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REFRIGERATED AIR DRYER
WARRANTY NOTICE
Failure to follow the instructions and
procedures in this manual or, misuse of this
equipment will VOID its warranty!
USER MANUAL
SR 10-480 AC
SAFETY WARNING
Users are required to read the entire User
Manual before handling or using the product.
Keep the User Manual in a safe place for
future reference.
MANUAL PART NUMBER:
02250246-045 R02
©SULLAIR LLC
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Summary of Contents for Sullair SR 10 AC
- Page 1 Failure to follow the instructions and Manual before handling or using the product. procedures in this manual or, misuse of this Keep the User Manual in a safe place for equipment will VOID its warranty! future reference. MANUAL PART NUMBER: 02250246-045 R02 ©SULLAIR LLC...
- Page 2 User Manual US-EN SR 10-480 AC Dear customer, Thank you for deciding in favour of the SR 10-480 AC compressed-air refrigeration dryer. Please read these installation and operating instructions carefully before mounting and starting up the SR 10-480 AC and follow our directions. Perfect functioning of the SR 10-480 AC and thus reliable compressed-air drying can only be guaranteed when the provisions and notes stipulated here are strictly adhered to.
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Page 3: Table Of Contents
User Manual US-EN SR 10-480 AC Contents Name plate Safety instructions Safety pictograms in accordance with DIN 4844 Signal words in accordance with ANSI Overview of the safety instructions Proper use 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 User Manual US-EN SR 10-480 AC 11.8 Aluminium heat exchanger 11.9 Hot-gas bypass valve 11.10 Refrigerant pressure switches LPS – HPS – PV 11.11 Safety temperature switch TS 11.12 DMC 15 electronics (control unit compressed-air dryer) 11.12.1 Switching the dryer on 11.12.2 Switching the dryer off 11.12.3...
- Page 5 Electric diagram SR 220 AC 13.3.5 Electric diagram SR 300 AC 13.3.6 Electric diagram SR 375 AC 13.3.7 Electric diagram SR 480 AC Pos: 1 /Sullair Technische Dokumentation/Überschriften/1/Sicherheitshinweise @ 0\mod_1183637609261_6.doc @ 5365 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions.
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Page 6: Name Plate
Pos : 2 /Sull air Technisc he Dokumentation/Global e T e xte/Allgemei ner Hinweis BM @ 0\mod_1183615737313_6.doc @ 4004 Pos : 3 /Sull air Technisc he Dokumentation/Sicherheit/Hi nweis Anl eitung SULLAIR @ 0\mod_1184147787557_6.doc @ 5758 Please check whether or not these instructions correspond to the device type. -
Page 7: Safety Pictograms In Accordance With Din 4844
Do not operate with open cover (housing) Maintenance works or controlling measures must only be carried out by qualified personnel Do not smoke Note Pos: 4 /Sullair Technische Dokumentation/Sicherheit/Gefahr Druckluft @ 0\mod_1184148143854_6.doc @ 5 ARIA Connection point compressed-air inlet LUFT... -
Page 8: Signal Words In Accordance With Ansi
User Manual US-EN SR 10-480 AC ARIA Connection point compressed-air outlet LUFT Connection point condensate drain 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 9 User Manual US-EN SR 10-480 AC For safe operation, the device must only be installed and operated in accordance with the indications in the operating instructions. In addition, the national and operational statutory provisions and safety regulations, as well as the accident prevention regulations required for the respective case of application, need to be observed during employment.
- Page 10 User Manual US-EN SR 10-480 AC os: 5 /Sullair Technische Dokumentation/Sicherheit/Maßnahmen Druckluft BM @ 0\mod_1184148284291_6.doc @ 5812 Pos: 6 /Sullair Technische Dokumentation/Sicherheit/Gefahr Netzspannung @ 0\mod_1184148186948_6.doc @ 5794 Danger! Supply voltage! Contact with non-insulated parts carrying supply voltage involves the risk of an electric shock resulting in injuries and death.
