Hydrovane Refrig Dryer HV04!05!07 Англ.Яз 2005

C OMPRESSED AIR D RYERS
R10 for V4-7.5KW
M AI N TE N A NC E A ND O P E R A TI N G M AN U A L
C OMPRESSED AIR D RYERS
MAINTENANCE AND OPERATING MANUAL

- Table of Contents
TABLE OF CONTENTS
TABLE OF CONTENTS....................................................................................................................1
Chapter 1
GENERAL INFORMATIONS.............................................................................................................3
1.1
Summary of possible configurations ........................................... 4

Chapter 2
SAFETY...........................................................................................................................................5
2.1
2.2
General ........................................................................................ 5
General precautions ..................................................................... 5
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.3
Compressed gases to be dried ............................................................. 5

Precautions when using compressed air ............................................. 5
Lifting and transport precautions ........................................................ 6
Precautions during installation and operation .................................... 6
Maintenance and repair precautions ................................................... 6
Refrigerant gases ......................................................................... 7

2.3.1 R134a safety card ................................................................................ 8
Chapter 3
TECHNICAL DATA .......................................................................................................................11

3.1
3.2
Data plate and meaning of abbreviations .................................. 11

Performances ............................................................................. 12
Chapter 4
DESCRIPTION ...............................................................................................................................13
4.1
4.2
Operating principle.................................................................... 13
Air and refrigerant circuits ........................................................ 13
4.2.1 Compressed air circuit ....................................................................... 13
4.2.2 Refrigeration circuit .......................................................................... 14
Chapter 5
INSTALLATION .............................................................................................................................15
5.1
5.2
5.3
Positioning................................................................................. 15
Piping......................................................................................... 16
Electrical connections................................................................ 17
Chapter 6
START UP .....................................................................................................................................19
Chapter 7
ELECTRONIC CONTROL ..............................................................................................................21
R10
7.1
Buttons and Leds....................................................................... 21

7.1.1 LED .................................................................................................... 21
7.1.2 Buttons ............................................................................................... 21
7.2
7.3
7.4
7.5
7.6
7.7
7.8
Temperature Probe .................................................................... 22

Starting the unit ......................................................................... 22
Thermostat function .................................................................. 23
Compressor delay...................................................................... 23
Condensate discharge................................................................ 23
Access to electronic board programming.................................. 24
Programming Procedures .......................................................... 25
7.8.1 PROG TON Procedure ...................................................................... 25
7.8.2 PROG RLE Procedure ...................................................................... 26
7.8.3 PROG HA1 Procedure ...................................................................... 27
7.9
Alarms ....................................................................................... 28
Chapter 8
CONDENSATE DISCHARGE SYSTEM ............................................................................................29

8.1
Timed condensate discharger.................................................... 29

8.1.1 Filter cleaning ................................................................................... 29
8.1.2 Solenoid valve maintenance .............................................................. 30
8.2
Intelligent condensate drain ...................................................... 31

Chapter 9
GENERAL OPERATING AND MAINTENANCE REGULATION ........................................................33

9.1
9.2
Operation................................................................................... 33
Maintenance .............................................................................. 33
9.2.1 Dryer access ...................................................................................... 33
9.2.2 Inspection and maintenance schedule ............................................... 34
Chapter 10
TROUBLE SHOOTING ...................................................................................................................35

Chapter 11
LIST OF ATTACHMENTS ..............................................................................................................39
R10
Chapter 1 - General informations
CHAPTER 1
GENERAL INFORMATIONS
The units described in this manual are called dryers.
They are designed to dry a compressed gas flow.
These dryers are equipped with a refrigeration circuit for cooling the compressed air to the
temperature called dewpoint under pressure.
In most applications the gas to be dried is the compressed air and this is why this term will
be used even if the gas to be dried is different. Furthermore, the term pressure will be used
to indicate the relative pressure.
The following symbols are shown on the stickers on the unit as well as on the dimensional
drawings and refrigeration circuits in this manual.
Their meaning is the following:
SYMBOL
DESCRIPTION
Air inlet in the unit
Air outlet from the unit
Condensate discharge
Cooling air flow (for aircooled units)
Direction of fan rotation (for

air cooled units)
Electric shock risk
Direction of the refrigerant gas

flow
Table 1
R10
SYMBOLS
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 original spare parts when
carrying out routine maintenance or repairs.
For all INFORMATION or requests for SPARE PARTS concerning the dryer please contact
your distributor or the nearest service centre, providing the SERIAL NUMBER and TYPE of
the unit shown on the data plate as well as on the first page of this manual.
1.1
Summary of possible configurations

The configuration of the unit to which this manual is attached was established in the
quotation.
The following table helps users to understand some of the descriptions contained in this
manual ( Chapter 6, Chapter 9) wherever it is necessary to precisely establish the
characteristics that differentiate a determined dryer from another.
This table shows all the possible configurations for each model and must therefore be
interpreted using both the quotation data and the drawings attached to this manual.
For example, a dryer with a power input of both 50 and 60 Hz cannot exist.
Characteristic
Power supply
Electr. board
units at 50 Hz
Electr. board
units at 60 Hz
Condensate
discharge
Alternative
Single phase at 50 Hz
Single phase at 60 Hz
R10
x
x
Easycard
Easycard
Timed discharge system

Intelligent discharge system
x
x
Table 2
SUMMARY OF POSSIBLE CONFIGURATIONS
R10
Chapter 2 - Safety
CHAPTER 2
SAFETY
ATTENTION
This unit has been designed to be safe when used for the purpose for which it was intended
provided it is installed, started up and serviced in accordance with the instructions
contained in this manual.The unit contains electrical components operating at mains voltage
as well as moving parts, such as fans. It must therefore be disconnected from the mains
supply network before being opened.All maintenance operations which require the unit to be
opened may only be carried out by expert or sufficiently trained people with a perfect
knowledge of the necessary precautions and directed by a qualified supervisor, wherever
possible.
2.1
General
The user should make sure that all the personnel connected with operating and
servicing the dryer and auxiliary equipment have read and understood all the
warnings, cautions, prohibitions and notes indicated both in this manual and on the
unit.
If the user makes use of operating procedures, instruments or methods of working which are
not specifically recommended, he must ensure that the dryer and auxiliary equipment will
not be damaged or made unsafe and that there are no risks to people or property.
2.2
General precautions
2.2.1
C o m p r es se d g as es t o b e d r i e d
Compressed gases to be dried should be compatible with the materials used to build the unit
(carbon steel, cast iron, copper and its alloys) and may be air, nitrogen, argon and helium,
for example.
In any case they must not cause corrosion dangerous for the pressure vessels and fire in
event of leakage.
2.2.2
P r e ca u t i o n s w h e n u si n g c o mp re s se d ai r
If using compressed air for cleaning purposes, make sure safety regulations are followed and
appropriate clothing and eye protection is worn.
Never direct compressed air towards your skin or other people.
Never use compressed air to remove dirt from clothing.
Before releasing compressed air through a hose make sure that the free end is held securely
so that it cannot whip and cause injury.
R10
2.2.3
Li f t i n g a n d t r a n sp o r t p re c au t i o n s
Make sure that all chains, hooks, shackles and slings are in good condition and are of the
correct capacity: they must be tested and approved according to local safety regulations.
Cables, chains or ropes must never be applied directly to eyebolts.
Arrange the lifting cables so that there are no sharp bends.
Use a spreader bar to avoid side loads on hooks and eyebolts.
While a load is being lifted, keep clear of the area beneath and around it.
Keep lifting acceleration and speed within safe limits and never leave a load hanging on a
hoist for longer than is necessary.
The units must be moved in accordance with the attached diagrams (please consult the final
part of this manual).
ATTENTION
The weights of the units are shown on their data plates and on the top side of the packaging.
2.2.4
P r ec a u t i o n s d u r i n g i n st al l at io n a n d o p e ra t i o n
For connections to the mains power supply, please see Chapter 5 Installation. and the
wiring diagrams.
All piping must be painted or clearly marked in accordance with local safety regulations.
Never remove or tamper with the safety devices, guards or insulation material fitted to the
unit or auxiliary equipment.
The unit and auxiliary equipment must be earthen and protected by fuses against shortcircuits and overloading.
When mains power is switched on, lethal voltages are present in the electrical circuits and
the greatest of care must be taken whenever it is necessary to do any work on the electrical
system.
Do not open any electrical panels while voltage is applied unless this is necessary for
measurements, tests or adjustments.
This job should only be carried out by a qualified electrician equipped with the proper tools
and wearing appropriate personal protection equipment against electrical hazards.
2.2.5
M ai nte na nce and r ep ai r pr ec aut ion s
When disposing of parts and waste material of any kind take care not to pollute drains or
water-course.
Do not burn any waste which could cause air pollution.
Protect the environment by using approved storage methods.
If replacement parts are needed always use original spares.
Keep a written record of all maintenance and repair work carried out on the unit and
auxiliary equipment.
The frequency and the nature of the work required over a certain period may give rise to
adverse operating conditions which should be corrected.
Use only refrigerant gas specified on the data plate of the unit.
Make sure that all operating and maintenance instructions are strictly followed and that the
complete unit, with all accessories and safety devices, is kept in good working order.
R10
Chapter 2 - Safety
Regularly check the accuracy of pressure and temperature gauges.

