BERG DRYBERG RF Operating And Maintenance Manual Download

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OPERATING AND MAINTENANCE MANUAL

REFRIGERATION DRYER

DRYBERG RF

Summary of Contents for DRYBERG RF

Page 1: ...OPERATING AND MAINTENANCE MANUAL REFRIGERATION DRYER DRYBERG RF ...

Page 2: ... s a t e d i s c h a r g e k e y The yellow condensate discharge key serves to open the relative valve manually if the condensate discharge function is set as timer controlled moreover if selected from parameter H1 3 the discharge time H4 can be reprogrammed in this case the flashing red discharge icon will be displayed 0 3 K e y p a d l o c k To lock or unlock the keypad press keys for 5 seconds ...

Page 3: ...heet 7 Chapter 3 TECHNICAL DATA 9 3 1 Data plate and meaning of abbreviations 9 3 2 Declaration of conformity 10 3 3 Performance 10 3 3 1 Sound level measurements 10 Chapter 4 DESCRIPTION 11 4 1 Operating principle 11 4 2 Overall dimensions 11 4 3 Minimum distances from the walls of the installation room 11 4 4 Air and refrigerant circuits 11 4 4 1 Air circuit 11 4 4 2 Refrigerant circuit 11 4 5 E...

Page 4: ...tion 22 9 2 Alarms table 23 Chapter 10 PARAMETERS 24 10 1 Description of parameters 24 10 2 Parameters table 25 10 2 1 User interface parameters 25 10 2 2 Alarms queue 26 10 2 3 Variables accessible solely via supervision 26 Chapter 11 SAFETY PRESSURE SWITCHES CONDENSATE DISCHARGE UNIT 28 11 1 Pressure switches 28 11 2 Condensate discharge system 28 11 2 1 Timed condensate discharge system 29 11 2...

Page 5: ...iagrams in this manual The meaning of each symbol is indicated below ATTENTION This manual gives the user the installer and the maintenance technician all the technical information required to install commission and operate the dryer and carry out the routine maintenance operations to ensure maximum service life Use only genuine parts when carrying out routine maintenance or repairs For all INFORM...

Page 6: ... u t i o n s 2 2 1 Compressed gases to be dried Compressed gases to be dried should be compatible with the materials used aluminium alloys carbon steel cast iron copper and its alloys and could be for example air nitrogen argon and helium ATTENTION The compressed gases must not give rise to phenomena of corrosion that could impair the condition of pressurized containers and they must not be able t...

Page 7: ...larly For all dryers establish a convenient time interval for cleaning procedures Never use an open flame as a light source to inspect parts of the dryer Before dismantling parts of a plant ensure that all mobile and heavy parts are securely fixed and ensure electrical power has been disconnected When a repair has been completed make sure that no tools detached parts or rags are left in the dryer ...

Page 8: ...ir at pressures above atmospheric pressure when the ratio by volume is greater than 60 Storage Close properly and store in a cool dry well ventilated place CONTROL OF EXPOSURE INDIVIDUAL PROTECTION Control parameters 1000 ppm v v or ml m3 as weighted average over an 8 hour period Respiratory protection For rescue and maintenance work in tanks use autonomous breathing apparatus The vapours are heav...

Page 9: ...ECOLOGICAL INFORMATION Global warming potential HGWP R11 1 0 28 Ozone depletion potential ODP R11 1 0 Considerations on disposal Can be recycled after reconditioning ...

Page 10: ...t REFRIGERANT QUANTITY This is the quantity of refrigerant fluid contained in the unit MAX REFRIGERANT PRESS Refrigerant circuit design pressure MAX REFRIGERANT TEMP Refrigerant circuit design temperature USER CIRC FLUID Fluid cooled by unit MAX WORKING PRESSURE Max design pressure of the user circuit MAX TEMPERATURE Maximum design temperature of the user circuit this should not be confused with t...

