Beko DRYPOINT RA CT 200-NA-FB, DRYPOINT RA CT 400-NA-FB, DRYPOINT RA CT NA, DRYPOINT RA CT 350-NA-FB, DRYPOINT RA CT 500-NA-FB Instructions For Installation And Operation Manual

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Instructions for installation and operation

Compressed air refrigeration dryer

DRYPOINT

RA CT 20-500 NA

Dear customer, Thank you for deciding in favour of the DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer. Please

read these installation and operating instructions carefully before mounting and starting up the DRYPOINT® RA CT 20500 NA and follow our directions. Perfect functioning of the DRYPOINT® RA CT 20-500 NA and thus reliable compressed-air drying can only be guaranteed when the provisions and notes stipulated here are strictly adhered to.

2 DRYPOINT® RA CT 20-500 NA

Contents

 Type plate 5

2 Safety instructions 5

2.1 Safety pictograms in accordance with DIN 4844 6

2.2 Signal words in accordance with ANSI 8

2.3 Overview of the safety instructions 8 3 Proper use 11 4 Exclusion from a field of application 11 5 Operating instructions in accordance with the 97/23/EC Pressure Equipment Directive 11 6 Transport 12 7 Storage 12 8 Technical description 13

8.1 Control panel 13

8.2 Functional description 14

8.3 Flow chart 15

8.4 Refrigerating compressor 16

8.5 Condenser 16

8.6 Filter dryer 16

8.7 Capillary tube 16

8.8 Aluminium heat exchanger 16

8.9 Hot-gas bypass valve 17

8.10 Refrigerant pressure switches LPS – HPS – PV 17

8.11 Compressor crankcase heater (RA CT 200-500 NA 3phase) 17

8.12 DMC 51 electronics (control unit compressed-air dryer) 18

8.12.1 Switching the dryer on 18

8.12.2 Switching the dryer off 18

8.12.3 Indication of the operating parameters 18

8.12.4 Indication of a Service Warning 19

8.12.5 Indication of an Alarm 19

8.12.6 Operation of the Service Warning / Alarm signal 20

8.12.7 How to change operating parameters – SETUP menu 20

8.13 Electronically level-controlled BEKOMAT condensate drain 20 9 Installation 21

9.1 Place of installation 21

9.2 Installation plan 22

9.3 Correction factors 23

9.4 Connection to the compressed-air system 24

9.5 Electrical connections 25

9.6 Condensate drain 25 10 Start-up 26

10.1 Preliminary stages 26

10.2 Initial start-up 26

10.3 Shut down and restart 27 11 Technical data 28

11.1 Technical data DRYPOINT RA CT 20-200 NA 1/115/60 28

11.2 Technical data DRYPOINT RA CT 20-500 NA 1/230/60 29

11.3 Technical data DRYPOINT RA CT 200-500 NA 3phase 3/460/50 30

11.4 Technical data DRYPOINT RACT 200-500 NA 3phase 3/380/60 31 12 Maintenance, troubleshooting, spare parts and dismantling 32

