FRIULAIR ACT ES 20-500 User Maintenance Manual And Spare Parts Download

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Refrigerating air dryer

ACT ES

20 – 500

EN -

User’s maintenance and spare parts manual

7425MUM320_EN_04.0

Summary of Contents for ACT ES 20-500

Page 1: ...Refrigerating air dryer ACT ES 20 500 EN User s maintenance and spare parts manual 7425MUM320_EN_04 0 ...

Page 2: ...acturing faults and to demonstrate that the device can perform all the functions for which it has been designed Once the dryer has been properly installed according to the instructions in this manual it will be ready for use without any further adjustment The operation is fully automatic and the maintenance is limited to few controls and some cleaning operations as detailed in the following chapte...

Page 3: ...hnical data ACT ES 200 500 3phase 3 575 60 18 7 Technical description 19 7 1 Control panel 19 7 2 Operation 20 7 3 Flow diagram 21 7 4 Refrigerating compressor 22 7 5 Condenser 22 7 6 Filter dryer 22 7 7 Capillary tube 22 7 8 Alu Dry module 22 7 9 Hot gas by pass valve 23 7 10 Refrigerant pressure switches LPS HPS PV 23 7 11 Compressor crankcase heater 23 7 12 Electronic instrument DMC51 24 7 12 1...

Page 4: ... ACT ES 75 48 9 2 4 ACT ES 100 49 9 2 5 ACT ES 125 150 50 9 2 6 ACT ES 200 250 51 9 2 7 ACT ES 300 350 52 9 2 8 ACT ES 400 500 53 9 2 9 ACT ES 200 250 3phase 54 9 2 10 ACT ES 300 350 3phase 55 9 2 11 ACT ES 400 500 3phase 56 9 3 Electric diagrams 57 9 3 1 ACT ES 20 100 57 9 3 2 ACT ES 125 150 58 9 3 3 ACT ES 200 250 59 9 3 4 ACT ES 300 350 60 9 3 5 ACT ES 400 500 61 9 3 6 ACT ES 200 500 3phase She...

Page 5: ...l faulty parts which will be repaired or replaced free of charge except the travel hotel and restaurant expenses of our engineer The warranty doesn t cover any responsibility for direct or indirect damages to persons animals or equipment caused by improper usage or maintenance and it s limited to manufacturing faults only The right to warranty repairs is subordinated to the strict compliance with ...

Page 6: ...Danger hazard Do not operate equipment with panels removed Maintenance or control operation to be performed by qualified personnel only 1 ARIA AIR LUFT AIR Compressed air inlet connection point ARIA AIR LUFT AIR Compressed air outlet connection point Condensate drain connection point Operations which can be performed by the operator of the machine if qualified 1 NOTE Text that specifies items of n...

Page 7: ...by accident modification misuse negligence or misapplication Unauthorized alterations will immediately void the warranty In case of fire use an approved fire extinguisher water is not an acceptable means in cases of electrical fire 3 3 Proper use of the dryer This dryer has been designed manufactured and tested for the purpose of separating the humidity normally contained in compressed air Any oth...

Page 8: ...piping TAMPERING MODIFICATION AND IMPROPER USE OF THE PRESSURE EQUIPMENT ARE FORBIDDEN Users of the equipment must comply with all local and national pressure equipment legislation in the country of installation 4 Installation 4 1 Transport Check for visible loss or damage if no visible damage is found place the unit near to the installation point and unpack the contents To move the packaged unit ...

Page 9: ...e from dust and protected from atmospheric disturbances The supporting area must be smooth horizontal and able to hold the weight of the dryer Minimum ambient temperature 34 F 1 C Maximum ambient temperature 122 F 50 C Ensure a proper cooling air replacement Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitate maintenance operations The dryer does not req...

Page 10: ...ional installation of a pre filter 5 micron minimum to prevent a clogging of the heat exchanger Type A installation is suggested when the compressor operates at reduced intermittence and the total consumption equals the compressor flow rate Type B installation is suggested when the air consumption can consistently change with peak values highly exceeding the flow rate of the compressors The capaci...

Page 11: ...pressure 120 psig 8 barg Ambient temperature 115 F 45 C Inlet air temperature 122 F 50 C Pressure DewPoint 50 F 10 C Factor F1 1 07 Factor F2 0 78 Factor F3 0 68 Factor F4 1 36 Each item of data has a corresponding numerical factor which multiplied by the design air flow is as follows Air flow capacity 75 x 1 07 x 0 78 x 0 68 x 1 36 58 scfm 99 m h 58 scfm 99 m h This is the maximum flow rate that ...

