Instruction Manual for TOOLOTS models including: DM240NF Refrigerated Compressed Air Dryer, DM240NF, Refrigerated Compressed Air Dryer, Compressed Air Dryer, Air Dryer, Dryer
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DocumentDocumentInstructions for installation and operation Compressed air refrigeration dryer MODELS: DM240NF 21.10. 20 Refrigerated Compressed Air Dryer Contents PREFACE..................................................................1 SAFETY WARNING SIGNS.......................................1 WARNING................................................................3 NOTICE OF INSTALLATION....................................3 AN INTRODUCTION TO THE CONTROLLER.........4 PARTS NAME...........................................................5 METHODS OF OPERATION.....................................6 ABOUT PRESSURE GAUGE......................................6 ABOUT POWER SUPPLY..........................................6 MAINTENANCE TO THE DRYER.............................7 MAIN TECHNICAL DATA OF THE DRYER..............7 NOTICE....................................................................10 TROUBLESHOOTING...............................................10 APPENDIX................................................................13 SUMMARY................................................................13 REFRIGERATED COMPRESSED AIR DRYER Preface We'd like to give our thanks hereof for your choosing our Refrigerated Compressed Air Dryer as well as your trust and support. We sincerely hope it will make a great contribution to your production. Please read this instruction manual before operation. In this way to ensure that you are able to control the machine, which will run steadily and safety. This manual is to introduce installation, operating, running, maintenance, wiring chart and troubleshooting etc. Please pay attention to the technical data and comprehend the parts'function of the flow as well as their operation condition to the whole system before operating. This purpose is to let the user master the general knowledge during the dryer's running and maintenance to ensure its running smoothly. Please feel free to contact us if there's any question. Safety warning signs Danger! Supply voltage! Contact with non-insulated parts carrying supply voltage involves the risk of an electric shock resulting in injuries and death. Only qualified and skilled personnel are authorised to run electrically-operated devices. Prior to undertaking maintenance measures at the device, the following requirements must be met: Make sure that the power supply is switched off and that the device is off and marked for maintenance measures. Please also ensure that the power supply cannot be re-established during the works. 1 Caution! Hot surfaces! During operation, several components can reach surface temperatures of more than 140°F. 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 3 . Beware of mechanical injury Caution! Avoid mechanical injury accidents! Extrusion, collision, impact, shearing, entanglement, twisting, throwing, cutting, cutting, puncturing, etc. Caused by mechanical equipment movement (stationary), parts, tools, and processed parts directly contacting the human body. 2 REFRIGERATED COMPRESSED AIR DRYER Warning It's prohibit to invert, shake, quiver and heavy break during transportation, sling and installation. Please operate the dryer strictly according to the ambient temperature and working conditions stipulated in this manual. Please maintain it timely. It will short the dryer's life due to the exceeding of working conditions for a long time. Check and make maintenance timely will extend it's using life, please appoint professional people to manage it. Notice of installation Install on the balanced, fastness floor. It's prohibited to place on the floor with heavy shock, slant, bumpiness and badness of drainage. 19.7 in 19.7 in Air convection The ambient temperature is below 113°F 19.7 in Install in the breezy place, and the ambient temperature can't extend 450C. It's also prohibited to place in the open air, humid, dust and erode gas existence. The radiators can't be opposite when there're many dryers placed together. Compressedairoutlet Compressedairinlet Bypassvalve Intakevalve Interface Outletvalve Controloperationpanel Wheninuse, thebypassvalveisusuallyclosed, andtheinletandoutletvalvesof theairdryerareopened. 3 Please use the linker to connect AIR INLET and AIR OUTLET. Please make sure you've configured by-pass pipeline in order to maintain. The weight of pipeline shouldn't be too much, and caution that you can't overexert when install the pipeline. Please whiff and clean the inner pipe thoroughly before installing it so as to avoid dust. Please also be noticed that the shaking of compressor can't be passed to the dryer. An introduction to the controller POWER SUPPLY ---- The power indicator, RED, it's lighting during electrifying OPERATION ----The operation indicator, GREEN, it's lighting if the dryer run smoothly. HIGH FAULT ----The high pressure fault indicator, ORANGE, it's lighting when high pressure exceeds, the dryer will stop automatically when it lights, and the light will extinguish when it comes to balance with the low pressure. LOW FAULT ---- The low pressure fault indicator, ORANGE, it's lighting when low pressure exceeds, the dryer will stop automatically when it lights, and the light will extinguish when it comes to balance with the high pressure. 