12.1 Checks and maintenance 32

12.2 Troubleshooting 33

12.3 Recommended spare parts 38

12.4 Maintenance works at the refrigeration cycle 41

12.5 Dismantling the dryer 41 13 Appendices 42

13.1 Dryer dimensions 42

13.1.1 Dryer dimensions DRYPOINT RA CT 20-50 NA 42

13.1.2 Dryer dimensions DRYPOINT RA CT 75 NA 43 DRYPOINT® RA CT 20-500 NA 3

13.1.3 Dryer dimensions DRYPOINT RA CT 100-150 NA 44

13.1.4 Dryer dimensions DRYPOINT RA CT 200-250 NA 45

13.1.5 Dryer dimensions DRYPOINT RA CT 300-350 NA 46

13.1.6 Dryer dimensions DRYPOINT RA CT 400-500 NA 47

13.1.7 Dryer dimensions DRYPOINT RA CT 200-250 NA 3phase 48

13.1.8 Dryer dimensions DRYPOINT RA CT 300-350 NA 3phase 49

13.1.9 Dryer dimensions DRYPOINT RA CT 400-500 NA 3phase 50

13.2 Exploded diagrams 51

13.2.1 Components of the exploded diagrams 51

13.2.2 Exploded diagram DRYPOINT RA CT 20-30 NA 52

13.2.3 Exploded diagram DRYPOINT RA CT 50 NA 53

13.2.4 Exploded diagram DRYPOINT RA CT 75 NA 54

13.2.5 Exploded diagram DRYPOINT RA CT 100 NA 55

13.2.6 Exploded diagram DRYPOINT RA CT 125-150 NA 56

13.2.7 Exploded diagram DRYPOINT RA CT 200-250 NA 57

13.2.8 Exploded diagram DRYPOINT RA CT 300-350 NA 58

13.2.9 Exploded diagram DRYPOINT RA CT 400-500 NA 59

13.2.10 Exploded diagram DRYPOINT RA CT 200-250 NA 3phase 60

13.2.11 Exploded diagram DRYPOINT RA CT 300-350 NA 3phase 61

13.2.12 Exploded diagram DRYPOINT RA CT 400-500 NA 3phase 62

13.3 Electric diagrams 63

13.3.1 Electric diagrams – list of components 63

13.3.2 Electric diagram DRYPOINT RA CT 20-100 NA 64

13.3.3 Electric diagram DRYPOINT RA CT 125-150 NA 65

13.3.4 Electric diagram DRYPOINT RA CT 200-250 NA 66

13.3.5 Electric diagram DRYPOINT RA CT 300-350 NA 67

13.3.6 Electric diagram DRYPOINT RA CT 400-500 NA 68

13.3.7 Electric diagram DRYPOINT RA CT 200-500 NA 3phase 1/3 69

13.3.8 Electric diagram DRYPOINT RA CT 200-500 NA 3phase 2/3 70

13.3.9 Electric diagram DRYPOINT RA CT 200-500 NA 3phase 3/3 71

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4 DRYPOINT® RA CT 20-500 NA

Type plate

1 Type plate

The type plate is on the back of the dryer and comprises all primary data of the device. Always refer to these when contacting the manufacturer or the sales department.

All guarantee claims will expire in the event that the type plate is modified or removed. The dryer model printed on the typeplate includes one or more suffixes that specify one or more features of dryer.

2 Safety instructions

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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. Therefore, it must be ensured that these operating instructions are read by the fitter and the responsible operator / certified skilled personnel prior to installation, start-up and maintenance.

The operating instructions must be accessible at all times at the place of application of the DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer.

In addition to these operating instructions, local and national regulations need to be observed, where required .

Ensure that operation of the DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer only takes place within the permissible limit values indicated on the type plate. Any deviation from these limit values involves a risk for persons and for the material, and may result in malfunction or a breakdown.

After installing the device correctly and in accordance with the instructions in this manual, the dryer is ready to operate, further settings are not required. Operation is fully automatic and maintenance is limited to several examinations and cleaning measures which are described in the followin g chapters. This manual must be available at all times for future reference and is a constituent part of the dryer. If you have any queries regarding these installation and operating instructions, please contact BEKO TECHNOLOGIES GMBH.

DRYPOINT® RA CT 20-500 NA 5

Safety instructions

2.1 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

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ARIA

AIR

LUFT

AIR

ARIA

AIR

LUFT

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

Connection point compressed-air inlet

Connection point compressed-air outlet

Connection point condensate drain

Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technic al training, who are

well-grounded in the respective provisions and laws and capable of c arrying out the required works and of identif ying and avoiding any risks during the machine transport, installation, operation and maintenance. Qualified and authorised operators are persons who are instructed by the manufacturer regar ding the handling of the refrigeration system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

6 DRYPOINT® RA CT 20-500 NA

Safety instructions

Works can be carried out by the operator of the plant, provided that they are skilled accordingly2.

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:

 CFC-free refrigerants  CFC-free insulation material  Energy-saving design  Limited acoustic emissions  Dryer and packaging comprise reusable materials

This symbol advises the user to observe the environmental aspects and comply with the recommendations connected with this symbol.

Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technic al training, who are

DRYPOINT® RA CT 20-500 NA 7

Safety instructions

2.2 Signal words in accordance with ANSI

Danger!

Warning!

Caution!

Notice!

Important!

Imminent hazard Consequences of non-observance: serious injury or death

Potential hazard Consequences of non-observance: possible serious injury or death

Imminent hazard Consequences of non-observance: possible injury or property damage

Potential hazard Consequences of non-observance: possible injury or property damage

Additional advice, info, hints Consequences of non-observance: disadvantages during operation and maintenance, no danger

2.3 Overview of the safety instructions Certified skilled personnel

Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to undertaking any measures on the DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer, the certified skilled personnel shall read up on the device by carefully studying the operating instructions. The operator is responsible for the adherence to these provisions. The respective directives in force apply to the qualification and expertise of the certified skilled personnel. For safe operation, the device must only be installed and operated in accordance with the indications in the operating instructions. In addition, the national and operational statutory provisions and safety regulations, as well as the accident prevention regulations required for the respective case of application, need to be observed during employment. This applies accordingly when accessories are used.

Danger! Compressed air! Risk of serious injury or death through contact with quickly or suddenly escaping compressed

air or through bursting and/or unsecured plant components.

Compressed air is a highly dangerous energy source. Never work on the dryer when the system is under pressure. Never direct the compressed-air outlet or condensate drain hoses at perso ns. The user is responsible for the proper installation of the dryer. Non-observance of the instructions in the "Installation" chapter leads to the expiration of the guarantee. Improper installation may result in

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dangerous situations for the personnel and/or the device.

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.