Replace them when acceptable tolerances are exceeded.
Keep the machine clean at all times.
During maintenance and repair work, protect components and exposed openings by covering
them with clean cloths.
Precautions must be taken when carrying out welding or other repair operations which
generate heat, flames or sparks.
Always protect nearby components with non-flammable material.
Never carry out welding or other repair operations which generate heat close to a component
containing oil.
Before carrying out these operations the systems must first be thoroughly purged and
cleaned, preferably by steam cleaning.
Never weld or otherwise modify a pressure vessel.
To prevent increases in working temperatures and pressures, inspect and clean the heat
transfer surfaces (e.g. condenser cooler fins) at regular intervals.
Prepare a suitable cleaning schedule for each unit.
Never use a light source such as a naked flame to inspect the inside of the unit.
Before dismantling any part of the unit ensure that all heavy movable parts are secured.
After completing a repair, make sure no tools, loose parts or rags are left inside the machine.
Check the direction of rotation of electric motors when starting up the unit for the first time
and after any work on the electrical connections or switch gear.
Put back all guards after carrying out repair or maintenance work.
Do not use flammable liquid to clean components while the unit is working.
If non-flammable chlorinated hydrocarbon fluids are used for cleaning, safety precautions
must be taken against the release of toxic vapours.
Before removing any panels or dismantling any part of the unit, carry out the following
operations:
2.3
Disconnect the power cable of the unit from the mains electricity supply.
Attach a warning label reading: WORK IN PROGRESS - DO NOT SWITCH
ON.
Do not switch on the mains electricity supply or attempt to start the unit if a
warning label is attached.
Refrigerant gases
Only R134a is used as refrigerant in these dryers.
The manufacturer's instructions and local safety regulations should always be observed when
handling and storing refrigerant gas cylinders.
R10
2.3.1
R 13 4a sa fe ty c ar d
PHYSICAL AND CHEMICAL PROPERTIES
Name:
R134a (1,1,1,2 - tetrafluoroethane)
Colour:
Colourless
Odour:
Similar to ether
Boiling point:
-26.5C / -15.7F at atmospheric pressure
Flammability:
Non-flammable
Relative density:
1.21 kg/l at 25C / 77F
Water solubility:
0.15% in weight at 25 C / 77F and atmospheric pressure

STABILITY AND REACTIVITY
Stability:
No reactivity if used in compliance with the instructions
Substances to be avoided:
Alkaline metals, alkaline-earth metals, granulated metal salts,

Al, Zn, Be, etc. in powder form
Dangerous decomposed
products:
Halogens acids, carbonyl halide traces

TOXICOLOGICAL INFORMATION
Acute toxicity:
ALC/inhalation/4 hours/ on rat = 567 ml/l
Local effects:
Concentrations higher than 1000 ppm v/v may cause narcotic

effects. Inhalation of a high concentration of decomposing
products may cause respiratory problems (pulmonary oedema)
Long-term toxicity:
No carcinogenic, teratogenic or mutagenic effects shown

during tests on animals
Specific effects:
A rapid evaporation of the liquid may cause ice

ECOLOGICAL INFORMATION
Potential global heating

HGWP (R11=1):
0.28
Potential ozone
impoverishment ODP
(R11=1):
Disposal considerations:
Can be re-used after reprocessing

HAZARD INDICATIONS
Main hazards:
Asphyxia
Specific hazards:
Unknown
FIRST-AID PRECAUTIONS
Inhalation:
Take the patient outdoors. If necessary give oxygen or

artificial respiration. Never give adrenaline or similar
substances
Contact with eyes:
Rinse the eye thoroughly with water for at least 15 minutes.

Seek medical attention
Contact with skin:
Wash immediately with water. Remove contaminated clothing

FIRE PRECAUTIONS
Means of extinction:
Any one
Specific hazards:
Pressure increase
Specific methods:
Cool the containers by spraying water

Table 3
R134A SAFETY CARD
R10
Chapter 2 - Safety
PRECAUTIONS IN CASE OF ACCIDENTAL LEAKAGE

Individual precautions:
Evacuate personnel to safety areas. Proper ventilation is

required. Use personal protection equipment
Environmental precautions:
Evaporate
Cleaning methods:
Evaporate
HANDLING AND STORAGE
Handling:
Technical precautions: only use in ventilated areas.Safety

recommendations: leakage test. Do not carry out pressure tests
using an air/R134A mixture. When mixed with air it can
become a combustible at a higher than atmospheric pressure
when the volume ratio is higher than 60%
Storage:
Technical precautions/storage method: close carefully and

keep in a fresh, dry and well ventilated place
INDIVIDUAL EXPOSURE/PERSONAL PROTECTION
Control parameters:
1000 ppm v/v or ml/m3 as the weighted average over 8 hours
Respiratory protection:
For rescue operations and when carrying out maintenance

work on vessels suitable for R134A use an independent
breathing apparatus. Vapours are heavier than the air, and they
therefore could cause suffocation by reducing the oxygen
available for breathing
Protection for eyes:
Safety goggles
Protection for hands:
Rubber gloves
Hygiene protection:
Do not smoke
Table 3
R10
R134A SAFETY CARD
10
R10
Chapter 3 - Technical Data
CHAPTER 3
TECHNICAL DATA
3.1
Data plate and meaning of

abbreviations
The main technical data of the dryer are indicated on the data plate:
MODEL and CODE
The model number and the code identify the size of the
unit and the type of construction.
MANUAL
Code number of this manual.
SERIAL NUMBER
Serial or construction number of the unit.
YEAR OR CONSTRUCTION
Year in which final testing of the unit took place.
VOLTAGE/PHASE/FREQUENCY
Power supply characteristics.
MAX. CONSUMPTION (I max)
Current absorbed by the unit at limit working conditions

(refrigerant condensing temperature 70C = 158F;
refrigerant evaporating temperature 10C = 50F).
INSTALLED POWER (P max)
Power absorbed by the unit at limit working conditions

(refrigerant condensing temperature 70C = 158F;
refrigerant evaporating temperature 10C = 50F).
PROTECTION DEGREE
As defined by EN 60529 European standard.
REFRIGERANT
Type of refrigerant in the unit.
QUANTITY OF REFRIGERANT
Quantity of refrigerant contained in the unit.
MAX. COOLING PRESSURE
Rated pressure of refrigeration circuit.
MAX. COOLING TEMPERATURE
Rated temperature of refrigeration circuit.
USER CIRCUIT FLUID
Fluid cooled by the unit.
MAX. WORKING PRESSURE
Maximum rated pressure of user circuit.
MAX. TEMPERATURE
Rated temperature of user circuit; this should not be

confused with the maximum working temperature which
is defined in the quotation.
CONDENSER COOLING FLUID
Fluid used by the unit to cool the condenser (this data is

not present if the unit condenser is air cooled).
MAX. COOLING PRESSURE
Maximum rated pressure of the condenser cooling

circuit (this data is not present if the unit condenser is air
cooled).
MAX. TEMPERATURE
Max. rated temperature of the condenser cooling circuit

(this data is not present if the unit condenser is air
cooled).
SOUND PRESSURE LEVEL
Free field sound pressure level in hemispherical

irradiation conditions (open field) at a distance of 1 m
from the unit, condenser side, and 1.2 m from the
ground.
AMBIENT TEMPERATURE
Min. and max. temperature of cooling air.
WEIGHT
Approximate weight of the unit before packing.

Table 4
R10
DATA PLATE AND MEANING OF ABBREVIATIONS
11
12
The following abbreviations are present on the data plate and wiring diagram:
3.2
IMAX
max. current;
PMAX
max. power;
ILR
current with rotor stopped;
In
rated current;
Icn
rated failure current.
Performances
ATTENTION
The performance of the dryer (dew-point, electrical power consumption, pressure drops,
etc.) mainly depends on the flow rate and pressure of the compressed gas to be dried and on
the temperature of the ambient air to cool the condenser.
These dryers are matched to the following air compressors and should not be used with
any other type or model:
R10: Hydrovane HV04, HV05, HV07 and HV07RS.
Refer to the relevant CompAir technical data sheet for further information.
R10
Chapter 4 - Description
CHAPTER 4
DESCRIPTION
4.1
Operating principle
A refrigeration circuit reduces the temperature of a patented thermal mass through which
the humid compressed air to be dried is passed.
As the air is cooled its water vapour condenses and is then separated and drained.
The temperature of the thermal mass is controlled by an electronic board which stops the
compressor when it reaches the fixed set point.
4.2
Air and refrigerant circuits

(See attached refrigerant drawings)
4.2.1
C om pr es se d ai r ci r cu it
The warm, wet compressed air enters the dryer and passes through the air-to-air heat
exchanger section of the thermal mass.
Here it is pre-cooled by the cold, dry compressed air leaving the air-to-refrigerant heat
exchanger section or the evaporator of the thermal mass.
The pre-cooled air then enters the evaporator section of the thermal mass where it is cooled
(in most applications to a temperature of approximately 3C / 37.4F) exchanging heat with
the evaporator refrigerant fluid and the silica thermal mass.
The heat is exchanged by conduction through the aluminium fins connecting the copper
tubes, inside which the compressed air flows, to the copper tubes, inside which the
refrigerant fluid evaporates.
The aluminium fins also exchange heat with the silica thermal mass keeping it at a
temperature of approximately 0C (32 F).
At this stage, the compressed air is in a saturated state and entrains the condensed moisture
produced during cooling.
It then passes into the high efficiency condensate separator (demister type with stainless
steel mesh) where the entrained moisture is precipitated out of the air and collects at the
bottom of the separator.
A timed or intelligent condensate discharger (depending on the unit configuration) opens at
intervals to force the condensate from the dryer with compressed air.
The cold, dry air leaving the separator then flows for a second time through the air-to-air
heat exchanger section of the thermal mass where it is reheated while pre-cooling the warm
wet air entering the dryer.
Not only does this air-to-air heat exchanger reduce the energy consumption required to dry a
given quantity of compressed air, but it also prevents condensation from forming on the
dryer outlet.
R10
13
14
4.2.2
R efr i g e r at i o n c ir c u i t
The compressed refrigerant gas flows to the condenser.

