Sullair SRC Service Manual
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Sullair SRC Service Manual

Cycling refrigerated air dryers
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Service Manual
for the
SRC Cycling Refrigerated
Air Dryers
Document PN#: 02250___-___

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Summary of Contents for Sullair SRC

  • Page 1 Service Manual for the SRC Cycling Refrigerated Air Dryers Document PN#: 02250___-___...

  • Page 2: Table Of Contents

    SRC Service Manual Revision 02 Aug 2007 Table of Contents 1. General Description 2. Specifications 2.1 Model Range 2.2 Operating Limits 2.3 Technical Specifications 2.4 Weight & Dimensions 3. System Design 3.1 The Air Circuit 3.1.1 Air-To-Air Heat Exchanger 3.1.2 Air-To-Coolant Heat Exchanger 3.1.3...
  • Page 3 SRC Service Manual Revision 02 Aug 2007 4. Control System 4.1 Power Supply 4.2 Controls on the SRC-150 to 200 4.3 Controls on the SRC-250 to 1000 4.3.1 Inputs 4.3.2 Outputs 4.3.3 Specifications 4.3.4 User Interface 4.3.4.1 Lights 4.3.4.2 Buttons 5.
  • Page 4 Preventative Maintenance Kits 12. Maintenance Procedures 12.1 Replacing a Pressure Switch 12.2 Replacing the Thermostat (SRC-150 to 200) 12.3 Replacing the Control Board (SRC-250 to 1000) 12.4 Replacing the Drain Valve 12.5 Cleaning the Condensate Strainer 12.6 Replacing the Coolant Pump 13.

  • Page 5: General Description

    The SRC is a “cycling” dryer, because it reduces it’s power consumption at reduced heat loads by cooling the air using a large tank of a cold glycol & water mixture (referred to as a thermal mass), which is in turn cooled by a refrigeration system.

  • Page 6: Specifications

    SRC Service Manual Revision 02 Aug 2007 2. Specifications 2.1 Model Range Rated Frame Compressor Control Expansion Sullair Voltage Port Size Flow* Size Type Type Device Part # Model Volt (scfm) (NPT-F) 02250 165 - 492 SRC-150 1-1/2" 02250 165 - 493...

  • Page 7: Technical Specifications

    SRC Service Manual Revision 02 Aug 2007 2.3 Technical Specifications SRC-150 SRC-175 SRC-200 SRC-250 SRC-325 R407C Type Refrigerant 2.43 lbs (1.1 kg) 3.97 lbs (1.8 kg) Charge 1.76 lbs (0.8 kg) 0.085" (2.16 mm) 0.098" (2.5 mm) Internal Diameter 0.072" (1.83 mm) Capillary Tube 98.4"...

  • Page 8: Weight & Dimensions

    SRC Service Manual Revision 02 Aug 2007 2.4 Weight & Dimensions SRC-150 to 200 SRC-250 to 500 SRC-700 to 1000 Weight Model in (mm) in (mm) in (mm) lbs (kg) SRC-150 28.5 (723) 42.5 (1080) 32.5 (826) 322 (146) SRC-175 28.5 (723)

