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SMC Networks IDF190D-3-W Series Operation Manual

Refrigerated air dryer
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Refrigerated Air Dryer
This manual is intended to explain the installation and operation of the product.
Only those who have thorough understanding of the fundamental operating
procedure or have basic knowledge and skills of handling industrial products are
qualified to perform installation and operation.
Please read this manual prior of using the air dryer.
PRODUCT NAME
MODEL / Series
IDF190D-3-(C,M,R)W
IDF240D-3-(C,M,R)W
Keep the manual readily available for reference.
2
4
0
IDX-OM-Y002

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  • Page 1 IDX-OM-Y002 PRODUCT NAME Refrigerated Air Dryer MODEL / Series IDF190D-3-(C,M,R)W IDF240D-3-(C,M,R)W This manual is intended to explain the installation and operation of the product. Only those who have thorough understanding of the fundamental operating procedure or have basic knowledge and skills of handling industrial products are qualified to perform installation and operation.
  • Page 2 Foreword Thank you for purchasing SMC’s refrigerated type air dryer (hereinafter referred to as the “product”). For safety and long life of the product, be sure to read this Operation Manual (hereinafter referred to as the “manual”) and clearly understand the contents. ...

  • Page 3: Table Of Contents

    IDX-OM-Y002 Contents Contents Chapter 1 Safety ................1-1 Before Using the Air Dryer ..................1-1 1.1.1 Danger, Warning and Caution in This Manual..............1-1 Hazard Classifications & Position of Hazard warning Labels ......1-2 1.2.1 Hazard of Electricity ......................1-2 1.2.2 Hazard of Hot Surface ......................
  • Page 4 IDX-OM-Y002 Contents Chapter 6 Troubleshooting ............... 6-1 Troubleshooting ....................... 6-1 Reset the Thermal relay and High Pressure Switch ..........6-3 Chapter 7 Documents ............... 7-1 Specifications ......................7-1 Refrigerant and GWP ....................7-2 Dimensions ......................7-3 Electrical circuit diagram ..................7-4 Air and refrigerant circuits and functions ..............

  • Page 5: Chapter 1 Safety

    IDX-OM-Y002 Chapter 1 Safety Chapter 1 Safety Before using the product, be sure to read and understand all the important actions highlighted in this manual. 1.1 Before Using the Air Dryer  This chapter is intended to specifically describe the safety related issues for handling the product. Read this before handling the product.

  • Page 6: Hazard Classifications & Position Of Hazard Warning Labels

    IDX-OM-Y002 Chapter 1 Safety 1.2 Hazard Classifications & Position of Hazard warning Labels To ensure the safety of the operators, potential hazards are classified and marked with warning labels. Confirm the potential hazards and positions of the labels before operation. WARNING - Transportation, installation, and maintenance involve risks and should only be carried out by people who have sufficient knowledge and experience about the product and its accessories.

  • Page 7: Cautions For Usage

    IDX-OM-Y002 Chapter 1 Safety 1.2.4 Cautions for usage WARNING Read with caution and pay attention to the notations on the caution labels. - Do not remove or rub the caution labels. - Ensure that the warning labels are placed in the correct position. Front 1.2.5 Cautions for refrigerant...
  • Page 8 IDX-OM-Y002 Chapter 1 Safety Front Hazard Classifications & Position of Hazard warning Labels IDF190D/240D Series...

  • Page 9: Waste Disposal

    IDX-OM-Y002 Chapter 1 Safety 1.3 Waste Disposal When you dispose of the product, you should collect the refrigerant and the refrigerant oil enclosed in the refrigerant circuit. CAUTION - The product uses hydro fluorocarbon type refrigerant (HFC). - This product is a Class 1 specified products of the Act on Rational Use and Proper Management of Fluorocarbon in Japan.

  • Page 10: Limited Warranty And Disclaimer/ Compliance Requirements

    IDX-OM-Y002 Chapter 1 Safety 1.4 Limited Warranty and Disclaimer/ Compliance Requirements The product used is subject to the following “Limited warranty and Disclaimer” and “Compliance Requirements”. Read and accept them before using the product. Limited Warranty and Disclaimer 1. The warranty period of the product is 1 year in service or within 1.5 years after the product is delivered.

  • Page 11: Chapter 2 Name And Function Of Parts

    IDX-OM-Y002 Chapter 2 Name and Function of Parts Chapter 2 Name and Function of Parts 2.1 Name and Function of Parts Mini front display Side ventilation grille The lamp is continuously on Radiates the heat generated during normal operation. in the unit. Do not block the Start and stop the operation.
  • Page 12 IDX-OM-Y002 Chapter 2 Name and Function of Parts Name and Function of Parts IDF190D/240D Series...