Here the cooling action causes the refrigerant gas to condense to a liquid.
The condenser is a finned coil heat exchanger cooled by a flow of air provided by one or two
electrically driven fan, according to the model,.
The condenser is generously sized in order to be partially used as a liquid receiver.
The cooling air enters the side grills, passing through the air filters (which can be removed)
and exits from the front side of the dryer.
After the condenser, the liquid refrigerant then passes through a filter-dryer to a capillary
tube which reduces its pressure in order to lower its boiling point.
The refrigerant then enters the evaporator tubes in the thermal mass and cools both the
thermal mass and the compressed air.
The refrigerant leaving the evaporator is now a cold vapour and returns to the compressor to
repeat the cycle.
Since the heat of the compressed air available to evaporate the refrigerant varies
considerably due to fluctuations in the air flow rate and inlet temperature, the dryer features
an electronic system which controls the temperature of the thermal mass temperature,
thereby achieving 3 important objectives:
to ensure that the dew-point under pressure is maintained at a constant value of
approximately +3C (+37.4F);
to prevent the compressed air temperature from falling below 0C (32F), a temperature at
which the condensed moisture could start to freeze;
to ensure that all the refrigerant leaving the evaporator is in the form of a vapour so that no
liquid refrigerant returns to the compressor.
When there is little or no load, the temperature in the thermal mass tends to fall.
At 0C (32F), the electronic board switches off the refrigerant compressor.
The compressed air that continues to flow in the evaporator is cooled by the cold energy
stored in the silica.
When the temperature of the latter eventually starts to increase, the refrigerant compressor is
automatically switched back on to cool it down again.
This system has the advantage of reducing the average energy consumption of the dryer
roughly in proportion to the demand.
R10
Chapter 5 - Installation
CHAPTER 5
INSTALLATION
DANGER
Before installing or operating these dryers, make sure that all personnel have read and
understood Chapter 2 Safety of this manual.
5.1
Positioning
1. Install the compressor and dryer in a well ventilated area where the ambient air is
clean and free from flammable gas or solvents.
2. Take care when installing the compressor and dryer in areas subject to low ambient
temperatures.
Take steps to prevent any discharged condensate from freezing in the drainage
system.
The minimum operating ambient temperature of the dryer is shown on the data
table applied on the unit.
3. The dryer may be placed on any sufficiently strong and level surface.
Allow the clearances shown in the installation drawings around the unit for
servicing access and to ensure an unrestricted flow of cool air through the
refrigeration condenser.
Position the dryer so that cooling air cannot recirculate in the ventilation inlet
grilles.
Make sure that the dryer is not subject to warm air flows from the air compressor,
after-coolers or other pieces of equipment.
R10
15
16
5.2
Piping
(see installation diagram)
The dryer is normally supplied already fitted to the air compressor, in which case proceed as
follows:
1. Air outlet connections are clearly marked (see Chapter 1 General informations).
Pipes and connections must be of the correct size and suitable for working
pressure.
Do not forget to remove blanking plugs from the pipe connections but take care to
prevent swarf, metal filings, pieces of tape or other solid particles from entering
the dryer during installation as these may block the filter or the discharge valve.
2. All piping must be properly supported. Flexible connections are recommended
in order to prevent pipe stress or the transmission of vibrations.
3. Connect the condensate discharge pipe to a suitable point.
The dryer discharge must not be connected to those from any other compressed air
equipment; ideally it should discharge into a open funnel.
Condensate drainage must never be piped into a common sewer drain as it may
contain oil.
Oil/water separators should be used to collect discharged oil.
Make sure that the drainage system complies with local regulations.
If the dryer is not supplied already fitted to the air compressor, proceed as follows:
1. Air inlet and outlet connections are clearly marked (see Chapter 1 General
informations).
Pipes and connections must be of the correct size and suitable for working
pressure.
Do not forget to remove blanking plugs from the pipe connections but take care to
prevent swarf, metal filings, pieces of tape or other solid particles from entering
the dryer during installation as these may block the filter or the discharge valve.
2. All piping must be properly supported. Flexible connections are recommended
in order to prevent pipe stress or the transmission of vibrations.
3. Connect the condensate discharge pipe to a suitable point.
The dryer discharge must not be connected to those from any other compressed air
equipment; ideally it should discharge into a open funnel.
Condensate drainage must never be piped into a common sewer drain as it may
contain oil.
Oil/water separators should be used to collect discharged oil.
Make sure that the drainage system complies with local regulations.
4. Connect the air supply from the compressor to the dryer using the flexible
connector and condensate separator kit provided by CompAir.
R10
Chapter 5 - Installation
5.3
Electrical connections
ATTENTION
In order to prevent the possible damages at the fuse-holder and at the fuse, they were
uninstalled and they were placed into the paper-holder, to protect them from any
accidental hit.
Before to connect the unit to the main power supply, it is necessary to reassemble the
fuse into the fuse-holder, and reinstall it.
The machine must be connected to the mains power supply in accordance with the laws and
regulations in force in the country of installation.
Voltage, frequency and the number of phases must comply with the values indicated on the
machine data plate.
Input voltage must always remain within the tolerances indicated in the electrical diagram.
Unless otherwise indicated, frequency tolerance is equal to +/-1% of its rated value (+/-2%
for short periods).
The voltage must be supplied between the phase and neutral and the latter conductor must be
earthed in its own transformation cabin (TN system according to IEC 364) or by the
electricity provider (TT system according to IEC 364).
The phase and earth conductors must not be exchanged.
For mains power input:
1. Connect the machine (PE terminal in the electrical panel) to the earth system of the
building;
2. Fit an automatic interruption in the event of insulation faults (protection against
indirect contact according to IEC 364) by means of a residual current circuit
breaker (normally with a rated cut-in current of 0.03 A);
3. Provide protection against direct contact of at least IP2X or IPXXB upline from
the power cable;
4. Fit a device protecting the power cable or the cable supplied with the machine
from overcurrent (short-circuit) (see indication in the electrical diagram) upline
from the power cable;
5. Use conductors which can carry the maximum current required at the maximum
ambient operating temperature, according to the type of installation chosen (IEC
364-5-523) (see indication in the electrical diagram).
R10
17
18
Indications in the electrical diagram:

A Maximum permitted size of gG fuse.
Generally speaking, the fuses can be replaced with an automatic switch
adjusted to the maximum current absorbed by the machine (contact the
manufacture if necessary);
B Cross-section and type of power cable (unless already supplied):
installation: insulated conductors, ducted multi-pole cable, overhead or

attached to the wall (type C according to IEC 364-5-523 1983) or not in contact
with any other cable;
operating temperature: maximum ambient operating temperature of the unit;
type of cable: copper conductors, PVC insulation to 70C / 158F (unless
specified) or EPR insulation to 90C / 194F.
R10
Chapter 6 - Start up
CHAPTER 6
START UP
ATTENTION
Before starting up or operating these dryers be sure that all personnel have read and
understood the Chapter 2 Safetyof this manual.
1. If the unit is equipped with an intelligent condensate discharge system, check

that it is correctly installed.
2. Check that the ambient temperature is within the range indicated on the data plate
of the unit.
3. Check that the main switch on the dryer panel is in the O position.
4. Power the dryer by means of the line protection device.
5. Turn the main switch of the dryer to the I position.
6. When the unit is powered, one of the LEDs on the electronic board lights up (see
Chapter 7 Electronic Control).
7. After switching on the electronic board and the pre-set delay, the refrigerant
compressor starts working for several minutes.
8. The fan starts immediately together with the compressor.
9. Check that the compressor stops when the thermal mass reaches the set
temperature.
10.Switch on the air compressor.
The dryer is now ready for normal operation (see Chapter 9 General operating and
maintenance regulation).
R10
19
20
R10
Chapter 7 - Electronic Control
CHAPTER 7
ELECTRONIC CONTROL
7.1
Buttons and Leds

The unit starts working if it is
connected to the main power supply
and if the main switch IG is closed
(I).
In these conditions, if no alarm
signal is present and if the unit is not
in the parameter programming mode
(see paragraph 7.7 Access to
electronic board programming ), the
LEDs and the buttons will have the
following functions:
7.1.1
L ED
L GREEN
L2 N GREEN
L1
L3
J RED
Power on LED, lights up when the electronic board is powered;

Energy saving LED, lights up when the refrigerant compressor is
off;
Alarm LED, flashes when the dew-point is too high or when
there is a fault in the electronic board.
Table 5
7.1.2
P1
LED
B uttons
Button for activating the condensate discharge solenoid valve (if
the condensate discharge is of timed type); or programming
button.
Table 6
BUTTONS
During programming operations (see paragraph 7.7 Access to electronic board

programming ), the above LEDs and button have different functions.
R10
21
22
7.2
Temperature Probe
The electronic board features a temperature probe which is inserted into the thermal mass to
measure the dew-point temperature in order to control the thermostat (see paragraph 7.4
Thermostat function ).
The probe is protected to IP67 (including the cable) and features an NTC sensor with an
operating temperature range of -10 / +65C (+14 / +149F).
The resistance-temperature ratio must correspond to that described by the resistance values
(rated), expressed in k, indicated in the Table 7.
Temperature
0 C / + 32 F
+10 C / +50F
+20 C / +68 F
+25 C / 77 F
+ 30 C / + 86 F
Table 7
B1 probe resistance
values
27.28 k
17.96 k
12.09 k
10.00 k
8.31 k
PROBE FEATURES
In the event of damage, only replace with original CompAir probes.
7.3
Starting the unit

After making electrical connections, close (I) the main switch IG to start the unit.
LED L1
L , indicating that the board is powered, and LED L2 N , indicating that the
refrigerant compressor is off, both light up.

