Ultrafilter BOREAS DSM SD 1200-60 Operator Instructions Manual Download

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I14 1001 0US

07.03

Operators Instruction
and
Maintenance Manual

BOREAS DSM

SD 1200-60 - SD 3000 W-60
SD 4000-60 - SD 5000 W-60

Summary of Contents for BOREAS DSM SD 1200-60

Page 1: ...I14 1001 0US 07 03 Operators Instruction and Maintenance Manual BOREAS DSM SD 1200 60 SD 3000 W 60 SD 4000 60 SD 5000 W 60 ...

Page 2: ...0 W 60 593W L0593001000 SD 5000 W 60 594W L0594001000 SD 1200 W 60 457W L04570010005000 SD 1400 W 60 458W L04580010005000 SD 1600 W 60 459W L04590010005000 SD 2000 W 60 460W L04600010005000 SD 2400 W 60 461W L04610010005000 SD 3000 W 60 462W L04620010005000 SD 4000 A 60 593A L05930010006000 SD 5000 A 60 594A L05940010006000 Construction Series Type code Version aircooled Version watercooled Versio...

Page 3: ...10 2 7 Connection cooling water 10 3 1 Designation 11 3 2 Purpose 11 3 3 Unit layout 11 3 4 Nominal power of CA dryer 12 3 5 Principle of operation 13 3 6 Mode of operation 13 3 7 SAB processor 15 3 8 Condensate draining 17 4 1 Commissioning 18 4 2 Starting 18 4 3 Operation 18 4 4 Stopping 18 5 1 Maintenance 19 5 2 Trouble shooting 19 Technical data Table of constancy Wiring diagrams Spare parts l...

Page 4: ... proper operation maintenance care and competent repair under consideration of these oper ating instructions Hints to figures and locations are in brackets e g Fig 5 2 Due to our position as suppliers of components we do not always know the final usage and total range of products applications We constantly improve our prod ucts to the latest state of science and technology and therefore we assume ...

Page 5: ... Use proper tools for maintenance and repair work only Use original spare parts only All maintenance and repair works must only be ex ecuted at stopped machine disconnected power sup ply and pulled mains plug Ensure that the CA dryer cannot be switched on by mistake Prior to dismounting a part under pressure discon nect the CA dryer from all pressure sources and de pressurize the CA dryer Do not u...

Page 6: ...ts escaped during filling or re pair work Cover with tape Leave the room immediately and only enter after the room has been sufficiently ventilated when refrigerant concentrations e g pipe line leakages appear sud denly Execute welding and soldering works on refrigerating systems in well ventilated rooms only Refrigerants will be decomposed in flames as well as in electrical arcs The resulting dec...

Page 7: ...efrigerants for refrigerant type see identification plate Never leave the victim unattended When disposing of used devices pay attention to oil and refrigerant in the hermetically sealed refrigerating circuit of the CA dryers Therefore before dismount ing these operation media must be disposed by a special company The used materials are listed on the recycling label inside the CA dryer Attention D...

Page 8: ...erse The CA dryer may be transported by a fork lift truck or stacker lift truck Transportation has to be carried out in the normal oper ating position of the CA dryer At the site of installation the CA dryer can be installed without anchorage or special foundation at the location desired The CA dryer is designed for an ambient temperature of 100 F Attention At different ambient conditions pay atte...

Page 9: ...k The connection must be executed acc to marking at the CA dryer fig 2 For service purposes the installation of a bypass line is recommended additional equipment Attention Before mounting the CA dryer welding residual rust or other pollution must be removed from the pipelines to be connected If pollution cannot be excluded proper filter system must be installed The compressed air pipes must be ins...

Page 10: ...nsate condensate escapes under operating pressure A minimum operation pressure of 30 psig is required for safe operation The condensate drain pipe fig 3 2 may be fixed to the wall with a rising slope of maximum 15 ft Thereby the minimum operation pressure increases for 1 2 psi per ft The collecting pipe fig 3 3 should be laid throughout its whole length at least as the cross section of the condens...

Page 11: ...l be dehumidified by the CA dryer Following components of the CA dryer are accessible from outside fig 4 1 Compressed air inlet 2 Compressed air outlet 3 Switch cabinet with power supply Fig 5 4 Cooling air inlet 5 Operating instructions 6 Condensate outlet 7 Cooling water inlet water cooled version 8 Cooling water outlet water cooled version 9 Access for service 3 4 5 6 7 8 9 2 1 9 ...