Page 12: ...LT IN DAMAGE 4 7 Electrical connections Qualified personnel should carry out connecting unit to the main power Be sure to check the local codes in your area Before connecting the unit to the electrical supply verify the data nameplate for the proper electrical information Voltage tolerance is 10 Dryer are supplied with power cord and plug two poles and ground Be sure to provide the proper fuses or...

Page 13: ...orrect and that the piping is suitably fixed and supported Ensure that the condensate drain pipe is properly fastened and connected to a collection system or container Ensure that the by pass system if installed is closed and the dryer is isolated Ensure that the manual valve of the condensate drain circuit is open Remove any packaging and other material which could obstruct the area around the dr...

Page 14: ...rn OFF the switch pos 1 on the control panel ACT ES 200 500 3phase Dryer remote control ON OFF Remove jump on terminals 1 and 2 of the terminal strip and wire a dry contact potential free see electric diagram Turn ON the switch pos 1 on the control panel Close contact on terminal 1 and 2 switch ON the dryer Open contact on terminal 1 and 2 switch OFF the dryer Use dry contacts only potential free ...

Page 15: ...Technical data ACT ES 20 500 15 EN 6 Technical data 6 1 Technical data ACT ES 20 200 1 115 60 ...

Page 16: ...Technical data 16 EN ACT ES 20 500 6 2 Technical data ACT ES 20 500 1 230 60 ...

Page 17: ...Technical data ACT ES 20 500 17 EN 6 3 Technical data ACT ES 200 500 3phase 3 460 60 ...

Page 18: ...Technical data 18 EN ACT ES 20 500 6 4 Technical data ACT ES 200 500 3phase 3 575 60 ...

Page 19: ... PQS0080 1 0 Set reset K 1 ON OFF switch 2 Electronic instrument 3 Air and refrigerant gas flow chart ACT ES 125 500 K 2 3 PQS0081 1 Set reset K 1 ON OFF switch 2 Electronic instrument 3 Air and refrigerant gas flow chart ACT ES 200 500 3phase K 3 A PQS0082 T4 T3 T1 T2 0 1 1 2 Set reset K A Main switch 1 ON OFF switch 2 Electronic instrument 3 Air and refrigerant gas flow chart ...

Page 20: ...ling mode Energy Saving ESS YES see section 7 12 7 The DMC51 electronic controller constantly monitors the temperature of the DewPoint In low load conditions the temperature of the DewPoint tends to fall close to the freezing point at this point the DMC51 controls the switching off of the compressor The compressor will be started again when the DewPoint temperature rises above a target value To av...

Page 21: ...efrigerant pressure switch LPS Compressor discharge ACT ES 125 500 ACT ES 300 500 ACT ES 200 500 3phase 13 Condensate drain service valve 4 Refrigerant pressure switch HPS 21 Electronic drainer ACT ES 300 500 ACT ES 200 500 3phase 25 Compressor crankcase heater ACT ES 200 500 3ph 5 Refrigerant pressure switch PV 36 Suction refrigerant separator 6 Compressor 82 Check valve CHV 7 Hot gas by pass val...

Page 22: ... 7 6 Filter dryer Traces of humidity and slag can accumulate inside the refrigerant circuit Long periods of use can also produce sludge This can limit the lubrication efficiency of the compressor and clog the expansion valve or capillary tube The function of the filter drier located before the capillary tubing is to eliminate any impurities from circulating through the system 7 7 Capillary tube It...

Page 23: ...brated pressure R 134 a Stop 10 2 psig 0 7 barg Restart 24 7 psig 1 7 barg R 407 C Stop 24 7 psig 1 7 barg Restart 39 2 psig 2 7 barg HPS This high pressure controller device located on the discharge side on the compressor is activated when the pressure exceeds the pre set value It features a manual resetting button mounted on the controller itself Calibrated pressure R 134 a Stop 290 psig 20 barg...

Page 24: ...button and keep it pressed to display the compressor discharge temperature probe T2 if installed Press the button and keep it pressed to display the hours remaining until the next maintenance Press the Set buttons simultaneously and keep them pressed to display the total number of operating hours of the dryer ie when dryer is powered Press the button and keep it pressed to display the of energy sa...