The unit starts working automatically according to the temperature measured by the probe,
respecting the thermostat function logic (see paragraph 7.4 Thermostat function ).
Please note: when the temperature measured by the probe reaches the value at which the
refrigerant compressor should start, it will only do so provided that the delay time set by
electronic control (see paragraph 7.5 Compressor delay ) has elapsed.
The compressor starting will be confirmed by LED L2
N switching off.
At unit starting, if it had been stopped for an extended period and if HA1 alarm (see
paragraph 7.8.3 PROG HA1 Procedure ) is enabled, LED L3
J (high dew point alarm)
could light up.

This could happen when the temperature measured by the probe at the beginning is balanced
with the ambient temperature, then it is 1C (1.8F) higher than HA1 high dew point alarm
threshold (see paragraph 7.8.3 PROG HA1 Procedure ).
The alarm signal should stop after a few minutes from refrigerant compressor starting (LED
L2 N off) when the temperature will decrease under HA1 threshold and LED L3 J will go
out.
If there is a power supply failure when the machine is working, the unit restart automatically
after power is restored following the process described above.
R10
7.4
Thermostat function
The thermostat function starts and stops the refrigerant compressor by comparing the value
measured by the probe with the SET (0C / 32.0F) and DIF (4C / 7.2F) values on the
electronic board.
The following graph illustrates the thermostat function operating logic.
When the compressor is enabled, it always starts after a timed delay set by the electronic
control (see paragraph 7.5 Compressor delay ).
The SET and DIF values of the thermostat function are fixed so they cannot be modified.
COMPR.ON
COMPR.OFF
Temperature measured
by the probe
SET
SET+DIF
The SET and DIF values of the thermostat function are fixed so they cannot be modified.
7.5
Compressor delay
The refrigerant compressor always starts with a delay of 120 seconds.
Therefore, even if the temperature measured by the probe is higher than SET+DIF and the
compressor start is called for, it cannot start until the delay time has elapsed, in the
following cases:
when the machine is switched on;

from when the compressor last stopped;
when the machine is powered again after an interruption while it was working.
ATTENTION
The compressor starting delay time (120 seconds) cannot be modified.
7.6
Condensate discharge
ATTENTION
The unit is furnished without a condensate discharge system.
The control board is set to use timed relay.
The electronic board is fitted with a relay for controlling condensate discharge.
It controls opening and closing of the solenoid valve.
Electronic board manages the condensate discharge relay in two different ways depending on
how the RLE parameter is set (see paragraph 7.8.2 PROG RLE Procedure ):
1. Relay permanently energised (if the condensate discharger is of intelligent
type):
The relay contact remains permanently closed (relay energised) and the P1
button has no function apart from programming.
R10
23
24
2. Timed relay (if the condensate discharger is of timed type):

The relay is energised every 120 seconds (TOFF) for a time equal to TON seconds.
When the machine is switched on, the cycle will always start with the energising
phase.
The following diagram illustrates the operating logic.
STATUS OF THE CONDENSATE
DISCHARGE RELAY
TON
TOFF
Energised
TON
Energised
De-energised
TIME
T=0 electronic board switching ON
TOFF (120 seconds) is fixed while TON is programmable.

For information on settings, please see paragraph 7.8.1 PROG TON Procedure .
With timed management of the condensate discharge relay, the solenoid valve may
.
energises the solenoid valve relay for as long as it is held down.
be manually controlled during unit operation by pressing button P1

P1
The manual control does not modify the current ON - OFF cycle.
Access to electronic board

programming
The Table 8 indicates information relative to the programmable control parameters.
The electronic board must be switched off before the programming mode can be accessed.
The machine remains inactive during the programming phase.
To programme a parameter (see Table 8):
Press the button indicated in the BUTTON/S column against the chosen parameter, power
the electronic board (turn on the main switch IG) and keep the button pressed down for the
time indicated in the HOLD TIME column.
The LED corresponding to the chosen parameter, indicated in the LED column of the Table
TON
RLE
opening time of
condensate
discharge
solenoid valve
condensate
discharge relay
mode
PROGRAMMING
PROCEDURE
LED
HOLD TIME
BUTTON/S
DESCRIPTION
8, starts flashing to confirm the programming mode has been accessed.
PARAMETER
7.7
P1
between 0
and 5 sec.
L2
see paragraph 7.8.1

PROG TON Procedure
P1
between 5
and 30 sec.
L1
see paragraph 7.8.2

PROG RLE Procedure
Table 8
TABLE OF PARAMETERS
R10
HA1
high temperature P1
alarm threshold
over 30 sec. L3
Table 8
PROGRAMMING
PROCEDURE
LED
HOLD TIME
BUTTON/S
PARAMETER
DESCRIPTION
see paragraph 7.8.3

PROG HA1 Procedure
TABLE OF PARAMETERS
DANGER
The above parameters must only be adjusted by qualified personnel and only in special
cases.
7.8
Programming Procedures
The tables in the following paragraphs indicate the possible programmable parameter
settings for each of the programming procedures of the electronic board.
Please note: the unit is normally supplied with all the control parameters pre-set for correct
operation (Please see the "FACTORY SETTINGS" attachment in the final part of this
manual).
7.8.1
P R O G T ON P r o c ed u r e
This procedure is only used if the unit has a timed condensate discharger.
It is used to set the solenoid valve ON time which manages the timed condensate discharge
(see paragraph 7.6 Condensate discharge ).
1. If the dryer is already switched on, it is necessary to switch off the electronic
board: operate on IG main switch putting it in open position (O);
2. While holding P1
button pressed, simultaneously switch on the electronic
board by putting IG main switch in closed position (I);
button pressed;
LED L2 N starts flashing, indicating correct
procedure: release P1 button;
Modify the parameter always using P1 button.
3. Keep P1
4.
5.
access to TON programming
The parameter can be modified within 5 seconds from programming procedure

access, otherwise the electronic board microprocessor automatically exits from the
programming phase.
The parameter value is shown by means of a combination of LED L1, L2 and L3
illumination.
With the first press of P1
button (within 5 seconds) the parameter value before
this procedure has been accessed is shown (see Table 9).

By pressing the P1
button as follows (within 5 seconds) the value shown can
be set (see Table 9).
R10
25
26
6. If the parameter value has been modified, it will be automatically stored 5 seconds
after P1
button has been released.
7. After storing the new parameter value, the electronic board microprocessor
automatically exits from the programming phase.
The unit will return to normal operation.
The association between the LEDs and solenoid valve time ON is shown in the following
table:
LED status
L1
OFF
OFF
OFF
L2
OFF
ON
ON
L3
Value
ON
OFF
OFF
3 seconds
6 seconds
12 seconds
Table 9
PROG TON
See the "FACTORY SETTINGS" attachment in the final part of this manual.
7.8.2
P R O G R L E P r o ce d u r e
It is used to set the operating modality of the condensate discharge relay (see paragraph 7.6
Condensate discharge ).
If the dryer is factory-fitted with intelligent condensate drain, this function will have been
pre-set, but follow these instructions in order to check it.
2. While holding P1
button pressed simultaneously switch on the electronic
button pressed for more than 5 seconds;

LED L2 N starts flashing, indicating access to TON programming procedure
(already described): continue to keep P1 button pressed;
LED L2 N goes out and LED L1 L starts flashing, indicating correct access to
RLE programming procedure: release P1 button;
3. Keep P1
4.
5.
6.

programming phase.
illumination.

With the following pressures of P1
button (within 5 seconds) the following
value can be set (see Table 10).

after P1
R10
The association between the LEDs and solenoid valve relay mode is shown in the following
table:
LED status
L1
L2
L3
Value
OFF
OFF
ON
OFF
ON
OFF
Timed relay (timed condensate

discharger)
Permanently energised relay
(intelligent condensate discharger)
Table 10
PROG RLE
ATTENTION
If Relay always energised mode is selected, TON programming (see paragraph 7.8.1
PROG TON Procedure ) is however possible but this parameters will not affect the
operation of the intelligent discharge system.
7.8.3
P R O G H A 1 P r o ce d u r e
It is used to set the high temperature alarm threshold:

2. While holding P1
button pressed, simultaneously switch on the electronic
button pressed for more than 30 seconds;

LED L2 N starts flashing, indicating access to TON programming procedure
(already desribed): continue to keep P1 button pressed;
LED L2 N goes out and LED L1 L starts flashing, indicating access to RLE
programming procedure (already described): continue to keep P1 button
3. Keep P1
4.
5.
pressed;
L goes out and LED L3 J starts flashing, indicating correct access to

button;
6. LED L1
HA1 programming procedure: release P1

7.

programming phase.
illumination.

