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Summary of Contents for FRIULAIR ACT ES 20-500
- Page 1 Refrigerating air dryer ACT ES 20 – 500 EN - User’s maintenance and spare parts manual 7425MUM320_EN_04.0...
- 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.
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Page 3: Table Of Contents
Contents 1 Identification plate 5 2 Warranty conditions 5 3 Safety rules 6 3.1 Definition of the conventional signs used in this manual 6 3.2 Warnings 7 3.3 Proper use of the dryer 7 3.4 Instructions for the use of pressure equipment according to PED directive 97/23/EC 8 ... - Page 4 Exploded views – List of components 36 Electric diagrams – List of components 36 9.1 Dryers dimensions 37 9.1.1 ACT ES 20 – 50 37 9.1.2 ACT ES 75 38 9.1.3 ACT ES 100 – 150 39 9.1.4 ACT ES 200 – 250 40 ...
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Page 5: Identification Plate
Identification plate Identification plate The identification plate is located on the back of the dryer and shows all the primary data of the machine. This data should always be referred to when calling the manufacturer or distributor. The removal or alteration of the identification plate will void the warranty rights. -
Page 6: Safety Rules
Safety rules Safety rules Definition of the conventional signs used in this manual Carefully read instruction manual before attempting any service or maintenance procedures on the dryer. Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not followed properly. -
Page 7: Warnings
Safety rules Warnings Compressed air is a highly hazardous energy source. Never work on the dryer with pressure in the system. Never point the compressed air or the condensate drain outlet hoses towards anybody. The user is responsible for the proper installation of the dryer. Failure to follow instructions given in the “Installation”... -
Page 8: Instructions For The Use Of Pressure Equipment According To Ped Directive 97/23/Ec
Installation Instructions for the use of pressure equipment according to PED directive 97/23/EC To ensure the safe operation of pressure equipments, the user must conform strictly to the above directive and the following: 1. The equipment must only be operated within the temperature and pressure limits stated on the manufacturer’s data nameplate. -
Page 9: Installation Site
Installation Installation site Failure to install dryer in the proper ambient conditions will affect the dryer’s ability to condense refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and performance, overheated condenser fan motors, electrical component failure and dryer failure due to the following: compressor loss, fan motor failure and electrical component failure. -
Page 10: Installation Layout
Installation Installation layout 1 Air compressor 2 Aftercooler 3 Condensate separator 4 Pre-Filter (min. 5 micron) 5 By-pass group 6 Dryer 7 Compressed air tank 8 Final filter 9 Condensate drain In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the heat exchanger. -
Page 11: 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 : Ambient temperature ºF ºC Factor (F2) 1.11 1.09 1.06 1.00 0.94 0.87... -
Page 12: Connection To The Compressed Air System
Installation Connection to the compressed air system Operations to be performed by qualified personnel only. Never work on system under pressure. The user is responsible to ensure that the dryer will never be operated with pressure exceeding the maximum pressure rating on the unit data tag. Over-pressurizing the dryer could be dangerous for both the operator and the unit. -
Page 13: Start-Up
Start-up Start-up Preliminary operation Verify that the operating parameters match with the nominal values stated on the data nameplate 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 14: Start-Up And Shut Down
Start-up Start-up and shut down ACT ES 200-500 3phase - For short periods of inactivity, (max 2-3 days) we recommend that power is maintained to the dryer and the control panel. Otherwise, before re-starting the dryer, it is necessary to wait at least 2 hours for the compressor crankcase heater to heat the oil of the compressor. -
Page 15: Technical Data
Technical data Technical data Technical data ACT ES 20 – 200 1/115/60 ACT ES 20 – 500 15 – EN... -
Page 16: Technical Data Act Es 20 - 500 1/230/60
Technical data Technical data ACT ES 20 – 500 1/230/60 16 – EN ACT ES 20 – 500... -
Page 17: Technical Data Act Es 200 - 500 3Phase 3/460/60
Technical data Technical data ACT ES 200 – 500 3phase 3/460/60 ACT ES 20 – 500 17 – EN... -
Page 18: Technical Data Act Es 200 - 500 3Phase 3/575/60
Technical data Technical data ACT ES 200 – 500 3phase 3/575/60 18 – EN ACT ES 20 – 500... -
Page 19: Technical Description
Technical description Technical description Control panel The control panel illustrated below is the only dryer-operator interface. ACT ES 20 – 100 1 ON-OFF switch 2 Electronic instrument reset 3 Air and refrigerant gas flow chart ACT ES 125 – 500 1 ON-OFF switch 2 Electronic instrument reset... -
Page 20: Operation
Technical description 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. The air then goes through the evaporator, also known as the air to refrigerant heat exchanger. -
Page 21: Flow Diagram
Technical description Flow diagram 12.2 P< P> 12.1 Alu-Dry module Filter dryer Air-to-air heat exchanger Capillary tube 1b Air-to-refrigerant heat exchanger 12.1 Temperature probe T1 – DewPoint Condensate separator 12.2 Temperature probe T2 Refrigerant pressure switch LPS Compressor discharge (ACT ES 125-500) (ACT ES 300-500 &... -
