Gardner Denver RNC125 Instruction Manual
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Gardner Denver RNC125 Instruction Manual

Gardner Denver RNC125 Instruction Manual

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5002737
Rev. J
02/17
18-2-670
RNC100-750 New Platform
INSTRUCTION MANUAL
RNC Series
Models: RNC100, RNC125, RNC150, RNC200,
RNC250, RNC300, RNC400, RNC500,
RNC600, RNC750
1st Edition
For Sales and Service: (800) 883-2477
Or visit Sales and Service at www.gardnerdenverproducts.com
REFRIGERATED
TYPE
COMPRESSED
AIR DRYERS

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  • Page 1 5002737 Rev. J 02/17 18-2-670 RNC100-750 New Platform 1st Edition INSTRUCTION MANUAL RNC Series Models: RNC100, RNC125, RNC150, RNC200, RNC250, RNC300, RNC400, RNC500, RNC600, RNC750 REFRIGERATED TYPE COMPRESSED AIR DRYERS For Sales and Service: (800) 883-2477 Or visit Sales and Service at www.gardnerdenverproducts.com...

  • Page 2: Table Of Contents

    CONTENTS GENERAL SAFETY INFORMATION ................1 RECEIVING, MOVING, AND UNPACKING ..............1 INSTALLATION Location ........................2 Mounting ........................2 Piping Connections ....................3 Electrical Connections ....................3 Moisture Separator ....................3 OPERATION Minimum/Maximum Operating Conditions ............. 4 Start-up ........................4 Timer Drain ........................

  • Page 3: General Safety Information

    GENERAL SAFETY INFORMATION RECEIVING, MOVING, AND UNPACKING 1. PRESSURIZED DEVICES: A. RECEIVING This equipment is a pressure containing This shipment has been thoroughly checked, packed and device. inspected before leaving our plant. It was received in good condition by the carrier and was so acknowledged. •...

  • Page 4: Installation Location

    (Option) 1.2 Mounting Condenser Mount the dryer on a level solid surface. Holes are provided in the dryer base to permanently mount the dryer to the floor. Models RNC125 & RNC150 Electrical Entry Control Panel Air Inlet Aftercooler Dryer Oil Removal...

  • Page 5: Piping Connections

    1.3 Piping Connections 1.5 Moisture Separator A. Model 100: A. Air Inlet - Connect compressed air line from air source Separator (and Oil Removal Filter where to air inlet. (Reference markings on dryer for air inlet/ applicable) has an internal drain which outlet connection locations) automatically discharges collected condensate.

  • Page 6: Operation

    2.0 OPERATION 2.1 Minimum/Maximum Operating Conditions A. Maximum inlet air pressure: refer to dryer serial number tag B. Minimum inlet air pressure: 30 psig (2.1 kgf/cm C. Maximum inlet air temperature: 120°F (49°C) D. Maximum ambient temperature: Air-cooled models: 110°F (43°C) Water-cooled models: 130°F (54°C) Minimum ambient temperature: 40°F (4°C) 2.2 Start-up...

  • Page 7: Timer Drain

    NOTE: In the event of a brief or extended period of power RNC100 loss, the unit will retain the existing program setting and RNC125 will begin a new cycle once power is reapplied. Had drain RNC150 been ready to drain before the loss of power, the drain RNC200 bowl’s capacity would prevent downstream flooding.
  • Page 8 Language selection I - CONTROLLER LEVEL 4 a. Use the ‘Up’ and ‘Down’ arrow buttons to scroll through the list of languages (choice of 13 available: English, Spanish, French, German, Portuguese, Italian, Polish, Danish, Dutch, Norwegian, Finnish, Swedish and Czech). b.
  • Page 9 Push ESC button to exit program mode. IMPORTANT: Refrigeration compressor must be restarted after power interruption. Manual Operation Check interface panel a. To manually turn the refrigeration system on or off use ‘On/Off’ button; Push ‘Schedule On/Off and NOTE: Interface panel will scroll through three screens Enter’...

  • Page 10: Using The Rs-485 Port Connector (J8)

    2.7 Using the RS-485 Port Connector (J8) 2.8 Using the USB Host Feature (J7) This connector provides RS-485 compatible signals from The dryer controller is equipped with a USB Host port located the internal master microprocessor. Using jumpers on at J7 on the control board which allows for the connection the headers supplied near the connector (J12), 120 ohm of a USB flash drive.
  • Page 11 USB Event History When a USB flash drive is installed in the controller it will begin to automatically log all dryer events: power loss, power recovery, alarms, state (standby/running), and mode (manual/scheduled/remote). Events are timestamped and recorded in the EVENT.TXT file With the dryer controller powered off install the USB flash stored in the root folder of the USB flash drive.

