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FRIULAIR ACT VC 3000 - 6000 Manual

Refrigerating air dryer
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Refrigerating air dryer
Air – water cooled
User's maintenance and spare parts manual
EN -
74MD0008A8-EN_00

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Summary of Contents for FRIULAIR ACT VC 3000 - 6000

  • Page 1 Refrigerating air dryer Air – water cooled User’s maintenance and spare parts manual EN - 74MD0008A8-EN_00...
  • Page 2 Dear Customer, thank you for choosing our product. In order to get the best performances out of this product, please read this manual carefully. To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and strictly follow the instructions contained in this manual.

  • Page 3: Table Of Contents

    Contents Safety instructions Safety pictograms in accordance with DIN 4844 Signal words in accordance with ANSI Overview of the safety instructions Proper use of the dryer Exclusion from a field of application Instructions for the use of pressure equipment according to PED directive 2014/68/EU Transport Storage Installation...
  • Page 4 Maintenance, troubleshooting, spare parts and dismantling 12.1 Checks and maintenance 12.2 Troubleshooting 12.3 Spare parts Maintenance operation on the refrigeration circuit 13.1 Dismantling of the dryer Attachments Exploded views – List of components Electric diagrams – List of components 14.1 Dryers dimension 14.1.1 ACT VS 3000 - 3750...

  • Page 5: Safety Instructions

    Safety instructions Safety instructions Please check whether or not these instructions correspond to the device type. Please adhere to all advice given in these operating instructions. They include essential information which must be observed during installation, operation and maintenance. Therefore, it must be ensured that these operating instructions are read by the fitter and the responsible operator / certified skilled personnel prior to installation, start-up and maintenance.

  • Page 6: Safety Pictograms In Accordance With Din 4844

    Safety pictograms in accordance with DIN 4844 Safety pictograms in accordance with DIN 4844 Observe operating instructions General danger symbol Supply voltage Danger: component or system under pressure Hot surfaces Non-breathable air Do not use water to extinguish the fire Do not operate with open cover (housing) Maintenance works or controlling measures must only be carried out by qualified personnel Do not smoke...

  • Page 7: Signal Words In Accordance With Ansi

    Safety pictograms in accordance with DIN 4844 Works can be carried out by the operator of the plant, provided that they are skilled accordingly NOTE: Text that contains important specifications to be considered – does not refer to safety precautions. The device was carefully designed with particular attention paid to environmental protection: •...

  • Page 8: Overview Of The Safety Instructions

    Safety pictograms in accordance with DIN 4844 Overview of the safety instructions Certified skilled personnel Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to undertaking any measures on the compressed-air refrigeration dryer, the certified skilled personnel shall read up on the device by carefully studying the operating instructions.
  • Page 9 Safety pictograms in accordance with DIN 4844 Caution! Improper use! The device is intended for the separation of water in compressed air. The dried compressed air cannot be used for breathing-air purposes and is not suitable for the direct contact with food. This dryer is not suitable for the treatment of contaminated air or of air containing solids.

  • Page 10: Proper Use Of The Dryer

    Proper use of the dryer Proper use of the dryer This dryer has been designed, manufactured and tested for the purpose of separating the humidity normally contained in compressed air. Any other use has to be considered improper. The Manufacturer will not be responsible for any problem arising from improper use; the user will bear responsibility for any resulting damage.

  • Page 11: Transport

    Transport Transport Check for visible loss or damage, if no visible damage is found place the unit near to the installation point and unpack the contents. • To move the packaged unit we recommend using a suitable trolley or forklift truck. Hand carrying is not recommended •...

  • Page 12: Installation

    Installation Installation Place of installation Note! Ambient conditions! In the event that the dryer is not installed under suitable ambient conditions, the ability of the device to condense refrigerant gas is impaired. This can result in a higher load of the refrigerating compressor, and in a loss of efficiency and performance of the dryer.

  • Page 13: Installation Layout

    Installation Installation layout Air compressor Aftercooler Condensate separator Pre-Filter (min. 5 micron) By-pass group Dryer Compressed air tank Final filter Condensate drain Dryer’s compressor and fan (air cooled) speed are adjusted to adapt power consumption to the dryer load. Although system is quite reactive, it cannot adapt its setting immediately to sudden load variation leading to dewpoint spikes/fluctuations.

  • Page 14: Correction Factors

    Installation Correction factors Correction factor for operating pressure changes: Inlet air pressure psig barg Factor (F1) 0.79 0.91 1.00 1.07 1.13 1.18 1.23 1.27 Correction factor for ambient temperature changes (Air-Cooled): Ambient temperature ºF ºC Factor (F2) 1.11 1.09 1.06 1.00 0.94 0.87...