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Caution! Refrigerant! The compressed-air refrigeration dryer uses HFC-containing refrigerants as a coolant.

Please observe the corresponding paragraph entitled "Maintenance works at the refrigeration cycle".

8 DRYPOINT® RA CT 20-500 NA

Safety instructions

Warning! Refrigerant leak! A refrigerant leak involves the danger of serious injury and damage to the environment.

The DRYPOINT® RA CT 20-500 NA 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). A certification in accordance with EC regulation 303/2008 must be available. The requirements of the EC 842/2006 directive must be met under all circumstances. Please refer to the indications on the type plate as regards the type and amount of refrigerant.

Comply with the following protective measures and rules of conduct:  Storage: Keep the container tightly closed. Keep it in a cool and dry place. Protect it against heat

and direct sunlight. Keep it away from ignition sources.

 Handling: Take measures against electrostatic charging. Ensure good ventilation/suction at the

workplace. Check fittings, connections and ducts for tightness. Do not inhale the gas. Avoid contact with the eyes or the skin.

 Prior to carrying out works on refrigerant-carrying parts, remove the refrigerant to such an extent

that safe working is possible.

 Do not eat, drink or smoke during work. Keep out of the reach of children.  Breathing protection: ambient-air-independent respi rator (at high concentrations).  Eye protection: sealing goggles.  Hand protection: protective gloves (e.g. made of leather).  Personal protection: protective clothing.  Skin protection: use protective cream.

In addition, the safety data sheet for the refrigerant needs to be observed!

Caution! Hot surfaces! During operation, several components can reach surface temperatures of more than 140°F

(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

Caution! Improper use!

The device is intended for the separation of water in compressed air. The dried air cannot be used for breathing-air purposes and is not suitable for the direct contact with food.

This dryer is not suitable for the treatment of contaminated air or of air containing solids.

Certified skilled personnel are persons who are auth orised by the manufacturer, with experience and technical training, who are well-grounded in the respective provisions and laws and capable of c arrying out the required works and of identif ying and avoiding any risks during the machine transport, installation, operation and maintenance. Qualified and authorised operators are persons who are instructed by the manufacturer regar ding the handling of the refrigeration system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

DRYPOINT® RA CT 20-500 NA 9

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 (e.g. CLEARPOINT F040), to avoid clogging of the heat exchanger.

Caution! Heating-up through fire! In the event of a heating-up through fire, the containers and pipes of the refrigerant system can

burst.

In this case, please proceed as follows: Switch off the refrigeration plant. Switch off the mechanical ventilation of the machinery compartment. Use ambient-air-independent respirators. Containers and plants which are filled with refrigerant can burst violently in the event of fire. The refrigerants themselves are incombustible, but they are degraded to very toxic products at high

temperatures. Remove the container/plant from the fire zone, as there is the risk of bursting! Cool down containers and bottles via a directed water jet from a safe position. In the event of fire, please use an approved fire extinguisher. Water is not a suitable agent to

extinguish an electrical fire.

This must only be carried out by persons who are trained and informed about the hazards emanating from the product.

Caution! Unauthorised intervention! Unauthorised interventions may endanger persons and plants and lead to malfunction.

Unauthorised interventions, modification and abuse of the pressure devices are prohibite d. The removal of sealings and leadings at safety devices is prohibited. Operators of the devices must observe the local and national pressure equipment regulations in the

country of installation.

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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.

This in turn leads to overheated condenser fan motors, to malfunction of electric components and to a breakdown of the dryer. Failures of this type will affect warranty considerations.

Do not install the dryer in an environment in which chemicals with a corrosive effect, explosive gases, toxic gases, evaporation heat, high ambient temperatures or extreme dust and dirt can be found.

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10 DRYPOINT® RA CT 20-500 NA

Proper use

3 Proper use

This dryer was designed, manufactured and tested to separate the moisture which normally exists in compressed air. Any other use is considered improper.

The manufacturer shall not be liable for problems occurring as a consequence of improper use. The user alone is responsible for any damage resulting from that.

Furthermore, the correct use includes the compliance with the installation instructions, in particular in respect of:

• The voltage and frequency of the main voltage supply.

• The pressure, temperature and flow rate of the inlet air.

• The ambient temperature. When delivered, the dryer is tested and fully assembled. The customer only needs to connect the device to the system

in accordance with the instructions in the following chapters.

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4 Exclusion from a field of application

Note! Improper use!

The device is intended for the separation of water in compressed air. The dried air cannot be used for breathing-air purposes and is not suitable for the direct contact with food.

This dryer is not suitable for the treatment of contaminated air or of air containing solids.

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5 Operating instructions in accordance with the 97/23/EC Pressure Equipment Directive

The DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer contains pressure equipment in the sense of the 97/23/EC Pressure Equipment Directive. Therefore, the entire plant needs to be registered with the supervisory authority if required in accordance with the local regulations.