- Page 11 User Manual US-EN SR 10-480 AC All components concerned are installed inside of the closed housing. The housing must only be opened by certified skilled personnel Caution! Improper use! The device is intended for the separation of water in compressed air. The dried air cannot be used for breathing-air purposes and is not suitable for the direct contact with food.
- Page 12 Do not install the dryer in an environment in which chemicals with a corrosive effect, explosive gases, toxic gases, evaporation heat, high ambient temperatures or extreme dust and dirt can be found. Pos : 12 /Sullair T ec hnische D okumentati on/Übersc hriften/1/Besti mmungsgemäß e Ver wendung @ 0 \mod_1183637706293_6.doc @ 5383 02250246-045 R02...
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Page 13: Proper Use
This dryer is not suitable for the treatment of contaminated air or of air containing solids. Pos : 16 /Sullair T ec hnische D okumentati on/Besti mmungsgemäß e Ver wendung/ SULLIM AX/Aussc hl uß Anwendung BM 31/32/33 @ 0\mod_1236003837511_6.doc @ 13736... - Page 14 User Manual US-EN SR 10-480 AC • No objects whatsoever must be installed at or placed on the SR 10-480 AC compressed-air refrigeration dryer and the connecting lines. • Installation of the plant in frost-free places only. • Operation of the plant is only permissible with fully closed and intact housing and cover panels. Operation of the plant with damaged housing/cover panels is prohibited.
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Page 15: Transport
User Manual US-EN SR 10-480 AC Transport Check the packaging for visible loss or damage. If no visible damage can be ascertained, place the unit in close proximity to the place of installation and unpack the device. During this procedure, the dryer must always remain in an upright position. The components may be damaged when the unit is tilted or turned upside down. -
Page 16: Installation Plan
Contaminated intake air! In the event that the intake air is strongly contaminated (ISO 8573.1 class 3.-3 or poorer quality), we recommend the additional installation of a prefilter (e.g. Sullair SXT or SXF), to avoid clogging of the heat exchanger. 02250246-045 R02... -
Page 17: Correction Factors
User Manual US-EN SR 10-480 AC Correction factors Correction factor for operating pressure modifications: 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 modifications: Ambient temperature ºF ºC Factor (F2) 1.10 1.07 1.04... -
Page 18: Connection To The Compressed-Air System
User Manual US-EN SR 10-480 AC 75 x 1.07 x 0.93 x 0.65 x 1.25 = 61 scfm (104 m³/h) Actual air throughput = 61 scfm (104 m³/h) is the maximum flow rate of the dryer under the aforementioned operating conditions. Selection of the best suitable model in accordance with the operating conditions: Requ. -
Page 19: Electrical Connections
Contaminated intake air! In the event that the intake air is strongly contaminated (ISO 8573.1 class 3.-3) or poorer quality, we recommend the additional installation of a prefilter (e.g. Sullair STX or SXF), to avoid clogging of the heat exchanger. -
Page 20: Start-Up Preliminary Stages
User Manual US-EN SR 10-480 AC Start-up Preliminary stages 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.). Prior to delivery, this dryer was thoroughly tested, packed and checked. -
Page 21: Shut Down And Restart
User Manual US-EN SR 10-480 AC – wait for the first interventions. • Ensure that the fan runs properly • Wait until the dew point remains stable. • Slowly open the air inlet valve. • Slowly open the air outlet valve. •... - Page 22 User Manual US-EN SR 10-480 AC The user is responsible for the compliance with these provisions. Irreparable damage can be caused when starting up the device too often. 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions.
