FRIULAIR ACT VS 1000 User’S Maintenance & Spare Parts Manual Download

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Refrigerating air dryer

ACT VS

800 - 2500

Air – water cooled

EN -

User’s maintenance and spare parts manual

74MD0059A4-EN_00

Summary of Contents for ACT VS 1000

Page 1: ...Refrigerating air dryer ACT VS 800 2500 Air water cooled EN User s maintenance and spare parts manual 74MD0059A4 EN_00 ...

Page 2: ...facturing 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 chapt...

Page 3: ... Operation 24 10 3 Flow diagram Air Cooled 25 10 4 Flow diagram Water Cooled 25 10 5 Refrigerating compressor 26 10 6 Condenser Air Cooled 26 10 7 Condenser Water Cooled 26 10 8 Condenser water regulating valve Water Cooled 26 10 9 Filter dryer 26 10 10 Electronic Expansion Valve EEV 27 10 11 Alu Dry module 27 10 12 Refrigerant pressure switches HPS 27 10 13 Compressor crankcase heater 27 10 14 El...

Page 4: ...ration circuit 56 11 5 Dismantling of the dryer 56 12 Attachments 57 Exploded views List of components 57 Electric diagrams List of components 57 12 1 Dryers dimension 58 12 1 1 ACT VS 800 1250 58 12 1 2 ACT VS 1500 2500 58 12 2 Exploded views 58 12 2 1 ACT VS 800 1250 Air Cooled 58 12 2 2 ACT VS 800 1250 Water Cooled 58 12 2 3 ACT VS 1500 2500 Air Cooled 58 12 2 4 ACT VS 1500 2500 Water Cooled 58...

Page 5: ...the place of application of the 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 compressed air refrigeration dryer only takes place within the permissible limit values indicated on the name plate Any deviation from these limit values involves a risk for persons and for the ...

Page 6: ...nt compressed air outlet Connection point condensate drain Connection point cooling water inlet water cooled Connection point cooling water outlet water cooled 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 identi...

Page 7: ...l advises the user to observe the environmental aspects and comply with the recommendations connected with this symbol 2 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 m...

Page 8: ...hrough 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 persons The user is responsible for the proper installation of the dryer Non observance of the instructio...

Page 9: ...ren 5 Breathing protection ambient air independent respirator at high concentrations 6 Eye protection sealing goggles 7 Hand protection protective gloves e g made of leather 8 Personal protection protective clothing 9 Skin protection use protective cream In addition the safety data sheet for the refrigerant needs to be observed Caution Hot surfaces During operation several components can reach sur...

Page 10: ...product Caution Unauthorised intervention Unauthorised interventions may endanger persons and plants and lead to malfunction Unauthorised interventions modification and abuse of the pressure devices are prohibited The removal of sealings and leadings at safety devices is prohibited Operators of the devices must observe the local and national pressure equipment regulations in the country of install...

Page 11: ...ssed air cannot be used for breathing air purposes and is not suitable for the direct contact with food This dryer is not suitable for the treatment of contaminated air or of air containing solids 4 Instructions for the use of pressure equipment according to PED directive 2014 68 EU To ensure the safe operation of pressure equipments the user must conform strictly to the above directive and the fo...

Page 12: ...ith care Heavy blows could cause irreparable damage 6 Storage Even when packaged keep the machine protected from severity of the weather Keep the dryer in vertical position also when stored Turning it upside down some parts could be irreparably damaged If not in use the dryer can be stored in its packaging in a dust free and protected site at a temperature of 1 C 50 C 34 F 122 F and a specific hum...

Page 13: ...hemicals with a corrosive effect explosive gases toxic gases evaporation heat high ambient temperatures or extreme dust and dirt can be found Minimum installation requirements Choose an area which is clean and dry free from dust and protected against atmospheric disturbances The load bearing zone must be even horizontal and able to bear the weight of the dryer Minimum ambient temperature 1 C 34 F ...