Page 25: ...he operator always leads to the dryer stop When an alarm is active the LED flashes When an alarm is no longer active but not reset yet so it has been stored Led is continuously on in any case the dryer remains OFF In both cases the display shows and the alarms which are active or which are no longer active but not yet reset Alarms are NOT automatically reset To RESET the alarm the Led must be cont...

Page 26: ...e on the display first parameter of menu Keep Set pressed to display the value of the selected parameter and use arrows and to change the value Release the button Set to confirm the value and skip to following parameter Press to exit setup menu if no button is pressed after 30 seconds the menu is exited automatically ID Description Limits Resolution Standard setup HdS High DewPoint Setting service...

Page 27: ... Service Led Green ON ready to work supplied Green blinking maintenance required Orange ON Circuit board defect TEST Button Discharge test keep pushed for 2 seconds Control panel for dryers ACT ES 400 500 and ACT ES 400 500 3phase Power Service Led green ON ready to work supplied Blinking maintenance required Alarm Led red Blinking alarm condition Power Alarm Led ON circuit board defect TEST Butto...

Page 28: ...the proper operation of the condensate drain systems Verify the condenser for cleanliness Every 200 hours or monthly With an air jet max 2 bar 30 psig blowing from inside towards outside clean the condenser repeat this operation blowing in the opposite way be careful not to damage the aluminum fins of the cooling package Close the manual condensate drain valve unscrew the strainer if installed and...

Page 29: ...ture becomes higher Activation of the compressor internal thermal protection wait 30 minutes and then retry Verify the electric wiring If installed the KC relay is faulty replace it If installed replace the internal thermal protection and or the start up relay and or the start up capacitor and or the working capacitor DMC51 The led is ON see specific point If the compressor still does not work rep...

Page 30: ...is always ON verify the electric wiring check the setting of PV pressure switch or PV pressure switch is faulty replace it The ambient temperature is too low restore nominal conditions The hot gas bypass valve is out of setting contact a refrigeration engineer to restore nominal setting Dew point too low with parameter ESS YES see sect 7 12 7 DewPoint on this type of dryer is fluctuating the compr...

Page 31: ... the coil verify the electric wiring The solenoid valve is not activated and there is no voltage to the coil the internal relay of DMC51 is faulty replace DMC51 The solenoid valve is not activated and there is voltage to the coil the coil is faulty replace it The solenoid valve is not activated and there is voltage to the coil the solenoid valve is jammed contact a refrigeration engineer for the r...

Page 32: ...ck which of the following reasons has caused the alarm 1 The inlet air is too cold restore the nominal conditions 2 The ambient temperature is too low restore the nominal conditions 3 The hot gas bypass valve is out of setting contact a refrigeration engineer to restore nominal setting 4 The solenoid valve EVH is not operating correctly see specific point The alarm ICE has been triggered Check whi...

Page 33: ...w point temperature and the active or not reset service warning The service warnings are displayed by the following messages 1 Hdp Dew point too high higher than the set HdS value see specific paragraph 2 Ldp Dew point too low see specific paragraph 3 SrV Service maintenance notification time expired parameter SrV carry out the scheduled maintenance and reset the hour meter NOTE after solving the ...

Page 34: ...ase of abnormal operation so avoiding to wait for the spares delivery In case of failure of other parts for example inside the refrigerating circuit the replacement must be worked out by a refrigerating systems specialist or in our factory NOTE To order the suggested spare parts or any other part it s necessary to quote the data reported on the identification plate ...

Page 35: ...TLV GWP R134a HFC CH2FCF3 1000 ppm 1300 R407C HFC R32 125 134a 23 25 52 CHF2CF3 CH2F2 CH2FCF3 1000 ppm 1653 8 5 Dismantling of the dryer If the dryer is to be dismantled it has to be split into homogeneous groups of materials Part Material Refrigerant fluid R407C R134a Oil Canopy and Supports Carbon steel Epoxy paint Refrigerating compressor Steel Copper Aluminium Oil Alu Dry Module Aluminium Cond...

Page 36: ... 17 Electronic instrument 84 Service valve Low pressure side 21 Electronic drainer 86 Liquid solenoid valve EVL 22 Main switch 87 Hot gas solenoid valve EVH 36 Liquid separator 100 Autotransformer Electric diagrams List of components MC1 Compressor EVL Liquid solenoid valve KT Compressor thermal protection KC Compressor operating relay KR Compressor starting relay LPS Low pressure switch CS Compre...

