of the electric system to make sure that they are fastened securely Check the device for broken and ruptured cables or cables without insulation Check the refrigeration cycle for signs of oil and refrigerant leaks Measure the current strength and note it down Ensure that the read va...

Page 37: ... compressed air or through bursting and or unsecured plant components Compressed air is a highly dangerous energy source Never work on the dryer when the system is under pressure Never direct the compressed air outlet or condensate drain hoses at persons The user is responsible for the proper maintenance of the dryer Non observance of the instructions in the Installation and Maintenance troublesho...

Page 38: ...the corresponding point If installed the power contactor KC1 does not work replace it In the event that the compressor still does not work replace it The fan of the condenser does not work Check the electric cabling SR 10 100 The DMC15 electronic instrument is faulty replace it SR 125 480 The PV pressure switch is defective Contact a SULLAIR service technician There is a leak in the refrigeration ...

Page 39: ...an is always ON the yellow LED of DMC15 electronic instrument is flashing see specific point SR 125 480 The fan runs continuously the PV pressure switch is defective replace it The ambient temperature is too low re establish the nominal conditions The hot gas bypass valve needs to be re adjusted contact a SULLAIR service technician to have the nominal setting re established Extreme pressure drop i...

Page 40: ...lease read the separate SULLIMAX installation and operating instructions Water in the line The dryer does not start see the corresponding point If installed untreated air flows through the bypass unit close the bypass The dryer does not drain condensate see the corresponding point Dew point too high see the corresponding point If installed the HPS high pressure switch has triggered Check which of ...

Page 41: ...ous Verify the electric wiring of T1 DewPoint probe The T1 DewPoint probe is faulty replace it The electronic instrument is faulty replace it Electronic instrument DMC15 The yellow led is flashing SR 10 100 Verify the electric wiring of T2 fan control probe SR 10 100 The T2 fan control probe is faulty replace it SR 125 480 Verify the electric wiring of resistance on terminal 1 and 2 The electronic...

Page 42: ... 994 1 1 9 1 Fan motor 02250248 068 1 1 1 1 02250248 069 1 1 02250248 070 1 02250248 071 1 1 1 9 2 Fan blade 02250248 131 1 1 1 1 02250248 132 1 1 02250248 133 1 02250248 134 1 02250248 135 1 1 9 3 Fan grid 02250248 138 1 1 1 02250248 139 1 02250248 140 1 1 10 Filter drier 02250248 009 1 1 02250248 010 1 1 1 1 1 02250248 011 1 1 1 12 Temperature probe 02250248 107 2 2 2 2 2 2 2 1 1 1 13 14 Condens...

Page 43: ...pass valve 02250248 018 1 1 1 1 8 Condenser 02250247 994 02250248 000 1 02250248 550 1 02250248 551 1 02250247 999 1 9 Complete fan 02250248 125 1 1 1 9 1 Fan motor 02250248 077 1 9 2 Fan blade 02250248 136 1 9 3 Fan grid 02250248 141 02250248 140 1 10 Filter drier 02250248 012 1 1 1 1 12 Temperature probe 02250248 107 1 1 1 1 14 Y strainer 02250248 144 1 1 1 1 15 Condensate drain solenoid valve 0...

Page 44: ...e room needs to be ventilated When the refrigeration cycle needs to be refilled please also contact a SULLAIR service technician You will find the refrigerant type and amount on the name plate of the dryer Properties of the refrigerants used Refrigerant Chemicalformula MIK GWP R134a HFC CH2FCF3 1000 ppm 1430 R407C HFC R32 125 134a 23 25 52 CHF2CF3 CH2F2 CH2FCF3 1000 ppm 1773 85 12 5 Dismantling th...

Page 45: ...pper brass We recommend observing the safety provisions in force for the disposal of each material type The refrigerant contains lubricating oil droplets which are released by the compressor The refrigerant must not be discharged into the environment It must to be sucked off from the dryer using a suitable device and then needs to be supplied to a collection point ...

Page 46: ...User Manual US EN SR 10 480 AC 02250246 045 R02 46 Subject to EAR ECCN EAR99 and related export control restrictions 13 Appendices 13 1 Dryer dimensions 13 1 1 Dryer dimensions SR 10 15 AC ...

Page 47: ...User Manual US EN SR 10 480 AC 02250246 045 R02 47 Subject to EAR ECCN EAR99 and related export control restrictions 13 1 2 Dryer dimensions SR 20 50 AC ...

Page 48: ...User Manual US EN SR 10 480 AC 02250246 045 R02 48 Subject to EAR ECCN EAR99 and related export control restrictions 13 1 3 Dryer dimensions SR 75 AC ...

Page 49: ...User Manual US EN SR 10 480 AC 02250246 045 R02 49 Subject to EAR ECCN EAR99 and related export control restrictions 13 1 4 Dryer dimensions SR 100 AC ...