  • Page 13: Chapter 3 Transportation And Installation

    IDX-OM-Y002 Chapter 3 Transportation and installation Chapter 3 Transportation and installation WARNING - Use the product in an appropriate manner, and pay attention to safety, particularly physical safety of operators, during the installation, operation, maintenance and checks of the product. - When the product is used for a critical facility or equipment, prepare a spare product or alternative machine in case of failure or stoppage of the product due to the operation of the protective equipment.

  • Page 14: Environment

    IDX-OM-Y002 Chapter 3 Transportation and installation 3.2 Installation 3.2.1 Environment The product must not be operated or stored in the following conditions. Potential malfunction or damage to the product may occur if these instructions are disregarded.  Place where the product is exposed to rain or wind. Humid place (more than 85% of relative humidity).

  • Page 15: Air Piping

    IDX-OM-Y002 Chapter 3 Transportation and installation 3.2.3 Air piping  Connect compressed air inlet and outlet using a JIS10K flange specified in Chapter 7- 7.1 Specifications  It is recommended to install a main line filter in the air inlet piping. Main line filter prevents the auto drain from malfunctioning by stopping rust and particles.

  • Page 16: Replacement Of Auto Drain

    IDX-OM-Y002 Chapter 3 Transportation and installation 3.2.4 Replacement of auto drain  Mount the nipple to the auto drain (included in the same package). Then connect it to the drain inlet of the dryer.  Connect the drain piping to the auto drain outlet. The drain piping should have an internal diameter of 8mm or more and be 5m or less in length.

  • Page 17: Wiring Of Signal Cable (Operation / Error / Remote Operation)

    IDX-OM-Y002 Chapter 3 Transportation and installation Power supply cable length Power cable length for the product shall be less than 30m. Power supply Connect the power cable and grounding cable to the terminal block. Wiring procedure 1) Remove the front panel. 2) Introduce the cable through the grommet with membrane to connect to the terminal block.

  • Page 18: Cooling Water Piping

    IDX-OM-Y002 Chapter 3 Transportation and installation 4) Mount the front panel back. [Remote control]  Voltage of AC200V is present on the terminal block. The black switch (stop) must be turned on while wiring. When wiring, shut off the supply breaker. 1) Connect the external switch terminals to the terminal blocks No.5 and No.6.

  • Page 19: Cautions About Reinstallation

    IDX-OM-Y002 Chapter 3 Transportation and installation 3.3 Cautions about Reinstallation CAUTION Only someone who has enough knowledge about the equipment and incidental devices should reinstall it in another place. If you move the product and reinstall it into another place after some operations (including trial running), all installation instructions in chapter 3 should be followed as well as the following instructions.
  • Page 20 IDX-OM-Y002 Chapter 3 Transportation and installation Cautions about Reinstallation IDF190D/240D Series...

  • Page 21: Chapter 4 Operation/ Shutdown

    IDX-OM-Y002 Chapter 4 Operation/ Shutdown Chapter 4 Operation/ Shutdown CAUTION Only someone who has enough knowledge and experience about the product and incidental devices should operate or shut down the product. 4.1 Check points before operation Before trial operation, check following points. Installation state ...

  • Page 22: Stop

    IDX-OM-Y002 Chapter 4 Operation/ Shutdown 7) For remote operation, the product is turned on/off using the external switch while the yellow switch (main unit / remote selector switch) is turned ON. Allow at least 3 minutes before restarting remote operation. If restart is attempted within 3 minutes, the protective equipment may trip and restart will not be possible.

  • Page 23: Chapter 5 Checks, Maintenance And Adjustment

    IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment Chapter 5 Checks, Maintenance and Adjustment WARNING - Only people who have sufficient knowledge and experience about the product and its accessories are allowed to perform maintenance. - Before maintenance, read and understand the important cautionary notifications in this operation manual.