  • Page 12: Using The Ethernet Feature (J3)

    2.9 Using the Ethernet Feature (J3) Figure 2: Event History The dryer controller is equipped with an Ethernet port located at J3 on the control board which allows the customer to connect the dryer to a local area network. The customer can then monitor the dryer status and performance via Web Interface or ModbusTCP.
  • Page 13 Figure 4: Settings Modbus TCP The Modbus TCP connection allows you to continuously monitor the dryer from a DCS system which implements a Modbus TCP master. The dryer controller implements a ModbusTCP server on port 502. The following Modbus register table provides a list of data that is available.
  • Page 14 Modbus Registers Holding Register Reference Address Name Units Description 40001 0x0000 DRYER_STATUS Status ID Status ID for the dryer 40002 0x0001 ALARM_STATUS Flag Bits Alarm flag bits 40003 0x0002 WARNING_STATUS Flag Bits Warning flag bits 40004 0x0003 RESERVED Reserved 40005 0x0004 SERVICE_TIMER Hours...
  • Page 15 Modbus Register Details Page 1 of 3 Dryer Status Register 40001 Decimal Description 0x0000 Standby 0x0001 Fixed 0x0002 0x0003 Reserved 0x0004 Reserved 0x0005 Reserved 0x0006 Reserved 0x0007 Reserved Dryer Alarm Flags Register 40002 Mask Description 0x0001 High Discharge Temperature 0x0002 High Refrigerant Pressure 0x0004 Low Refrigerant Pressure...
  • Page 16 Modbus Register Details Page 2 of 3 Dryer Model Register 40017 Decimal Description 0x0000 Non-Cycling MRD 0x0001 Non-Cycling LRD 0x0002 ES-MRD 90 0x0003 ES-MRD 120 0x0004 ES-MRD 140 0x0005 ES-MRD 190 0x0006 ES-MRD 245 0x0007 ES-MRD 280 0x0008 ES-MRD 360 0x0009 ES-MRD 450 0x000A...
  • Page 17 Modbus Register Details Page 3 of 3 UI Language Register(s) 40021 Decimal Mask Description 0x0000 English 0x0001 Spanish 0x0002 French 0x0003 German 0x0004 Portuguese 0x0005 Italian 0x0006 Polish 0x0007 Danish 0x0008 Dutch 0x0009 Norwegian 0x000A Finnish 0x000B Swedish 0x000C Czech 0x000D Reserved 0x000E...

  • Page 18: Electronic Demand Drain - I-Controller Level 4

    2.10 Electronic Demand Drain – I-Controller Level 4 The condensate flows through the feed line (1) into the condensate drain and accumulates in the housing A. An automatic electric demand drain (EDD) discharges (2). A capacitive sensor (3) continuously registers the condensate removed by the separator.

  • Page 19: Maintenance Condenser Coil

    Depressurize filter by slowly opening manual drain by- pass valve. Remove bowl Models RNC125 thru RNC150 For models RNC100 through RNC150 - bayonet mount - push bowl up, turn bowl 1/8th turn to your left, and pull bowl straight down b.

  • Page 20: Check Separator Daily To Be Sure Automatic Drain Is Discharging

    3.3 Check separator daily to be sure automatic drain is discharging. NOTE: Units with two stage filtration have two sets of drains. 3.4 Blow down separator weekly by pushing test button on control panel. 3.5 Rebuild drain mechanism annually. To facilitate service, maintenance kits are available. Models RNC200 thru RNC750 Separator Element or Optional Oil Removal Element...

  • Page 21: Troubleshooting Guide I-Controller Level 1 & I-Controller Level 2

    4.0 TROUBLESHOOTING GUIDE: I-CONTROLLER LEVEL 1 & I-CONTROLLER LEVEL 2 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION A) Water downstream of dryer. 1. Residual free moisture remaining in Blow out system with dry air. downstream pipelines. 2. Air bypass system is open. Check valve positions.

  • Page 22: I-Controller Level 4 (Models 200-750)

    TROUBLESHOOTING GUIDE: I-CONTROLLER LEVEL 4 (MODELS 200-750) SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION A) Water downstream of dryer 1. Residual free moisture remaining in 1. Blow out system with dry air downstream pipelines 2. Air bypass system is open 2. Check valve positions 3.