Page 14: ... and frequently after the dryer if the air consumption variation is very wide frequent and sudden or both to have the best load variation dampness Compressed air tanks can be installed as capacity dampers installed before the dryer Type A if the compressor capacity varies suddenly and often after the dryer Type B if the change in air consumption is very large frequent and sudden or both to have th...

Page 15: ...sure 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 800 x 1 07 x 0 78 x 0 68 x 1 36 617 scfm 1048 m h 617 scfm 1048 m h This is the maximum flow rate th...

Page 16: ...uld result necessary In order to perform maintenance operations it is recommended to install a dryer by pass system In realising the dryer particular measures have been taken in order to limit the vibration which could occur during the operation Therefore we recommend to use connecting pipes able to insulate the dryer from possible vibrations originating from the line flexible hoses vibration damp...

Page 17: ...ngerous for the operator but also for the device The temperature and the amount of cooling water must comply with the limits indicated on the technical characteristics chart The cross section of the connection pipes preferably flexible must be free from rust chips and other impurities We recommend to use connecting pipes able to insulate the dryer from possible vibrations originating from the line...

Page 18: ... 100 mg l or ppm Nitrite NO2 0 1 mg l or ppm Sulphide S2 1 mg l or ppm Tube bundle condenser Temperature 15 C 30 C 59 F 86 F 1 Pressure 3 10 barg 43 5 145 psig 2 Delivery pressure 3 bar 43 5 psi 2 3 PH 7 5 9 0 Total hardness 6 0 15 dH Conductivity 10 1000 μS cm Sulphates SO4 2 100 mg l or ppm Hydrogen carbonate Sulphates HCO3 SO4 2 1 0 mg l or ppm Ammonia NH3 0 5 mg l or ppm Manganous ion Mn2 0 05...

Page 19: ...s B is suggested The cross section of the power supply cables must comply with the consumption of the dryer while keeping into account also the ambient temperature the conditions of the mains installation the length of the cables and the requirements enforced by the local Power Provider Compressor and fan s proper rotation direction are managed automatically by the inverters It is not necessary to...

Page 20: ...condensate drain coming from compressors dryers tanks filters etc 8 Start up 8 1 Preliminary operation Note Exceeding of the operating parameters Ensure that the operating parameters comply with the nominal values indicated on the name plate of the dryer voltage frequency air pressure air temperature ambient temperature etc This dryer has been thoroughly tested packaged and inspected prior to ship...

Page 21: ...tch Turn on the main switch pos 1 on the control panel Wait about 45 seconds the initialization of the electronic controller DMC55 Select the desired language and the current date and time Wait at least two hours before starting the dryer compressor crankcase heater must heat the oil of the compressor Keep pressed the button at least 3 seconds the dryer starts and the display shows If the temperat...

Page 22: ...w minutes verify that the DewPoint temperature displayed on electronic controller is correct and that the condensate is regularly drained Switch on the air compressor Shut down refer to section 10 1 Control Panel Check that the DewPoint temperature displayed on electronic controller is within range Shut down the air compressor Keep pressed the button at least 3 seconds the dryer stops and the disp...

Page 23: ...Technical data ACT VS 800 2500 23 EN 9 Technical data 9 1 Technical data ACT VS 800 2500 3 460 60 ...

Page 24: ... about three minutes the compressor works at a set speed equivalent to approximately 40 50 of its maximum speed to enable the lubricating oil to circulate correctly in the compressor at the beginning If the evaporation pressure is too low the controller activates the EHGBV electronic bypass valve which keeps the evaporation pressure constant above the freezing point After three minutes the control...

Page 25: ...led 35 Electronic Expansion Valve EEV 9 Condenser fan Air Cooled 36 Liquid separator 10 Filter dryer 37 Refrigerant pressure transducer BHP 12 1 T1 Temperature probe DewPoint 39 Refrigerant pressure transducer BLP 12 2 T2 Temperature probe Air IN 43 Oil separator ACT 1500 2500 12 3 T3 Temperature probe Compressor suction 78 Electronic by pass valve EHGBV 12 4 T4 Temperature probe Compressor discha...