For the examination prior to the start-up and for periodic inspections, the national regulations need to be observed, such as the industrial safety regulation in the United States of America. In countries outside the US, the respective regulations in force there need to be adhered to.

The proper use of pressure devices is the basic requirement for safe operation. As regards pressure devices, the following points need to be observed:

 The DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer must only be employed within the pressure

and temperature range limits indicated by the manufacturer on the type plate.

 No welding must be carried out on the pressure parts.  The DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer must neither be installed in insufficiently

ventilated rooms nor near heat sources or inflammable substances.

 To avoid fractures resulting from material fatigue, the refrigeration dryer should not be exposed to vibrations during

operation.

 The maximum operating pressure indicated by the manufacturer on the type plate must not be exceeded. It is the

installer's responsibility to install the appropriate safety and control devices. Prior to the start-up of the DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer, the connected pressure generator (compressor etc.) must be set to the max. permissible operating pressure. The integrated safeguard needs to be checked by an approved inspection agency.

 The documents related to the DRYPOINT® RA CT 20-500 NA compressed-air refrigeration dryer (manual,

operating instructions, manufacturer's declaration etc.) must be kept safe for future reference.

 No objects whatsoever must be installed at or placed on the DRYPOINT® RA CT 20-500 NA compressed-air

refrigeration dryer and the connecting lines.

 Installation of the plant in frost-free places only.  Operation of the plant is only permissible with fully closed and intact housing and cover panels. Operation of the

plant with damaged housing/cover panels is prohibited.

DRYPOINT® RA CT 20-500 NA 11

Transport

6 Transport

Check the packaging for visible loss or damage. If no visible damage can be ascertained, place the unit in close proximity to the place of installation and unpack the device.

During this procedure, the dryer must always remain in an upright position. The components may be damaged when the unit is tilted or turned upside down.

Store the device in a dry environment and do not expose it to extreme weather conditions. Handle with care. Strong shocks can cause irreparable damage.

7 Storage

Keep the device away from extreme weather conditions even when packaged.

Keep the dryer in an upright position, also while it is stored. Tilting the device or turning it upside down can cause irreparable damage to some components.

When the dryer is not in use, it can be stored in its packaging in a dust-free and protected place at a temperature of up to max. 122°F (50°C) and at a specific humidity of max. 90%. If the storage period exceeds 12 months, you should contact the manufacturer.

0 C C S

The packaging material is recyclable. Dispose of the material in accordance with the directives and provisions in force in the country of destination

12 DRYPOINT® RA CT 20-500 NA

Technical description

8 Technical description

8.1 Control panel

The control panel explained below is the only dryer user interface.

RA CT 20 –100

1 Main switch

Electronic control unit DMC 51

Air and refrigerant gas flow chart

RA CT 125 – 500

1 Main switch

Electronic control unit DMC 51

Air and refrigerant gas flow chart

0 S Q P

Set

reset

0 S Q P

Set

reset

RA CT 200 – 500 3phase

A Main switch

1 ON-OFF switch

2 Electronic control unit DMC 51

3 Air and refrigerant-gas flow chart

1 0

Set

reset

T4 T3

0 S Q P

DRYPOINT® RA CT 20-500 NA 13

Technical description

8.2 Functional description Operating principle – All dryer models described in this manual function according to the same principle. The hot and

moisture-loaded air is led into an air/air heat exchanger. Afterwards, the air flows through an evaporator, which is also known as an air/refrigerant heat exchanger. The air temperature is reduced to approximately 36°F (2°C), so that water vapour condenses to liquid. The continuously accumulating condensate is collected in the separator to be discharged via the condensate drain. Subsequently, the cold and dry air is led through the air/air heat exchanger, so that it is reheated to up to 46°F (8°C) below the inlet temperature when leaving the dryer.

Refrigeration cycle

pressure. There, cooling-down takes place, making the refrigerant condense to a liquid state which is under high pressure. The liquid is pressed through a capillary tube where the resulting pressure drop ensures that the refrigerant evaporates at a defined temperature. The liquid refrigerant which is under low pressure is led into the heat exchanger, where it expands. The cold resulting from the expansion serves to cool down the compressed air in the heat exchanger. During this process, the refrigerant evaporates. The low-pressure gas is resupplied to the compressor, where it is compressed again.

Operation in cycling mode (Energy Saving, ESS=YES – see section 8.12.7) – The DMC51 electronic controller constantly monitors the temperature of the DewPoint. In low load conditions, the temperature of the DewPoint tends to fall close to the freezing point, at this point the DMC51 controls the switching off of the compressor.

The compressor will be started again when the DewPoint temperature rises above a target value. To avoid an excessive number of cycles, DMC51 keeps the compressor on for a minimum time (about 6 minutes) within which, if necessary, will activate a solenoid valve EVH that enables the operation of the hot gas by-pass valve. In this way the compressor cannot make more than 10 cycles per hour. The solenoid valve EVL and the check valve CHV (where installed) help to extend the off time of the compressor and avoid the immediate balancing of high and low pressures of the refrigerant circuit. The solenoid valve EVL is activated before the compressor to balance the pressures and is kept active for the entire time during which the compressor is on.