With the following pressures of P1
button (within 5 seconds) the following
value can be set (see Table 11).

after P1
R10
27
28
The association between the LEDs and the high temperature alarm threshold is shown in the
following table:
LED status
L1
OFF
OFF
OFF
L2
OFF
ON
ON
Value
L3
ON
OFF
OFF
10 C / 50F
15 C / 59 F
Disabled
Table 11
PROG HA1
See the "FACTORY SETTINGS" attachment in the final part of this manual.
Alarms
L3 J
flashing
Temperature
probe
damaged or
faulty
L3
Fault in the
L3
electronic
board
microprocesso
r
J on
J on
NOTES
RESET
EFFECT
LED
High dewpoint
temperature
ACTIVATION
TIME
The electronic board manages the alarms listed in the following table:
ALARM
7.9
Instantaneou warning only automatic The alarm trips if the

s
temperature
measured is greater
than or equal to the
value of parameter
HA1+1C
(HA1+1.8F); it will
reset if the
temperature
measured returns
under the value of
parameter HA1 (see
paragraph 7.8.3
PROG HA1
Procedure ).
Instantaneou refrigerant
automatic A probe measuring
s
compressor
a temperature
stops
outside the -10/+65
C (+14 / +149F)
range may be
considered as faulty.
Instantaneou refrigerant
automatic If the alarm
s
compressor
reappears after the
stops
machine has been
turned on and off
(using the main
switch IG), replace
the electronic board.
Table 12
EASYCARD ALARMS
R10
Chapter 8 - Condensate discharge system
CHAPTER 8
CONDENSATE DISCHARGE SYSTEM

ATTENTION
The unit is furnished without a condensate discharge system.
The control board is set to use timed relay.
Each unit is fitted with either a timed or intelligent condensate discharge assembly
depending on which option is ordered.
The timed condensate drain is automatically controlled by the electronic board with which it
is possible to set the condensate discharge intervals (see Chapter 7 Electronic Control).
The intelligent condensate drain features an electronic condensate level control system with
a capacitive sensor.
The electronic board of the drain continuously reads the signal sent to it by the capacitive
sensor.
When the level of condensate increases above the sensor, the solenoid valve is energised
after a delay time of 23 seconds in order to allow the discharge of condensate.
When the level of condensate falls again below the sensor, the solenoid valve is de-energised
and stops the condensate discharge.
8.1
Timed condensate discharger

The timed condensate drain must be carefully checked and serviced in order to prevent the
separated condensate from being entrained with the flow of compressed air into the
distribution system.
8.1.1
F il te r cl e ani ng
When a dryer is installed for the first time, it is common for particles of rust, pipe scale,
metal filings etc. to find their way into the separator and then into the filter.
It should therefore be cleaned about a month after installation.Thereafter it should be
cleaned once every 3 months.
In some installations, even more frequent cleaning may be required.
A Filterstop valve with incorporated strainer (see adjacent figure) is installed.
R10
The timed condensate discharger is fitted with a Filterstop valve: just close the
valve.
Press the manual condensate discharge button P1 to check that the filter is
not pressurised.
Open the IG main switch to disconnect the power supply to the dryer.
Carefully unscrew the filter cap [1] retaining the sealing gasket [2] and remove
the strainer mesh [3].
Once cleaned, reinsert the mesh making sure it is home and square and tighten
cap [1].
Replace the sealing gasket if it is damaged.
29
30
After re-opening the Filterstop valve, switch on IG again and re-start the unit.
Filterstop valve
1. Filter cap
2. Sealing gasket
3. Strainer
8.1.2
S o l en o id v al v e m a int en a n c e
The solenoid valve must always be protected by an appropriate filter to prevent solid
particles preventing it from opening and closing correctly.
However, if these particles manage to cross the filter and cause the valve to malfunction, all
its internal components must be cleaned.
To access to the solenoid valve follow the same indications described for the strainer (see
paragraph 8.1.1 Filter cleaning ).
Proceed as follows:
isolate and depressurise the dryer;

open the main switch IG to turn off power to the dryer;
unscrew the nut fixing the cap for the valve power supply;
lift up and remove the cap;
R10
Chapter 8 - Condensate discharge system
remove the solenoid valve from the pipe and Condensate discharge solenoid
valve
tightly clamp the body in a vice;
unscrew the nut [1] fixing the solenoid valve
[2] and remove it from the tie-rod [3];
unscrew the tie-rod from the valve seat;
check the condition of the O-ring seal [4]
and of all other components and clean them
carefully;
re-assemble the components by reversing the
above procedures;
make sure that the valve is re-installed with
1. Fixing Nut
the arrow pointing in the right direction.
2. Solenoid
3. Rod
4. O-ring
DANGER
Do not tighten the nut [1] excessively as this could cause the valve to open and close
incorrectly.
8.2
Intelligent condensate drain

The intelligent condensate drain is normally supplied already wired and connected to the
dryer power unit and is therefore ready to work.
It can also be retro-fitted using the appropriate CompAir kit.
The operating and maintenance instructions for the intelligent condensate drain are
contained inside the dedicated instruction manual of the drain itself.
R10
31
32
R10
Chapter 9 - General operating and maintenance regulation
CHAPTER 9
GENERAL OPERATING AND MAINTENANCE

REGULATION
9.1
Operation
Do not switch off the dryer if there is no compressed air flow.
The dryer switches on and off automatically.
The number of starts and stops depends on the flow of compressed air, its temperature and
ambient temperature.
As explained in the Chapter 5 Installation, the control board automatically switches off the
refrigerant compressor when there is no air flow.
In this case, the refrigerant compressor will run occasionally and for brief periods to
compensate for the dispersion of heat between the thermal mass and the surrounding ambient
air.
The dryer is therefore ready to dry compressed air as soon as the flow is restarted.
However, it is perfectly safe to switch off the dryer at night or at weekends when the air
compressor is not running.
In this case, remember to start the dryer at least 10-15 minutes before the air
compressor.
9.2
Maintenance
ATTENTION
Before starting up or operating these dryers be sure that all personnel have read and
understood Chapter 2 Safety of this manual.
These dryers will give many years of trouble-free service if they are properly maintained and
serviced.
9.2.1
D r ye r a cc e ss
Consult the Air Compressor manual for details of access to the dryer.
R10
33
34
Check there are no alarm signals.

If the dryer is fitted with a timed condensate discharge system, find out if
there is an excessive production of condensate and, if so, increase the
opening (ON) time of the valve.Make sure the solenoid valve opens
correctly observing the times set with the electronic board.
Check that the compressed air inlet temperature is lower than the limit
for which dryer was selected (normally 35-40C 95-104F).
With the compressor running, check the top part is not too hot (over 50C
/ 122F approx.).
Check current consumption of dryer lies within data plate values.
Remove, clean and put back the condensate discharge system filter.
If the filter is always clogged with material it may be necessary to
dismantle and clean the whole condensate discharge system.
Make a visual inspection of the refrigerant circuit to make sure the piping
has not deteriorated and that there are no traces of oil which may indicate
a leak of refrigerant.
Check the condition and safety of piping connections.
Check the tightness, condition and safety of the wiring and electrical
connections.
Check that the ambient air temperature is lower than the limit used to
select the dryer (normally 25-30C / 77-86F). Check the area is well
ventilated.
Check that the fan-motor assembly is switched on automatically and
check for any unusual noises.
If cooling air filters fitted, check condition of the cooling air filters and
clean if necessary.
If cooling air filters fitted, clean the cooling air filters or replace if
necessary.
If cooling air filters fitted, replace the cooling air filters.
Table 13
annual
6 months
OPERATION
1 month
I n s p ec t i o n a n d m a i n t e n an c e s ch e d u l e
1 day
9.2.2
INSPECTION AND MAINTENANCE SCHEDULE
ATTENTION
The above maintenance schedule is based on average operating conditions. In some cases it
may be necessary to increase maintenance frequency.
R10
Chapter 10 - Trouble shooting
CHAPTER 10
TROUBLE SHOOTING
PROBLEM
A
Dew-point
higher than
expected.
CAUSE
SYMPTOM
A1 Compressed air inlet temperature too
A1.1
high.
Dew-point and compressed air

inlet temperatures higher than
expected;
the alarm signal relative to the
problem is displayed on the
electronic board panel
(see paragraph 7.9 Alarms );
A2 Compressed air pressure too low.

