User manual - Zander Sales
Contents
1. 500 19 69 co 231 40 ofS 9 08 157 eoa T d o o ol Culoo Cul Ss m g SIn nas Plon a Roc OOO0000000000 OOOO OOOO m POLE CN OO000000000 D OD PIED Oo Oo OOOO OOD o Y 1 o i 150 163 5 91 PE 6 42 e MIN LJ C Co DTD Cl mm inches Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 11 NA Dimensional drawing PRD50 PRD100 12 6 69 520 ep 20 47 ye 231 26 225 aloo 252 40 E 508 1533 8 86 as 9 93 157 i i gt B d uo e D i g lt lt ole Qul e NM me lt 1 se alu ina VIN ola 1 _ uo ni __ 22 9 LO ju Coo Cul o e 9 Q 5 e I Y 50 81 150 S 178 197 3 00 Cas 590 mu 701 1 x odes 29 65 9 09 ie dem e MIT 113 26 113 ne e Qu so MIONN amp gt ME Qul a e HS oz 45 E p B2. 0422 2012 Parker Hannifin Corporation Product names are trademarks or registered trademarks of their respective companies Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422
3. 813 571 0422 10 699 FM gt 041 490 El Dimensional drawing PRD10 PRD15 8 6 y Bhs n IE UL 2691 zi DE ur e 91 iL C02 ae Ger G n ij gt Y QU Es ds am E min al Be oe 699 86 09 071 t Go Lj V VvV c 4 x au 00 Jj vv y EOI 82 ala er m peer uw mM A gv X Ulis or zx a a IS o x i ze E ny I ae 8 a uso Rios 02 Qj CTS e e Tes a ne d d e L le a maja SZ 02 tres Po 25 uoc Tcl Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 LL Dimensional drawing PRD25 PRD35 195 4 NS E 11957 m 103 2 S E E j 8 27 1 j m cu SL 2 lt lt Qc d 5 lt lt H in ed as 50 gl 197 1 1320 O S 29 65 Uo e X 133 126 113 om m al wn l1 UE SIN Dios Y l5 e7 uwo 7 C45 28 A z alo ga CN 186 5 734
4. OFF 116 PSIg 32 PSIg 1 5 0 ee n PRD25 PRD100 2 2 bar 0 1 0 Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 84 LI Spare parts list 8 5 PRD10 PRD15 PRD25 PRD35 PRD50 PRD75 PRD100 115V 1Ph 60Hz SP 147439 SP 147405 SP 147100 SP 147339 SP 147341 a Compressor kit D 230V 1Ph 60Hz SP 147398 115V 1Ph 60Hz SP 381679 SP 381793 SP 381616 ds 230V 1Ph 60Hz 9 SP 381794 e Automatic expansion valve kit 9 SP 473108 SP 473109 Refrigerant condenser Q SP 114800 SP 114801 SP 114802 SP 114803 SP 114754 Evaporator Separetor Air air heat exchanger CONG SP 472157 SP 472158 SP 472159 Power cable 6 SP 256347 Refrigerant filter SP 206214 d Dewpoint indicator D SP 354317 Fan pressure switch SP 354376 High temperature safety thermostat 3 SP 473399 Main power switch SP 255132 Cover 5 SP 137926 SP 137928 SP 137931 Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 8 5 Exploded drawing o Of gt M AN NS Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax
5. Q a 11 5 7 0 eu ga 45 1 28 oH mm pes 186 5 i inches T U341 Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 8 7 Refrigerant circuit G E gt 6 CO Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 13 8 8 L Wiring diagram PRD10 PRD15 14 LIMIT OF EQUIPMENT KA1 Alarm Probe KA1 Alarm Contact 5 6 T 8 2 KAI TO 9 SOLO PER LA VERSIONE CON CONTATTI PULITI ONLY FOR FREE CONTACT VERSION A1 COMP W5V1Ph BOHz it sss eee ee PT L R1 55 lalo m p gt EJ e 2 QF lan 0 3A RECOMMENDED RACCOMANDATO wo Lal ES HT PV d us as z E B x m KT KAI zl 3 N EN FN m RT Si a amp E CN lt LL Lo 7 hat a Lu E pas Al ELECTRO Col AN CO TAR mn HIGH TIME SWITCH C DRAIN POWER SUPPLY PRESSOR MOTOR MOTOR
6. and or options are fully comprehensive for the correct or foreseeable use of the machine itself or its components A IMPORTANT The manufacturer reserves the right to modi fy this manual at any time For the most comprehensive and updated information the user is advised to consult the manual supplied with the unit 1 4 Residual risks The installation start up stopping and maintenance of the ma chine must be performed in accordance with the information and instructions given in the technical documentation supplied and always in such a way to avoid the creation of a hazardous situa tion The risks that it has not been possible to eliminate in the design stage are listed in the following table part affected residual risk manner of exposure precautions heat exchanger coil small cuts contact avoid contact wear protective gloves fan grille and fan lesions insertion of poin ted objects through the grille while the fan is in operation do not poke objects of any type through the fan grille or place any objects on the grille inside the unit compressor and discharge pipe contact avoid contact wear protective gloves inside the unit metal parts and electrical wires intoxication electrical shock serious burns defects in the insu lation of the power supply lines up stream of the elec trical panel live metal parts adequate electrical protection of the