Page 22: Refrigerating Compressor
Technical description Refrigerating compressor The refrigerating compressor is the pump in the system, gas coming from the evaporator (low pressure side) is compressed up to the condensation pressure (high pressure side). The compressors utilized are manufactured by leading manufacturers and are designed for applications where high compression ratios and wide temperature changes are present. -
Page 23: Hot Gas By-Pass Valve
Technical description Hot gas by-pass valve This valve injects part of the hot gas (taken from the discharge side of the compressor) in the pipe between the evaporator and the suction side of the compressor, keeping the evaporation temperature/pressure constant at approx. +2 °C. This injection prevents the formation of ice inside the dryer evaporator at every load condition. -
Page 24: Electronic Instrument Dmc51
Technical description 7.12 Electronic instrument DMC51 Led - temperature in °C Led - temperature in °F Led - compressor ON Led – Alarm reset Led - service warning Button – access configuration menu / Discharge temp. Button – decrease / service DISPLAY Button –... -
Page 25: How A Service Warning Is Displayed
Technical description 7.12.4 How a service warning is displayed A service warning is an exceptional event and requires the attention of the operator/service technician. The dryer will not be stopped. When a service warning is active, the Led flashes. When a service warning is no longer active but not reset yet (so it has been stored) Led is continuously on. -
Page 26: Operation Of The Service Warning / Alarm Signal
Technical description 7.12.6 Operation of the service warning / alarm signal The DMC 51 is equipped with a 12Vdc signal (max 15 mA) to indicate service warning or alarm conditions. Dryer is switched on, no service warning and no alarm (active and not yet reset) are indicated. -
Page 27: Electronic Drainer
Technical description 7.13 Electronic drainer This drainer consists of a condensate accumulator where a capacitive sensor continuously checking liquid level is placed: 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. For a complete condensate discharge the valve opening time will be adjusted exactly for each single drain operation. -
Page 28: Maintenance, Troubleshooting, Spare Parts And Dismantling
Maintenance, troubleshooting, spare parts and dismantling Maintenance, troubleshooting, spare parts and dismantling Checks and maintenance Only qualified personnel should perform troubleshooting and or maintenance operations. Prior to performing any maintenance or service, be sure that : no part of the machine is powered and that it cannot be connected to the mains supply. -
Page 29: Troubleshooting
Maintenance, troubleshooting, spare parts and dismantling Troubleshooting Only qualified personnel should perform troubleshooting and or maintenance operations. Prior to performing any maintenance or service, be sure that : no part of the machine is powered and that it cannot be connected to the mains supply. - Page 30 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION The compressor does not work – see specific point. Dew point too The DewPoint probe T1 doesn’t correctly detect the temperature - ensure the high. sensor is pushed into the bottom of probe well.
- Page 31 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION If installed - untreated air flows through the bypass unit – close the bypass. Water within The dryer does not drain condensate – see specific point. the line.
- Page 32 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION Check which of the following reasons has caused the alarm: If T2 installed: 1. Excessive thermal load – restore the standard operating conditions. the alarm 2. The inlet air is too hot – restore the nominal conditions. (Hdt) 3.
- Page 33 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION DMC51 - The With LED flashing, one or more service warnings are active. is ON With LED lit: one or more service warnings are waiting to be reset. The or flashing display shows the dew point temperature and the active or not reset service warning.
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Page 34: Spare Parts
Maintenance, troubleshooting, spare parts and dismantling Spare parts The suggested spare parts list will enable you to promptly intervene in case of abnormal operation, so avoiding to wait for the spares delivery. In case of failure of other parts, for example inside the refrigerating circuit, the replacement must be worked out by a refrigerating systems specialist or in our factory. -
Page 35: Maintenance Operation On The Refrigeration Circuit
Maintenance, troubleshooting, spare parts and dismantling Maintenance operation on the refrigeration circuit Maintenance and service on refrigerating systems must be carried out only by certified refrigerating engineers only, according to local rules. All the refrigerant of the system must be recovered for its recycling, reclamation or destruction. Do not dispose the refrigerant fluid in the environment. -
Page 36: Attachments
Attachments Attachments Exploded views – List of components Alu-Dry module Front panel 1.1 Insulation material Back panel Refrigerant pressure switch LPS Right lateral panel Refrigerant pressure switch HPS Left lateral panel Refrigerant pressure switch PV Cover Compressor Base plate Hot-gas bypass valve Upper plate Condenser Support beam... -
Page 37: Dryers Dimensions
Attachments Dryers dimensions 9.1.1 ACT ES 20 – 50 ACT ES 20 – 500 37 – EN... - Page 38 Attachments 9.1.2 ACT ES 75 38 – EN ACT ES 20 – 500...