A3 ambient temperature too high.
REMEDY
Reduce the compressed air inlet
temperature to within rated
limits.
Increase the compressed air
operating pressure to within
rated limits.
If the unit is installed indoors,
reduce the ambient temperature
to within rated limits (e.g. install
fans to extract the air).
A4 cooling air filters dirty or clogged.
Clean or replace air filters.
A5 obstruction of dryer cooling airflow intakes
Remove obstruction.
or discharge.
A6 Shortage of refrigerant fluid in circuit.
A6.1
B1 See A2.
B1.1 Possible increase in dew-
Increase the compressed air

pressure and flow to within
rated limits.
B2 There is an increase in pressure drop and
B2.1 See point C.
See point C.
B3 Heat exchanger tubes blocked by
B3.1 Pressure downline from the
Clean the exchanger tubes with

a mild detergent suitable for
steel and copper. Install a
prefilter.
C1 Incorrect position of temperature probe
C1.1 The value measured by the
C2 A calibration error or malfunction in the
C2.1 The compressor doesnt stop Replace the control board.
If you suspect that the dryer is short of

refrigerant, measure the suction
temperature (equivalent suction pressure)
of the refrigerant compressor by using the
relative Schraeder valve. Slowly vary the
air flow through the dryer until a
temperature value of 3C (+37.4F) is
displayed; the suction temperature
(shown on the temperature scale of the
refrigerant fluid used) will vary from -3C
(26.6F) to 0C (32F) approx.; if the
temperature is lower, the dryer is probably
short of refrigerant.
Excessive
compressed air
pressure drop.
point (see also A1.1);

pressure downline from the
dryer lower than expected.
the dryer ices up.
impurities conveyed by the compressed

air.
Dryer blocked
and no airflow.
Call in a qualified refrigeration

Compressor doesn't stop even if engineer to check for leaks and
fill circuit with refrigerant.
there is a little or no air flow;
the head of the refrigerant
compressor is very hot;
frosting on the evaporator
capillary inlet;
power absorption lower than
expected;
see also A1.1.
dryer lower than expected.
and as a result the thermal mass

temperature reduced to below 0C (32F)
with consequent freezing inside exchanger
tubes.(The temperature probe may have
been dislodged from its position during
maintenance work carried out inside the
dryer)
electronic board cause ice to form.
Adjust the position of the probe

in the collector by pushing it in
probe remains higher than
up to the relative indicator
0C (32F) even if the
compressor operates for long marked on the probe.
periods (e.g. more than 1015 minutes) without
compressed air flowing.
even if the dew-point is near

to 0C (32F).
C3 Incorrect calibration of temperature probe. C3.1 Everything seems to work
Use a tester to check the ohmic

resistance of the probe at 20C
/ 68F as indicated in Chapter 7
Electronic Control.
If necessary, replace the probe.
D1 The piping of the distribution line is
Insulate the piping exposed to

low ambient temperatures.
properly but the air doesnt

flow.
D Presence of
condensate
downline from
dryer.
located in a cold environment

(temperature lower than the pressure
dew-point of the compressed air) and is
not insulated.
In this case, condensation forms on the
internal surfaces of the piping.
Table 14
R10
D1.1 Dryer runs normally.
Problems are caused by

external factors.
TROUBLE SHOOTING
35
36
PROBLEM
CAUSE
SYMPTOM
REMEDY
Presence of
condensate
downline from
the dryer.
E1 Condensate discharge system fault.
E1.1 The condensate and/or
Refer to the Instruction Manual

for the level sensing drain.
Repair or replace the
condensate discharge system.
Compressor
protection trips.
F1 Ambient and compressed air inlet
F1.1
Stop the unit and reduce the air

flow and temperature to within
rated limits.
Wait a few minutes before
starting the unit again.
Before replacing the fuse, check
the conditions of all the safety
devices (built-in or external
motor circuit breakers)
positioned downline from the
fuse or automatic switch.
In case of doubt, replace all the
devices.
temperatures too high.
compressed air are not

discharged when the manual
check button is pressed.
The head and the body of the

compressor are very hot;
the compressor stops and tries
to restart after a short time
(even a few seconds).
F2 Compressed air temperature too high
Call in a qualified refrigeration

engineer to check for leaks and
fill up the circuit with
refrigerant.
devices.
combined with a shortage of refrigerant

(see also A6).
G All LEDs off
although the
main switch IG
is on (I).
H Temperature
probe fault
alarm (see
paragraph 7.9
Alarms ).
G1 Control board circuit breaker trips.
Power supply fluctuations or 'spikes'.
G1.1 Despite the presence of
Provide cleaner power supply to

power at the input terminals, the dryer.
the digital display and all
If the circuit breaker continues
LEDs remain unlit.
to trip, replace the control
board.
G2 Abnormal power consumption by one or

more of the control board components.
H1 Probes in open circuit or in short circuit.
H1.1
Refrigerant compressor stops;
I1.1 The alarm signal relative to

Alarm relative to I1 Control board microprocessor initialising
the
error or microprocessor mistake in reading
the problem is displayed on
microprocessor
data.
the electronic board (see
or its Eprom
paragraph 7.9 Alarms ) and
memory (see
the unit is blocked.
paragraph 7.9
Alarms ).
Table 14
Check that the temperature

probe is correctly connected to
the control board terminals and
that the cable is undamaged. If
necessary replace the
temperature probe.
Turn the unit off and on.
If this doesnt solve the
problem, contact the nearest
service centre.
TROUBLE SHOOTING
R10
Chapter 10 - Trouble shooting
PROBLEM
J
Fuses fitted on
the unit trip
(see wiring
diagram).
CAUSE
SYMPTOM
J1 Compressor motor or compressor supply
J2 Short-circuit of solenoid valve, fan and
J2.1 Apparent power supply
line short-circuited.
electronic board supply lines.
failure.
J3 Short circuit in the fan or in the fan and
Table 14
Use a tester to check the

components and cables.
Replace the damaged
component or cable.
devices.
Use a tester to check the
components and cables.
Replace the damaged
component or cable.
devices.
transformer auxiliary power lines.
R10
REMEDY
J1.1 The compressor doesnt start Use a tester to check the motor
windings and supply line.
even if the thermostat
Replace the compressor or the
function requires it to.
cable if necessary.
devices.
TROUBLE SHOOTING
37
38
R10
Chapter 11 - List of attachments
CHAPTER 11
LIST OF ATTACHMENTS
R10
FACTORY SETTINGS
LIFTING AND TRANSPORT DIAGRAMS
EXPLODED VIEW
OVERALL DIAGRAMS
REFRIGERANT CIRCUIT DIAGRAM
ELECTRICAL DIAGRAMS
39
40
R10
ALLEGATI
ATTACHMENTS
ANLAGEN
ANNEXES
ANEXOS
BILAGOR
BIJLAGEN
BILAG
LIITTEET
SETTAGGI DI FABBRICA
FACTORY SETTINGS
WERKSEITIGE EINSTELLUNGEN
RGLAGES DUSINE
AJUSTES DE FBRICA
FABRIKSINSTLLNINGAR
FABRIEKSINSTELLINGEN
FABRIKSINDSTILLINGER
TEHDASASETUKSET
Le tabelle di questo capitolo contengono i valori dei settaggi di

fabbrica con i quali la macchina stata collaudata. La dotazione
di un determinato tipo di centralina elettronica e la presenza dei
pressostati, del termostato di sicurezza dello scaricatore di
condensa temporizzato o di quello intelligente, dipendono dalla
configurazione della macchina ( PROSPETTO RIASSUNTIVO
DELLE CONFIGURAZIONI POSSIBILI).Nel caso fosse necessario
verificare le impostazioni di fabbrica della centralina elettronica,
del o dei pressostati e del termostato di sicurezza fare
riferimento ai relativi capitoli di questo manuale.
The tables in this chapter contains the factory setting values

used for testing the unit.The type of electronic board, the
presence of pressure switches, safety thermostat, timed or
intelligent condensate discharger depend on the unit
configuration ( THE LIST OF CONFIGURATIONS)If it is
necessary to check the factory settings of electronic board, of
pressure switch(es) and of safety thermostat make reference to
the appropriate chapters of this manual.
Die Tabellen in diesem Kapitel enthalten die Werte der

werkseitigen Einstellungen, mit denen die Maschine geprft
worden ist.Das Vorhandensein einer bestimmten elektronischen
Steuereinheit und der Druckschalter, des
Sicherheitsthermostats des Kondensatablassers mit Zeitgebung
oder des intelligenten Kondensatablassers hngen von der
Gestaltung der Maschine ab ( ZUSAMMENFASSENDE TABELLE
DER MGLICHEN GESTALTUNGEN ).Falls eine berprfung der
werkseitigen Einstellungen der elektronischen Steuereinheit,
des oder der Druckschalter und des Sicherheitsthermostats
notwendig sein sollte, wird auf die jeweiligen Kapitel in dieser
Anleitung verwiesen.
Les tableaux de ce chapitre contiennent les valeurs de rglage

dusine avec lesquels la machine a t essaye.Lattribution dun
certain type dunit de commande lectronique et la prsence
des pressostats, du thermostat de scurit du purgeur de
condensat temporis ou intelligent, dpendent de la
configuration de la machine. ( RSUM DES CONFIGURATIONS
POSSIBLES).En cas de ncessit de vrifier les prrglages
dusine de lunit de commande lectronique, du ou des
pressostats de scurit, voir les chapitres correspondants de ce
manuel.
Las tablas de este captulo contienen los valores de los ajustes

de fbrica con los que la mquina ha sido probada.El
equipamiento de un determinado tipo de cuadro electrnico y la
presencia de los presstatos, termstato de seguridad del
dispositivo de desage del lquido de condensacin temporizado
o inteligente, dependen de la configuracin de la mquina (
RESUMEN DE LAS CONFIGURACIONES POSIBLES).Si fuera
necesario comprobar las configuraciones de fbrica del cuadro
electrnico, del o de los presstatos y del termstato de
seguridad, refirase a los captulos correspondientes de este
manual.
Tabellerna i detta avsnitt innehller vrdena fr maskinens