Page 12: ...ata is related to a working pressure of 14 1 2 psig a compressed air inlet temperature of 100 F as well as an ambient temperature of 100 F acc CAGI Lower working pressure higher compressed air inlet temperature and or higher ambient temperatures over load the compressor which causes to an increased pres sure dew point and the compressor can be stopped by internal safety devices At an essentially m...

Page 13: ...ted dur ing this process The cooling to the pressure dew point is performed in the second cooling stage the refrigerant to air heat ex changer cooled by the refrigerant system installed Sub sequently the cooled compressed air is reheated in the air to air heat exchanger as already described The pressure dew point temperature is indicated on the switch cabinet fig 5 5 The refrigerant is injected in...

Page 14: ... registered by a pressure pick up are transmitted to a Siemens Logo which ensures the minimum runtimes of the compressors The Siemens Logo has a fixed factory setting and must not be changed by unauthorized persons If the load rises again to more than 50 the second compressor is switched on again via the same components The values registered by a pressure pick up are transmitted to a Siemens Logo ...

Page 15: ...emperature 4 Ambient temperature Incoming measured values will be compared and the resulting average values will be processed Rapid changes of the incoming measured values on steady higher or lower value resp will be checked If the value changes are too high it is recognized as measuring failure 2 limit values are provided for each temperature between which the temperatures must be during normal o...

Page 16: ...10 minutes the temperatures are read into and up dated in a memory Additionally date and time of all values are stored too So the temperatures of the last 24 hours can be followed up During normal operation the display indicates the dew point temperature Following values can be recalled con secutively when the data input and output keys are pressed 1 Pressure dew point compressed air 2 Suction gas...

Page 17: ...densate is forced by the working pressure into the discharge pipe The condensate drain electronic system ensures the clos ing of the outlet opening before any compressed air can escape 1 Condensate drain is ready for operation LED lights 2 Manual draining operate button for max 30 sek 3 Failure LED blinks see 5 2 3 At standstill or very small volume flow of the CA dryer a time controlled solenoid ...

Page 18: ... the CA dryer to achieve a pressure compensation within the refrigeraion system After some hours of operation under load it should be controlled that condensate is generated and drained The CA dryer is designed for continuous operation and may remain switched on during periods of no load as it adapts to the required performance automatically Operation is indicated by the luminous operation switch ...

Page 19: ...r vals below are only to be understood as general recom mendations a Check function of condensate drain Condensate drain Operate Test button fig 9 2 check if water is drained b Monitoring of all temperatures Inspection and cleaning of condensate draining system if necessary Attention Maintenance work must be performed at the depressu rized condensate drain only For this purpose the instal lation o...

Page 20: ... of CA dryer Lower machine room temperature Check load conditions of CA dryer Check control call for service Check aftercooler of CA dryer Lower machine room temperature Check control call for service Check control call for service Increase compressed air inlet temperature Increase machine room temperature After 45 seconds the indication always goes back to the failure appeared first which was als...

Page 21: ...sed air inlet temperature Cause at installed bypass line 5 2 4 3 Bypass valve of bypass line opened 5 2 4 4 Bypass valve of bypass line leaking Part 5 Maintenance Remedy check power supply replace condensate drain if neces sary Indication by blinking LED Remedy Open ball cock in condensate pipe Open ball cock in swinging pipe clean pipe Ensure operation pressure of system Replace condensate drain ...

Page 22: ...elected increase CA dryer s capacity Install aftercooler behind the compressed air compres sor or check if already installed Ensure proper ventilation of CA dryer s location Replace fan or cooling water regulator resp call for service Clean condenser Increase operating pressure check whether CA dryer s capacity is properly selected For failure acknowledgement press reset button at pressure limiter...

Page 23: ...rential pressure min psi 19 Refrigerant quantity R134A lb oz 9 14 3 4 35 4 1 2 58 6 3 4 66 2 1 4 Pos 1 68 F 14 1 2 psig 100 F 100 psig 100 F 38 F max 140 F Pos 14 15 85 F min 35 F max 120 F Date Page 1 of 2001 06 14 1 Designation Type No Technical Data Sheet Refrigerated Compressed Air Dryer 457 462 593 594 operating pressure I1T 1010 0US ambient temperature pressure dew point at CA dryer outlet C...

Page 24: ...e 100 100 ñ ñ ñ ó Hydrogen sulphide H2S 0 05 0 05 ñ ñ ñ ó ò Glycol part 20 20 50 50 ñ ñ ñ ñ ñ ñ Total hardness 4 0 8 5 dH ñ ñ max 60 C ñ under normal circumstances good constancy ó danger of corrosion especially if more substances with ó present ò not suitable Hint The table shows a summary of the limit values for stainless steel 1 4401 AISI 316 as well as pure copper 99 9 in water considering sev...