Page 26: ... temperature of the refrigerating gas The temperature of the inlet water must not exceed the nominal values It must also guarantee an adequate flow and that the water entering the exchanger is free from dust and other impurities 10 8 Condenser water regulating valve Water Cooled The condenser water regulating valve is used to keep the condensing pressure temperature constant when the Water Cooled ...

Page 27: ...e separator is located within the heat exchanger module No maintenance is required and the coalescing effect results in a high degree of moisture separation 10 12Refrigerant pressure switches HPS 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 prote...

Page 28: ...roximately 40 50 of its maximum speed to enable the lubricating oil to circulate correctly in the compressor at the beginning This phase is illustrated with a bar symbol under the icon which gradually becomes blue and shows the time that has lapsed since the dryer started After three minutes the bar disappears and the dryer works normally The display will show Current date time and ON status of th...

Page 29: ...ured traces 6 Touch the graph on the screen to position the cursor roughly near the required time 7 Use the cursor keys to fine tune the position of the graph cursor on the required time Positioning accuracy is 15 seconds 8 The table on the right of the screen displays the process values stored in the time period selected by the graph cursor in numerical format NOTE The stored process values which...

Page 30: ...as the cause has been removed With dryer operating the presence of one or more Warnings is flagged on the display with the status bar changing from green to orange If there are several active anomalies simultaneously the status area displays them in order When the dryer is off one or more Warnings are not highlighted on the display other than the W11 Warning Low ambient temperature which automatic...

Page 31: ...ant fluid temperature High compressor supply side temperature supply over normal limits but within safe limits T4 100 0 C 60 sec T4 95 0 C W8 BLP transducer Evaporation pressure High pressure R407C LP 6 8 barg R134 a LP 5 0 barg 6 min R407C LP 6 8 barg R134 a LP 5 0 barg W9 BHP transducer Condensation pressure Low Pressure Variable 10 min Variable W10 BHP transducer Condensation pressure High pres...

Page 32: ...eeding phases It is only when the operator wants to start the dryer with the key that the control unit prevents the dryer starting up and displays the Alarm status by changing the colour of the status bar red Clearing an Alarm 1 Touch the screen on the status bar where the Alarm is shown to display a list of stored Alarms 2 Touch the screen on the Alarm to be cleared 3 Press to confirm the Alarm i...

Page 33: ...P 5 5 barg 2 Restore normal conditions A13 BHP transducer Condensation pressure Low Pressure Variable 2 Restore normal conditions A15 0 INV2 Drive Fan Fan speed out of control From INV2 Drive 60 sec Restore normal conditions A16 INV1 Drive Chiller compressor Chiller compressor speed out of control From INV1 Drive 60 sec Restore normal conditions A17 BLP BHP transducers HP and LP pressures unbalanc...

Page 34: ...t which is removed from the bottom of the list Downloading the Alarm log 4 Install a USB storage drive as described in Installing and removing the USB storage drive and press to download the Alarm log 5 Confirm with the intention to download or to exit the command Remove the USB drive as described in the section Installing and removing the USB storage drive 6 Press to return to the previous screen...

Page 35: ...ing the USB storage drive Remove power from the dryer and ensure that it cannot be restarted accidentally Open the control panel door with the special key provided with the dryer Remove the USB storage drive USB stick Close the control panel door carefully Restore power to the dryer 10 15 9 Compressor and fan drive process values 1 With the dryer operating press to access the dryer s menu 2 Press ...

Page 36: ...ion The default graph includes traces for both the process values 5 Use the keys to display hide the corresponding coloured traces 6 Touch the graph on the screen to position the cursor roughly near the required time 7 Use the cursor keys to fine tune the position of the graph cursor on the required time Positioning accuracy is 15 seconds 8 The table on the right of the screen displays the process...