Page 37: ...Attachments ACT ES 20 500 37 EN 9 1 Dryers dimensions 9 1 1 ACT ES 20 50 ...

Page 38: ...Attachments 38 EN ACT ES 20 500 9 1 2 ACT ES 75 ...

Page 39: ...Attachments ACT ES 20 500 39 EN 9 1 3 ACT ES 100 150 ...

Page 40: ...Attachments 40 EN ACT ES 20 500 9 1 4 ACT ES 200 250 ...

Page 41: ...Attachments ACT ES 20 500 41 EN 9 1 5 ACT ES 300 350 ...

Page 42: ...Attachments 42 EN ACT ES 20 500 9 1 6 ACT ES 400 500 ...

Page 43: ...Attachments ACT ES 20 500 43 EN 9 1 7 ACT ES 200 250 3phase ...

Page 44: ...Attachments 44 EN ACT ES 20 500 9 1 8 ACT ES 300 350 3phase ...

Page 45: ...Attachments ACT ES 20 500 45 EN 9 1 9 ACT ES 400 500 3phase ...

Page 46: ...Attachments 46 EN ACT ES 20 500 9 2 Exploded views 9 2 1 ACT ES 20 30 ...

Page 47: ...Attachments ACT ES 20 500 47 EN 9 2 2 ACT ES 50 ...

Page 48: ...Attachments 48 EN ACT ES 20 500 9 2 3 ACT ES 75 ...

Page 49: ...Attachments ACT ES 20 500 49 EN 9 2 4 ACT ES 100 ...

Page 50: ...Attachments 50 EN ACT ES 20 500 9 2 5 ACT ES 125 150 ...

Page 51: ...Attachments ACT ES 20 500 51 EN 9 2 6 ACT ES 200 250 ...

Page 52: ...Attachments 52 EN ACT ES 20 500 9 2 7 ACT ES 300 350 ...

Page 53: ...Attachments ACT ES 20 500 53 EN 9 2 8 ACT ES 400 500 ...

Page 54: ...Attachments 54 EN ACT ES 20 500 9 2 9 ACT ES 200 250 3phase ...

Page 55: ...Attachments ACT ES 20 500 55 EN 9 2 10 ACT ES 300 350 3phase ...

Page 56: ...Attachments 56 EN ACT ES 20 500 9 2 11 ACT ES 400 500 3phase ...

Page 57: ...ote Sheet 01 of FRACTESSEL0170 Drawing no 01 00 PE N L1 4 1 2 5 See dryer nameplate RCD Id 0 03A suggested 1 230V 50Hz PE FUSE MAX 10 A 1 230V 60Hz PE OR SUPPLY BY PLUG 1 115V 60Hz PE OR EVH EVL 1 2 4 CV MV1 M 1 ELD NTC 10k BT1 BN 1 BU 2 13 14 Set reset K MC1 KT M 1 C CS KR R S 13 N 14 L 12 16 11 15 10 17 EVH EVL K 7 8 12VDC 2 1 3 T2 T1 5 6 LPS PV R Power OFF Alarm NO Alarm Power ON and or MAX 15m...

Page 58: ...te RCD Id 0 03A suggested 1 230V 50Hz PE FUSE MAX 13 A 1 230V 60Hz PE OR SUPPLY BY PLUG 1 115V 60Hz PE OR ELD DMC51 Air Dryer Controller 13 N 14 L 12 16 11 15 10 17 EVH EVL K EVH EVL KC KT S CR R C M 1 PV 1 2 4 CV MV1 M 1 KC 1 6 14 11 12 1 4 12 11 14 MC1 2 1 3 5 6 LPS BN 1 BU 2 13 14 Set reset K FUSE MAX 10 A Power OFF Alarm NO Alarm Power ON and or MAX 15mA 0VDC 12VDC 24 22 21 N U A1 A2 NTC 10k B...

Page 59: ...D Id 0 03A suggested 1 230V 50Hz PE FUSE MAX 13 A 1 230V 60Hz PE OR SUPPLY BY PLUG 1 115V 60Hz PE OR 4 3 1 2 2 4 ELD DMC51 Air Dryer Controller 13 N 14 L 12 16 11 15 10 17 EVH EVL K EVH EVL KC KT S CR R C M 1 PV 1 2 4 CV MV1 M 1 KC 1 6 14 11 12 MC1 2 1 3 5 6 LPS BN 1 BU 2 13 14 Set reset K FUSE MAX 10 A Power OFF Alarm NO Alarm Power ON and or MAX 15mA 0VDC 12VDC 1 4 12 11 14 24 22 21 N U A1 A2 NT...