With these dryers, the energy consumption will be adjusted closely proportional to the thermal load applied to the dryer itself, allowing considerable energy savings in the majority of applications.

Operation in hot gas by-pass mode (NO Energy Saving, ESS=NO – see section 8.12.7) – The DMC51 electronic controller constantly keep activated the compressor, the solenoid valve EVH and the solenoid valve EVL. In cases of a reduced compressed-air load, the excess refrigerant is bypassed automatically to the compressor via the hot gas bypass valve.

– The refrigerant is conducted through the compressor and reaches a condenser under high

14 DRYPOINT® RA CT 20-500 NA

Technical description

8.3 Flow chart

2 4

12.2

P>5PV

12.1

0 F

G D

1 Aluminium heat exchanger module 10 Filter dryer

a – Air/air heat exchanger 11 Capillary tube b – Air/refrigerant heat exchanger 12.1 T1 temperature sensor (dew point)

c – Condensate separator 12.2 Refrigerant pressure switch LPS (P<)

(RA CT 300-500 and RA CT 200-500 3phase) Refrigerant pressure switch HPS (P>)

(RA CT 300-500 and RA CT 200-500 3phase)

5 Refrigerant fan pressure switch PV 25

T2 temperature sensor (compressor discharge) (RA CT 125-500)

13 Condensate drain service valve 21 BEKOMAT condensate drain

Compressor crankcase heater (RA CT 200-500 3phase)

6 Refrigerating compressor 36 Suction refrigerant separator 7 Hot-gas bypass valve 82 Check valve CHV 8 Condenser 86 Liquid solenoid valve EVL 9 Condenser fan 87 Hot gas solenoid valve EVH

Compressed-air flow direction

Refrigerant gas flow direction

DRYPOINT® RA CT 20-500 NA 15

Technical description

8.4 Refrigerating compressor

The employed refrigerating compressors are constructed by leading manufacturers. The hermetically sealed construction is absolutely gastight. The integrated safeguard protects the compressor against overheating and excess current. The protection is automatically reset as soon as the nominal conditions are reached again.

8.5 Condenser

The condenser is the component in which the gas coming from the compressor is cooled down, condensed and liquefied. Under no circumstances must the temperature of the ambient air exceed the nominal values. It is also important that the condenser unit is kept free from dust and other impurities.

8.6 Filter dryer

Despite controlled vacuuming, traces of moisture can accumulate in the refrigeration cycle. The filter dryer serves to absorb this moisture and to bond it.

8.7 Capillary tube

The capillary tube is a copper tube with a reduced diameter which is located between the condenser and the evaporator, serving as a restrictor to reduce the pressure of the refrigerant. The pressure reduction serves to reach an optimum temperature inside of the evaporator. The lower the outlet pressure at the capillary tube, the lower the evaporation temperature. The length and the inner diameter of the capillary tube are exactly dimensioned to ensure the performance of the dryer. Settings or maintenance works are not required.

8.8 Aluminium heat exchanger

The heat exchanger module consists of an air/air heat exchanger, an air/refrigerant heat exchanger, and of a highperformance separator. The compressed air flows top-down through the heat exchanger. The large cross-sections of the flow passages cause low flow rates and low compressed-air losses. In the air/air heat exchanger, the heat exchange is effected in a reverse current. This guarantees maximum heat transfer. The heat transfer in the air/refrigerant heat exchanger also takes place in a reverse current. This allows full evaporation of the refrigerant. The high-performance separator ensures almost complete separation of the condensate. Maintenance of the highperformance separator is not required.

16 DRYPOINT® RA CT 20-500 NA

Technical description

8.9 Hot-gas bypass valve

At partial load, the valve directly returns a part of the hot gas to the suction line of the refrigerating compressor. The evaporation temperature and the evaporation pressure remain constant.

ADJUSTMENT

The hot gas by-pass valve is adjusted during the manufacturing testing phase. As a rule no adjustment is required; anyway if it is necessary the operation must be carried out by an experienced refrigerating engineer.

WARNING the use of ¼” Schrader service valves must be justified by a real malfunction of the refrigerating system. Each time a pressure gauge is connected, a part

4 mm

5/32 in.

of refrigerant is exhausted.

Without compressed air flow through the dryer, rotate the adjusting screw (position A on the drawing) until the following value is reached:

0 0 0 Y L V

Hot gas setting : R134.a pressure 31.9 psig (+ 1.45 / -0 psi) [2.2 barg (+0.1 / -0 bar)] R407C pressure 68.2 psig (+1.45 / -0 psi) [4.7 barg (+0.1 / -0 bar)]

8.10 Refrigerant pressure switches LPS – HPS – PV

To ensure the operational reliability and the protection of the dryer, a series of pressure switches are installed in the gas cycle.