Page 37: ...With the stopped dryer press the Reset key to reset the count of the hours remaining before the next service parameter SrV default 8000 hours This function is useful in the case of maintenance carried out on the dryer before the hours remaining till the next service have lapsed This is a PIN protected function no 3333 to prevent the counter being reset accidentally 4 Press Reset to clear the parti...

Page 38: ... REMOTE ON OFF contact The dryer will stop and the status bar will turn blue and display REMOTE STANDBY NOTE In REMOTE operating mode It is impossible to operate and stop the dryer with commands from the display It is impossible to manage and reset Alarms from the display It is possible to carry out all other operations such as the condensation drain test the management of Alarms and access to the...

Page 39: ...e parameter to be changed to display the possible settings then select one of the settings If the parameter to be changed requires a numerical value set the new value using the numerical keypad within the max and min limits shown 5 Confirm the setting by pressing or to return to the parameter list without making any changes Repeat operations 3 4 5 for all parameters to be changed 6 Press to access...

Page 40: ...till the next service With SrV 0 the counter is disabled 0 12000 hours 1 hour 8000 hours AS Automatic dryer restart following a voltage drop YES the dryer restarts automatically if it had been on NO The dryer must be restarted using the key YES NO NO Ard Enables disables the W5 Warning to be cleared automatically YES automatic clearing NO manual clearing YES NO YES ACM Selects the triggering logic...

Page 41: ...he dryer In this case reset the setting DCC YES 2 With DPS 3 the dew point varies according to the ambient temperature 3 With RbP NO the maximum number of remote resets allowed within 60 minutes is three 4 With TtPR 0 when NoA Alarms are reached the dryer asks for the Service PIN to be entered to reset the Alarm 5 With PSPR YES the SrV parameter can only be modified with the Service PIN 10 15 17 L...

Page 42: ...ture and pressure C bar or F psi Setting of the programmed start stop timer 3 Press to access the weekly timer functions 4 Touch the display inside the graphic area to set the weekly automatic start time for the dryer The programmed time is highlighted by colouring the graphic area in blue or green Light blue area Programmed time and timer disabled Green colour area Programmed time and timer enabl...

Page 43: ...d maintenance easily At dryer start up verify that this valve is open Control panel 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 Button Discharge test keep pushed for 2 seconds Troubleshooting Only qualified personnel should perform troubleshooting and or maintenance operations Pr...

Page 44: ...smantling chapters leads to the expiration of the guarantee Improper maintenance may result in dangerous situations for the personnel and or the device Danger Supply voltage Contact with non insulated parts carrying supply voltage involves the risk of an electric shock resulting in injuries and death Only qualified and skilled personnel are authorised to run electrically operated devices Prior to ...

Page 45: ...tives in force apply to the qualification and expertise of the certified skilled personnel For safe operation the device must only be installed and operated in accordance with the indications in the operating instructions In addition the national and operational statutory provisions and safety regulations as well as the accident prevention regulations required for the respective case of applicatio...

Page 46: ...e BHP pressure transducer or DMC55 controller DewPoint too high The dryer doesn t start see specific fault The DewPoint probe does not detect the temperature correctly push the probe until it reaches the bottom of the measuring well Temperature probe BT1 failure check the electric wiring and or replace the probe The chiller compressor does not work see specific fault The room temperature is too hi...

Page 47: ... is off check electrical wiring and FU3 fuse The DewPoint is too low the condensate is frosted see specific fault The air pressure is too low and the water is not drained restore nominal conditions The condensate drain is not working properly see the specific section The dryer continuously drains condensate The condensation drainer is obstructed see the specific section The condensate drain is fau...

Page 48: ... check the electric wiring of the valve or contact a refrigeration engineer to replace it Too high condensing pressure The room temperature is too high or the room air circulation is insufficient provide proper ventilation air cooled The inlet air is too hot restore nominal conditions The inlet air flow rate is higher than the dryer s restore nominal conditions The condenser filter is dirty clean ...