  • Page 15: Connection To The Compressed Air System

    Installation Connection to the compressed air system DANGER! Compressed air! All works must only be carried out by qualified skilled personnel. Never work on compressed-air systems which are under pressure. The operator or the user must ensure that the dryer is never operated with a pressure exceeding the maximum pressure value indicated on the name plate.

  • Page 16: Electrical Connections

    Installation Electrical connections Danger! Supply voltage! The connection to the electric mains should only be carried out by qualified skilled personnel and must correspond to the legal provisions in force in your region. Prior to connecting the device, please check the name plate to avoid exceeding the indicated values. The voltage tolerance is +/- 10%.

  • Page 17: Connection To The Cooling Water Network (Water-Cooled)

    Installation Connection to the cooling water network (Water-Cooled) DANGER! Compressed air! All works must only be carried out by qualified skilled personnel. Never work on compressed-air systems which are under pressure. The operator or the user must ensure that the dryer is never operated with a pressure exceeding the maximum pressure value indicated on the name plate.

  • Page 18: Start-Up

    Start-up Start-up Preliminary operation Note! Exceeding of the operating parameters! Ensure that the operating parameters comply with the nominal values indicated on the name plate of the dryer (voltage, frequency, air pressure, air temperature, ambient temperature etc.). This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unit could be damaged during transportation, check the integrity of the dryer during first start-up and monitor operation during the first hours of operation.

  • Page 19: Start-Up And Shut Down

    Start-up CAUTION! Please observe the direction of rotation of the fix speed compressors! In this system, the direction of rotation of the fix speed compressors is supervised by a reverse- phase protector (RPP). When this guard is triggered, the DMC50 goes into alarm mode (the status bar flashes red and shows alarm n.5 “Compressor Protection”).

  • Page 20: Technical Data

    Technical data 10 Technical data 10.1 Technical data 3000 – 6000 Air-Cooled Water-Cooled 20 – EN ACT VS 3000 - 6000...

  • Page 21: Technical Description

    Technical data 11 Technical description 11.1 Control panel The control panel explained below is the only dryer user interface. Main switch Electronic instrument DMC50 11.2 Operation Operating principle - The dryer models described in this manual operate all on the same principle. The hot moisture laden air enters an air to air heat exchanger.

  • Page 22: Flow Diagram (Air-Cooled)

    Technical data 11.3 Flow diagram (Air-Cooled) 12.4 P< 12.3 P> 12.2 12.1 11.4 Flow diagram (Water-Cooled) 12.4 P< 12.3 P> 12.2 12.4 12.1 Alu-Dry module Condenser (Water-Cooled) Air-to-air heat exchanger Condenser water regulating valve (Water-Cooled) Air-to-refrigerant heat exchanger Refrigerant accumulator Condensate separator Electronic drainer Refrigerant pressure switch LPS...

  • Page 23: Refrigerating Compressor

    Technical data 11.5 Refrigerating compressor The refrigerating compressor is the pump of the system, gas coming from the evaporator (low pressure side) is compressed up to the condensation pressure (high pressure side). Dryer is equipped with multiple compressors, of which one in variable speed. Variable speed compressor It is used a scroll fully hermetic compressor encapsulated with a BLDC (Brush Less Direct Current) motor which is the latest and most efficient technology available for this application.

  • Page 24: Electronic Expansion Valve (Eev)

    Technical data 11.10 Electronic Expansion Valve (EEV) The electronic expansion valve (EEV) is an expansion device which is composed by a valve body operated from a stepper motor. This component is managed from its driver according to heat exchanger superheating. This parameter is calculated from the driver using a temperature sensor BS and a pressure sensor BP installed at evaporator outlet refrigerant pipe.

  • Page 25: Dmc50 Electronic Control Unit

    Technical data 11.15 DMC50 electronic control unit The DMC50 electronic control unit is a device which controls the dryer's functional processes, provides a dialogue interface for the operator, and consists of a power module within the control panel and a touch screen module positioned on the front panel of the dryer.

  • Page 26: Displaying Process Values T1, T2, T3, T4, Hp, Lp

    Technical data 11.15.4 Displaying process values T1, T2, T3, T4, HP, LP, % 1- With the dryer operating (ON mode) press the button to access the dryer's menu. 2- Press the button to display the refrigeration circuit diagram and the dryer's instantaneous process values: ➢...