LPS :

Low-pressure guard on the suction side of the compressor, which is triggered when the pressure drops below the predetermined value. The values are reset automatically as soon as the nominal conditions are reestablished.

HPS :

Calibrated pressure :

The high-pressure control unit on the discharge side of the compressor is activated when the pressure

R 134.a Stop 10.2 psig (0.7 barg) - Restart 24.7 psig (1.7 barg) R 407 C Stop 24.7 psig (1.7 barg) - Restart 39.2 psig (2.7 barg)

exceeds the predetermined value. It has a manual reset button on the control itself.

PV :

Calibrated pressure :

Fan control pressure switch which is installed on the discharge side of the compressor. It keeps the

R 134.a Stop 290 psig (20 barg) - Manual reset P<203 psi (P<14 bar) R 407 C Stop 435 psig (30 barg) - Manual reset P<334 psi (P<23 bar)

condensation temperature and pressure constantly in the range of the preadjusted limit values

Calibrated pressure : R 134.a Start 160 psig (+7.25 / -0 psi) [11 barg (+0.5 / -0 bar)]

Stop 116 psig (+0 / -7.25 psi) [8 barg (+0 / -0.5 bar)]

R 407 C Start 261 psig (+7.25 / -0 psi) [18 barg (+0.5 / -0 bar)]

Stop 203 psig (+0 / -7.25 psi) [14 barg (+0 / -0.5 bar)]

8.11 Compressor crankcase heater (RA CT 200-500 NA 3phase)

At low temperatures, the oil can more easily intermix with the refrigerant gas. When the compressor starts, oil can be drawn into the refrigeration cycle, leading to "hydraulic shocks".

To prevent this, a resistance heater is installed in the suction side of the compressor. When the system is connected with the electric mains and the compressor is idle, the heater will keep the oil at the correct temperature.

This heater is controlled via a temperature switch which prevents the overheating of the oil. Note: The heater must be connected to the mains at least a few hours prior to the start-up of the refrigerating

compressor.

DRYPOINT® RA CT 20-500 NA 17

Technical description

8.12 DMC 51 electronics (control unit compressed-air dryer)

Led - temperature in °C

Led - temperature in °F Led - compressor ON

reset

0 S Q P

Set

Led – Alarm Led - service warning

Button – access configuration menu /

Set

Discharge temp. Button – decrease / service

DISPLAY

Button – increase / % energy saved

The DMC51 controls all the operations, alarms and dryer operation set-up.

8.12.1 Switching the dryer on

Connect the dryer to the electric mains and switch it on via the ON/OFF switch (pos. 1 Section 8.1). During normal operation, the display shows the dew point temperature.

8.12.2 Switching the dryer off

Switch the device off via the ON/OFF switch (pos. 1 Section 8.1).

8.12.3 Indication of the operating parameters

During normal operation, the display shows the dew point temperature (in °C or °F). Led Press the Press the Press the

shows that the compressor is ON.

Set

button and keep it pressed to display the compressor discharge temperature (probe T2 if installed).

button and keep it pressed to display the hours remaining until the next maintenance.

Set

+ buttons simultaneously and keep them pressed to display the total number of operating

hours of the dryer (ie when dryer is powered) Press the

Note:

The temperatures are indicated in °C or °F (LED

button and keep it pressed to display the % of energy saved.

or is on).

The total operating hours and the hours until the next maintenance are indicated in the field 0...999 hours, and in thousand hours from 1.0 hours onwards (example: when the display shows 35, this means 35 hours and when the display shows 3.5, this means 3,500 hours).

The % of energy saved is calculated considering the running hours of the compressor against the operating hours of the dryer (example: during 10 hours of powered dryer, compressor has ran for 4 hours, display shows 60% of energy saved).

18 DRYPOINT® RA CT 20-500 NA

Technical description

8.12.4 Indication of a Service Warning

A service warning is an exceptional event and requires the attention of the operator/service technician. The dryer will not be stopped.

When a service warning is active, the Led flashes. When a service warning is no longer active but not reset yet (so it has been stored)

Led is continuously on.

In both cases the display shows the dew point temperature and the service warnings which are active or which are no longer active but not yet reset.

Service warnings are NOT automatically reset. To RESET the service warning, the

Set

+ buttons for three seconds. Only the stored service warning will be reset. Service warnings which

are still active continue to be indicated by the

Led must be continuously on (not flashing), keep pressed simultaneously

Led flashing.

NOTE: the operator/service technician must check the dryer and eliminate the problem that caused the service warning.

Service warning Description

HdP – High dew point: dew point too high, higher than the adjusted HdS value LdP – Low dew point: dew point too low

Setting T1< -1°C (30°F) delay five minutes / reset T1> -0.5°C (31°F) SrV - Service: maintenance service time expired SrV

8.12.5 Indication of an Alarm

An alarm is an exceptional event which, to avert damage from to the machine and the operator, always leads to the dryer stop.

