Sullair SRC Service Manual Download

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Service Manual

for the

SRC Cycling Refrigerated

Air Dryers

Document PN#: 02250___-___

Summary of Contents for SRC

Page 1: ...Service Manual for the SRC Cycling Refrigerated Air Dryers Document PN 02250___ ___ ...

Page 2: ...vel Sensor 11 3 2 The Coolant Circuit 11 3 2 1 The Thermal Mass Concept 12 3 2 2 Coolant to Refrigerant Heat Exchanger 13 3 2 3 Coolant Tank 14 3 2 4 Coolant Pump 14 3 2 5 Coolant Pressure Relief Valve 15 3 2 6 Coolant Expansion Tank 15 3 3 Refrigeration Circuit 15 3 3 1 Compressor 16 3 3 2 Condenser Fan 16 3 3 3 Refrigerant Filter 17 3 3 4 Expansion Device 17 3 3 5 Refrigerant 17 3 3 6 High Press...

Page 3: ...ist 32 8 Cycling Operation 33 8 1 SRC 150 to 200 33 8 2 SRC 250 to 1000 33 9 Condensate Drain Operation 35 9 1 SRC 150 to 200 35 9 2 SRC 250 to 325 35 9 3 SRC 400 to 1000 35 9 4 Drain Operating Mode Parameter D3 37 9 5 Manual Drain Activation 37 10 Alarms Warnings 38 10 1 Alarm Warning List 38 10 2 Troubleshooting Alarms Warnings 39 10 2 1 HP High Pressure Alarm 39 10 2 2 LP Low Pressure Alarm 40 ...

Page 4: ...11 Recommended Maintenance 50 11 1 Maintenance Schedule 50 11 2 Preventative Maintenance Kits 50 12 Maintenance Procedures 51 12 1 Replacing a Pressure Switch 51 12 2 Replacing the Thermostat SRC 150 to 200 51 12 3 Replacing the Control Board SRC 250 to 1000 52 12 4 Replacing the Drain Valve 52 12 5 Cleaning the Condensate Strainer 53 12 6 Replacing the Coolant Pump 53 13 Confirming Dryer Sizing 5...

Page 5: ...y as the dryer is absorbing less heat that it is designed for The SRC is a cycling dryer because it reduces it s power consumption at reduced heat loads by cooling the air using a large tank of a cold glycol water mixture referred to as a thermal mass which is in turn cooled by a refrigeration system When there is less heat load the thermal mass absorbs less heat and the refrigerant system is cycl...

Page 6: ...165 519 575 Maximum rated flow at 100 deg F 38 deg C 100 psig 7 bar g inlet 100 deg F 38 deg C ambient Frame Size Compressor Type Compliant Scroll 1 1 2 3 3 3 2 2 1 1 2 60 60 250 325 60 60 850 1000 SRC 400 SRC 325 SRC 250 SRC 1000 SRC 850 SRC 700 SRC 500 Control Type Expansion Device Capillary Tube 2 Micro processor Part Sullair 1 1 2 Voltage SRC 150 150 700 3 Thermostatic Valve 400 500 1 60 Analo...

Page 7: ...lbs 1 8 kg Refrigerant Capillary Tube Coolant Temperature at tank outlet Discharge Temperature Suction Temperature Fan Pressure Switch Coolant Pump Power Consumption Fan Power Consumption Compressor Power Consumption 8 3 A 1 3 A 1 1 A 0 77 A 0 63 A 0 13 A 6 9 A 0 57 A 0 15 A 50 F 10 C 113 F 45 C 34 7 F 1 5 C 0 47 A 42 Glycol 58 Water Freezing Point 13F 140 F 60 C 143 6 F 62 C 122 F 50 C 406 psig 2...

Page 8: ...3 42 5 1080 32 5 826 335 152 SRC 200 28 5 723 42 5 1080 32 5 826 335 152 SRC 250 29 0 737 52 1 1323 42 3 1074 562 255 SRC 325 29 0 737 52 1 1323 42 3 1074 562 255 SRC 400 29 0 737 52 1 1323 42 3 1074 591 268 SRC 500 29 0 737 52 1 1323 42 3 1074 591 268 SRC 700 29 0 737 72 6 1844 55 3 1405 895 406 SRC 850 29 0 737 72 6 1844 55 3 1405 970 440 SRC 1000 29 0 737 72 6 1844 55 3 1405 970 440 Model Page ...