7. dryer design pressure 4 Filter 3 micron filtration or better near dryer air inlet A x 5 Tank in position A or in B A gt Hoses for air connections if the system undergoes vibrations 6 Outlet filter A Gc Suitable dampers if the system undergoes pulsations 7 Oil Water separator 8 Condensate drain Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 8 3 Ll Technical data Weieht Refri t MIN MAX Mini Compressed Connections sp LHperan Ambient temperature eu air inlet outlet Tightening torque Compressed Air side f Amb air inlet max working FLA A ee Le i R134a Kg temperature pressure f During transport After ror eenen E x and stockage installation 115V 10 230V 10 Ib ke 0 ks A fg aud Sin Max 1ph 60Hz 1ph 60Hz NPT Nem aBa PRD10 41 8 19 5 99 0 17 3 74 NPT 50 PRD15 compatible d o o 1 2 32 122 F 41 122 F 149 F 232 PSI PRD25 51 8 23 5 9 52 0 27 A 5 4 78 3G16AWG 50 PRD35 0 50 C 5 50 C 65 C 16 bar PRD50 584 265 881 025 8 31 NPT 55 PRD75 68 3 31 9 52 027 10 23 with adaptor PRD100 772 35 1234 035 12 44 6 22 3 Calibration values Expansion automatic valve Fan pressure switch AEV D Pv 35 PSIg 1 5 0 PRD10 PRD15 z ON 160 PSIg 2 4 bar 0 1 0
8. panels operations requiring open ing with tools must be carried out by skilled and qualified person nel EF Do not exceed the design limits given on the dataplate A EF It is the user s responsibility to avoid loads different from the internal static pressure The unit must be appropriately protected whenever risks of seismic phenomena exist A The safety devices on the compressed air circuit must be pro vided for by the user Only use the unit for professional work and for its intended pur pose The user is responsible for analysing the application aspects for product installation and following all the applicable industrial and safety standards and regulations contained in the product instruction manual or other documentation supplied with the unit Tampering or replacement of any parts by unauthorised person nel and or improper machine use exonerate the manufacturer from all responsibility and invalidate the warranty The manufacturer declines and present or future liability for damage to persons things and the machine due to negligence of the operators non compliance with all the instructions given in this manual and non application of current regulations regard ing safety of the system The manufacturer declines any liability for damage due to alter ations and or changes to the packing It is the responsibility of the user to ensure that the specifications provided for the selection of the unit or components
9. PRESSOR OVERLOAD PROTECTOR ING RELAY RESSOR START CAPACITOR TEMPERATURE SAFETY SWITCH PRESSURE SWITCH D RELAY ALARM SWITCH Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 A Wiring diagram PRD25 PRD100 115V 1Ph 60Hz 230V 1Ph 60Hz e Mo ie e fi S 2 EN m de Sl E A si QF lan 0 3A RECOMMENDED T gt RACCOMANDATO 2 2 HT KT P L Be Qs z PV E E 7 ca KT KAI lt E a PS ES E RI S1 R4 5 CN zu Go PM n KA1 Alarm Probe KA1 Free Contact lb Tess gt amp E 5 8 Y EV Le e Les KM TO 8 1 SOLO PER VERSIONE CON CONTATTI PULITI ONLY FOR FREE CONTACT VERSION QS MAIN SWTCH CN ELECTRONIC DRAIN POWER SUPPLY MC COMPRESSOR MOTOR EV FAN MOTOR PV FAN PRESSURE SWITCH SK COMPRESSOR OVERLOAD PROTECTOR KA STARTING RELAY C STARTING CAPACITOR HT HIGH TEMPERATURE SAFETY SWITCH KT TIMED RELAY KAT ALARM SWITCH Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 15 Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571
10. User manual Refrigeration Dryer PRDIO PRDIS5 PRD25 PRD35 PRD50 PRD75 PRD100 DATE 2012 06 20 Rev 2 CODE 272889 Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 Index 1 Safety 2 Introduction 3 Installation 4 Commissioning 5 Control 6 Maintenance 7 Troubleshooting 8 Appendix LL There are symbols whose meaning is given in the paragraph 8 1 8 1 Legend 8 2 Installation diagram 8 3 Technical data 8 4 Spare parts list 8 5 Exploded drawings 8 6 Dimensional drawings 8 7 Refrigerant circuits 8 8 Wiring diagram 1 Safety 11 Importance of the manual Keep it for the entire life of the machine Read it before any operation e It is subject to changes for updated information see the ver sion on the unit 1 2 Warning signals A Instruction for avoiding danger to persons Instruction for avoiding damage to the equipment Y The presence ofa skilled or authorized technician is required There are symbols whose meaning is given in the para 8 LL 1 3 Safety instructions A Always disconnect the dryer from the main power sup ply before starting maintenance work A The manual is intended for the end user only for opera tions performable with closed