Page 50: ...User Manual US EN SR 10 480 AC 02250246 045 R02 50 Subject to EAR ECCN EAR99 and related export control restrictions 13 1 5 Dryer dimensions SR 125 150 AC ...

Page 51: ...User Manual US EN SR 10 480 AC 02250246 045 R02 51 Subject to EAR ECCN EAR99 and related export control restrictions 13 1 6 Dryer dimensions SR 175 220 AC ...

Page 52: ...User Manual US EN SR 10 480 AC 02250246 045 R02 52 Subject to EAR ECCN EAR99 and related export control restrictions 13 1 7 Dryer dimensions SR 300 375 AC ...

Page 53: ...User Manual US EN SR 10 480 AC 02250246 045 R02 53 Subject to EAR ECCN EAR99 and related export control restrictions 13 1 8 Dryer dimensions SR 480 AC ...

Page 54: ...tch 4 Refrigerant pressure switch HPS 5 Refrigerant fan pressure switch PV 51 Front panel 6 Compressor 52 Back plate 7 Hot gas bypass valve 53 Right sidewall 8 Condenser 54 Left sidewall 9 Condenser fan 55 Cover 9 1 Motor 56 Base plate 9 2 Blade 57 Upper plate 9 3 Grid 58 Carrier support 10 Filter dryer 59 Support bracket 11 Capillary tube 60 Control panel 12 T1 temperature probe dew point 61 Elec...

Page 55: ...User Manual US EN SR 10 480 AC 02250246 045 R02 55 Subject to EAR ECCN EAR99 and related export control restrictions 13 2 2 Exploded diagram SR 10 15 AC Timed Zero loss drain ...

Page 56: ...User Manual US EN SR 10 480 AC 02250246 045 R02 56 Subject to EAR ECCN EAR99 and related export control restrictions 13 2 3 Exploded diagram SR 20 35 AC Timed Zero loss drain ...

Page 57: ...User Manual US EN SR 10 480 AC 02250246 045 R02 57 Subject to EAR ECCN EAR99 and related export control restrictions 13 2 4 Exploded diagram SR 50 AC Timed Zero loss drain ...

Page 58: ...User Manual US EN SR 10 480 AC 02250246 045 R02 58 Subject to EAR ECCN EAR99 and related export control restrictions 13 2 5 Exploded diagram SR 75 100 AC Timed Zero loss drain ...

Page 59: ...User Manual US EN SR 10 480 AC 02250246 045 R02 59 Subject to EAR ECCN EAR99 and related export control restrictions 13 2 6 Exploded diagram SR 125 220 AC Zero loss drain Timed ...

Page 60: ...User Manual US EN SR 10 480 AC 02250246 045 R02 60 Subject to EAR ECCN EAR99 and related export control restrictions 13 2 7 Exploded diagram SR 300 375 AC Zero loss drain Timed ...

Page 61: ...User Manual US EN SR 10 480 AC 02250246 045 R02 61 Subject to EAR ECCN EAR99 and related export control restrictions 13 2 8 Exploded diagram SR 480 AC Zero loss drain Timed ...

Page 62: ... T1 Temperature probe dew point BT2 T2 Temperature probe fan control HPS Pressure switch compressor discharge side HIGH PRESSURE LPS Pressure switch compressor suction side LOW PRESSURE PV Pressure switch fan control TS Safety temperature switch ELD SULLIMAX drain S1 ON OFF switch TR Autotransformer BOX Electrical connection NT1 Only air cooled NT2 Check the transformer connections with regard to ...

Page 63: ...User Manual US EN SR 10 480 AC 02250246 045 R02 63 Subject to EAR ECCN EAR99 and related export control restrictions 13 3 2 Electric diagram SR 10 100 AC ...

Page 64: ...User Manual US EN SR 10 480 AC 02250246 045 R02 64 Subject to EAR ECCN EAR99 and related export control restrictions 13 3 3 Electric diagram SR 125 175 AC ...

Page 65: ...User Manual US EN SR 10 480 AC 02250246 045 R02 65 Subject to EAR ECCN EAR99 and related export control restrictions 13 3 4 Electric diagram SR 220 AC ...

Page 66: ...User Manual US EN SR 10 480 AC 02250246 045 R02 66 Subject to EAR ECCN EAR99 and related export control restrictions 13 3 5 Electric diagram SR 300 AC ...

Page 67: ...User Manual US EN SR 10 480 AC 02250246 045 R02 67 Subject to EAR ECCN EAR99 and related export control restrictions 13 3 6 Electric diagram SR 375 AC ...

Page 68: ...User Manual US EN SR 10 480 AC 02250246 045 R02 68 Subject to EAR ECCN EAR99 and related export control restrictions 13 3 7 Electric diagram SR 480 AC ...

Page 69: ...Michigan City IN 46360 USA www sullair com 1 800 SULLAIR USA only 1 219 879 5451 non USA Information and specifications are subject to change without prior notice Subject to EAR ECCN AR99 and related export control restrictions ...

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