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Page 23: Technical Data
User Manual US-EN SR 10-480 AC 10 Technical data 10.1 Technical data SR 10-480 -P (1/115/60) UL 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 24: Technical Data Sr 125-480 Na -E (1/230/60) Ul
User Manual US-EN SR 10-480 AC 10.2 Technical data SR 125-480 NA -E (1/230/60) UL 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 25: Technical Description
User Manual US-EN SR 10-480 AC 11 Technical description 11.1 Control panel The control panel explained below is the only dryer user interface. SR 10 – 175 AC DMC 15 sec - min SR 220 – 480 AC DMC 15 sec - min ON-OFF Switch Electronic instrument... - Page 26 User Manual US-EN SR 10-480 AC pressure. The liquid is pressed through a capillary tube where the resulting pressure drop ensures that the refrigerant evaporates at a defined temperature. The liquid refrigerant which is under low pressure is led into the heat exchanger, where it expands.
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Page 27: Flow Chart
User Manual US-EN SR 10-480 AC 11.3 Flow chart Sullimax Aluminium heat exchanger module Condenser fan a – Air/air heat exchanger Filter dryer b – Air/refrigerant heat exchanger Capillary tube 12.1 c – Condensate separator T1 temperature sensor (dew point) 12.2 Refrigerant pressure switch LPS (SR 480) Temperature probe T2 –... -
Page 28: Refrigerating Compressor
User Manual US-EN SR 10-480 AC 11.4 Refrigerating compressor The employed refrigerating compressors are constructed by leading manufacturers. The hermetically sealed construction is absolutely gastight. The integrated safeguard protects the compressor against overheating and excess current. The protection is automatically reset as soon as the nominal conditions are reached again. 11.5 Condenser The condenser is the component in which the gas coming from the compressor is cooled down, condensed and liquefied. - Page 29 User Manual US-EN SR 10-480 AC ADJUSTMENT The hot gas by-pass valve is adjusted during the manufacturing testing phase. As a rule no adjustment is required; anyway if it is necessary the operation must be carried out by an experienced refrigerating engineer. 4 mm 5/32 in.
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Page 30: Refrigerant Pressure Switches Lps - Hps - Pv
User Manual US-EN SR 10-480 AC 11.10 Refrigerant pressure switches LPS – HPS – PV To ensure the operational reliability and the protection of the dryer, a series of pressure switches are installed in the gas cycle. LPS : Low-pressure guard on the suction side of the compressor, which is triggered when the pressure drops below the predetermined value. -
Page 31: Dmc 15 Electronics (Control Unit Compressed-Air Dryer)
User Manual US-EN SR 10-480 AC 11.12 DMC 15 electronics (control unit compressed-air dryer) Led – Power ON DMC15 Led - Drain ON sec - min Led – Condenser fan ON (SR 10-100) Button – Setup menu access DISPLAY Button – Increase / Drain test The DMC15 displays DewPoint temperature, controls the condenser fan activation and the timed drainer. - Page 32 User Manual US-EN SR 10-480 AC NOTE : fan is forced always ON. Display 10th (right) led is flashing DewPoint too high DewPoint too low Display 1st (left) led is flashing (lower than -1°C / 30°F). 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions.
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Page 33: Control Of The Condenser Fan (Sr 10-100)
User Manual US-EN SR 10-480 AC 11.12.4 Control of the condenser fan (SR 10-100) A temperature probe T2 is located on the discharge side of the condenser. The condenser fan is activated (ON) when the T2 temperature is higher than FANon setting (standard 35°C / 96°F) and led is ON. -
Page 34: Maintenance, Troubleshooting, Spare Parts And Dismantling
User Manual US-EN SR 10-480 AC These Sullimax condensate drains were designed in particular for the operation in a refrigeration dryer. The installation in other compressed-air processing systems or the replacement with another drain brand can lead to malfunction. The maximum operating pressure (see name plate) must not be exceeded! Ensure that the upstream valve is open when the dryer starts operation. - Page 35 User Manual US-EN SR 10-480 AC Only qualified and skilled personnel are authorised to run electrically-operated devices. Prior to undertaking maintenance measures at the device, the following requirements must be met: Make sure that the power supply is switched off and that the device is off and marked for maintenance measures.
- Page 36 User Manual US-EN SR 10-480 AC 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 •...
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Page 37: Troubleshooting
User Manual US-EN SR 10-480 AC 12.2 Troubleshooting Certified skilled personnel Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to undertaking any measures on the SR 10-480 AC compressed-air refrigeration dryer, the certified skilled personnel shall read up on the device by carefully studying the operating instructions. - Page 38 SR 10-100 - The DMC15 electronic instrument is faulty – replace it. work SR 125-480 - The PV pressure switch is defective. Contact a SULLAIR service technician. There is a leak in the refrigeration cycle – contact a SULLAIR service technician.
- Page 39 The dryer does not discharge the condensate – see the corresponding point. The hot-gas bypass valve needs to be re-adjusted – contact a SULLAIR service technician to have the nominal setting re-established. There is a leak in the refrigeration cycle – contact a SULLAIR service technician.
- Page 40 Reset the pressure switch by pressing the button on the controller itself – check the proper functioning of the dryer. The HPS pressure switch is defective – contact a SULLAIR service technician for the replacement. If installed: There is a leak in the refrigeration cycle –...
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Page 41: Recommended Spare Parts
The hot-gas bypass valve needs to be re-adjusted – contact a specialist for refrigerating plants to have the nominal calibration re-established. There is a leak in the refrigeration cycle – please contact a SULLAIR service technician. Reset the temperature switch by manually pushing the button on the temperature switch – check the perfect functioning of the dryer. -
Page 42: Sr 10-175 115V Ul (Rac) Spare Parts
User Manual US-EN SR 10-480 AC 12.3.1 SR 10-175 115V UL (RAc) spare parts SR NA 1/115/60 Description Part number 02250249-319 02250249-320 Complete heat exchanger 02250249-321 02250249-322 02250249-323 Pressure switch 02250248-092 02250247-957 02250247-958 Compressor 02250247-959 02250247-960 02250247-961 02250248-017 Hot gas by-pass valve 02250248-018 02250248-539 02250248-540... -
Page 43: Sr 220-480 230V Ul (Rac)
User Manual US-EN SR 10-480 AC 12.3.2 SR 220-480 230V UL (RAc) SR NA 1/230/60 Description Part number 02250249-323 Complete heat exchanger 02250249-324 02250249-325 Pressure switch 02250248-097 Safety thermo switch 02250248-106 Pressure switch 02250248-099 02250248-092 Pressure switch 02250248-095 02250247-966 Compressor 02250247-967 02250247-968 Hot gas by-pass valve... -
Page 44: Maintenance Works At The Refrigeration Cycle
Caution! Refrigerant! Maintenance and repair works at refrigeration systems must only be carried out by SULLAIR service technicians 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 45 User Manual US-EN SR 10-480 AC Electric cable Copper, PVC Electric parts PVC, copper, brass We recommend observing the safety provisions in force for the disposal of each material type. The refrigerant contains lubricating-oil droplets which are released by the compressor. The refrigerant must not be discharged into the environment.
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Page 46: Appendices
User Manual US-EN SR 10-480 AC 13 Appendices 13.1 Dryer dimensions 13.1.1 Dryer dimensions SR 10-15 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 47: Dryer Dimensions Sr 20-50 Ac
User Manual US-EN SR 10-480 AC 13.1.2 Dryer dimensions SR 20-50 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 48: Dryer Dimensions Sr 75 Ac
User Manual US-EN SR 10-480 AC 13.1.3 Dryer dimensions SR 75 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 49: Dryer Dimensions Sr 100 Ac
User Manual US-EN SR 10-480 AC 13.1.4 Dryer dimensions SR 100 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 50: Dryer Dimensions Sr 125-150 Ac
User Manual US-EN SR 10-480 AC 13.1.5 Dryer dimensions SR 125-150 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 51: Dryer Dimensions Sr 175-220 Ac
User Manual US-EN SR 10-480 AC 13.1.6 Dryer dimensions SR 175-220 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 52: Dryer Dimensions Sr 300-375 Ac
User Manual US-EN SR 10-480 AC 13.1.7 Dryer dimensions SR 300-375 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 53: Dryer Dimensions Sr 480 Ac
User Manual US-EN SR 10-480 AC 13.1.8 Dryer dimensions SR 480 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 54: Exploded Diagrams
User Manual US-EN SR 10-480 AC 13.2 Exploded diagrams 13.2.1 Components of the exploded diagrams Alu drying module Coil for condensate drain solenoid valve 1.1 Insulation material Air dryer control Refrigerant pressure switch LPS Sullimax drain Safety temperature switch TS Main switch Refrigerant pressure switch HPS Refrigerant fan pressure switch PV... -
Page 55: Exploded Diagram Sr 10-15 Ac
User Manual US-EN SR 10-480 AC 13.2.2 Exploded diagram SR 10-15 AC Zero loss drain Timed 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 56: Exploded Diagram Sr 20-35 Ac
User Manual US-EN SR 10-480 AC 13.2.3 Exploded diagram SR 20-35 AC Timed Zero loss drain 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 57: Exploded Diagram Sr 50 Ac
User Manual US-EN SR 10-480 AC 13.2.4 Exploded diagram SR 50 AC Zero loss drain Timed 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 58: Exploded Diagram Sr 75-100 Ac
User Manual US-EN SR 10-480 AC 13.2.5 Exploded diagram SR 75-100 AC Zero loss drain Timed 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 59: Exploded Diagram Sr 125-220 Ac
User Manual US-EN SR 10-480 AC 13.2.6 Exploded diagram SR 125-220 AC Timed Zero loss drain 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 60: Exploded Diagram Sr 300-375 Ac
User Manual US-EN SR 10-480 AC 13.2.7 Exploded diagram SR 300-375 AC Zero loss drain Timed 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 61: Exploded Diagram Sr 480 Ac
User Manual US-EN SR 10-480 AC 13.2.8 Exploded diagram SR 480 AC Zero loss drain Timed 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 62: Electric Diagrams
User Manual US-EN SR 10-480 AC 13.3 Electric diagrams 13.3.1 Electric diagrams – list of components Compressor KT : Compressor thermal protection KR : Compressor starting relay (if installed) CS : Compressor starting capacitor (if installed) CR : Compressor operating capacitor (if installed) Condenser fan CV : Fan starting capacitor (if installed) DMC15... -
Page 63: Electric Diagram Sr 10-100 Ac
User Manual US-EN SR 10-480 AC 13.3.2 Electric diagram SR 10-100 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 64: Electric Diagram Sr 125-175 Ac
User Manual US-EN SR 10-480 AC 13.3.3 Electric diagram SR 125-175 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 65: Electric Diagram Sr 220 Ac
User Manual US-EN SR 10-480 AC 13.3.4 Electric diagram SR 220 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 66: Electric Diagram Sr 300 Ac
User Manual US-EN SR 10-480 AC 13.3.5 Electric diagram SR 300 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 67: Electric Diagram Sr 375 Ac
User Manual US-EN SR 10-480 AC 13.3.6 Electric diagram SR 375 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. -
Page 68: Electric Diagram Sr 480 Ac
User Manual US-EN SR 10-480 AC 13.3.7 Electric diagram SR 480 AC 02250246-045 R02 Subject to EAR. ECCN EAR99 and related export control restrictions. - Page 69 Sullair, LLC 1 Sullair Way Michigan City, IN 46360 USA www.sullair.com 1-800-SULLAIR (USA only) 1-219-879-5451 (non-USA) Information and specifications are subject to change without prior notice. Subject to EAR, ECCN AR99 and related export control restrictions.
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