When an alarm is active, the LED flashes. When an alarm is no longer active but not reset yet (so it has been stored)

Led is continuously on (in any case,

the dryer remains OFF). In both cases the display shows

and the alarms which are active or which are no longer active but not yet reset.

Alarms are NOT automatically reset. To RESET the alarm, the

Led must be continuously on (not flashing), keep pressed simultaneously

Set

buttons for three seconds. Only the stored alarm will be reset. Alarms which are still active continue to be

indicated by the Led flashing.

The dryer will start automatically subsequent to the reset of the alarms.

NOTE: the operator/service technician must check the dryer and eliminate the problem that caused the alarm.

Alarm Description

LP – Low pressure: the refrigerant low-pressure switch LPS has tripped. Hdt – High outlet temperature: compressor outlet temperature outside the safety limit

Setting T2> 110°C (230°F) delay one minute / reset T2< 90°C (194°F) ICE - ICE / Icing: Temperature in the exchanger (probe T1) is too low and leads to icing

of the condensate. Setting T1< -2°C (28°F) delay one minute / reset T1> 0°C (32°F)

toC – Too many Cycles : compressor has been cycled On/OFF unusually too often (stopped more than 5 times before reaching its minimum ON time)

PF1 – Probe 1 failure: failure probe T1 PF2 – Probe 2 failure: failure probe T2

DRYPOINT® RA CT 20-500 NA 19

Technical description

8.12.6 Operation of the Service Warning / Alarm signal

The DMC 51 is equipped with a 12Vdc signal (max 15 mA) to indicate service warning or alarm conditions.

Dryer is switched on, no service warning and no alarm (active and not yet reset) are indicated.

Dryer is off or a service warning or an alarm (active and not yet reset) is indicated.

8.12.7 How to change operating parameters – SETUP menu

The setup menu can be used to change the dryer’s operating parameters.

Only qualified personnel must be allowed to access to the setup menu. The manufacturer is not responsible for malfunctioning or failure due to modification to the operating parameters.

With dryer ON simultaneously press buttons Access to the menu is confirmed by message

Keep

Set

the value. Release the button Press

Set

+ for at least 5 seconds to enter the setup menu.

on the display (first parameter of menu).

pressed to display the value of the selected parameter and use arrows and to change

Set

to confirm the value and skip to following parameter.

+ to exit setup menu (if no button is pressed after 30 seconds the menu is exited

automatically).

ID Description Limits Resolution

HdS - High DewPoint Setting : service warning threshold for a high DewPoint (the service warning disappears when the temperature drop 0.5°C / 1°F below set point)

Hdd - High DewPoint Delay : high DewPoint service warning enable delay

SrV - Service Setting : setting of service warning timer.

0.0 = service warning timer disabled.

0.0…25.0 °C or

32 … 77 °F

00 … 20

minutes

0.0 … 9.0 (x 1000)

hours

0.5 °C or

1 °F

1 min 15

0.1

(x1000) hours

Standard

setup

8.0

SCL - Scale: display scale of temperatures. °C … °F - °C or °F ESS – Energy Saving Set: selection if dryer run in energy

YES…nO - YES

saving cycle. YES = Energy saving mode is active (cycling mode). nO = Energy saving mode is not active (Hot Gas by-pass

sytem)

8.13 Electronically level-controlled BEKOMAT condensate drain

The electronically level-controlled BEKOMAT condensate drain boasts a special condensate management which ensures that condensate is discharged safely and without an unnecessary loss of compressed air. This drain has a condensate collection container in which a capacitive sensor continuously monitors the liquid level. As soon as the switching level is reached, the capacitive sensor transmits a signal to the electronic control and a membrane solenoid valve opens to discharge the condensate. The BEKOMAT closes before compressed air emerges.

Note!

These BEKOMAT condensate drains were designed in particular for the operation in a DRYPOINT RA CT refrigeration dryer. The installation in other compressed-air processing systems or the replacement with another drain brand can lead to malfunction. The maximum operating pressure (see type plate) must not be exceeded!

Ensure that the upstream valve is open when the dryer starts operation. To obtain detailed information regarding drain functions, troubleshooting, maintenance and spare parts, please read the installation and operating instructions of the BEKOMAT condens ate drain.

20 DRYPOINT® RA CT 20-500 NA

Installation

9 Installation

9.1 Place of installation Note!

Ambient conditions!

This in turn leads to overheated condenser fan motors, to malfunction of electric components and to a breakdown of the dryer. Failures of this type will affect warranty considerations.

Do not install the dryer in an environment in which chemicals with a corrosive effect, explosive gases, toxic gases, evaporation heat, high ambient temperatures or extreme dust and dirt can be found.

Minimum installation requirements:

• Choose an area which is clean and dry, free from dust and protected against atmospheric disturba nces.