  • Page 27: How The Dmc50 Control Unit Displays And Processes A Service Warning

    Technical data 11.15.5 How the DMC50 control unit displays and processes a service warning The service warning is an irregular event that must be flagged to operators/maintenance technicians. It does not jeopardise the safety of the machine/operators and it does not stop the dryer, with the exception of the HdS parameter (STOP dryer due to high dew point), which can be set to stop the dryer.

  • Page 28: How The Dmc50 Control Unit Displays And Processes An Alarm

    Technical data 11.15.6 How the DMC50 control unit displays and processes an alarm The alarm is an irregular event that always causes the dryer to stop to ensure the safety of operators and the machine. In the presence of an alarm the status bar shows a description of the event and turns flashing red. In this condition it is not possible to reset the alarm as the cause is still present.
  • Page 29 Technical data Alarm Description Delay Reset - Pressure switches - Pressure switch HPS or Contact Flag Restore LPS has triggered open immediately contact Refrigerant pressure High or LOW - Expansion valve - Contact Flag Restore Electronic Expansion Valve EEV fault open immediately contact...

  • Page 30: Displaying The Log File Of Stored Alarms

    Technical data 11.15.7 Displaying the log file of stored alarms 1- With the dryer stopped (STANDBY) or operating (ON mode), ress the button to access the dryer's menu of functions. 2- Press the button to display the log file for the last 50 alarms stored. 3- Scroll through the list of alarms using the buttons.

  • Page 31: Downloading The Process Values Stored Following An Alarm

    Technical data 11.15.8 Downloading the process values stored following an alarm NOTE! Only qualified skilled personnel should perform following operations. Process values for stored alarms can be downloaded in .txt format onto a USB stick after resetting an alarm (see section 10.15.6, step 7-), or from the screen for consulting the alarms log file (see section 10.15.7, step 7-).

  • Page 32: Displaying Technical Maintenance And Energy Savings Data

    Technical data 11.15.10 Displaying technical maintenance and energy savings data 1- With the dryer stopped (STANDBY) or operating (ON mode), press the button to access the dryer's menu of functions. 2- Press the button to display: ➢ 2a- The total percentage of energy savings for the dryer, with respect to its continuous operation at 100%.

  • Page 33: Controlling The Dryer From A Remote Workstation

    Technical data 11.15.11 Controlling the dryer from a remote workstation DMC50 power module is provided with a digital input set up for dryer start up (ON) - stop (STANDBY) mode from a remote workstation. 1- Only qualified and skilled personnel are authorized to run electrically- operated devices.

  • Page 34: Displaying / Changing Process User Parameters

    Technical data 11.15.14 Displaying / changing process user parameters 1- With the dryer stopped (STANDBY) or operating (ON mode), press the button to access the dryer's menu of functions. 2- Press the button to display the list of process user parameters and respective current settings.
  • Page 35 Technical data Factory Description Limits Scale setting - Dryer Remote Control - Local / Local Enables/disables dryer remote control Remote 0…25.0°C - High Dewpoint Alarm - 0.5°C 20.0°C Sets the service warning intervention threshold 32…77°F high dew point 1°F 68°F - High Dewpoint Delay - 1…20 Sets the service warning delay time...

  • Page 36: Changing The System Date / Time

    Technical data 11.15.15 Changing the system date / time 1- With the dryer stopped (STANDBY) or operating (ON mode), press the button to access the dryer's menu of functions. 2- Press the button to display the list of process user parameters and respective current settings.