  • Page 9: System Design

    SRC Service Manual Revision 02 Aug 2007 3. System Design The SRC dryer consists of three circuits from right to left: The Air Circuit, the Coolant Circuit, and the Refrigeration Circuit: • The Air Circuit: Consisting primarily of: A. Air-to-Air heat Exchanger, B.
  • Page 10 It them passes through the Refrigerant Filter (I) where any impurities are removed. It then passes through the Expansion Device (J) where it is expanded. 3.1 The Air Circuit The SRC is unique in that it’s entire air circuit is combined into a single compact 4-in-1 unit, combining: •...
  • Page 11 SRC Service Manual Revision 02 Aug 2007 3.1.1 Air-to-Air Heat Exchanger An Air-to-Air Heat Exchanger is an aluminium fin, cross flow exchanger. The Air-to-Air Heat Exchanger is also often called a “Pre-cooler / Re-heater” because the hot air entering the dryer is pre- cooled by the cold air exiting the dryer;...
  • Page 12 Air-to-Coolant Heat Exchanger. At this point in the dryer, the temperature of the air equals the dew point. On the SRC-150 to 200 this controls the color Dew Point Indicator on the top of the dryer. On the SRC-250 to 1000, this is the dew point temperature which is shown on the digital display during normal operation.
  • Page 13 The controls of the SRC dryer monitor the temperature of the Coolant in the Coolant Tank, and allow it to fluctuate between an upper and lower limit.
  • Page 14 On the SRC-150 through 500 the evaporator is a coaxial tube design. The outer tube is made of PVC to allow it to expand without damage in the case of a system upset causing ice formation.
  • Page 15 SRC Service Manual Revision 02 Aug 2007 3.2.3 Coolant Tank The coolant circuit includes an accumulation tank with the Coolant-to- Refrigerant Heat Exchanger inside (they cannot be separated). The tank acts as thermal energy storage, allowing the system to accumulate a mass of chilled water/glycol coolant.
  • Page 16 High Pressure Switch - to shut down the dryer in the event of overpressure of the refrigerant system, • Low Pressure Switch (SRC-250 to 1000) – to prevent freezing in the event of a system upset, and • Fan Pressure Switch – to cycle the condenser fan on and off.
  • Page 17 The axial fans are supplied with external rotor electric motors and die-cast aluminium blades, complete with protection grilles. On the SRC-250 to 1000, the electric motors of the fans are protected by thermal and over-current relays.
  • Page 18 (i.e. compressor electrical energy) to output energy (i.e. chilling of the coolant). All SRC models feature R407C refrigerant. R407C is classified as an environmentally friendly refrigerant, and offers an O.D.P. (Ozone Depletion Potential) of zero;...
  • Page 19 Settings: On: 21.7 psig (1.5 barg), Off: 36.2 psig (2.5 barg). The SRC-250 to 100 have a Low Pressure Switch to shut down the dryer in the event of low pressure at the compressor inlet, as this indicates a refrigerant temperature below freezing.
  • Page 20 SRC Service Manual Revision 02 Aug 2007 3.4 Physical Arrangements 3.4.1 SRC-150 to 200 3.4.2 SRC-250 to 500 Page 19 of 56...
  • Page 21 SRC Service Manual Revision 02 Aug 2007 3.4.3 SRC-700 to 1000 Page 20 of 56...

  • Page 22: Control System

    SRC Service Manual Revision 02 Aug 2007 4. Control System The SRC-150 to 200 feature a base analog controller, while the SRC-250 to 1000 are fitted with a microprocessor. 4.1 Power Supply The following power supplies are offered: • 115V/1ph/60Hz +/-10% on SRC-125 & 150 •...

  • Page 23: Controls On The Src-250 To 1000

    Aug 2007 Controls on the SRC-250 to 1000 The microprocessor controls on the Sullair SRC-250 to 1000 Cycling Dryers allows you to turn the dryer on and off, controls the operation of the dryer, and continuously monitors the working parameters, informing the user of possible problems through lights, alarms and a digital display.

  • Page 24: Outputs

    SRC Service Manual Revision 02 Aug 2007 4.3.2 Outputs All outputs are digital. Digital Outputs (J1 & J3) Common 4 NO1 Compressor Contactor (KM1) 6 C4 Alarm (Common) 7 NO2 “Dryer On” Relay (KA2) 9 NO4 Alarm/Warning (N/O) Contact 10 NO3...
  • Page 25 SRC Service Manual Revision 02 Aug 2007 4.3.4.1 Lights Power LED o Yellow: indicates the dryer is off, but connected to a power supply. o Green: indicates the dryer is operating. Warning LED o Red: indicates the dryer has a warning or alarm.
  • Page 26 SRC Service Manual Revision 02 Aug 2007 4.3.4.2 Buttons Alarm Reset / Up o Standard Function: Resets Alarm or Warning. o In Alarm Menu: Scrolls up to previous alarm or item. o In Parameter Menu: Scrolls up to previous parameter or increases a value (when modifying a parameter).