Page 9: ...wflow Demister Separator C where the condensate is separated from the air The condensate collects in the Condensate Chamber D before being discharged from the system by a condensate drain not shown The air passes back through the Air to Air Heat Exchanger where it is reheated by the incoming air before leaving the dryer The Coolant Circuit Consisting primarily of B Air to Coolant Heat Exchanger E ...

Page 10: ...into a single compact 4 in 1 unit combining the Air to Air Heat Exchanger the Air to Coolant Heat Exchanger a Slowflow Demister Separator and a Condensate Chamber into a single component patent pending This combined component performs the functions of cooling the incoming air to the desired temperature using first the cold outgoing air and then the coolant as well as separating the liquid form the...

Page 11: ...s Heat Exchanger is part of both the air and coolant circuits 3 1 3 Demister Separator All models are equipped with a Slowflow demister type moisture separator to remove the condensed liquids from the compressed air The liquid droplets impact the stainless steel fibers of the demister and coalesce into larger drops where they are pulled into the Condensate chamber by gravity The demister combines ...

Page 12: ...sate Drain Valve Details of Condensate Drain Operation are covered in Section 9 3 2 The Coolant Circuit The Coolant Circuit consists of the Air to Coolant Heat Exchanger described in 3 1 2 above as well as the Coolant to Refrigerant Heat Exchanger which is mounted inside the Coolant Tank and the Coolant Re circulation Pump The Coolant Circuit is pre filled and pressurized with a 58 Water 42 Glycol...

Page 13: ...to the significant mass of cold material to absorb this heat the temperature rises very slowly The controls of the SRC dryer monitor the temperature of the Coolant in the Coolant Tank and allow it to fluctuate between an upper and lower limit When the temperature of the Coolant reaches the upper limit it turns the Refrigerant Compressor on and the resulting cooling effect in the Coolant to Refrige...

Page 14: ...otected and thermally isolated the exchange of heat between the evaporator and the surrounding coolant further improves the efficiency and the space saved means that the already compact dimensions of the dryer are reduced even further On the SRC 150 through 500 the evaporator is a coaxial tube design The outer tube is made of PVC to allow it to expand without damage in the case of a system upset c...

Page 15: ... improved insulation and efficiency An air bleed valve at the top of the tank and a drain valve at the bottom are fitted as standard An expansion vessel and safety valve are fitted as standard ensuring safety of operation The tank does not form part of the dryer s structural framework and is therefore easily removable in the unlikely event it needs to be substituted offering an important maintenan...

Page 16: ... main components of the refrigeration circuit are the Compressor the Condenser the Refrigerant Filter the Expansion Device and the Coolant to Refrigerant Heat Exchanger Evaporator as described in 3 2 2 above In addition there are several control components High Pressure Switch to shut down the dryer in the event of overpressure of the refrigerant system Low Pressure Switch SRC 250 to 1000 to preve...

Page 17: ...t causing it to condense back to a liquid All models are offered with an air cooled condenser which uses ambient air as the cooling medium The condenser comprises one or more finned coils copper pipes aluminium fins across which air is blown by one or more axial fans The axial fans are supplied with external rotor electric motors and die cast aluminium blades complete with protection grilles On th...

Page 18: ...ides a specific pressure drop and choked flow rate The SRC 700 to 1000 use a thermostatic expansion valve The valve adjusts the flow of refrigerant entering the evaporator to maintain a specific superheating When the superheating increases the valve opens to allow more refrigerant to enter the heat exchanger When the superheating decreases the valve closes to reduce the amount of refrigerant getti...

Page 19: ... shut down the dryer in the event of low pressure at the compressor inlet as this indicates a refrigerant temperature below freezing The microprocessor has a delay of 5 minutes before going into alarm When this 5 minutes has passed the display will show the LP Low Pressure alarm and the remote alarm contacts will be activated The switch automatically resets when the pressure returns above 36 2 psi...

Page 20: ...SRC Service Manual Revision 02 Aug 2007 3 4 Physical Arrangements 3 4 1 SRC 150 to 200 3 4 2 SRC 250 to 500 Page 19 of 56 ...

Page 21: ...SRC Service Manual Revision 02 Aug 2007 3 4 3 SRC 700 to 1000 Page 20 of 56 ...

Page 22: ...ph 60Hz 10 on SRC 125 through 250 230V 3ph 60Hz 10 on SRC 250 460V 3ph 60Hz 10 on SRC 250 through 1000 575V 3ph 60Hz 10 on SRC 250 through 1000 4 2 Controls on the SRC 150 to 200 The SRC 150 to 200 use an analog controller It features the following functions Dryer on off switch Dryer on signal green lamp Alarm signal red lamp Dew point indicator o green dew point ok o red high dew point o blue ris...