fabriksinstllningar.De elektroniska styrenheternas utfrande,
med tryckvakter, skerhetstermostat fr tidsinstlld eller
intelligent kondenstmningsenhet, beror p maskinens
konfiguration ( SAMMANSTLLNING AV MJLIGA
KONFIGURATIONER).Kontrollera, om det r ndvndigt,
fabriksinstllningarna fr den elektroniska styrenheten,
lysdioderna eller tryckvakterna och skerhetstermostaten. Se
aktuellt kapitel i denna bruksanvisning.
De tabellen van dit hoofdstuk bevatten de

fabrieksafregelwaarden waarmee de machine getest is.De
uitrusting met een bepaald soort elektronische regeleenheid en
de aanwezigheid van drukschakelaars, van de
veiligheidsthermostaat van de condensafvoer met tijdschakelaar
of van de intelligente condensafvoer zijn afhankelijk van de
machineconfiguratie ( OVERZICHT MOGELIJKE
CONFIGURATIES ).Raadpleeg de desbetreffende hoofdstukken
van deze handleiding indien de fabrieksinstellingen van de
elektronische regeleenheid, de drukschakelaars of
veiligheidsthermostaat gecontroleerd moeten worden.
Tabellerne i dette kapitel indeholder de fabriksindstillede

vrdier, de vrdier som maskinen er blevet prvekrt med.Den
ene eller den anden type elektronisk centralenhed trykreler,
sikkerhedstermostat med timer eller "intelligent"
kondensataflb, afhnger af maskinens konfiguration (
SAMMENFATTENDE PROSPEKT AF DE MULIGE
KONFIGURATIONER).Om ndvendigt kontrolleres
fabriksindstillingerne p den elektroniske centralenhed,
trykreler og sikkerhedstermostaten under de relative kapitler i
denne manual.
Tmn luvun taulukoista lytyvt tehdasasetusten arvot, joilla

kone on koekytetty.Varustus mrtyn tyyppisell
elektronisella yksikll ja painekatkaisimilla ja lauhdeveden
ajastetun tai lypoistolaitteen turvatermostaatilla riippuvat
koneen kokoonpanosta ( TIIVISTELM MAHDOLLISISTA
KOKOONPANOISTA).Jos elektronisen yksikn,
painekatkaisimen/mien ja turvatermostaatin tehdasasetuksia
joudutaan tarkistamaan, ks. ohjekirjan aihekohtaisia lukuja.
R10
3817
IMPOSTAZIONI UNITA' SCHEDA EASYCARD

SETTINGS FOR UNITS WITH EASYCARD CONTROL BOARD
EINSTELLUNGEN DER STEUEREINHEIT MIT EASYCARD
PRRGLAGES UNITAVEC CARTE EASYCARD
CONFIGURACIONES DE LA UNIDAD TARJETA EASYCARD
INSTLLNING AV ENHET MED STYRENHETEN EASYCARD
INSTELLINGEN EENHEID MET EASYCARD
INDSTILLINGER TIL ENHEDER MED KORTET EASYCARD
EASYCARD-KORTILLA VARUSTETUN YKSIKN ASETUKSET
PARAMETRO
PARAMETER
PARAMETER
PARAMTRE
PARMETRO
PARAMETER
PARAMETER
PARAMETER
PARAMETRI
L1 L
L2
TON
OFF
OFF
RLE
(unit provvista di scaricatore temporizzato / unit with timed

condensate discharger / Einheit mit Kondensatablasser mit
Zeitgebung / unit munie de purgeur temporis / unidad
OFF
equipada con dispositivo de desage temporizado / enhet
frsedd med tidsinstlld tmningsenhet / eenheid met
condensafvoer met tijdschakelaar / enhed med timeraflb /
ajastetulla poistolaitteella varustettu yksikk)
HA1
3817
(unit provvista di scaricatore intelligente / unit with

intelligent condensate discharger / Einheit mit intelligentem
Kondensatablasser / unit munie de purgeur intelligent /
unidad equipada con dispositivo de desage inteligente /
enhet frsedd med intelligent tmningsenhet / eenheid met
intelligente condensafvoer / enhed med "intalligent"aflb /
lypoistolaitteella varustettu yksikk)
VALORE DEL SET

SET VALUE
SOLLWERT
VALEUR DU SET
VALOR DEL SET
BRVRDE
SET-WAARDE
SETVRDIER
SET-ARVO
SET
SET
SET
SET
SET
SET
INGESTELD
SET
SET
OFF
L3
ON
3 sec. / sec. / Sek. / sec. / seg.

/ sek. / sec. / s.
ON
gestione temporizzata / timed

management / Betrieb mit
Zeitgebung / gestion temporise
/ gestin temporizada /
tidsinstlld styrning / aansturing
met tijdklok / drift med timer /
ajastettu ohjaus
OFF
ON
OFF
OFF
ON
OFF
rel sempre eccitato / relay

always energised / Relais immer
erregt / Relais toujours excit /
rel siempre excitado /
permanent aktivt rel /
permanent ingeschakeld relais /
rel altid pvirkelig / rele aina
aktivoitu
15 C / 59F
R10
ALLEGATI
ATTACHMENTS
ANLAGEN
ANNEXES
ANEXOS
BILAGOR
BIJLAGEN
BILAG
LIITTEET
MOVIMENTAZIONE DELLA MACCHINA / LIFTING AND TRANSPORT DIAGRAMS / ZEICHNUNGEN FR

DIE VERSCHIEBUNG DES GERTS / DESSINS DE MANUTENTION DE LA MACHINE / DIBUJOS DE
DESPLAZAMIENTO DE LA MQUINA / SKISSER VER FRFLYTTNING AV MASKINEN /
MACHINEVERPLAATSINGSTEKENINGEN / TEGNINGER OVER MASKINENS BEVGELSER / KONEEN
LIIKUTUSPIIRROKSET
L min
(mm)
D min
(mm)
500
350
PESO LORDO (kg)

GROSS WEIGHT (kg)
BRUTTOGEWICHT (kg)
POIDS BRUT (kg)
PESO BRUTO (kg)
BRUTTOVIKT (kg)
BRUTOGEWICHT (kg)
BRUTTOVGT (kg)
BRUTTOPAINO (kg)
44
R10
3817
3817
R10
ALLEGATI
ATTACHMENTS
ANLAGEN
ANNEXES
ANEXOS
BILAGOR
BIJLAGEN
BILAG
LIITTEET
ESPLOSO COMPONENTI / EXPLODED VIEW / DETAILZEICHNUNG DER KOMPONENTEN / VUE

CLATE DES COMPOSANTS / DIBUJO DE DESPIECE DE LOS COMPONENTES / SPRNGSKISSER
OPENGEWERKTE TEKENING / EKSPLOSIONSTEGNING OVER KOMPONENTER /
KOMPONENTTIEN HAJOTUSKUVA
R10
3817
3817
PANNELLO LATERALE
SINISTRO
BASE
PANNELLO ANTERIORE
PANNELLO LATERALE
DESTRO
GRUPPO SCARICO
CONDENSA MECCANICO
SUPPORTI DI BASE
MONTANTE
TUBO CON CAPILLARI
COLLETTORI VERTICALI
FILTRO ARIA
14
15
16
17
18
19
20
21
22
23
PLANCIA COMANDI
PANNELLO POSTERIORE
EVAPORATORE
COPERCHIO
GRUPPO SCARICO
CONDENSA INTELLIGENTE
13
SCATOLA
12
PIATTO
PRESSOSTATI
FILTRO + CAPILLARE
SCHEDA ELETTRONICA
CONSENSATORE
11
VENTILATORE
10
COMPRESSORE
AIR FILTER
VERTICAL COLLECTORS
PIPE WITH CAPILLARIES
RISER
BASE SUPPORTS
MECHANICAL
CONDENSATE DISCHARGE
SYSTEM
RIGHT SIDE PANEL
FRONT PANEL
BASE
LEFT SIDE PANEL
BACK PANEL
COVER
ELECTRONIC BOARD
PRESSURE SWITCHES
CONTROL BOARD
EVAPORATOR
INTELLIGENT
CONDENSATE DISCHARGE
SYSTEM
BOX
PLATE
FILTER + CAPILLARY
CONDENSER
FAN
COMPRESSOR
COMPRESSEUR
LUFTFILTER
VERTIKALE KOLLEKTOREN
ROHR MIT KAPILLAREN
STEIGLEITUNG
FILTRE AIR
COLLECTEURS VERTICALS
TUYAU AVEC CAPILLARES
COLONNE MONTANTE
BASE SUPPORTS
GROUPE DE PURGE DU
CONDENSANT
MCANIQUE
MECHANISCHE
KONDENSATABLEITER
SOCKELAUFLAGEN
PANNEAU LATRAL DROIT
PANNEAU ANTRIEUR
BASE
PANNEAU LATRAL
GAUCHE
PANNEAU POSTRIEUR
COUVERCLE
TABLEAU LECTRONIQUE
PRESSOSTATS
PUPITRE DES COMMANDES
RECHTE SEITENPANEEL
FRONTPANEEL
SOCKEL
LINKE SEITENPANEEL
RCKWAND
DECKEL
ELEKTRONISCHE
STEUERKARTE
DRUCKSHALTER
SCHALTKASTEN
VAPORATEUR
GROUPE DE PURGE DU
CONDENSANT
INTELLIGENT
INTELLIGENTE
KONDENSATABLEITER
VERDAMPFER
BOTIER
PLATEAU
FILTRE + CAPILLAIRE
CONDENSEUR
VENTILATEUR
GEHUSE
BODENPLATTE
FILTER + KAPILLARE
KONDENSATOR
VENTILATOR
KOMPRESSOR
KOMPRESSOR
VERDAMPER
FILTRO AIRE
COLECTORES VERTICALES
TUBERA CON CAPILARES
COLUMNA VERTICAL
VERTIKALA
FRFRENINGSRR
RR MED KAPILLRRR
STOLPE
BASSTD
VERTICALE
VERDEELSTUKKEN
BUIS MET CAPILLAIR
STAANDER
BASISONDERSTEUNING
MECHANISCHE
CONDENSAFVOERGROEP
MEKANISK
TMNINGSENHET
GRUPO DE DESAGE DEL