  • Page 37: Electronic Drainer

    Technical data 11.16 Electronic drainer This drain consists of a condensate accumulator where a capacitive sensor checks the liquid level continuously: as soon as the accumulator is filled, the sensor passes a signal to the electronic control and a diaphragm solenoid valve will open to discharge the condensate.
  • Page 38 Maintenance, troubleshooting, spare parts and dismantling 12 Maintenance, troubleshooting, spare parts and dismantling 12.1 Checks and maintenance Certified skilled personnel Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to undertaking any measures on the compressed-air refrigeration dryer, the certified skilled personnel shall read up on the device by carefully studying the operating instructions.
  • Page 39 Maintenance, troubleshooting, spare parts and dismantling DAILY: • Check whether the dew point indicated on the electronics is correct. • Ensure that the condensate drain system functions properly. • Make sure that the condenser is clean. EVERY 200 HOURS OR MONTHLY •...
  • Page 40 Maintenance, troubleshooting, spare parts and dismantling Prior to carrying out maintenance works at the dryer, switch it off main switch (control panel pos.1) and wait for at least 30 minutes. Caution! Hot surfaces! During operation, several components can reach surface temperatures of more than +60°C. There is the risk of burns.
  • Page 41 Maintenance, troubleshooting, spare parts and dismantling Contact a refrigeration engineer to verify and compare the correct evaporating pressure value. If required replace BLP pressure transducer and/or DMC50 controller.  One or more Electronic Expansion Valve EEV doesn't work properly - see specific point. ◆...
  • Page 42 Maintenance, troubleshooting, spare parts and dismantling  ◆ Compressor Check which of the following has caused the failure: 1. Excessive thermal load – restore nominal conditions. discharge temperature too 2. The inlet air is too hot - restore nominal conditions. high.
  • Page 43 Maintenance, troubleshooting, spare parts and dismantling  ◆ Status area blinking red : one or more alarms are active. The display shows the ID code Electronic and the description of the active alarm. controller DMC50  Status area steady red : one or more alarms need to be reset. The display shows the ID in alarm condition code and the description of alarm which is no longer active but which still need to be (status area red...
  • Page 44 Maintenance, troubleshooting, spare parts and dismantling 27 – Fault in condenser fan drive, replace the driver. 28 – Fault in condenser fan drive, replace the driver. 29 – Power board over temp – Heatsink cut-out temperature has been reached. Check and correct: - ambient temperature is too high - restore nominal conditions (Air-Cooled).
  • Page 45 Maintenance, troubleshooting, spare parts and dismantling information refer to the manual of the refrigerant compressor driver. To reset the alarm conditions, switch off the dryer main switch (Control panel pos.1) wait at least 60 seconds, and then restore the power. If one or more alarms are active, the compressor drive’s display will show active alarm code number.
  • Page 46 Maintenance, troubleshooting, spare parts and dismantling  ◆ Electronic Status area blinking orange : one or more service warnings are active. The display shows the ID code and the description of the active warning. controller DMC50  Status area steady orange : one or more service warnings need to be reset. The display in service warning shows the ID code and the description of warning which is no longer active but which still condition (status...
  • Page 47 Maintenance, troubleshooting, spare parts and dismantling Electronic Expansion Valve EEV doesn't Each dryer is equipped with a DRVD display (display for DRV available in the following work properly picture) required for DRV troubleshooting. 1. DRVD display Connect the DRVD display to each DRV, one by one, in order to check which of the following has caused the activation: 1.
  • Page 48 Maintenance, troubleshooting, spare parts and dismantling 12.3 Spare parts Spare parts list is printed on a dedicated sticker applied inside the dryer. On this sticker each spare part is identified with its ID Number and related Spare Part Number. Here below the cross reference table between ID Numbers and exploded drawings Ref.
  • Page 49 Maintenance operation on the refrigeration circuit 13 Maintenance operation on the refrigeration circuit Caution! Refrigerant! Maintenance and repair works at refrigeration systems must only be carried out by certified refrigerating engineers only in accordance with the local provisions. The total amount of refrigerant in the system must be collected for recycling purposes, resource recovery or disposal.
  • Page 50 Attachments 14 Attachments Exploded views – List of components Alu-Dry module Condenser fan variable speed drive INV2 Insulation material Electrical panel fan Refrigerant pressure switch LPS Oil separator Refrigerant pressure switch HPS Electrical panel filter Compressor MC1 VS Front panel Compressor MC2 –...
  • Page 51 Attachments 14.1 Dryers dimension 14.1.1 ACT VS 3000 - 3750 14.1.2 ACT VS 4000 - 5000 14.1.3 ACT VS 6000 Air-Cooled 14.1.4 ACT VS 6000 Water-Cooled 14.2 Exploded views 14.2.1 ACT VS 3000 – 3750 Air-Cooled 14.2.2 ACT VS 3000 – 3750 Water-Cooled 14.2.3 ACT VS 4000 –...
  • Page 52 Attachments 52 – EN ACT VS 3000 - 6000...
  • Page 53 Attachments ACT VS 3000 - 6000 EN - 53...
  • Page 54 COSTRUTTORE / MANUFACTURER : FRIULAIR S.r.l. Sede Legale e Operativa: 33050 - Cervignano del Friuli (UD) – ITALY Via Cisis, 36 - S.S.352 Km 21 Fraz. Strassoldo www.friulair.com Istruzioni originali in ITALIANO - Con riserva di modifiche ed errori Original instructions are in ITALIAN - Subject to technical changes without prior notice; errors not excluded...

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