Page 11: ...data 3 3 P e r f o r m a n c e ATTENTION The performance of the dryer dew point power consumption pressure drops etc depends mainly on the flow rate and pressure of the compressed gas to be dried and on the condenser cooling fluid temperature ambient temperature These data which are usually defined at the time of the offer constitute the basic point of reference in relation to dryer performance 3 ...

Page 12: ...s the evaporator where it is cooled further transferring heat to the refrigerant which consequently evaporates At the point the compressed air is in a saturated condition and it entrains the condensate resulting from the cooling process The condensate is separated from the air flow by a metal mesh AISI304 demister and it falls due to gravity onto the bottom of the thermal module from where it is c...

Page 13: ...ive solvents 4 The minimum and maximum working ambient temperature are specified on the unit data plate Ensure that the unit is not installed in flows of hot air emitted by other equipment In extremetemperature conditions the protection devices may trip 5 Do not obstruct or interfere with the air flow produced by the unit comply strictly with the minimum spaces distances specified in the installat...

Page 14: ...f the possibility of oil contents We recommend the use of oil water separators for the collection of discharged oil Ensure that the drainage system complies with all local regulations 5 Install shut off valves on the compressed air inlet and outlet connections so that the dryer can be isolated if necessary Fit as suitably sized pressure relief valve upline from the shut off valves 6 Install a bypa...

Page 15: ...maximum required voltage at the maximum operating ambient temperature according to the chosen installation type see the indications on the electrical schematic Indications on the electrical schematic 1 maximum permissible size of the fuse type gG In general fuses can be replaced by an automatic circuit breaker adjusted in relation to the machine maximum current input consult the manufacturer if ne...

Page 16: ...he compressor and fan unit will start 6 Wait for the compressor to stop when the thermal mass has reached the programmed temperature 7 Slowly open the dryer inlet valve to pressurize the unit 8 Slowly open the dryer outlet valve 9 Close the dryer by pass valve 10 Press the manual discharge button and check that the discharge solenoid valve opens 11 If the unit is equipped with a smart condensate d...

Page 17: ...nctions BUTTON FUNCTION Switches controller on and off press for 1 second Manual condensate discharge press for 1 second Direct parameters display or edit press for 5 seconds or display and edit of password protected parameters press for 2 seconds During programming phase it selects a parameter or confirms a value In programming mode scrolls parameter codes or increases a parameter value In progra...

Page 18: ...stopped due to times management Off Unit ON compressor ON Lit Unit ON compressor ON Step capacity control ON Unit ON compressor OFF Flashing Not used Off Condensate discharge disabled Lit Condensate discharge enabled Flashing Not used Off Step capacity control OFF Lit Step capacity control ON Flashing Not used Off No alarm condition Lit Only illuminates during consultation of the alarms history Fl...

Page 19: ... mode In addition if parameter H1 is set to 3 discharge time H4 can be reprogrammed i e the discharge time becomes equal to the time for which the yellow key is pressed in this case the flashing red discharge icon is displayed 7 5 3 Controller programming The instrument has 2 programming levels the first U USER concerns parameters that can normally be changed by the user The second level S SERVICE...

Page 20: ...d unlocked is shown with POn The type of lock can be selected using parameter blK the message is shown on the display blK 0 keypad enabled blK 1 entire keypad disabled blk 2 only ON OFF key enabled When the keypad is disabled pressing any key will produce the message POF NOTE When the unit is shipped from the factory the keypad is unlocked ...

Page 21: ...e system offers four condensate discharge modes selectable by means of parameter H1 H1 0 disabled H1 1 timer H1 2 fixed H1 3 timed from keypad With timer controlled condensate discharge the relay is energized cyclically at intervals H5 for time H3 if the compressor is stopped or for time H4 if the compressor is running When the unit is powered on cyclic control starts with a relay energization Wit...