  • Page 24: Regular Maintenance

    IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment 5.2 Regular maintenance 5.2.1 Maintenance for water-cooled condenser When a water-cooled air dryer is used for a certain amount of time, the compression performance decreases due to the contamination of the cooling water side of the water-cooled condenser. Because of this, compression pressure abnormally increases, starting the protection equipment installed in the air dryer, stopping the air dryer operation.
  • Page 25 IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment 2）Water quality check (monthly) When tap water (well） or ground water is used as cooling water for water-cooled condenser, test the water quality based on（ Testing Methods for industrial Water) or methods compliant with JISK0101 for items in Table -1.
  • Page 26 IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment Stop supplying the cooling water and remove the Y shaped strainer mesh for inspection. When foreign matter has accumulated, remove it using a brush or air gun so that the mesh is not deformed or damaged.
  • Page 27 IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment b） Cleaning procedure when cooling tower is used (circulating method) 1. Connect the cleaning circulation pump (if necessary, use an acid resistant pump) to the cooling water inlet and outlet of the tank heat exchanger with a hose. 2.

  • Page 28: Auto Drain Maintenance

    IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment 5.2.2 Auto Drain Maintenance Remove the dust accumulated in the auto drain every month. Use neutral detergent for cleaning. When cleaning does not improve the operation, replace the element and bowl assembly. From the next time on, clean them in intervals shorter than a month.
  • Page 29 IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment [Cleaning and replacement of the auto drain] Follow the procedure below for the auto drain maintenance. Pilot air exhaust port Note: Before maintenance Flush button When disassembling the auto drain for cleaning, Body replacing parts, etc., be sure to completely remove the air pressure as follows.

  • Page 30: Adjustment

    IDX-OM-Y002 Chapter 5 Checks, Maintenance and Adjustment (D) Replacement of the main valve (discharge valve) Purchase the replacement kit of the main valve and replace it referring to the attached Replacement Procedure. Replacement requires a specific tool. Replacement procedure must be followed to reuse the product and prevent the parts from being damaged.

  • Page 31: Chapter 6 Troubleshooting

    IDX-OM-Y002 Chapter 6 Troubleshooting Chapter 6 Troubleshooting 6.1 Troubleshooting Refer to the table below if any abnormality is found. If there is something that is not clear, please turn off the power supply and contact our service office. Problem Possible causes Action Air dryer does not Power cable is loose or not...
  • Page 32 IDX-OM-Y002 Chapter 6 Troubleshooting Problem Possible causes Action Water-cooled condenser is - Clean the air-cooled condenser. Compressor stops contaminated. with the operation LED ON with no Facility water supply decreased - Inspect the strainer once a month. Remove foreign because foreign matter has matter when it has accumulated.

  • Page 33: Reset The Thermal Relay And High Pressure Switch

    IDX-OM-Y002 Chapter 6 Troubleshooting 6.2 Reset the Thermal relay and High Pressure Switch When the lamp goes off and the compressor stops during operation, the thermal relay or high voltage pressure switch has activated to protect the compressor for refrigeration. It is necessary to reset it manually.
  • Page 34 IDX-OM-Y002 Chapter 6 Troubleshooting Reset the Thermal relay and High Pressure Switch IDF190D/240D Series...

  • Page 35: Chapter 7 Documents

    IDX-OM-Y002 Chapter 7 Documents Chapter 7 Documents 7.1 Specifications Models IDF190D-3-W IDF240D-3-W Item Standard 50Hz condition Note 1) 60Hz Air flow capacity (ANR) / min Compressor 50Hz inlet condition Note 2) 60Hz Inlet air pressure Inlet air temperature Cooling water M P a 0 .

  • Page 36: Refrigerant And Gwp

    IDX-OM-Y002 Chapter 7 Documents Note 4) If the operating conditions are different from rated, select the product model according to the selection method specified in the catalogue. Note 5) For the power supply voltage, refer to ‘How to Order’ in the catalogue. Note 6) These values are reference values under rated conditions and are not guaranteed.

  • Page 37: Dimensions

    IDX-OM-Y002 Chapter 7 Documents 7.3 Dimensions 【IDF190D-3-W】 Parts marked with square brackets are included in the package 10K 80 Flange Compressed air inlet 10K 80 Terminal Flange block Compressed air outlet Power supply port signal connection port Cooling water outlet Rc 1/2 Grommet with membrane...

  • Page 38: Electrical Circuit Diagram

    IDX-OM-Y002 Chapter 7 Documents 7.4 Electrical circuit diagram ■IDF190D-3-W Remote operation For Option R Operation Error signal signal Symbol Name Refrigerating compressor PRS2 High pressure switch PRS3 Low pressure switch Phase reverse relay. Terminal block Fuse Main unit/ remote selector switch Start switch Stop switch Remote operation switch...
  • Page 39 IDX-OM-Y002 Chapter 7 Documents ■IDF240D-3-W Remote operation Operation For Option R Error signal signal Symbol Name Refrigerating compressor PRS2 High pressure switch PRS3 Low pressure switch Phase reverse relay. Terminal block Fuse Main unit/ remote selector switch Start switch Stop switch Remote operation switch (Prepared by customer) Electromagnetic...

