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Summary of Contents for FRIULAIR ACT VS Series
- Page 1 Refrigerating air dryer ACT VS 800 - 2500 Air – water cooled EN - User’s maintenance and spare parts manual 74MD0059A4-EN_00...
- Page 2 Note, these instructions are in addition to the safety rules that apply in the country where the dryer is installed. Before packing for shipment each ACT VS series refrigerated air dryer undergoes a rigorous test to ensure the absence of any manufacturing faults and to demonstrate that the device can perform all the functions for which it has been designed.
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Page 3: Table Of Contents
Contents 1 Safety instructions 5 Safety pictograms in accordance with DIN 4844 Signal words in accordance with ANSI Overview of the safety instructions 2 Proper use of the dryer 11 3 Exclusion from a field of application 11 ... - Page 4 10.15.17 List of spare parts 10.15.18 System settings and weekly timer 10.16 Electronic drainer 11 Maintenance, troubleshooting, spare parts and dismantling 44 11.1 Checks and maintenance 11.2 Troubleshooting 11.3 Spare parts ...
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Page 5: Safety Instructions
Safety instructions Safety instructions Pos: 2 /Beko Technische Dokumentation/Globale Texte/Allgemeiner Hinweis BM @ 0\mod_1183615737313_6.doc @ 4004 Pos: 3 /Beko Technische Dokumentation/Sicherheit/Hinweis Anleitung BEKO @ 0\mod_1184147787557_6.doc @ 5758 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. -
Page 6: Safety Pictograms In Accordance With Din 4844
Safety instructions 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 Note... - Page 7 Safety instructions 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: ...
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Page 8: Signal Words In Accordance With Ansi
Safety instructions Signal words in accordance with ANSI Imminent hazard Danger! Consequences of non-observance: serious injury or death Potential hazard Warning! Consequences of non-observance: possible serious injury or death Imminent hazard Caution! Consequences of non-observance: possible injury or property damage Potential hazard Notice! Consequences of non-observance: possible injury or property damage... - Page 9 Safety instructions Warning! Refrigerant leak! A refrigerant leak involves the danger of serious injury and damage to the environment. The compressed-air refrigeration dryer contains fluorinated greenhouse gas/refrigerant. Installation, repair and maintenance works at the refrigeration system must only be carried out by certified skilled personnel (specialists).
- Page 10 Safety instructions Note! 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 (5 micron minimum), to avoid clogging of the heat exchanger.
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Page 11: 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.Moreover, the correct use requires the adherence to the installation instructions, specifically: ... -
Page 12: 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 13: 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 14: Installation Layout
Installation Installation layout - A - Air compressor Aftercooler Condensate separator Pre-Filter (min. 5 micron) By-pass group Dryer Compressed air tank Final filter - B - 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 15: 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 16: 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 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: Minimum Cooling Water Requirements
Installation Minimum cooling water requirements: Copper brazed stainless steel condenser Temperature +15°C…+30°C (+59°F…+86°F) *1 Pressure 3…10 barg (43.5…145 psig) *2 Delivery pressure > 3 bar (43.5 psi) *2 *3 7.5…9.0 Total hardness 6.0…15 °dH Conductivity 10…500 μS/cm Sulphates (SO < 100 mg/l or ppm Hydrogen Carbonate / Sulphates (HCO / SO >... -
Page 19: 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. Before connecting the unit to the electrical supply, verify the data nameplate for the proper electrical information. Voltage tolerance is +/- 10%. -
Page 20: Condensate Drain
Start-up Condensate drain Danger! Compressed air and condensate under pressure! The condensate is discharged at system pressure. The drain pipe needs to be secured. Never direct the condensate drain pipe at persons. The dryer comes already fitted with an electronic condensate drainer. Connect and properly fasten the condensate drain to a collecting plant or container. -
Page 21: First Start-Up
Start-up First start-up The method below should be applied during the first start-up, after longer downtimes or subsequent to maintenance works.The start-up must be carried out by certified skilled personnel. Sequence of operations (refer to section 10.1 Control Panel). Ensure that all the steps of the “Installation” chapter have been observed. ... -
Page 22: Start-Up And Shut Down
Start-up Start-up and shut down During short-term shut down (max. two to three days), it is advisable to leave the dryer and the control panel connected to the supply current circuit. Otherwise, it would be necessary at a restart of the dryer to wait two hours, until the oil in the compressor has reached the specified operating temperature. -
Page 23: Technical Data
Technical data Technical data Technical data ACT VS 800 – 2500 3/460/60 ACT VS 800 - 2500 23 – EN... -
Page 24: Technical Description