  • Page 23: Reference Sizing

    5.0 REFERENCE SIZING Determining dryer capacity at actual operating conditions To determine the maximum inlet flow capacity of a dryer at various operating conditions, multiply the rated capacity from Table 1 by the multipliers shown in Table 2. Example: How many scfm can an air-cooled model RNC750 handle when compressed air to be dried is at 200 psig and 100°F;...

  • Page 24: Engineering Data Table Models 100-250

    ENGINEERING DATA TABLE: MODELS 100-250 Air System Data Rated Flow Capacity at 100°F, 100 psig Inlet, 100°F Ambient Temperature Maximum / Minimum Inlet Air Pressure (compressed air at inlet to dryer) 232 psig (16 barg) / 30 psig (2.1 barg) Maximum / Minimum Inlet Air Temperature (compressed air at inlet to dryer) 120°F (49°C) / 40°F (4°C) Maximum / Minimum Ambient Temperature...

  • Page 25: Models 300-750

    ENGINEERING DATA TABLE: MODELS 300-750 Air System Data Rated Flow Capacity at 100°F, 100 psig Inlet, 100°F Ambient Temperature Maximum / Minimum Inlet Air Pressure (compressed air at inlet to dryer) 232 psig (16 barg) / 30 psig (2 barg) Maximum / Minimum Inlet Air Temperature (compressed air at inlet to dryer) 120°F (49°C) / 40°F (4°C) Maximum / Minimum Ambient Temperature...

  • Page 26: Dryer Set Point Table

    DRYER SET POINT TABLE DIP Switch Settings DIP Switch Description Evaporator Outlet Temperature Sensor Disabled Enabled Status Menu Scrolling Disabled Enabled Reserved Reserved Dryer Configuration Description Units Lower Upper Increment Default Service Interval Hours 9999 4000 Energy Cost Decimal 0.00 0.99 0.01 0.13...

  • Page 27: Dryer Alarm Table

    DRYER ALARM TABLE Alarm Conditions Alarm Text Alarm Trigger Delay Monitored Exit Condition Alarm Action HIGH PRESSURE High pressure switch open 1 Second Always Manually reset the Halt compressors high pressure switch. De-energize alarm Alarm reset button relay #1 pressed LOW PRESSURE Low pressure switch open 3 Minutes...

  • Page 28: Controller Screen Shots Status Menu Screens

    CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Status Menu Screens Status Menu VERSION x.x Power-up Delay mm/dd/yyyy hh:mm MANUAL MODE Up/Down HRS TO SERVICE 4970 Up/Down Total Hours Up/Down DISCHARGE xxx.x°C / xxx°F Up/Down EVAPORATOR IN xxx.x°C / xxx°F Up/Down Up/Down Hidden if evaporator...

  • Page 29: Setup Menu Screens

    CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Setup Menu Screens Setup Menu MAIN MENU LANGUAGE Enter LANGUAGE ENGLISH Down/Up MAIN MENU DATE & TIME Enter DATE & TIME 02/24/2011 09:40 Down/Up MAIN MENU SCHEDULE Enter SCHEDULE MON ON IGNORE Down/Up MAIN MENU 02/24/2011 09:55...

  • Page 30: Network Menu Screens

    CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Network Menu Screens Network Menu Network Menu NETWORK MENU IP ADDRESS TYPE Enter IP ADDRESS TYPE DYNAMIC Up/Down NETWORK MENU IP ADDRESS Enter IP ADDRESS 192.168.0.2 Up/Down Up/Down NETWORK MENU SUBNET MASK Enter SUBNET MASK 255.255.255.0...

  • Page 31: Dimensions / Weights

    6.0 DIMENSIONS / WEIGHTS Dimensions, inches (mm) Model 37.56 (954) 37.56 (954) 37.56 (954) 38.60 (980) 38.60 (980) 45.38 (1153) 45.38 (1153) 58.06 (1475) 58.06 (1475) 58.06 (1475) 25.62 (651) 25.62 (651) 25.62 (651) 32.15 (817) 32.15 (817) 32.15 (817) 32.15 (817) 32.15 (817) 32.15 (817)

  • Page 32: Wiring Diagram

    7.0 WIRING DIAGRAM I-Controller Level 1 Model 100 (120/230 VAC)

  • Page 33: I-Controller Level 2

    WIRING DIAGRAM I-Controller Level 2 Model 100 thru 150 (115 or 208-230V/60 Hz, 100 or 240V/50 Hz)

  • Page 34: Models 200 Thru 600 (230-400-460V/3/50-60 Hz)

    WIRING DIAGRAM I-Controller Level 2 Models 200 thru 600 (230-400-460V/3/50-60 Hz) Sheet 1 of 2...
  • Page 35 WIRING DIAGRAM I-Controller Level 2 Models 200 thru 600 (230-400-460V/3/50-60 Hz) Sheet 2 of 2...