4 REFRIGERATED COMPRESSED AIR DRYER ELEC FAULT ---- The electrical fault indicator, ORANGE, it's lighting when the electric system has a fault, the dryer will stop automatically when it lights. ON ---- Start button, GREEN, the start interval should at least last for 3 minutes. OFF ---- Stop button, RED. Parts name Compressedairoutlet Compressedairinlet Filter Aftercooler Highvoltagecircuitbreaker Coolingfan Operationcontrolpanel Coldcoalevaporator Waterseparator Condenserfan Coldcoalcompressor Distributionbox Automaticdrainage Highandlowvoltage controlswitch 5 Methods of operation Check and make sure the dryer is installed correctly, you can go on preliminary operation, pressure the "ON" button to start. The "OPERATION" indicator will light and according to the ambient temperature, the fan and motor inside will run and stop reduplicative. If the evaporating pressure gauge exceeds 7kg under the continuous running of the fan, it may be overload. Press the "OFF" button to stop. The auto-drain/electric drain will drain out after a period of time. When the orange button lights, there're some faults of the dryer, it will stop automatically. Please restart after the clearance faults. About pressure gauge Evaporating pressure gauge, evaporating temperature shows the pressure of low-pressure refrigerant. The index should between 4~6kg of normal load. And it'll be a bit lower if non-loaded. Air pressure gauge, shows the compressed air pressure of the surrounding air outlet. About power supply Please use 220V or 380V special interface. Please be sure you've installed the leakage protector. You're required to make the earth wire before connecting the power supply. 6 REFRIGERATED COMPRESSED AIR DRYER Dedicated line 220V-380V Set up leakage terminal circuit breaker Ground wire Maintenance to the dryer 1. Unload the auto-drain to clean monthly, but it's not necessary if it's electric drain.Open the by-pass valve; close the inlet & outlet valve before unloading the drain to lessen the pressure inside auto-drain to zero. Unscrew the lower shell with pipe pliers; infuse some neutral abluent to clean it. It absolutely prohibited by using menstruum. After that, please re-install to the home position, locking with the O-ring. Close the by-pass valve than open the inlet valve. 2. Clean the radiator-grid weekly with aspirator, brush or air gun etc. 3. You can use the air gun only to clean the electric switch box and circuit board. Main technical data of the dryer 1. Air-cooling refrigerated air dryer Inlet temperature: Normal temp.:113°F High temp.:176°F Cooling method: Air cooling Ambient temperature: 100°F Dew point: 35.6-50 Refrigerant: R22 Inlet pressure: 0.6~1.0Mpa Pressure drop: 0.02Mpa 2. Water-cooling refrigerated air dryer Inlet temperature: Normal temp.:113°F High temp.:176°F Cooling method: water cooling Dew point: 35.6-50 Refrigerant: R22 Inlet pressure: 0.6~1.0Mpa Pressure drop: 0.02Mpa Cooling water inlet temperature: 89.6°F Cooling water inlet pressure: 0.2~1.4Mpa 7 DM240NF series refrigerated air dryer Product Information Brand Model Max air volume Pressure dew point Working pressure Technical Details Demargo DM240NF 141CFM 35.6-50 87Psi The largest Working pressure Inlet temperature: Ambient temperature: 145Psi < 113 100 Working hours way to control Continuously working Microcomputer control Pressure loss 2.9Psi Drain valve Cooling method Refrigerant model Power supply Compressor power Electronic drain valve Air-cooled R134a 220V1ph 60HZ 0.66KW / 0.88HP Fan Power 0.18HP Air pipe connection Air inlet and outlet pipe size Dimensions (L × W × H) NPT Threaded connection 1.5''internalthreadDN40 34.6''-18.7''-31.9'' Installation method Simple and convenient 8 REFRIGERATED COMPRESSED AIR DRYER 87 9 10 11 6 5 4 1 3 2 1 Pressure controller 2 Compressor 3 Dry filter 4 Capacitance 5 Controller 6 Cold coal low pressure meter 7 Fan 8 President of Heat Exchanger 9 Electronic drain 10 Ball valve 11 Condenser 9 Notice 1. Note: If the evaporating pressure gauge exceeds 7KG during working, it may be over-loaded, please check the over-loaded conditions as bellows. 2.Loading conditions: It will go to over loaded under the following conditions and run constrainedly. Then it will stop running when the protector "orange" indicators light. 1). Compressed air temperature is excessive. 2). Compressed air capacity is exceeded. 3). Ambient temperature is higher than 113. 4). Voltage under 198V (220V rated) or under 340V (380V rated). 5). Badness of thermolysis. 3.Attention: The auto-drain may not act as there's some impurity contained in the compressed air, please check if there's condensate water coming out from the draining hole everyday. According to the characteristic and structure of drain, it may drain out from the draining hole provide the pressure is under 1.5kg/cm2. Therefore, the pressure may not be raised if gas production of air compressor is too small. Please pay attention to it. Troubleshooting Familiar faults caused by the refrigerated air dryer itself and external factors conditions as well as its trouble-shooting as follows: Pressure drop is excessive phenomena The differential pressure is too large of the whole air compression station Shortage of the air using Ice over of the evaporator Causation The piping valves don 't be fully opened. The pipe(s) is too slim. Pipeline is too long, lots of elbow and tie-in. Much leakage of the piping connections. Block of the piping filters. Actual using capacity exceeds the compressor rated capacity. Fall physically Fault of temperature switch . Invalidation of expansion valve . Troubleshooting Open the valve fully. Enlarge the pipe(s). Re-configurate the piping system. Check the elbows and connections. Clean the filters or change new one(s). Change larger compresso r, or increase pressure. Decrease air flowrate. Renew temperature switch. Renew expansion valve . 