Technical description 10 Technical description 10.1 Control panel The control panel illustrated below is the only dryer-operator interface. 1 – Main switch 2 – Electronic instrument DMC55 10.2 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 25: Flow Diagram (Air-Cooled)
Technical description 10.3 Flow diagram (Air-Cooled) 10.4 Flow diagram (Water-Cooled) Alu-Dry module 18 Condenser (Water-Cooled) Air-to-air heat exchanger 19 Condenser water regulating valve (Water-Cooled) Air-to-refrigerant heat exchanger 20 Refrigerant accumulator (Water-Cooled) Condensate separator 21 Electronic drainer Refrigerant pressure switch HPS 25 Compressor crankcase heater Compressor 34 Liquid sight glass... -
Page 26: Refrigerating Compressor
Technical description 10.5 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). 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 27: Electronic Expansion Valve (Eev)
Technical description 10.10 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 28: Dmc55 Electronic Control Unit
Technical description 10.15 DMC55 electronic control unit The DMC55 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 29: Chilling Circuit Process Values
Technical description 10.15.4 Chilling circuit process values 1- With the dryer operating press to access the dryer's menu. 2- Press to display the chilling circuit diagram and the dryer's instantaneous process values: T1 - BT1 probe - Dew point temperature T2 - BT2 probe - Air temperature at exchanger inlet T3 - BT3 probe - Temperature of refrigerant gas on compressor suction side T4 - BT4 probe - Temperature of refrigerant gas on compressor supply side... -
Page 30: Warning Condition
Technical description 14- Confirm your intention to stop the recording in progress with , or to exit the command Once you have finished recording, remove the USB drive as described in the section "Installing and removing the USB storage drive." 10.15.5 WARNING condition A WARNING is an irregular event that must be flagged to operators/maintenance technicians. - Page 31 Technical description Warning description Delay Reset BT1 probe - Dew point temperature T1 < -1.0°C 3 min T1 ≥ 0.0°C Low temperature BT1 probe - Dew point temperature T1 > HdA Parameter Parameter High temperature parameter HdA-1K BT2 probe - Inlet air temperature Fault Flag Reset...
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Page 32: Alarm Condition
Technical description 10.15.6 ALARM condition An ALARM is an irregular event that always causes the dryer to switch off 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 clear the Alarm as the cause is still present. - Page 33 Technical description Alarm description Delay Reset Opening Flag Closing HPS pressure switch - Refrigerant high pressure Digital Input HPS immediately Digital Input HPS R407C R407C LP < 1.7 barg LP > 2.7 barg BLP transducer - Evaporation pressure 2 sec Parameterised for "LPS pressure switch"...
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Page 34: Alarm History
Technical description 10.15.7 Alarm history 1- With the stopped or operating dryer press to access the dryer's menu. 2- Press to display the history file for the last 50 stored Alarms. 3- Scroll through the list of Alarms using the cursor keys. Alarms are stored chronologically. -
Page 35: Installing And Removing The Usb Storage Drive
Technical description 10.15.8 Installing and Removing the USB storage drive NOTE The following operations should only be performed by qualified and trained personnel. Installing the USB storage drive - Remove power from the dryer and ensure that it cannot be restarted accidentally. - Open the control panel door with the special key provided with the dryer. -
Page 36: Electronic Expansion Valve Process Values
Technical description 10.15.10 Electronic expansion valve process values 1- With the dryer operating press to access the dryer's menu. 2- Press to display the list of instantaneous process values for the electronic expansion valve. 3- Scroll through the list of values using the cursor keys. 4- Press to display the values log file of "SH"... -
Page 37: Energy Saving Data And Operating Hours
Technical description 10.15.11 Energy saving data and operating hours 1- With the stopped or operating dryer press to access the dryer's menu. 2- Press to display the energy consumption / energy-saving data and the dryer's operating hours. NOTE The following operations should only be performed by qualified and trained personnel. -
Page 38: Remote Start/Stop, Remote Reset Of Faults/Alarms
Technical description 10.15.12 Remote start/stop, remote reset of faults/alarms The power module of the controller is equipped with two digital inputs (DI6 and DI8, M10 connector) for the remote control of: - dryer RUN / STOP - RESET Warnings/Alarms NOTE Preliminary operations A-, B-, C-, D-, E- must only be performed by qualified and trained personnel. -
Page 39: Rs485 Modbus Rtu Communication Port
Technical description 10.15.15 RS485 MODBUS RTU communication port The control unit power model is provided with a communication port (M14 connector) for the remote dryer monitoring via a supervision system. Contact the manufacturer for further information . 10.15.16 Changing process user parameters 1- With the stopped or operating dryer press to access the dryer's menu. - Page 40 Technical description User parameters Factory Description Limits Scale setting Refrigerant compressor operating mode at low thermal load YES / NO YES = Cyclic operation ON-OFF NO = Continuous operation Local / Dryer control modes Remote / Local Modbus Dew point level -1…3 -1 = Performance;...