  • Page 36: Model 750 (230-400-460V/3/50-60 Hz)

    WIRING DIAGRAM I-Controller Level 2 Model 750 (230-400-460V/3/50-60 Hz) Sheet 1 of 2...
  • Page 37 WIRING DIAGRAM I-Controller Level 2 Model 750 (230-400-460V/3/50-60 Hz) Sheet 2 of 2...

  • Page 38: Models 200-600, (460 Vac)

    WIRING DIAGRAM I-Controller Level 4 Models 200-600, (460 VAC) Sheet 1 of 2...
  • Page 39 WIRING DIAGRAM I-Controller Level 4 Models 200-600, (460 VAC) Sheet 2 of 2...

  • Page 40: Model 750, (460 Vac)

    WIRING DIAGRAM I-Controller Level 4 Model 750, (460 VAC) Sheet 1 of 2...
  • Page 41 WIRING DIAGRAM I-Controller Level 4 Model 750, (460 VAC) Sheet 2 of 2...

  • Page 42: 575-460/3/60 Transformer Pack (Models 200-750)

    WIRING DIAGRAM 575-460/3/60 Transformer Pack (Models 200-750)

  • Page 43: Replacement Parts Cabinets (All Models)

    Cabinet Panel - Left G5002278 G5002278 G5002284 G5002284 G5002294 G5002294 G5002294 Cabinet Panel - Right upper G5002279 G5002279 G5002285 G5002288 G5002295 G5002295 G5002295 Cabinet Panel - Right lower G5002280 G5002280 G5002286 G5002286 G5002296 G5002296 G5002296 Gardner Denver Inc. Phone: (800) 682-9868 Web: www.gardnerdenverproducts.com...

  • Page 44: Models Rnc100 Through Rnc150

    REPLACEMENT PARTS: MODELS RNC100 THROUGH RNC150 VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) 13 14 LEFT REAR, VIEW-C (covers and center support shelf removed for clarity)
  • Page 45 * Condensing Unit Assembly consists of: Compressor, Condenser, Fan Assembly, Hot Gas Bypass Valve, Filter/Dryer, Base Pan, Accumulator (in some cases) and interconnecting piping. ** Items 20 and 21 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. Gardner Denver Inc. Phone: (800) 682-9868...

  • Page 46: Models Rnc200 Through Rnc750 Air-Cooled Units

    REPLACEMENT PARTS: MODELS RNC200 THROUGH RNC750 (AIR-COOLED UNITS) VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) 33F......39F 1C.......4C IC2 Control Panel RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) 11 12 LEFT REAR, VIEW-C (covers and center support shelf removed for clarity)
  • Page 47 Items 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, and 26 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. NOTE: Consult factory with the dryer serial number when ordering Item 19, Digital PC Board (IC 4). Gardner Denver Inc. Phone: (800) 682-9868...

  • Page 48: Water-Cooled Units

    REPLACEMENT PARTS: MODELS RNC200 THROUGH RNC750 (WATER-COOLED UNITS) VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) 19 20 33F......39F 1C.......4C IC2 Control Panel RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) LEFT REAR, VIEW-C (covers and center support shelf removed for clarity)
  • Page 49 Items 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, and 21 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. NOTE: Consult factory with the dryer serial number when ordering Item 14, Digital PC Board (IC 4). Gardner Denver Inc. Phone: (800) 682-9868...

  • Page 52: Warranty

    Gardner Denver Inc. 1800 Gardner Expressway, Quincy, IL 62305 Telephone: (800) 682-9868 FAX: (217) 224-7814 Visit our Web Site: www.gardnerdenverproducts.com © 2017 Gardner Denver, Inc. Printed in U.S.A 5002737 Rev. J 02/17 18-2-670 RNC100-750 New Platform 1st Edition...

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