  • Page 27: Installation

    Aug 2007 5. Installation The SRC-150 to 1000 dryers are have Nema 1 protection against the ingress of moisture and particles. They must be installed indoors or provided adequate protection against wind, rain and direct sunlight. Faults occurring from improper installation are not covered by warranty.
  • Page 28 SRC Service Manual Revision 02 Aug 2007 • Pressure safety relief valves must be installed in the compressed air system in accordance with local regulations. Verify that these valves will protect the dryer from any pressure above 203 psig at all times.
  • Page 29 The Power LED light turns from yellow to green, the Refrigerant Compressor (3.3.1) starts and the digital display shows the B1 temperature reading (dryer dew point temperature). On three-phase units (SRC-250 to 1000), if the phases are inverted, the compressor and the fan will rotate in the wrong direction. In this case: a) The scroll compressor is not displacing any refrigerant.
  • Page 30 SRC Service Manual Revision 02 Aug 2007 7. Operation & Control (SRC-250 to 1000) 7.1 Turning the Dryer On or Off Once the dryer has been switched on by turning the main switch to position “I/ON”, the controller does an internal check, during which for a couple of seconds the display shows “d.t.1”, indicating the installed software version.
  • Page 31 SRC Service Manual Revision 02 Aug 2007 7.2 User Parameter List Parameter Description Units Default Temperature Unit of Measure Dryer Working Hours Dryer Working Hours x 1000 hr x 103 Compressor Working Hours Compressor Working Hours x 1000 hr x 103...
  • Page 32 • Press Enter to save your changes. • Press Exit to leave the parameter. * Parameters B3 & B8 are passcode protected and cannot be changed or reset without the proper code. Contact Sullair for further information. Note that once inside the parameters menu, the meaning of the buttons is different from the standard operation.
  • Page 33 Altering the values of these parameters by anyone other than a trained authorized factory technician, or without the express written authorization of the factory, will void warranty. Contact Sullair for further information. Parameter Description...
  • Page 34 Coolant Temperature Compressor Compressor 8.2 SRC-250 to 1000 Cycling operation on the SRC-250 to 1000 is controlled by the microprocessor in line with the following Factory Parameters. (Note: Factory Parameters are locked and should NOT be adjusted.) Parameter Units Min...
  • Page 35 SRC Service Manual Revision 02 Aug 2007 There are 3 additional parameters as follows: 1) C4 - Immediate Compressor Off Temperature: The temperature at which the compressor is turned off immediately, even in the Compressor Off Time Delay (C3) has not passed. (Default 2) C5 –...
  • Page 36 9.2 SRC-250 to 325 The SRC-250 & 325 have a solenoid valve (coil YV1) that is controlled as a timed drain by the microprocessor on the dryer. The user can adjust the operation of the drain by changing User Parameters D1 (Interval) and D2 (Duration) on the dryers control panel.
  • Page 37 If desired the user can force the drain on the SRC-400 through 1000 to always operate in timed mode or they can deactivate drain control completely*. This is achieved by adjusting Parameter D3 – Drain Operating Mode.
  • Page 38 SRC Service Manual Revision 02 Aug 2007 9.4 Drain Operating Mode (Parameter D3) Parameter D3 changes the operating mode of the condensate drain. There are 3 settings available for this parameter: Capacitive (Zero Air Loss): The drain solenoid valve (output YV1) is controlled by the level sensor (input ID4) found inside the integrated condensate chamber.
  • Page 39 SRC Service Manual Revision 02 Aug 2007 Alarms & Warnings 10.1 Alarm & Warning List Code Description Type Action High Pressure (Refrigerant) Alarm Immediate. Stops dryer. Low Pressure (Refrigerant) Alarm 5 minute delay. Stops dryer Low Dewpoint (B1) Alarm Immediate. Stops dryer.
  • Page 40 SRC Service Manual Revision 02 Aug 2007 10.2 Troubleshooting Alarms & Warnings 10.2.1 High Pressure (Alarm) What it means: High pressure switch registers a refrigerant pressure above 406 psig. What it does: Cuts power to compressor contactor & alarm contacts. Turns dryer OFF. Turns on Warning Light &...
  • Page 41 SRC Service Manual Revision 02 Aug 2007 10.2.2 Low Pressure (Alarm) What it means: Low pressure switch registers a refrigerant pressure below 22 psig for 5 minutes. What it does: Cuts power to compressor compressor contactor & alarm contacts. Turns dryer OFF.
  • Page 42 SRC Service Manual Revision 02 Aug 2007 10.2.3 Low dewpoint (Alarm) What it means: Temperature sensor B1 (dew point temperature) registers a temperature below freezing (0 What it does: Cuts power to compressor contactor & alarm contacts. Turns dryer OFF. Turns on Warning Light &...