11. d in case of machine malfunction otherwise any damage caused by incorrect refriger ant charging will not be covered by the warranty 6 2 Refrigerant 9 Charging any damage caused by incorrect refrigerant replace ment carried out by unauthorized personnel will not be covered by the warranty gt At normal temperature and pressure the R134a refrigerant is a colourless gas classified in SAFETY GROUP A1 EN378 group 2 fluid according to Directive PED 97 23 EC GWP Global Warming Potential 1300 A In case of refrigerant leakage ventilate the room 6 3 Preventive Maintenance Programme To guarantee lasting maximum dryer efficiency and reliability Maintenance Maintenance Interval Activity Description standard operating conditions Activity Weekly 4 Months 12 Months Check POWER ON indicator is lit Check control panel indicators gt 27 Daily Check condensate drain Clean condenser fins Check electrical absorption AN Depressurize the dryer The following are available see par 8 4 a compressor kits b fan kits c automatic expansion valve kits d individual spare parts 6 4 Dismantling The refrigerant and the lubricating oil contained in the circuit must be recovered in conformity with current local environmen tal regulations ORY Recycling Disposal structural work steel epoxy polyest
12. er resins exchanger aluminium pipes aluminium copper drain polyamide exchanger insulation EPS sintered polystyrene pipe insulation synthetic rubber check Y service compressor steel copper aluminium oil Complete drain maintenance 4 p a mae condenser steel copper aluminium Depressurize the dryer Y Repalce pre and post filter ele refrigerant R154a ments valves brass electrical cables copper PVC Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 7 Troubleshooting Overload protector SK HT tripped Cooling air outlet too high High dew point Ambient temperature over 122 F 50f C Reduce temperature Excessive thermal load compressor head too hot Reduce compressed air quantity or air temperature Insufficient refri gerant repair any leaks and recharge the circuit CAUSE Excessive current consumption Compressor noisy Fan does not work Compressor components perished Compressor winding insulation partially perished compressor too hot Repair or replace com pressor REMEDY High pressure drop on air side Heat exchanger fouled with debris Clean heat exchanger blow compressed air in to operating air flow Fit renew prefilter op
13. n a clean area protected from direct at mospheric agents including sunlight EF Comply with the instructions given in par 8 2 and 8 3 All dryers must be fitted with adequate pre filtration near the dryer air inlet Seller is excluded any obbligation of compensation or refund for any direct or indirect damage caused by its absence EF Pre filter element for 3 micron filtration or better must be replaced at least once a year or sooner as per manufacturer recommendations EF Do not invert the compressed air inlet and outlet connec tions and observe the maximum tightening torque N x m as spe cified in par 8 3 3 2 Operating space EF Leave a space of 60 inches 1 5 m around the unit 3 3 Tips To prevent damage to the internal parts of the dryer and air com pressor avoid installations where the surrounding air contains solid and or gaseous pollutants e g sulphur ammonia chlorine and installations in marine environments The ducting of extracted air is not recommended for versions with axial fans 3 4 Electrical connection Use approved cable in conformity with the local laws and regula tions for minimum cable section see par 8 3 Install a differential thermal magnetic circuit breaker with contact opening distance gt 0 12 inches 3 mm ahead of the sys tem IDn 0 3A see the relevant current local regulations The nominal current In of the magnetic circuit breaker must be equal to the FLA with a