Page 22: ...ished by parameter A6 a number of pressure switch trips is reached equivalent to the number set in parameter A7 the alarm will be generated The message E14 is displayed the compressor is stopped and control suspended When the input is active the compressor is always stopped 8 5 S e r i a l c o n n e c t i o n The electronic controller can be equipped with a ModBus RS485 serial output The optional ...

Page 23: ...eview the alarm duration 1 Press for 5 seconds 2 Scroll through the list with the arrow keys 3 Use the key to review the duration 4 A second press of serves to quit the alarms queue NOTE The duration is to be construed as a partial value if the alarm is still in progress The alarms for which this function is active are as follows E03 E04 E05 E06 PS the duration of the last alarm to trip is display...

Page 24: ...ure alarm BEAOT On automatic OFF See parameter AA E07 Eeprom error unit parameters On automatic OFF See parameter AA E08 Eeprom error operating parameters On automatic OFF See parameter AA E09 DI1 display only warning On automatic See parameter AA E10 DI1 delayed alarm On automatic OFF See parameter AA E11 DI1 alarm after multiple trips On Manual OFF See parameter AA E12 DI2 display only warning O...

Page 25: ...ate discharge from keypad H3 Adjusts condensate discharge output activation H2 0 always on H2 1 on only with unit ON With H2 1 when unit switches to OFF the condensate discharge intervals are reset H4 Sets the condensate discharge valve opening time with compressor stopped H5 Sets the condensate discharge valve opening time with compressor running AcH Defines compressor maintenance alarm set point...

Page 26: ...and Power ON Power up and ON OFF for exclusion of the temperature alarms rev Firmware update Parameter Label Description Value Min Max U M Type ModBus R W Lev 5 9 Temperature measurement unit 0 C 1 F 0 0 1 D 39 R W U H0 Serial connection address 1 0 207 I 130 R W S H1 Condensate discharge type 0 Disabled 1 Timer controlled 2 Fixed 3 Timer controlled from keypad 1 if timed discharge 2 if ID dischar...

Page 27: ...essure switch trips 1 1 15 I 154 R W U A9 Temperature alarm delay 600 0 999 s I 155 R W U A10 Temperature alarm delay at controller ON 60 0 999 min I 156 R W U rev Firmware update 0 99 9 A 0 R U Parameter Label Description Value Min Max U M Type ModBus R W Lev AL3 Alarm duration E03 0 999 min I 145 R U AL4 Alarm duration E04 0 999 min I 146 R U AL5 Alarm duration E05 0 999 min I 147 R U AL6 Alarm ...

Page 28: ...isplay only warning E12 0 1 D 21 R Delayed DI2 alarm E13 0 1 D 22 R Alarm DI2 after several trips E14 0 1 D 23 R Compressor maintenance warning E15 0 1 D 24 R Manual reset alarms reset 0 0 1 D 38 R W Alarms queue reset 0 0 1 D 37 R W Controller On off from keypad supervision 1 0 1 D 42 R W Controller On Off status 1 0 1 D 43 R Compressor run time minutes 0 999 min I 138 R Description Value Min Max...

Page 29: ...compressor see electrical schematic 1 1 2 C o n d e n s a t e d i s c h a r g e s y s t e m The unit is furnished with a condensate discharge unit which can be of timed or of intelligent type The type of discharge system will be decided at the time of the offer The timed discharge unit is controlled automatically by the electronic controller on which the condensate discharge intervals can be set s...

Page 30: ...retaining gasket 2 and remove strainer mesh 3 Once cleaned refit the strainer making sure it is correctly seated and refit cap 1 Renew the O ring 2 if it is damaged Shut off valve with filter and solenoid valve 1 Filter cap 2 O ring 3 Strainer If any particles are not captured by the filter and consequently cause the valve to malfunction all the valve s internal components must be cleaned Proceed ...

Page 31: ...n as the air flow is restored 1 2 2 M a i n t e n a n c e ATTENTION Before installing or operating these dryers ensure that all personnel involved have read and understood Chapter 2 Safety in this manual These dryers will give many years of trouble free service if they are properly maintained and serviced 12 2 1 Access to the dryer To access the components of the refrigerant and electrical circuit...