  • Page 43 SRC Service Manual Revision 02 Aug 2007 10.2.4 Coolant Temperature Sensor Error (Alarm) What it means: Temperature sensor B2 (Coolant temperature) is short-circuited, open, or getting a signal outside it’s range (-10 C to +90°C). What it does: Cuts power to compressor contactor & alarm contacts. Turns dryer OFF. Turns on Warning Light &...
  • Page 44 SRC Service Manual Revision 02 Aug 2007 3) The dewpoint temperature sensor (B1) is out of calibration, causing a high reading. This can be confirmed by using a temperature gun to check the temperature at the location of the dew point probe, and comparing it to what the probe is reading.
  • Page 45 SRC Service Manual Revision 02 Aug 2007 10.2.6 Drain Error (Warning) What it means: Drain Operating Mode (Parameter D3) is set to Capacitive (Zero Air Loss) Mode, and although the drain valve has been open for 30 seconds, the condensate level sensor is still registering condensate in the chamber.
  • Page 46 Press ALARM RESET. Power restored to alarm relay & Warning Light goes off for 24 hours. To reset the alarm for another 6000 hours, contact Sullair or your authorized Sullair distributor and ensure the dryer & filters are inspected and maintained in accordance with the schedules in their respective user guides.
  • Page 47 SRC Service Manual Revision 02 Aug 2007 10.3 Resetting or Modifying the Service Required Warning (Sr) Every 6000 hours the dryer will display the “Sr” (Service Required) warning. The dryer will continue to function normally while this warning is displayed. The purpose of this warning is to ensure that the dryer is maintained in accordance with the maintenance schedule outlined in Section 10.1.
  • Page 48 SRC Service Manual Revision 02 Aug 2007 10.3.2 How to Change the Service Required (Sr) Warning Interval: 1) Press the Alarm Reset & Alarm Report buttons simultaneously to access the User Parameter & Menu. The display will show you are at Parameter “A1”.
  • Page 49 SRC Service Manual Revision 02 Aug 2007 10.4 Alarm History Report Each alarm or warning (with the exception of the Service Required Warning “Sr”) is recorded in the alarm report. The controller stores the last 8 alarms or warnings. New alarms will overwrite the oldest.
  • Page 50 Aug 2007 10.5 Remote Monitoring Option The SRC-250 to 1000 can be simply connected to an external supervisor system (otherwise known as BMS or Building Management System). To do so an (optional) RS485 serial card is fitted to the back of the microprocessor.
  • Page 51 SRC Service Manual Revision 02 Aug 2007 11. Recommended Maintenance 11.1 Maintenance Schedule Daily Check the digital display for warnings or alarms. Verify the dew point on the digital display is between 35 - 41 deg F. Higher values may indicate operating conditions above the maximum rating of the dryer.
  • Page 52 Place the gasket inside the switch connection with a drop of oil or grease to keep it in position while screwing the switch onto the valve. 12.2 Replacing the Thermostat (SRC-1 50 to 200) • Open the electrica l cabinet and remove the old thermostat from its housing.
  • Page 53 Remove the white connector containing the electrical supply & digital inputs & outputs. • Disconnect the temperature sensor wires. • Disconnect the level sensor (SRC-400 to 1000 ONLY) Pull firmly on the connector, being careful not to damage it. Level sensor Electrical supply &...
  • Page 54 SRC Service Manual Revision 02 Aug 2007 12.5 Cleaning the Condensate Strainer The internal strainer of the drain valve should be cleaned at least every four to six months. • Unscrew the cap at the bottom side of the drain valve.
  • Page 55 SRC Service Manual Revision 02 Aug 2007 • Vent the coolant circuit through two venting valves at the highest points of the coolant circuit: 1. At the top of the coolant tank, and 2. At the top of the coolant piping coming from the air to coolant heat exchanger.
  • Page 56 The correction factors given below make several assumptions and approximations, and as such, provide only a rough method of determining a dryer’s maximum capacity. If possible, the SRC selection software should be used, as this will provide more accurate sizing data. In addition the sizing software can provide actual performance criteria of the dryer at the input operating conditions.
  • Page 57 High Dew point alarm. You can tell him that he needs to call his local Sullair distributor and order an SRC-500, which would adequately handle his 300 cfm at these warm conditions (since 500 cfm x 1 x 0.63 x 1.03 = 324 cfm).

This manual is also suitable for:

Src-150Src-175Src-200Src-250Src-325Src-400 ... Show all

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