LQUIDO DE
CONDENSACIN
MECNICO
SOPORTES DE BASE
RECHTERZIJPANEEL
VOORPANEEL
BASIS
LINKERZIJPANEEL
ACHTERPANEEL
DEKSEL
ELEKTRONISCHE
REGELEENHEID
DRUKSCHAKELAAR
BEDIENINGSPANEEL
HGER SIDOPANEL
FRONTPANEL
BAS
VNSTER SIDOPANEL
BAKRE PANEL
KPA
ELEKTRONISK STYRENHET
TRYCKSTRMSTLLARE
MANVERPANEL
PANEL LATERAL DERECHO
PANEL DELANTERO
BASE
PANEL LATERAL
IZQUIERDO
PANEL TRASERO
TAPA
CUADRO ELECTRNICO
PRESSTATOS
TABLERO DE MANDOS
FRNGARE
INTELLIGENTE
CONDENSAFVOERGROEP
INTELLIGENT
TMNINGSENHET
GRUPO DE DESAGE DEL

LQUIDO DE
CONDENSACIN
INTELIGENTE
EVAPORADOR
BOX
PLAAT
CAPILLAIR + FILTER
CONDENSATOR
VENTILATOR
COMPRESSOR
LDA
PLATTA
KAPILLR + FILTER
KONDENSOR
FLKT
CAJA
DISCO
FILTRO + CAPILAR
CONDENSADOR
VENTILADOR
COMPRESOR
KOMPRESSOR
LODRET SAMLINGSRR
RR MED KAPILLR
STANDER
BASESTTTE
MEKANISK
TMNINGSENHED
HJRE FORPANEL
FORPANEL
BASE
VENSTRE SIDEPANEL
BAGPANEL
DKSEL
ELEKTRONISK KORT
LUFTTRYKESKONTAKTER
STYREPANEL
FORDAMPER
INTELLIGENT
TMNINGSENHED
SKE
PLADE
FILTER + KAPILLR
KONDENSATORE
VENTILATOR
PYSTYKOKOOMAPUTKET
PUTKI JA
KAPILLAARIPUTKET
PYLVS
PERUSTAN TUET
MEKAANINEN
LAUHDEVEDEN
POISTOYKSIKK
OIKEANPUOLEINEN
SIVULEVY
ETULEVY
PERUSTA
VASEMMANPUOLEINEN
SIVULEVY
TAKALEVY
KANSI
ELEKTRONINEN KORTTI
PAINEKATKAISIMET
OHJAUSTAULU
HAIHDUTIN
LAUHDEVEDEN
LYPOISTOYKSIKK
RASIA
LEVY
SUODATIN +
KAPILLAARIPUTKI
LAUHDUTIN
TUULETIN
KOMPRESSORI
R10
ALLEGATI
ATTACHMENTS
ANLAGEN
ANNEXES
ANEXOS
BILAGOR
BIJLAGEN
BILAG
LIITTEET
Lista parti di ricambio-Spare parts list
LISTA PARTI DI RICAMBIO-SPARE PARTS LIST
RIF.
REF.
(I) Descrizione
(GB) Description
(F) Description
(D) Beschreibung
(S) Descripcin
(I) Codice
(GB) Code
(F) Code
(D) Kode
(S) Cdice
(I) Quantit impiegata sulla macchina

(GB) Quantity used in the machine
(F) Quantit utilise dans la machine
(D) Quantitt benutztet in der Maschine
(S) Cantidad utilizada en las mquinas
--
Interruttore bianco 22x30

White switch 22x30
Interrupteur Blanc 22x30
weier Schalter 22x30
interruptor blanco 22x30
3652452
11
Scheda Elettronica+sonda
Electr. Board + Probe
carte lectronique+sonde
elektr. Platte +Sonde
Tarjeta electrnica+ Sonda
365013602
Ventilatore MA-VIB V02-C041.02+EL5.230.31.AA

Fan MA-VIB V02-C041.02+EL5.230.31.AA
Ventilateur MA-VIB V02-C041.02+EL5.230.31.AA
Ventilator MA-VIB V02-C041.02+EL5.230.31.AA
Ventilador MA-VIB V02-C041.02+EL5.230.31.AA
351062440
Compressore Danfoss SC15GX

Compressor Danfoss SC15GX
Compresseur Danfoss SC15GX
Kompressor Danfoss SC15GX
compresor Danfoss SC15GX
345055000
--
Coperchio protezione per compressore SC15/SC21

protective cap for Compressor SC15/SC21
couvercle de protection pour le compresseur SC15/SC21
Schutzdeckel fr der Kompressor SC15/SC21
tapa de proteccin para el compresor SC15/SC21
345131830
--
Pallet
Pallet
Pallet
Pallet
Pallet
380004855
--
Imballo cartone
Cardboard Packing
Emballage en carton
Kartonverpackung
Embalaje en cartn
380035200
--
Fusibile 6A gG 10,3x38 500V

Fuse 6A gG 10,3x38 500V
Fusible 6A gG 10,3x38 500V
Sicherung 6A gG 10,3x38 500V
Fusible 6A gG 10,3x38 500V
36526802002 --
Filtro
Filter
Filtre
Filter
Filtro
352260100
--
--
Attacco carica 1/4 SAE+tubo rame

Charge connection 1/4 SAE + copper tube
Connexion de charge 1/4 SAE + tube de cuivre
Fllungsverbindung 1/4 SAE + Kupferrohr
Conexin de carga 1/4 SAE + tubo de cobre
3727594
--
R10
+
+
+
+
+
Capillare
Capillary
Capillaire
Kapillare
Tubo capilar
3817
3817
R10

Hydrovane Refrig Dryer HV04!05!07 Англ.Яз 2005

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Hydrovane Refrig Dryer HV04!05!07 Англ.Яз 2005

Uploaded by

Copyright:

Available Formats

C OMPRESSED AIR D RYERS

R10 for V4-7.5KW

C OMPRESSED AIR D RYERS

MAINTENANCE AND OPERATING MANUAL

Summary of possible configurations ........................................... 4

Compressed gases to be dried ............................................................. 5

Refrigerant gases ......................................................................... 7

TECHNICAL DATA .......................................................................................................................11

Data plate and meaning of abbreviations .................................. 11

ELECTRONIC CONTROL ..............................................................................................................21

Buttons and Leds....................................................................... 21

Temperature Probe .................................................................... 22

CONDENSATE DISCHARGE SYSTEM ............................................................................................29

Timed condensate discharger.................................................... 29

Intelligent condensate drain ...................................................... 31

GENERAL OPERATING AND MAINTENANCE REGULATION ........................................................33

TROUBLE SHOOTING ...................................................................................................................35

LIST OF ATTACHMENTS ..............................................................................................................39

MAINTENANCE AND OPERATING MANUAL

Chapter 1 - General informations

Air outlet from the unit

Cooling air flow (for aircooled units)

Direction of fan rotation (for

Direction of the refrigerant gas

Summary of possible configurations

Timed discharge system

SUMMARY OF POSSIBLE CONFIGURATIONS

MAINTENANCE AND OPERATING MANUAL

M ai nte na nce and r ep ai r pr ec aut ion s

MAINTENANCE AND OPERATING MANUAL

Regularly check the accuracy of pressure and temperature gauges.

R134a (1,1,1,2 - tetrafluoroethane)

-26.5C / -15.7F at atmospheric pressure

1.21 kg/l at 25C / 77F

0.15% in weight at 25 C / 77F and atmospheric pressure

No reactivity if used in compliance with the instructions

Alkaline metals, alkaline-earth metals, granulated metal salts,

Halogens acids, carbonyl halide traces

ALC/inhalation/4 hours/ on rat = 567 ml/l

Concentrations higher than 1000 ppm v/v may cause narcotic

No carcinogenic, teratogenic or mutagenic effects shown

A rapid evaporation of the liquid may cause ice

Potential global heating

Can be re-used after reprocessing

Take the patient outdoors. If necessary give oxygen or

Contact with eyes:

Rinse the eye thoroughly with water for at least 15 minutes.

Contact with skin:

Wash immediately with water. Remove contaminated clothing

Cool the containers by spraying water

R134A SAFETY CARD

MAINTENANCE AND OPERATING MANUAL

PRECAUTIONS IN CASE OF ACCIDENTAL LEAKAGE

Evacuate personnel to safety areas. Proper ventilation is

Technical precautions: only use in ventilated areas.Safety

Technical precautions/storage method: close carefully and

1000 ppm v/v or ml/m3 as the weighted average over 8 hours

For rescue operations and when carrying out maintenance

Protection for eyes:

Protection for hands:

R134A SAFETY CARD

MAINTENANCE AND OPERATING MANUAL

Chapter 3 - Technical Data

Data plate and meaning of

button (within 5 seconds) the parameter value before