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Page 41: List Of Spare Parts
Technical description Advanced parameters (service) Factory Description Limits Scale setting Warning/Alarm clearing YES = resetting only allowed locally YES / NO NO = resetting allowed locally and remotely [3]. With RbP = YES - Maximum number of local resets allowed 1…10 within the time frame defined in TtPR 0…24... -
Page 42: System Settings And Weekly Timer
Technical description 10.15.18 System settings and weekly timer 1- With the stopped or operating dryer press to access the dryer's menu. 2- Press to access the system settings. Then touch the screen at the function you want to change. You can change/update the following functions: - system language - Current date and time - date format (dd/mm/yy or mm/dd/yy) -
Page 43: Electronic Drainer
Technical description 10.16 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 44: Maintenance, Troubleshooting, Spare Parts And Dismantling
Maintenance, troubleshooting, spare parts and dismantling 11 Maintenance, troubleshooting, spare parts and dismantling 11.1 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 45: Troubleshooting
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 46 Maintenance, troubleshooting, spare parts and dismantling Caution! Hot surfaces! During operation, several components can reach surface temperatures of more than +60°C. There is the risk of burns. All components concerned are installed inside of the closed housing. The housing must only be opened by certified skilled personnel.Some components can reach high temperatures during operation.
- Page 47 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION NOTE: Slightly negative DewPoint peaks usually occurs with low loads and when DewPoint too low. refrigerant compressor is in ON/OFF (DCC=YES parameter), cyclic mode. The fan is always on – check that the BHP (air-cooled) pressure transducer is working properly. ...
- Page 48 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION There is a gas refrigerant leak - contact a refrigeration engineer. Too The evaporating pressure measured with DMC55 and BLP pressure transducer is not correct. evaporating Please contact a refrigeration engineer to verify and compare the evaporating pressure value.
- Page 49 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION Excessive thermal load – restore nominal conditions Too high The inlet air is too hot - restore nominal conditions. evaporating The room temperature is too high or the room air circulation is insufficient - provide proper pressure ventilation (air-cooled).
- Page 50 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION Blinking red status area: one or more alarms are active. The display shows the ID code and DMC55 the description of the active alarm. electronic Steady red status area: one or more alarms need to be cleared. The display shows the ID code controller with and the description of alarm which is no longer active but which still need to be cleared.
- Page 51 Maintenance, troubleshooting, spare parts and dismantling INV1 drive failure - replace the drive A FD 1001 - Fan Drive comm. lost: Interrupted communication between DMC55 power module and the fan INV2 drive INV2 drive not powered - check that the QV1 circuit breaker is working correctly / is active. Check the drive correct wiring.
- Page 52 Maintenance, troubleshooting, spare parts and dismantling Check and correct short-circuit on drive - compressor connection cables A KD 014 - Mains Phase Loss_AL-004: Missing input power phase or voltage imbalance too high Check supply voltage A KD 017 - Internal Fault AL-038: Drive failure - Replace ...
- Page 53 Maintenance, troubleshooting, spare parts and dismantling the room temperature is too high - restore nominal conditions. condenser cleaning or any obstruction to the fan ventilation (condenser ducting is not permitted). the fan motor current consumption is higher than nominal - check the correct fan motor operation ...
- Page 54 Maintenance, troubleshooting, spare parts and dismantling SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION Blinking orange status area: one or more alarms are active. The touch screen display shows Electronic the ID code and description of the active alarm. controller DMC55 Steady orange status area: one or more alarms need to be cleared.
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Page 55: Spare Parts
Maintenance, troubleshooting, spare parts and dismantling 11.3 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 56: Maintenance Operation On The Refrigeration Circuit
Maintenance, troubleshooting, spare parts and dismantling 11.4 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 57: Attachments
Attachments 12 Attachments Exploded views – List of components Alu-Dry module Electrical panel fan Insulation material Oil separator Refrigerant pressure switch HPS Electrical panel filter Compressor Front panel Condenser (Air-Cooled) Back panel Condenser fan (Air-Cooled) Right lateral panel Filter dryer Left lateral panel BT1 temperature probe (dew point) Cover... -
Page 58: Dryers Dimension
Attachments 12.1 Dryers dimension 12.1.1 ACT VS 800 – 1250 12.1.2 ACT VS 1500 – 2500 12.2 Exploded views 12.2.1 ACT VS 800 – 1250 Air Cooled 12.2.2 ACT VS 800 – 1250 Water Cooled 12.2.3 ACT VS 1500 – 2500 Air Cooled 12.2.4 ACT VS 1500 –... - Page 60 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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