Page 60: ...16 A 1 230V 60Hz PE 1 230V 50Hz PE RCD Id 0 03A suggested OR Set reset K EVH EVL KC KT S CR R C M 1 1 2 4 CV MV1 M 1 KC 1 6 14 11 12 12 11 14 MC1 BN 1 BU 2 13 14 13 N 14 L 12 16 11 15 10 17 EVH EVL K 2 1 3 5 6 LPS PV Power OFF Alarm NO Alarm Power ON and or MAX 15mA 0VDC 12VDC PE BN 1 BU 2 PE N L1 4 3 1 2 2 4 SUPPLY BY PLUG 1 4 24 22 21 N U P HPS P LPS X1 1 L X1 2 N T2 T1 NTC 10k NTC 10k BT2 BT1 7...

Page 61: ... PE 1 230V 50Hz PE RCD Id 0 03A suggested OR BN 1 BU 2 ELD Set reset K EVH EVL KC KT S CR R C M 1 1 2 4 CV MV1 M 1 KC 1 6 14 11 12 12 11 14 MC1 13 14 13 N 14 L 12 16 11 15 10 17 EVH EVL K 2 1 3 5 6 LPS PV Power OFF Alarm NO Alarm Power ON and or MAX 15mA 0VDC 12VDC PE BN 1 BU 2 PE N L1 4 3 1 2 2 4 SUPPLY BY PLUG 1 4 24 22 21 N U P LPS CO X2 2 NC X2 3 NO X2 1 X1 1 L X1 2 N T2 T1 NTC 10k NTC 10k BT2...

Page 62: ...1 2 2 FU2 TF 21 22 PV P FU1 3 400V 50Hz PE 3 460V 60Hz PE Technical modifications are subject to change without notice errors not excluded FRACT5478QCD017 CV M 3 T S TP MV1 MV1 TP U2 1 M 3 400V 50Hz PE OR 3 460V 60Hz PE OR 3 380V 60Hz PE 1 OR 3 575V 60Hz PE 1 FUSE MAX 16 A RCD Id 0 03A suggested Smin 2 5sqmm 14AWG TR See dryer nameplate 1 With Auto Transformer TR installed ...

Page 63: ...ge without notice errors not excluded A B S1 5 2 4 1 Set reset K DMC51 Air Dryer Controller 13 14 12 16 11 15 10 17 EVH EVL K 7 8 12VDC 2 1 3 T2 T1 5 6 LPS EVH NTC 10k NTC 10k BT2 BT1 4 2 1 4 2 1 HPS BK WH BK LPS A1 A2 KC1 1 2 1 3 11 5 12 6 3 4 1 8 1 3 1 3 EVL BU BN BU BN BK BK X1 2 X1 1 N L X1 2 X1 1 N L CO X2 2 NC X2 3 NO X2 1 Power OFF Alarm NO Alarm Power ON and or MAX 15mA 0VDC 12VDC ...

Page 64: ...5 20 HPS LPS 14 RC2 RC1 00 10 7 16 6 21 8 17 9 18 10 19 11 12 12 11 ELECTRONIC LEVEL DRAINER ELD LIQUID SOLENOID VALVE HOT GAS SOLENOID VALVE Technical modifications are subject to change without notice errors not excluded 1 12 DAS 4 2 13 REMOTE ON OFF P U R0 to CV V W to CV S0 CBC 4 PV M 3 MV1 FAN PRESSURE SWITCH FAN MOTOR FAN PRESSURE SWITCH FAN MOTOR PV M 1 MV1 R0 U P CBC 4 S0 W V FAN PRESSURE ...

Page 65: ...Blank pages ACT ES 20 500 65 EN 10 Blank pages ...

Page 66: ...Blank pages 66 EN ACT ES 20 500 ...

Page 67: ...Blank pages ACT ES 20 500 67 EN ...

Page 68: ... Reg Impr 00430110312 Sede Operativa 33050 Cervignano del Friuli UD ITALY Via Cisis 36 S S 352 Km 21 Fraz Strassoldo www friulair com Istruzioni originali in ITALIANO Con riserva di modifiche ed errori Original instructions are in ITALIAN Subject to technical changes without prior notice errors not excluded EN Subject to technical changes without prior notice errors not excluded Translation of ori...

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