Page 32: ... F When the compressor is running check that its upper part is not too hot more than approximately 50 C 122 F Check that the dryer s current draw is within the rated values Remove clean and refit the condensate filter If the filter is always clogged with material it may be necessary to dismantle and clean the solenoid valve Make a visual inspection of the refrigerant circuit to make sure the pipin...

Page 33: ...imits A4 Air cooled dryers Ambient temperature too high If the unit is installed indoors reduce ambient temperature to within rated limits e g installing fans to extract the air A5 Water cooled dryers cooling water temperature too high low water flow Take steps to reduce the water inlet temperature within the design limits increase the water flow A6 Air cooled dryers Condenser fins fouled Clean th...

Page 34: ... and the dryer freezes B2 1 See point C See point C B3 Exchanger obstructed by impurities entrained by the compressed air B3 1 Pressure down line from the dryer lower than expected Renew the exchanger C The dryer is obstructed and the air does not flow C1 Incorrect position of temperature probe so the thermal mass has fallen below zero thereby freezing the condensate it may have occurred that foll...

Page 35: ...in such a way that it operates without capacity steps the manometric temperature read on the temperature scale of the refrigerant utilized must vary from approximately 3 C 26 6 F to 0 C 32 F if the manometric temperature is lower than these values the circuit probably contains insufficient refrigerant Refer also to A2 and A3 D2 1 Dew point and compressed air inlet temperatures higher than expected...

Page 36: ...solenoid valve clean the components and re assemble the solenoid valve see 11 2 Condensate discharge system E6 The electronic board relay controlling the solenoid valve doesn t work Use a tester to check that the relay contacts controlling the solenoid valve do not close when the manual discharge button is pressed If the relay doesn t work replace the electronic board F Presence of condensate down...

Page 37: ...ay tripped if present on the controller fitted on the unit see Chapter 7 Electronic controller RF Reduce the water temperature to within rated limits Start the unit again see heading 9 2 Alarms table G8 Water cooled dryers excessively low water flow rate If the cooling circuit uses mains water or it is an open circuit with cooling towers the concentration of calcium carbonates and magnesium in the...

Page 38: ...to G8 Use special attention to check operation of the safety devices present thermal protections incorporated in the motors and or external and high pressure switch if present In case of doubt replace all the devices See also points from G1 to G8 I Electronic board off even if main power switch is on I I1 Damaged circuit board I1 1 Power on the circuit board terminals Renew circuit board contact a...

Page 39: ...Contact of body parts with refrigerant gas or parts of cooling circuit pipelines launched at high speed Strictly observe all manual instructions Chapter 2 Safety and Chapter 5 Installation 7 Risk of high pressure fluid ejection from pipelines and or pressure tanks in cooling circuit due to design pressure values being exceeded Contact of body parts with refrigerant gas or residual parts of cooling...

Page 40: ...rom the machine and by materials used to construct the machine inhalation of refrigerant gases Inhalation of refrigerant gas Strictly observe all manual instructions Chapter 2 Safety 17 Hazards generated by materials or substances handled used produced or offloaded from the machine and materials used to construct the machine drainage of condensate containing oils or discharge of oil contained in c...

Page 41: ...ectric power supply is restored Strictly observe all manual instructions Chapter 2 Safety Chap 5 3 Electrical connections and Chapter 6 Start up 26 Inadvertent start up overtravel unexpected excess speed or any other similar malfunction caused by external factors on the electrical equipment EMC Electrical hazards associated with electric stress on internal machine components short circuits and ove...

Page 42: ...observe all graphic safety signs on the machine and replace when worn or illegible Strictly observe all manual instructions Chapter 1 General information 34 Hazards generated by absence of and or position of measures instruments influencing safety manual Hazards associated with incorrect preparation of the manual due to lack of and or unclear information required to ensure operator safety and safe...

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