Page 25: ...tion 2 1 11 3 6 7 8 11 RAH 457 462 list of contents cabinet view assembley plate wiring diagramms list of materials terminal plans IND APPD DATE NAME DATE DR CK STD IEC 1346 1 FILE REV TYPE compr air dryer TITLE SHEET OF DRAWING NO list of contents 22 3 2796 2796 21 02 01 ...

Page 26: ...plate 2 11 4S3 6A4 RAH 3F5 4T7 3T7 5K2 5K3 4K3 4K4 4K5 457 462 compr air dryer IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO switch cabinet 010 4962 000 dimension 500x400x200 colour door RAL5013 other RAL7032 3Q1 5K4 22 3 2796 2796 21 02 01 ...

Page 27: ... 5 2 RAH 4 1 4 1 457 462 IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET compr air dryer DRAWING NO compressor motor 3AC M U V W PE 3M3 control volt transformer 230V 100VA 460V 0 460 230 0 3T7 0 5A 0 5A 0 4A L1 L2 L3 power supply 460V 3 60Hz 1 X0 4A 3F5 5 3 5 6 3 4 1 2 5K3 5 6 3 4 1 2 5K2 22 3 2796 2796 21 02 01 ...

Page 28: ...2 4K4 3 8 5 1 3 8 5 1 PE 1 X2 2 3 X2 4 X2 15 X2 7 X2 8 PE 6 PE 16 X2 5 X2 457 462 IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET compr air dryer DRAWING NO operating switch 4 3 X2 X1 4S3 remote control 5 1 A P overpressure 4 2 1 PE 4F5 P low pressure 2 4 1 PE 4F4 overcurrent C B A 4T7 crankcase heater 1 2 PE 4E2 overcurrent detector 2 1 4T7 4 3 4 3 B A C 21 22 5K2 22 ...

Page 29: ...SHEET compr air dryer DRAWING NO 4 4 4 4 L1 2 4 8 A 4 8 4 8 L2 1 30 32 31 6A4 6 2 12 11 14 4K3 12 11 14 4K4 12 11 14 4K5 fan contactor A1 A2 5K3 13 14 5 6 3 4 1 2 compressor contactor A1 A2 5K2 13 14 5 6 3 4 1 2 22 32 21 31 13 X2 14 PE X2 condensate drain L N PE Ein COM Aus 5A5 SV condensate drain 1 2 5Y5 16 15 18 5K4 5 4 PE 12 X2 11 X2 B1 pulse relay A1 A2 5K4 5 4 5 4 15 18 16 9 X2 22 3 2796 2796...

Page 30: ...ouble signal 4 common trip signal 1 X10 8 6 5 3 2 5 2 6 3 6 4 5 1 6 3 6 4 5 1 32 31 30 6 5 4 9 8 7 COM NO NC COM NO NC service unit socket oil pressure overpressure overcurrent 010 8061 000 common trip signal suct gas temp ambient temp inlet temp dewpoint temp dewpoint trouble sig temperature sensors COM NO NC PROCESSOR SP3 low pressure SAB processor SP3 6 5 4 9 8 7 3 2 22 23 24 25 26 27 28 29 1 1...

Page 31: ...0 4S3 700 HA32 A 03 03 4K3 700 HA32 A 03 03 4K4 700 HA32 A 03 03 4K5 100 C16 KF 01 100 FB11 5K2 100 M05NA3 5K3 control volt transformer operating switch relay with socket relay with socket relay with socket compressor contactor fan contactor ST0 1 460V 230V 100VA 1 1 1 1 1 1 1 IKS Rockwell Automation Rockwell Automation Rockwell Automation Rockwell Automation Rockwell Automation Rockwell Automatio...

Page 32: ...er bridges X0 1 2 3 1 2 4 3 1 3 6 3 2 PE 3 2 8 11 RAH 457 462 IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV compr air dryer DRAWING NO SHEET OF function text ground terminal strip power supply power supply power supply power supply page path 3Q1 3Q1 3Q1 22 3 2796 2796 21 02 01 ...

Page 33: ...2 3 5 5 4 3 5 6 6 3 5 7 2 3 6 8 4 3 6 9 6 3 6 PE 3M3 PE 3 3 PE 3 5 PE 3 6 9 11 5K2 5K2 5K2 5K3 5K3 5K3 5K3 5K3 5K3 RAH 457 462 ground ground ground funktion text compressor compressor compressor compressor IND APPD DATE NAME DATE DR CK STD JN TITLE TYPE DRAWING NO SHEET OF IEC 1146 1 FILE REV terminal strip page path compr air dryer 22 3 2796 2796 21 02 01 ...