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Page 39: Act Es 100 - 150
Attachments 9.1.3 ACT ES 100 – 150 ACT ES 20 – 500 39 – EN... -
Page 40: Act Es 200 - 250
Attachments 9.1.4 ACT ES 200 – 250 40 – EN ACT ES 20 – 500... -
Page 41: Act Es 300 - 350
Attachments 9.1.5 ACT ES 300 – 350 ACT ES 20 – 500 41 – EN... -
Page 42: Act Es 400 - 500
Attachments 9.1.6 ACT ES 400 – 500 42 – EN ACT ES 20 – 500... -
Page 43: Act Es 200 - 250 3Phase
Attachments 9.1.7 ACT ES 200 – 250 3phase ACT ES 20 – 500 43 – EN... -
Page 44: Act Es 300 - 350 3Phase
Attachments 9.1.8 ACT ES 300 – 350 3phase 44 – EN ACT ES 20 – 500... -
Page 45: Act Es 400 - 500 3Phase
Attachments 9.1.9 ACT ES 400 – 500 3phase ACT ES 20 – 500 45 – EN... -
Page 46: Exploded Views
Attachments Exploded views 9.2.1 ACT ES 20 – 30 46 – EN ACT ES 20 – 500... - Page 47 Attachments 9.2.2 ACT ES 50 ACT ES 20 – 500 47 – EN...
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Page 48: Act Es
Attachments 9.2.3 ACT ES 75 48 – EN ACT ES 20 – 500... -
Page 49: Act Es 100
Attachments 9.2.4 ACT ES 100 ACT ES 20 – 500 49 – EN... -
Page 50: Act Es 125 - 150
Attachments 9.2.5 ACT ES 125 – 150 50 – EN ACT ES 20 – 500... -
Page 51: Act Es 200 - 250
Attachments 9.2.6 ACT ES 200 – 250 ACT ES 20 – 500 51 – EN... -
Page 52: Act Es 300 - 350
Attachments 9.2.7 ACT ES 300 – 350 52 – EN ACT ES 20 – 500... -
Page 53: Act Es 400 - 500
Attachments 9.2.8 ACT ES 400 – 500 ACT ES 20 – 500 53 – EN... -
Page 54: Act Es 200 - 250 3Phase
Attachments 9.2.9 ACT ES 200 – 250 3phase 54 – EN ACT ES 20 – 500... -
Page 55: Act Es 300 - 350 3Phase
Attachments 9.2.10 ACT ES 300 – 350 3phase ACT ES 20 – 500 55 – EN... -
Page 56: Act Es 400 - 500 3Phase
Attachments 9.2.11 ACT ES 400 – 500 3phase 56 – EN ACT ES 20 – 500... -
Page 57: Electric Diagrams
Attachments Electric diagrams 9.3.1 ACT ES 20 – 100 ACT ES 20 – 500 57 – EN... -
Page 58: Act Es 125 - 150
Attachments 9.3.2 ACT ES 125 – 150 58 – EN ACT ES 20 – 500... -
Page 59: Act Es 200 - 250
Attachments 9.3.3 ACT ES 200 – 250 ACT ES 20 – 500 59 – EN... -
Page 60: Act Es 300 - 350
Attachments 9.3.4 ACT ES 300 – 350 60 – EN ACT ES 20 – 500... -
Page 61: Act Es 400 - 500
Attachments 9.3.5 ACT ES 400 – 500 ACT ES 20 – 500 61 – EN... -
Page 62: Act Es 200 - 500 3Phase Sheet 1 Of 3
Attachments 9.3.6 ACT ES 200 – 500 3phase Sheet 1 of 3 62 – EN ACT ES 20 – 500... -
Page 63: Act Es 200 - 500 3Phase Sheet 2 Of 3
Attachments 9.3.7 ACT ES 200 – 500 3phase Sheet 2 of 3 ACT ES 20 – 500 63 – EN... -
Page 64: Act Es 200 - 500 3Phase Sheet 3 Of 3
Attachments 9.3.8 ACT ES 200 – 500 3phase Sheet 3 of 3 64 – EN ACT ES 20 – 500... -
Page 65: Blank Pages
Blank pages 10 Blank pages ACT ES 20 – 500 65 – EN... - Page 66 Blank pages 66 – EN ACT ES 20 – 500...
- Page 67 Blank pages ACT ES 20 – 500 67 – EN...
- Page 68 COSTRUTTORE / MANUFACTURER : FRIULAIR S.r.l. Sede Legale: 34077 - Ronchi dei Legionari (GO) – ITALY Via Joze Srebernic, 10 Cap.Soc. € 12.480 i.v. P.IVA 00430110312 Export MGO001913 COD.ID.CEE IT 00430110312 R.E.A.GO n.51691 Cod.Fisc.e Reg.Impr. 00430110312 Sede Operativa: 33050 - Cervignano del Friuli (UD) – ITALY Via Cisis, 36 - S.S.352 Km 21 Fraz.
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