Page 23: ...xternal Modbus RTU protocol compatible system by installing an optional RS 485 communication port See Section 10 5 for further information The electrical panel is located inside the dryer and positioned for easy access It is directly accessible from the front via a hinged door with a door lock integrated into the dryer s main switch The power section comprises a main isolator switch protection aga...

Page 24: ... 3 3 Electrical Specifications Power Supply 24 Vac 20 Temperature Sensor B1 B2 Reading Range 10o C to 90 C 1 C Input for High Low Pressure Remote On Off 24 Vac Output for Drain Level Sensor 5Vc c 15mA Output to KM1 YV1 KA2 Vmax 30Va c Imax 1A Output for Alarm Warning Vmax 30Va c Imax 1A 4 3 4 User Interface On Off Switch Energy Saving Indicator Digital Display Control Buttons The main control pane...

Page 25: ...dicates the dryer has a warning or alarm Drain LED o Green indicates the drain valve is open Alarm Reset Up Drain Test Exit Alarm LED Drain LED Power LED Alarm Report Down On Off Enter Energy Saving LED o Green indicates that the parameters for cycling the refrigerant compressor off have been met The refrigerant compressor is currently off and the dryer is therefore saving energy Page 24 of 56 ...

Page 26: ... next alarm or item o In Parameter Menu Scrolls down to previous parameter or decreases a value when modifying a parameter Drain Exit o Standard Function Manually operates the drain valve according to timed mode settings See Section 8 5 o In Alarm Menu Exits the current alarm item or menu o In Parameter Menu Exits the current parameter or menu On Off Enter o Standard Function Turns the dryer on an...

Page 27: ... 3 Amps Connect the inlet and outlet compressed air piping connections to the dryer using the correct ports as indicated on the dryer Install a bypass line around the dryer and inlet and outlet isolation valves so that maintenance or calibration operations can be carried out without interrupting the downstream compressed air supply Do not flow air through the dryer when it is OFF Open they bypass ...

Page 28: ...ical products which may be aggressive against the aluminium heat exchanger or the other components inside the dryer Take particular care with sulphur ammonia chlorine and installations in marine environments Protect the dryer from instantaneous or continuous flows in excess of the dryers maximum rated capacity This may require installation of a down stream air receiver Ensure the drain outlet is f...

Page 29: ...erted the compressor and the fan will rotate in the wrong direction In this case a The scroll compressor is not displacing any refrigerant It will be noisy and the dryer will vibrate Since the dryer is not producing any cooling effect after 15 minutes the Hd High dew point warning will come on b The fan is moving air in the wrong direction This can be verified by comparing the air flow to the air ...

Page 30: ...ed on To turn the dryer ON press the ON OFF button or provide the command via an external control system The display will show the B1 dewpoint temperature sensor reading and the refrigerant compressor will turn on To turn the dryer OFF press the ON OFF button or provide the command via an external control system The display goes off and the refrigerant compressor stops The dryer can also be turned...

Page 31: ...0 15 B1 ID Number in Modbus Network 1 200 1 B2 Serial Communication Speed baud 1200 19200 9600 B3 Reset Service Required Warning 0 no 1 yes 0 no B8 Service Required Warning Interval hrs x 103 1 999 6 D1 Drain Duration Time open sec 1 60 5 D2 Drain Interval Time closed sec 1 900 120 D3 Drain Operation Mode CAP Con TIM Parameters B3 B8 are passcode protected and cannot be changed or reset without th...

Page 32: ...ode Contact Sullair for further information Note that once inside the parameters menu the meaning of the buttons is different from the standard operation See section 3 2 It is not possible to Turn the dryer On or Off Reset a warning or alarm Display the alarm report Activate the drain valve Once in the parameters menu if the user does not press any button for 5 minutes the controller will exit the...

Page 33: ...0 15 A8 Low Dewpoint Alarm Setting o C 9 9 10 0 B4 Reset Working Hours 0 no 1 yes 0 no B5 Coolant Tank Temperature o C o F B6 Disable Access to Factory Parameters 0 no 1 yes 0 no B7 Reset Alarm Report 0 no 1 yes 0 no C1 Coolant Temperature Setting o C 9 9 70 1 C2 Coolant Temperature Differential o C 0 30 1 C3 Compressor OFF Time Delay sec 0 600 1 C4 Immediate Compressor OFF Temp o C 9 9 15 0 5 C5 ...