14. n intervention curve type D 3 5 Condensate drain connection The dryer is supplied either with a float drain a timed drain or an electronic level sensing drain If a timed or electronic unloader is installed use terminals CN R1 S1 see par 8 8 For timed and electronic drains refer to separate manual sup plied with the dryer for specific details concerning the condensate drain gt Make the connection to the draining system avoiding con nection in a closed circuit shared by other pressurized discharge lines Check the correct flow of condensate discharges Dispose of all the condensate in conformity with current local environ mental regulations 4 Commissioning 4 1 Preliminary checks Before commissioning the dryer make sure a installation wascarried out according that givenin the section 3 b the air inlet valves are closed and that there is no air flow through the dryer c the power supply is correct 4 2 Starting a Start the dryer before the air compressor by means of the main power switch 9 the power lamp will illuminate green b after at least 5 minutes slowly open the air inlet valve and subsequently open the air outlet valve the dryer is now performing its air drying function 4 3 Operation a Leave the dryer on during the entire period the air compres sor is working b the dryeroperates in automatic mode therefore field settings are not required 2 c inthe event of unfore
15. posite direction Ice formation on evaporator low evapora tion pressure By pass air flow keeping air inlet open Open con densate drain valve manually Restart appliance checking setting of expansion valve High refriger ant discharge pressure Fan pressure switch PV calibration error or damaged Replace pressure switch Clean condenser Replace fan Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 Seek external assistance 8 Appendix 8 1 Legend Meaning Meaning MC Compressor 42 PV Fan pressure switch Refrigerant condenser 3 HT High temperature safety thermostat EV Fan motor Qs Main power switch D Evaporator E Cover O Separator CN Electronic condensate drain power supply Power cable SK Overload protector AEV Expansion automatic valve KA Starting relay Refrigerant filter C Compressor starting capacitor Air air exchanger QF Residual current automatic circuit breaker 0 Dewpoint indicator Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 8 2 Installation diagram 7 1 Air compressor 2 Dryer 3 By pass unit Safety valves for not exceeding
16. power supply line ensure metal parts are properly con nected to earth outside the unit area surroun ding the unit intoxication serious burns fire due to short circuit or overhea ting of the supply line upstream of the unit s electrical panel 2 Introduction This manual refers to refrigeration dryers designed to guarantee high quality in the treatment of compressed air 2 1 Transport The packed unit must a remain upright b be protected against atmospheric agents c be protected against impacts 2 2 Handling Use a fork lift truck suitable for the weight to be lifted avoiding any type of impact Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 ensure conductor cross sectional areas and the sup ply line protection system conform to applicable regula tions 2 3 Inspection a Allunits are assembled wired filled with coolant and oil and tested under standard operating conditions in the factory b on receiving the machine check its condition immediately notify the transport company in case of any damage c unpack the unit as close as possible to the place of installa tion 2 4 Storage If several units have to stacked follow the notes given on the packing Keep the unit packed in a clean place protected from damp and bad weather 3 Installation 3 1 Procedures Install the dryer inside i
17. seen excess air flows by pass to avoid overloading the dryer 4 4 Stop a Stop the dryer 2 minutes after the air compressor stops or in any case after interruption of the air flow b do not allow compressed air to flow through the dryer when the latter is not running c switch off at the main power switch The power light goes out and the compressor stops 5 Control 1 Dewpoint indicator Main power switch The dewpoint indicator can show one of three conditions blue dewpoint too low green dewpoint ideal red dewpoint too high Manufacturers Distributor Inc www ZanderSales com sales ZanderSales com Phone 727 835 0649 Fax 813 571 0422 6 Maintenance a The machine is designed and built to guarantee continuous operation however the life ofits components depends on the maintenance performed b when requesting assistance or spare parts identify the ma chine model and serial number by reading the dataplate lo cated on the unit 6 1 General instructions A Before any maintenance make sure e the pneumatic circuit is no longer pressurized e the dryer is disconnected from the main power supply EF Always use the Manufacturer s original spare parts other wise the Manufacturer is relieved of all liability regarding ma chine malfunctioning EF In case of refrigerant leakage contact qualified and author ized personnel gt The Schrader valve must only be use
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