• The load-bearing zone must be even, horizontal and able to bear the weight of the dryer.

• Minimum ambient temperature 34°F (+1°C).

• Maximum ambient temperature +122°F (+50°C).

• Ensure a proper cooling air replacement.

• Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitate maintenance operations.

The dryer does not require attachment to the floor surface.

Do not obstruct the ventilation grille.

Prevent any recirculation of the outgoing cooling air. Protect the dryer against draughts.

Note!

Dryers models RA CT 20 – 75 can be wall-mounted. See fixing dimensions on dimensional drawings in the appendices section.

The hanging mounting inevitably causes the obstruction of the ventilation grid positioned on the panel facing the wall fixing. This obstruction, in any case, does not prejudge the efficiency of the ventilation inside the dryer which is guaranteed by other grids on the other panels.

DRYPOINT® RA CT 20-500 NA 21

Installation

9.2 Installation plan

1 Air compressor 2 Aftercooler

- A -

OUT

3 Condensate separator 4 Prefilter 5 Bypass group 6 Dryer 7 Compressed-air tank 8 Final filter

9 Bekomat condensate drain

- B -

9 9

OUT

Installation type A is recommended when the total consumption corresponds to the throughput rate of the compressor. Installation type B is recommended when the air consumption constantly varies, with peak values which considerably

exceed the throughput rate of the compressor. The storage capacity of the tank must be dimensioned in such a way that a possible short-term high air demand (peak air consumption) can be compensated.

Do not obstruct the ventilation grille.

Prevent any recirculation of the outgoing cooling air. Protect the dryer against draughts.

Note! Contaminated intake air!

22 DRYPOINT® RA CT 20-500 NA

Installation

9.3 Correction factors

Correction factor for operating pressure modifications: Inlet air pressure psig 60 80 100 120 140 160 180 203

barg 4 5.5 7 8 10 11 12 14

Factor (F1) 0.79 0.91 1.00 1.07 1.13 1.18 1.23 1.27 Correction factor for ambient temperature modifications:

Ambient temperature ºF 80 90 95 100 105 110 115 122

ºC 27 32 35 38 40 43 45 50

Factor (F2) 1.11 1.09 1.06 1.00 0.94 0.87 0.78 0.69 Correction factor for inlet air temperature modifications:

Air temperature ºF 90 100 110 122 130 140 150 158

ºC 32 38 43 50 55 60 65 70

Factor (F3) 1.16 1.00 0.82 0.68 0.61 0.52 0.45 0.40 Correction factor for DewPoint modifications:

DewPoint ºF 38 41 45 50

ºC 3 5 7 10

Factor (F4) 1.00 1.08 1.20 1.36

Calculation of the actual air throughput:

Actual air throughput = air throughput acc. to planning x factor (F1) x factor (F2) x factor (F3) x fac tor (F4)

Example:

The DRYPOINT RA CT 75 NA has a planned nominal capacity of 75 scfm (127 m³/h). The highest achievable air mass under the following operating conditions is:

 Air inlet pressure = 120 psig (8 barg)  Ambient temperature = 115°F (45°C)  Air inlet temperature = 122°F (50°C)  Pressure dew point = 50°F (10°C)

 Factor (F1) = 1.07  Factor (F2) = 0.78  Factor (F3) = 0.68  Factor (F4) = 1.36

Every function parameter corresponds to a numerical factor which, multiplied by the planned nominal capacity, determines the following:

Actual air throughput = 75 x 1.07 x 0.78 x 0.68 x 1.36 = 58 scfm (99 m³/h)

58 scfm (99 m³/h) is the maximum flow rate of the dryer under the aforementioned operating conditions.

Selection of the best suitable model in accordance with the operating conditions:

Requ. air throughput

Air throughput acc. to planning =

Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)

Example:

The following operating parameters are known:

 Required air mass = 100 scfm (170 m3/h)  Air inlet pressure = 120 psig (8 barg)  Ambient temperature = 115°F (45°C)  Air inlet temperature = 122°F (50°C)

 Factor (F1) = 1.07  Factor (F2) = 0.78  Factor (F3) = 0.68  Factor (F4) = 1.36

 Pressure dew point = 50°F (10°C) To find out the correct dryer version, the required air mass must be divided by the correction factors of the

parameters indicated above:

100

Air throughput acc. to planning =

1.07 x 0.78 x 0.68 x 1.36

= 130 scfm (221 m³/h)

The suitable model for these requirements is DRYPOINT RA CT 150 NA (with a spec. nominal capacity of 150 scfm [255 m³/h]).

DRYPOINT® RA CT 20-500 NA 23

+ 53 hidden pages

Beko DRYPOINT RA CT 200-NA-FB, DRYPOINT RA CT 400-NA-FB, DRYPOINT RA CT NA, DRYPOINT RA CT 350-NA-FB, DRYPOINT RA CT 500-NA-FB Instructions For Installation And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual