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Ultrafilter BOREAS DSM SD 1200-60 Operator Instructions Manual

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Operators Instruction
and
Maintenance Manual
BOREAS DSM
SD 1200-60 - SD 3000 W-60
SD 4000-60 - SD 5000 W-60
I14 1001 0US
07.03

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  • Page 1 Operators Instruction Maintenance Manual BOREAS DSM SD 1200-60 - SD 3000 W-60 SD 4000-60 - SD 5000 W-60 I14 1001 0US 07.03...

  • Page 2: Type Code

    Type Code Construction BOREAS DSM Series Model Type-No. Material-no. Type code SD 1200-60 457A L0457001000 Version SD 1400-60 458A L0458001000 aircooled SD 1600-60 459A L0459001000 SD 2000-60 460A L0460001000 SD 2400-60 461A L0461001000 SD 3000-60 462A L0462001000 SD 4000 W-60 593W L0593001000 Version...

  • Page 3: Table Of Contents

    Table of contents Page Type Code Part 1 Important user infor- General Notes mation Safety regulations Handling with refrigerant All safety notes in this operating instruction which may cause harm to personnel or equipment, when ignored, are marked by the following symbols: General danger symbol Electrical danger symbol First aid...

  • Page 4: Part 1 Important User Infor

    Part 1 Important User Information General notes • This refrigerated compressed air-dryer is referred to below as CA-dryer. • The Company does not accept responsibility if safety regulations are not met during handling, operation, maintenance and repair, even though these are not strictly stated in these operating instructions.

  • Page 5: Mation

    Part 1 Important user Information Safety regulations Attention! The operator has to observe the national working-, op- erating- and safety regulations. Also existing internal fac- tory regulations must be met. Maintenance and repair work must only be carried out by specially trained personnel and, if necessary, under supervision of a person qualified for this work.

  • Page 6: Handling With Refrigerant

    Part 1 Important user Information Handling with • Wear eye protection and protective gloves refrigerant • Avoid contact of liquid refrigerants with your skin (frost- bite). • Do not inhale refrigerant vapours. • To avoid higher concentrations, all work rooms must be ventilated very well.

  • Page 7: First Aid

    Part 1 Important user Information First aid • Take victim immediately into the fresh air or into a very well ventilated room. • Splashes of refrigerant in the eyes must be blown out with the mouth. Then rinse eyes with plenty of water. Do not wipe with cloth! •...

  • Page 8: Part 2 Installation

    Part 2 Installation Transportation The CA-dryer can be transported for a short time in an inclined position of up to 45 °. For transportation or lifting by means of a crane it is possible to use lifting eyes on the upper side of the frame (fig. 1). Fig.

  • Page 9: Compressed Air Connection

    Part 2 Installation 2.3.1 Version air cooled The cooling air for the refrigerant condenser will be sucked in at the front panel (fig. 2). This area must be kept free and not be obstructed. If necessary, the cooling air may be led to the CA-dryer from outside through wall openings.

  • Page 10: Electric Connection

    Part 2 Installation Electric connection The CA-dryers are completely equipped and wired. They merely have to be connected to a power supply. The CA- dryers are to be protected by slow-blow fuses as defined in the wiring diagram. Voltage: acc. to name plate or wiring diagram resp. The power supply is provided in the switch cabinet.

  • Page 11: Part 3 Description

    Part 3 Description Designation Refrigerated compressed air-dryer (CA-dryer). Version see type code (page 2) Purpose Compressed air will be dehumidified by the CA-dryer. Unit Layout Following components of the CA-dryer are accessible from outside (fig. 4). Fig. 4: Complete system 1 Compressed-air inlet 2 Compressed-air outlet 3 Switch cabinet with power supply (Fig.

  • Page 12: Nominal Power Of Ca-Dryer

    Part 3 Description 3.3.1 Switch cabinet Fig. 5 Switch cabinet 1 Main switch 2 Operation switch 3 Data input and output key 4 Measuring point indication 5 Temperature and working hour indication Nominal power of The nominal power of the CA-dryer mentioned in the CA-dryer technical data is related to a working pressure of 14 1/2 psig, a compressed air inlet temperature of 100°F as...

  • Page 13: Principle Of Operation

    Part 3 Description Principle of opera- The CA-dryer includes a refrigerant system cooling the tion compressed air flow. The steam saturation limit is low- ered causing condensate to fall out, which is removed by the condensate drain. The higher the cooling temperature difference of the air, the higher is the amount of condensate.
  • Page 14 Part 3 Description 3.6.4 Capacity levels 3.6.4.1 Types 593A, 593 W, The CA dryer disposes of two parallel refrigerant 594A, 594 W compressors. If the load is reduced to less than 50 % one compressor is switched off depending on the refrigerant pressure in order to reduce the power consumption of the CA dryer.

  • Page 15: Sab-Processor

    Part 3 Description SAB-Processor The SAB-Processor measures, shows and stores tem- peratures, working hours and failures. 3.7.1 Display The display consists of a 2-digit measuring point indica- tion (fig. 6/2) and a 3-digit indication for the correspond- ing values (fig. 6/3). The data to be requested can be get by short operation of the data input/output key (fig.
  • Page 16 Part 3 Description 3.7.5 Pressure dew The customer of these CA-dryers has the possibility to point report adapt the upper error value of the pressure dew point to the company´s needs, if necessary. The actual status of the DIP-switches is read during the program start only, i.e., after each change of the switch position, a power disconnection must be executed Switches 1 and 2 are used for the upper switching point...

  • Page 17: Condensate Draining

    Part 3 Description 3.7.8 Operating status - Corresponding to the set limit values, at critical opera- alarm / failure tion phases an alarm, and at prohibited operation condi- tions a failure report is triggered by the processor´s monitoring system (see 5.2.2). 3.7.9 SAB-service unit The SAB-service unit permits changes of limit values,...

  • Page 18: Commissioning

    Part 4 Operation Commissioning After installion, the CA-dryer can be switched on with the main switch (fig. 5/1). So the refrigerating compressor heating and the SAB- Processor is supplied with power. Before operating the operation switch (fig. 5/2), a waiting period of at least 6 hours is necessary, to enable a pre- heating of the refrigeration compressor.

  • Page 19: Maintenance

    Part 5 Maintenance Maintenance Attention! Prior to any maintenance works all safety regulations for electrical systems and units must be observed. 5.1.1 Daily maintenance Maintenance intervals highly depend on the mode of operation and the ambient conditions on site, the inter- vals below are only to be understood as general recom- mendations.
  • Page 20 Part 5 Maintenance 5.2.2 Reports of the SAB-processor: 5.2.2.1 Alarm indications Pressure dew point Check load conditions of CA-dryer in critical range Suction gas tempera- Check control (call for service) ture in critical range A 3 Inlet temperature in Check aftercooler of CA-dryer critical range A 4 Ambient tempera- Lower machine room temperature...
  • Page 21 Part 5 Maintenance 5.2.3 Reports of the con- densat drain Fig. 10: Condensate drain failure reports 5.2.3.1 No reports (fig. 10/1) Cause Remedy No power supply, check power supply, replace condensate drain if neces- sary 5.2.3.2 Failure reports Indication by blinking LED (fig.
  • Page 22 Part 5 Maintenance 5.2.5 Stopping CA-dryer during operation: Cause Remedy Stopping of CA-dryer - eliminate cause of trouble by installed pressure - open left side panel limiter due to overload 5.2.5.1 CA-volume flow too Check whether CA-dryer´s capacity is properly selected, high increase CA-dryer´s capacity 5.2.5.2 CA-inlet temperature...

  • Page 24: Table Of Constancy

    Table of Constancy Stainless, steel m.-no. (AISI 316) and copper (materials of water-cooled condenser in plate design) Content of water: Concentration M.-no.: 1.4401 Copper [mg/l] ñ ó Organic elements ñ ó < 70 Hydrogen carbonate (HCO ñ ñ 70 – 300 ñ...
  • Page 32 terminal strip: destination external destination internal function text -3Q1 power supply -3Q1 power supply -3Q1 power supply ground power supply...
  • Page 33 terminal strip: destination external destination internal funktion text compressor -5K2 compressor -5K2 compressor -5K2 -5K3 -5K3 -5K3 -5K3 -5K3 -5K3 compressor ground ground ground...
  • Page 34 terminal strip: destination external destination internal funktion text compressor heater -4E2 -5K2 /4.2 compressor heater -4E2 ground /4.2 remote control -4T7 /4.3 remote control -4S3 /4.3 low pressure -4F4 -4T7 /4.4 low pressure -4F4 -4K4 /4.4 overpressure -4F5 /4.5 overpressure -4F5 -4K5 /4.6...
  • Page 35 -X10 terminal strip: destination external destination internal funktion text common trip signal -6A4 common trip signal -6A4 common trip signal -6A4 dewpoint trouble sig. -6A4 dewpoint trouble sig. -6A4 dewpoint trouble sig. -6A4 operation signal -5K2 operation signal -5K2...
  • Page 47 terminal strip: destination external destination internal function text -3Q1 /3.1 power supply -3Q1 /3.1 power supply -3Q1 /3.2 power supply /3.2 power supply ground...
  • Page 48 terminal strip: destination external destination internal function text -3M3 -8K1 /3.3 compressor1 -3M3 -8K1 /3.3 compressor1 -3M3 -8K1 /3.4 compressor1 -3M4 -8K2 /3.5 compressor2 -3M4 -8K2 /3.5 compressor2 -3M4 -8K2 /3.5 compressor2 -4M2 -8K3 /4.2 fan motor 1 -4M2 -8K3 /4.2 fan motor 1 -4M2...
  • Page 49 terminal strip: destination external destination internal function text -5R1 -8K1 /5.1 heater compr.1 -5R1 -4T7 /5.1 heater compr.1 -5R2 -8K2 /5.2 heater compr.2 -5R2 -4T7 /5.2 heater compr.2 -4T7 /6.1 remote control -6S1 /6.1 remote control -6F3 -6S1 /6.3 overpressure -6F3 -5A4 /6.2...
  • Page 50 -X10 terminal strip: destination external destination internal function text -9A4 /10.1 common trip signal -9A4 /10.1 common trip signal -9A4 /10.2 common trip signal -9A4 /10.2 dewpoint trouble -9A4 /10.2 dewpoint trouble -9A4 /10.3 dewpoint trouble -8K1 /10.3 operation signal -8K1 /10.4 operation signal...

This manual is also suitable for:

Boreas dsm sd 3000 w-60Boreas dsm sd 4000-60Boreas dsm sd 5000 w-60

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