Page 34: ...sure low pressure low pressure low pressure overpressure terminal strip IND APPD DATE NAME DATE DR CK STD TITLE TYPE IEC 1146 1 JN FILE REV DRAWING NO SHEET OF compr air dryer page path 1 5K2 22 4E2 1 4 2 2 4E2 2 4 2 3 4T7 B 4 3 4 4S3 3 4 3 5 4T7 B 4F4 1 4 4 6 4K4 A1 4F4 4 4 4 7 4F5 1 4 5 8 4K5 A1 4F5 2 4 6 9 4T7 B 5 3 10 5K3 A1 5 3 11 5K4 18 5Y5 5 5 12 5Y5 5 5 13 5K4 15 5A5 L 5 5 14 5A5 N 5 5 15 ...

Page 35: ...4 5 6 7 8 9 13 5K2 5K2 6A4 6A4 6A4 6A4 6A4 6A4 457 462 page path funktion text dewpoint trouble sig dewpoint trouble sig dewpoint trouble sig operation signal common trip signal common trip signal common trip signal operation signal IND APPD DATE NAME DATE DR CK STD JN TITLE TYPE IEC 1146 1 FILE REV SHEET OF DRAWING NO compr air dryer terminal strip 22 3 2796 2796 21 02 01 ...

Page 36: ...drains SAB processor SPIII voltage free conacts list of material terminal strip X0 terminal strip X1 terminal strip X2 terminal strip X10 switch cabinet view assembly plate supply compressors fans control volt transformer 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO compr air dryer l i st of cont...

Page 37: ... door RAL5013 other RAL7032 0 9A4 6S1 X0 X1 X2 X10 4T7 4F2 6T6 6T7 8K1 8K2 8K3 5A4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO compr air dryer 593A 594A 22 3 2837 2837 2 15 22 02 02 ...

Page 38: ...4 5 6 8K2 M 3 compressor 1 V100 1 2 3 PE 3M3 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO compr air dryer pre fuse max 63A L1 L2 L3 PE M 3 V100 compressor 2 1 2 3 PE 3M4 power supply 460V 3 60Hz PE 593A 594A 22 3 2837 2837 3 15 22 02 02 ...

Page 39: ...C 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO compr air dryer 250VA 1 25A 1 25A 1 00A 250VA 0 460 0 230 4T7 M200 M200 M200 M200 M 3 Ventilatormotor fan motor 0 8A 500W U1 V1 W1 PE U2 V2 W2 4M2 M 3 fan motor Ventilatormotor 0 8A 500W U1 V1 W1 PE U2 V2 W2 4M3 M 3 fan motor Ventilatormotor 0 8A 500W U1 V1 W1 PE U2 V2 W2 4M4 M 3 fan motor Ventilatormotor 0 8A 500W U1 V1 W1 PE U2 V2 W2 4M5 593A 594A...

Page 40: ...city control logic module 12 inputs 8 contact outputs 10A comp contactor1 compr contactor2 overpressure low pressure overcurrent N I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I11 I12 L1 Q1 Q1 Q2 Q2 Q3 Q3 Q4 Q4 Q5 Q5 Q6 Q6 Q7 Q7 Q8 Q8 5A4 heater compr 1 50W 2 1 5R1 heater compr 1 50W 2 1 5R1 heater compr 2 50W 2 1 5R2 over pressure 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME D...

Page 41: ... 5A4 LOGO INPUT freeze protection I3 5A4 LOGO INPUT overcurrent compr 1 I4 5A4 LOGO INPUT overcurrent compr 2 I5 5A4 A H1 H2 0 selection switch 1 2 6S1 P overpressure PZAH 2 4 1 PE 6F3 P low pressure PSAL 2 4 1 PE 6F4 freeze protection 30 32 31 9A4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO com...

Page 42: ...p2 I9 5A4 LOGO INPUT capacity control I11 5A4 LOGO INPUT capacity control I12 5A4 P pressure sensor PSHL 756 4 2 1 PE 7S6 A H1 H2 0 selection switch 3 4 6 8 7 5 6S1 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO compr air dryer 593A 594A 22 3 2837 2837 7 15 22 02 02 ...

Page 43: ...4 5 6 3 4 1 2 LOGO OUTPUT comp contactor1 Q1 5A4 compr contactor2 Q2 5A4 LOGO OUTPUT Q3 5A4 SV condensate drain A1 A2 PE 8Y4 4 3kW fan contactor A1 A2 8K3 7 5kW compr contator2 A1 A2 8K2 7 5kW compr contator1 A1 A2 8K1 condensate drain A100 1 2 PE 3 4 8B6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING...

Page 44: ... ambient temp suct gas temp dewpoint temp service unit socket underpressure oil pressure overpressure overcurrent dewpoint trouble sig common trip signal SAB processor SP3 temperature sensors 6 5 4 9 8 7 3 2 22 23 24 25 26 27 28 29 1 14 15 16 17 18 19 20 21 10 11 12 13 3 6 5 7 30 31 32 9A4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 T...

Page 45: ... 9 8 7 4 5 6 9A4 2 common trip signal 1 X10 dewpoint trouble 4 X10 operation signal 7 X10 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 A B C D E F A B C D E F RAH IND APPD DATE NAME DATE DR CK STD JN IEC 1146 1 TITLE TYPE FILE REV OF SHEET DRAWING NO compr air dryer 593A 594A 22 3 2837 2837 10 15 22 02 02 ...

Page 46: ...ektronik WGS elektronik Krauss Naimer ultratroc gmbh Block Transformatoren WAGO Kontakttechnik Rockwell Automation Siemens AG Rockwell Automation Rockwell Automation Rockwell Automation 1 1 ultratroc gmbh 011 0574 000 RAH name main switch fuse socket control volt transformer logic module current detector current detector selection switch compr contator1 compr contator2 fan contactor SAB processor ...

Page 47: ...erminalnumber bridges page path function text X0 power supply 1 3Q1 1 L1 3 1 power supply 2 3Q1 3 L2 3 1 power supply 3 3Q1 5 L3 3 2 power supply PE PE 3 2 Norm JN RAH DR CK IND APPD DATE Name DATE IEC 1146 1 FILE TYPE REV drawing no PAGE OF ground compr air dryer 593A 594A 22 3 2837 2837 12 15 22 02 02 ...

Page 48: ... 15 4 4 16 4 5 17 4 5 18 4 5 compressor 1 PE 3M3 PE 3 3 compressor 2 PE 3M4 PE 3 5 PE 4 2 PE 4 3 PE 4 4 PE 4 5 Norm JN RAH DR CK IND APPD DATE Name DATE IEC 1146 1 FILE TYPE REV drawing no PAGE OF ground ground ground ground ground ground fan motor 1 4M2 U1 fan motor 1 4M2 fan motor 1 4M2 V1 W1 U1 V1 W1 U1 V1 W1 U1 V1 W1 4M3 4M4 4M5 fan motor 2 fan motor 3 fan motor 4 4M3 4M4 4M5 fan motor 2 fan m...

Page 49: ...F4 4 6 4 pressure sensor 11 6T6 1 7S6 1 7 6 pressure sensor 12 5A4 I12 7S6 2 7 6 pressure sensor 13 5A4 I11 7S6 4 7 6 14 8 3 15 8K3 A1 8 3 SV condensate drain 16 5A4 Q3 8Y4 A1 8 4 SV condensate drain 17 4T7 0 8Y4 A2 8 4 condensate drain 1 18 6T6 B 8B6 1 8 6 condensate drain 1 19 4T7 0 8B6 2 8 6 overpressure PE 6F3 PE 6 2 low pressure PE 6F4 PE 6 3 pressure sensor PE 7S6 PE 7 6 SV condensate drain ...

Page 50: ...ommon trip signal 2 9A4 5 10 1 common trip signal 3 9A4 6 10 2 dewpoint trouble 4 9A4 7 10 2 dewpoint trouble 5 9A4 8 10 2 dewpoint trouble 6 9A4 9 10 3 operation signal 7 8K1 13 10 3 operation signal 8 8K1 14 10 4 operation signal 9 8K2 14 10 4 Norm JN RAH DR CK IND APPD DATE Name DATE IEC 1146 1 FILE TYPE REV drawing no PAGE OF compr air dryer 593A 594A 22 3 2837 2837 15 15 22 02 02 ...

Page 51: ...1 pcs Transformer 593 594 593W 594W 0110366000 6K1 6K3 1 pcs Compressor Contactor 593 594 593W 594W 0108063000 6K2 1 pcs Compressor Auxiliary Relay 593 594 593W 594W 0109346000 6K4 1 pcs Fan Contactor 593 594 0106305000 5K4 5K6 1 pcs Auxiliary Relay 593 594 593W 594W 0109968000 4F2 1 pcs Fuses Primary 593 594 593W 594W 0111049000 V500 6Y6 1 pcs Refrigerant Circuit Dryer 593 594 593W 594W 010628000...

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