Page 49: ...k see specific fault Low differential pressure between HP and LP values The fan does not work properly the speed is too high see specific fault air cooled The room temperature is too low restore nominal conditions Air flows through the condenser even with fan off protect dryer against wind or external air flows not caused by dryer s fan air cooled The cooling water temperature is too low restore n...

Page 50: ...ol The operating speed returned by the compressor does not correspond to the speed required by the DMC55 controller A17 Pressure Balance Failure When starting the refrigeration compressor the LP and HP pressures are not balanced HGBV electronic bypass valve is not working correctly check the electric wiring of the valve or contact a refrigeration engineer to replace it The evaporating pressure mea...

Page 51: ...k Excessive compressor load Drive cooling fan failure replace the drive Check the electrical box filter cleaning Check the setting and electrical wiring of the HT thermostat Replace thermostat if necessary Electrical box MCP fan failure replace the fan A KD 002 Earth Fault_AL 014 Discharge from output phases to ground Check and correct the ground fault of the cables between the drive and the compr...

Page 52: ...flashing status area switch off the power supply to the dryer using the main switch wait at least 60 seconds and then restore the power supply The status area turns steady red and the alarm can now be reset A FD 001 Power board over temp_AL 029 The shutdown temperature of the heat sink has been reached The room temperature is too high restore nominal conditions Obstruction in the cooling air flow ...

Page 53: ...otor phase V missing_AL 031 Motor V phase missing Check the phase A FD 021 Motor phase W missing_AL 032 Motor W phase missing Check the phase A FD 028 Earth fault_AL 044 Discharge from output phases to ground Check and correct the ground fault of the motor connections or the motor fan connections A FD 029 Drive Initialised AL 080 Drive parameters have been deleted Contact the dealer to reset the f...

Page 54: ...te drain does not work properly ALARM contact open see specific fault This fault could occur with dryer running but without compressed air flow W6 Programmed Service Maintenance warning time expired exceeding the value set in parameter SrV carry out the programmed maintenance and reset the hour counter W7 High Discharge Temperature Compressor discharge T4 temperature too high but within the safety...

Page 55: ...rts list is printed on a dedicated sticker applied inside the dryer On this sticker each spare part is identified with its ID Number and related Spare Part Number Here below the cross reference table between ID Numbers and exploded drawings Ref with their description and quantity installed in the dryers ...

Page 56: ... of refrigerants used Refrigerant Chemical formula TLV GWP R134a HFC CH2FCF3 1000 ppm 1430 R407C HFC R32 125 134a 23 25 52 CHF2CF3 CH2F2 CH2FCF3 1000 ppm 1773 85 11 5 Dismantling of the dryer When the dryer is dismantled all parts and operating materials related to the plant need to be disposed of separately Part Material Refrigerant fluid R134a R407C Oil Canopy and Supports Carbon steel Epoxy pai...

Page 57: ... transducer BHP 83 Refrigerant service valve H P side 39 Refrigerant pressure transducer BLP 84 Refrigerant service valve L P side 40 Compressor variable speed drive INV1 86 EEVtemperature sensor BS 41 Condenser fan variable speed drive INV2 87 EEV pressure transducer BP Electric diagrams List of components MC1 Compressor HPS High pressure switch RC Compressor crankcase heater EHGBV Electronic by ...

Page 58: ... 12 1 2 ACT VS 1500 2500 12 2 Exploded views 12 2 1 ACT VS 800 1250 Air Cooled 12 2 2 ACT VS 800 1250 Water Cooled 12 2 3 ACT VS 1500 2500 Air Cooled 12 2 4 ACT VS 1500 2500 Water Cooled 12 3 Electric diagrams 12 3 1 ACT VS 800 1250 12 3 2 ACT VS 1500 1750 12 3 3 ACT VS 2000 250 ...

Page 59: ......

Page 60: ...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 original instructions ...

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FRIULAIR ACT VS 1000, User’S Maintenance & Spare Parts Manual

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