  • Page 40: Air And Refrigerant Circuits And Functions

    IDX-OM-Y002 Chapter 7 Documents 7.5 Air and refrigerant circuits and functions リヒータ Reheater クーラ Cooler 容量調整弁 Capacity control valve 圧縮空気入口 Compressed air inlet ｷｬﾋﾟﾗﾘﾁｭｰﾌﾞ Capillary tube 空気圧力計 Auto drain Air Pressure gauge ｵｰﾄﾄﾞﾚﾝ 圧縮空気出口 Compressed air outlet 冷媒ドライヤ Refrigerant dryer 蒸発温度計...
  • Page 41 IDX-OM-Y002 Chapter 7 Documents Air circuit The humid hot air that enters the air dryer first goes into the reheater, and exchanges its heat with dehumidified cold air to pre-cool it. Then, the air enters the evaporator, where it releases its heat to a cold HFC, and is dehumidified and cooled further to let moisture separate.
  • Page 42 IDX-OM-Y002 Chapter 7 Documents Air and refrigerant circuits and functions IDF190D/240D Series...

  • Page 43: Chapter 8 Option C

    IDX-OM-Y002 Chapter 8 Option C Chapter 8 Option C 8.1 Specifications Special epoxy resin is coated on the copper tube surface to improve the corrosion resistance. The special epoxy resin is only applied where the copper tubes are not protected or insulated. 8.2 Precautions for installation and handling 1) The epoxy resin minimizes the corrosion of the coated copper tubes against corrosive gas.
  • Page 44 IDX-OM-Y002 Chapter 8 Option C Precautions for installation and handling IDF190D/240D Series...

  • Page 45: Chapter 9 Option M

    IDX-OM-Y002 Chapter 9 Option M Chapter 9 Option M 9.1 Safety instructions for use Refer to the instructions below when handling the product WARNING - Before replacing the auto drain, on the compressed air side confirm that the pressure gauge indicates zero. Do not remove the auto drain with any air pressure remaining internally.

  • Page 46: Specifications

    IDX-OM-Y002 Chapter 9 Option M 9.2 Specifications Motor type auto drain (ADM200) is installed instead of the float type auto drain (standard). Table 1. Models IDF190/ 240D-3-MW Item Product number IDF-S0511 Maximum operating 1.0MPa pressure Fluid Compressed air Operation cycle 4 cycles per minute Operating time 2 sec/ cycle...

  • Page 47: Installation Of Motor Type Auto Drain

    IDX-OM-Y002 Chapter 9 Option M 9.3 Installation of Motor type Auto Drain 1) Screw the nipple and the motor type auto drain (drain inlet port hex size: 30mm) into the connection port of this product in order. Mount the auto drain vertically while facing the drain port downwards. (Allowable inclination difference in the vertical direction is 5°) Note 1) Apply sealant tape or sealant to fit the barrel nipple and long nipple.
  • Page 48 IDX-OM-Y002 Chapter 9 Option M Electrical circuit diagram IDF190D/240D Series...

  • Page 49: Chapter 10 Option R

    IDX-OM-Y002 Chapter 10 Option R Chapter 10 Option R 10.1 Safety instructions for use Refer to the instructions below when handling the product. WARNING All electrical work must be carried out in a safe manner by a qualified person in compliance with applicable national regulations.

  • Page 50: Connection Of Power Supply

    IDX-OM-Y002 Chapter 10 Option R 10.3 Connection of power supply Connect the power cable according to the procedure below. 1) Remove the case of the earth leakage breaker. 2) Insert the power supply cable prepared by customer into the rubber grommet and draw the power supply cable close to the earth leakage breaker through the base hole.

  • Page 51: Chapter 11 Inspection Record

    IDX-OM-Y002 Chapter 11 Inspection record Chapter 11 Inspection record 11.1 Inspection record We recommend keeping the inspection record for maintenance or service. Product No. Description Contents of check Date IDF60/70/80/90 Series 11.1 Inspection record 11-1...
  • Page 52 Revision 4-14-1, Sotokanda, Chiyoda-ku, Tokyo 101-0021 JAPAN Tel: + 81 3 5207 8249 Fax: +81 3 5298 5362 URL https://www.smcworld.com Note: Specifications are subject to change without prior notice and any obligation on the part of the manufacturer. © 2020 SMC Corporation All Rights Reserved...

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