Page 34: ...e Setting o C 9 9 70 0 1 0 C2 Coolant Temperature Differential o C 0 0 30 0 1 0 C3 Compressor OFF Time Delay sec 0 600 1 C4 Immediate Compressor OFF Temp o C 9 9 15 0 0 5 C5 Software Version d t 1 d t 1 d t 1 C6 Compressor ON Time Delay sec 0 900 60 The compressor is turned ON when the Coolant Temperature B5 reaches 2o C Coolant Temperature Setting C1 Coolant Temperature Differential C2 0 1 2 3 Te...

Page 35: ...mperature at which the compressor is turned off immediately even in the Compressor Off Time Delay C3 has not passed Default 0 5o C 2 C5 Software Identifier The software installed on the dryer designates cycling software 3 C6 Compressor ON Time Delay This is the minimum time between consecutive starts Default 60 seconds Page 34 of 56 ...

Page 36: ...rain by the microprocessor on the dryer Factory Parameters D4 through D8 control the operation to ensure zero air loss operation Note Factory Parameters are locked and should NOT be adjusted Parameters Units Min Max Default D4 Drain Open Delay sec 0 900 60 D5 Drain Close Delay Normal Cycle sec 0 120 5 D6 Drain Close Delay Extended Cycle sec 0 300 10 D7 Extended Cycle Interval 0 900 100 D8 Drain Al...

Page 37: ...drE flashes on the display and the microprocessor automatically changes to timed operation in accordance with the interval and duration settings in User Parameters D1 D2 When the Level Sensor stops sensing liquid the microprocessor will automatically change back to zero air loss operation If desired the user can force the drain on the SRC 400 through 1000 to always operate in timed mode or they ca...

Page 38: ...roprocessor would get no signal to open and would keep the valve closed permanently Note that when the drain is set to Continuous Deactivated Mode the drain solenoid valve must be removed and an external self controlled condensate drain must be installed The external drain can be powered through the board output NO3 24V or directly from the electrical cabinet 9 5 Manual Drain Activation When set i...

Page 39: ... Mode Dewpoint Temp Sensor Error B1 Warning Immediate Service Required Warning Immediate The control board is provided with an alarm relay with NO NC contacts The relay is normally energized once the controller is powered in order to provide an alarm indication when a fault happens or when power is disconnected When the controller gets a signal to indicate an alarm or warning it cuts power to the ...

Page 40: ...t to bend the fins 3 The condenser fan is not coming on because of a failure of the fan motor contacts or pressure switch Can be confirmed by checking the condensing pressure with a gauge Remedy Replace the detective component 4 Excessive thermal load on the dryer due to excessive air flow rate and or air inlet temperature Can be confirmed using the instructions in Section 13 Remedy Improve the ef...

Page 41: ...harge the dryer with the correct amount of refrigerant as specified in the Section 2 3 2 A defective low pressure switch is giving a wrong signal to the controller Can be confirmed by checking the evaporator pressure with a gauge Remedy Replace the detective component 3 The coolant pump is not coming on and therefore not circulating coolant through the evaporator The lack of thermal load and there...

Page 42: ...oling of the refrigerant Remedy Replace the defective component 3 The dewpoint temperature sensor B1 is out of calibration causing a low reading This can be confirmed by using a temperature gun to check the temperature at the location of the dew point probe and comparing it to what the probe is reading Remedy Replace the defective component 4 The coolant temperature sensor B2 is out of calibration...

Page 43: ...ing Light alternates between Hd and the dewpoint reading on the digital display Possible Causes Remedies 1 High ambient temperature in the compressor room due to a Warm weather b Poor compressor room ventilation c Poorly located dryer restricted air flow through the condenser d Compressor aftercooler is exhausting warm air near the dryer Remedy increase ventilation to the compressor room duct the ...

Page 44: ...being adequately cooled Remedy Check or leaks at welds threaded connections schrader valve caps and joints of the condenser and evaporator Repair the leak pull the system to deep vacuum and charge the dryer with the correct amount of refrigerant as specified in the Section 2 3 6 Scroll compressor is rotating backwards because the phases are inverted In this case the compressor does not compress th...

Page 45: ...uated efficiently and is backing up in the heat exchanger Remedy Find the cause of the blockage restriction or back pressure and fix it 2 Defective condensate level sensor gives a signal indicating condensate is present even if there is none Remedy Replace the defective component 3 Defective condensate drain valve Remedy Replace the defective component To Reset Drain will automatically return to C...

Page 46: ... than the Service Required Warning Interval Parameter B8 Default 6000 hours without service or inspection What it does Cuts power to the alarm contacts Turns on Warning Light alternates between Sr and the dewpoint reading on the digital display To Reset Press ALARM RESET Power restored to alarm relay Warning Light goes off for 24 hours To reset the alarm for another 6000 hours contact Sullair or y...

Page 47: ...recommendations This may lead to compromised performance higher operating costs and eventual failure of the equipment For this reason the procedures presented below are intended ONLY for authorized factory and distributor service technicians 10 3 1 How to Reset the Service Required Sr Warning 1 Press the Alarm Reset Alarm Report buttons simultaneously to access the User Parameter Menu The display ...

Page 48: ... you it s value is 6 6000 hours The value cannot be changed by pressing the Up or Down buttons 4 Press the Up Enter buttons simultaneously for 5 seconds This unlocks the parameter so it can be modified or 5 Press the Up or Down buttons to change it s value min 1000 hours max 999 000 hours 6 Press Enter to save your changes and exit the parameter The display will show you are at Parameter B8 Press ...

Page 49: ...Report Button for 3 seconds The alarm records are displayed starting from the oldest If there are alarms or warnings recorded the display will shows ALx where x is the number of alarms recorded up to a maximum of 8 If there are no alarms or warning recorded the display temporarily shows three dashes To scroll through the alarms and warnings press the Up or Down Buttons AL1 indicates the most recen...

Page 50: ... System To do so an optional RS485 serial card is fitted to the back of the microprocessor This allows direct connection to a BMS using the MODBUS RTU protocol without the need for any intermediate Gateway Once connected to the BMS it is possible to achieve Visualization of Dew point other temperatures Alarms Working hour counters Control of Dryer on off Alarm reset if allowed Page 49 of 56 ...

Page 51: ...heck for presence of oil stains indicating a refrigerant leak X Blow compressed air backwards through the condenser coils condenser pre filter to clean them Use steam to remove oily deposits X Clean the condenser filters when dryer is installed in dirty and dusty places X Clean the condensate strainer prior to the condensate drain valve X Check the current drawn is within the limits specified for ...

Page 52: ...copper gasket to guarantee a seal Place the gasket inside the switch connection with a drop of oil or grease to keep it in position while screwing the switch onto the valve 12 2 Replacing the Thermostat SRC 1 Open the electrica 50 to 200 l cabinet and remove the old onnectors compressor thermostat from its housing Remove the three green c output temperature sensor electrical supply from the old th...

Page 53: ...l not to damage it Electrical supply digital input output connections Level sensor connection Temperature sensor connections Unscrew the six screws holding the board in place Replace the old board with the new one Reinstall the temperature sensors wires in the same locations 12 4 Replacing the Drain Valve Loosen the 3 piece union Unscrew the electrical connector Remove the fixing nut Remove the ol...

Page 54: ...e coolant don t dispose of it Coolant tank capacities are cated in Section 2 3 The total amount of coolant in the circuit is approximately 5 to 10 above tank capacity Coolant is 42 glycol 58 water Proper tools may be required to verify the correct mixture if coolant is being added Remove the coolant from the charge discharge port on the bottom of the coolant tank Remove the old pump by disconnecti...

Page 55: ...highest points of the coolant circuit 1 At the top of the coolant tank and 2 At the top of the coolant piping coming from the air to coolant heat exchanger Close the vent valves and pressurize the coolant circuit to approximately 15 22 psig 1 1 5 bar g using a hand pump or other device Page 54 of 56 ...

Page 56: ...rst case scenario Do not use simply the instantaneous or average values If the operating parameters only exceed the maximum capacity of the dryer by a relatively small amount often the dryer will continue to operate however the outlet dewpoint will rise However if conditions greatly exceed the dryer s maximum capacity it will eventually reach a point where the dryer cannot reject all the heat it i...

Page 57: ...around noon his SRC 400 shows an Hd High Dewpoint alarm You ask him to confirm the actual operating conditions when the alarm occurs and after consulting with his plant manager he tells you the following Air Flow cfm 300 cfm Ambient Temperature o F 100 o F Inlet Air Temperature o F 120 o F Inlet Air Pressure psig 125 psig Using the above correction factor tables you quickly find the three Correcti...

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