10 Badness of draining phenomena Liquid water content Abnormity of the evaporating gauge. REFRIGERATED COMPRESSED AIR DRYER Causation The air by-pass valve doesn't be fully closed. Compressed air doesn't go through the dryer. The flowrate is too much. Badness of the drain. The drainpipe is higher than the auto - drain. Compressor is too large, while the dryer is too small. Evaporating temperature is too high. The ambient air pollution or badness of ventilation. Block of the expansion valve . Leakage of refrigerant. Spoiling of the gauge. Troubleshooting Close the by-pass valve. Open the inlet and outlet valves of dryer. Re-design the compressor system. Clean or change. Re-setting the drainpipe. Re-setup the compressor and dryer. Check the air load of compressor. Improve the ventilation and ambient conditions. Change the expansion valve. Check the leakage, and infuse some refrigerant. Change the gauge. Out of operation phenomena Out of power supply. Power supply is in normal, but it can't start. All switches in normal, but it can't start. Evaporating temperature indicator too lower. Evaporating temperature indicator too higher. Causation The fuse blew out or trip of the fuse disconnecting switch. Power-off. Abnormity of voltage or too slim of the power cord. (voltage drop) Badness of switch. badness of contactor Badness of overload relay. Badness of electric capacity. Badness of start relay. Badness of pressure switches. Badness of temperature switches. Badness of refrigerated compressor. Trips of high-low pressure and desn't go to restoration. Electromagnetic switch doesn't go to restoration. High pressure switch doesn't go to restoration. Setting error of the temperature switches. Badness of refrigerated compressor. Evaporating temperature (badness of low pressure gauge). Block of the expansion valve. Setting lower of the temperature and pressure switches. Leakage of refrigerant. Ambient temperature is too high. Invalidity of the thermal by-pass valve. Block of the condenser. The capacity is too much. Abrasion of the valve flap of refrigerant compressor. Troubleshooting Check if the power lack of phase or short circuit. Check the fuse. Check and maintain. Please choose voltage according to the rated on the name plate. Change. Change. Change. Change capacitor. Change. Change. Change. Change. Check the reason of trips, press "RESET". Check and pressure "RESET". Check and pressure "RESET". Reset or change. Change. Change. Change. Please adjust the setting. Check the leakage points, and infuse some refrigerant. Improve the ambient temperature or change place for ventilation. Adjust or change. Clean. Reposition of the matching. Change. 11 Badness of drainage system phenomena Causation The using pressure is under1.5kg/cm 2. Badness of drainage. Spoiling of ball valve. Slant or disrepair of the valve. Pressure is too high. Block of the filtering of drain. Block of the waterspout. Troubleshooting Normal pressure should be 2 ~10 kg/cm2. Change. Improve, fasten or change. Please use according to the rated pressure. Clean. Clean. Badness after starting phenomena Causation Abnormity of voltage. After starting, it's short circuit. Thought the high pressure trip is restoration, it 's can't start. Badness of pressure switch. Badness of fan. Trip of the overload protector. Begrime of the condenser. Excessive of refrigerant. The ambient temperature is too high. Trip of the carrying relay. Block or closed of expansi on valve. Block of refrigerant filter. Badness of start relay. Badness of capacitor. Badness of pressure switch. Refrigerated compressor is overload ed. The ambient temperature is too high. The relay rated electric current is too low. Badness of relay connection. Lack phase of power supply. Badness of connector. Troubleshooting Reposition of the control circuitry and switches. Change. Change. Check the reasons. Clean it thoroughly. Less some refrigerant. Improve the ambient temperature and ventilation. Change. Change. Change. Change capacitor. Change. Decrease air capacity. Improve the ambient temperature and ventilation. Adjust the rate. Clean or renew. Check the reasons. Clean or renew. REFRIGERATED COMPRESSED AIR DRYER Appendix: Guarantee card Thank you for choosing Demargo refrigerated compressed air dryer. The dryer is manufactured by holding abundant experience and mature technology, it's the advanced product. We ensure one year guarantee from your buying date. We will answer your questions timely and carefully. File card in duplicate Customer name: Contact person: Telephone No.: Fax No.: Address: Buying date: Model No.: Serial No.: Installation place: Customer name: Contact person: Telephone No.: Fax No.: Address: Buying date: Model No.: Serial No.: Installation place: 12 13Corel PDF Engine Version 17.1.0.572 CorelDRAW X7