Fu Sheng Co FR005AP, FR010AP, FR020AP, FR030AP, FR050AP Operating Manual

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Page 1

Operating Manual

Refrigerated Compressed-Air Dryer

Air Dryer

FR005AP FR010AP FR020AP FR030AP FR050AP FR075AP FR100AP

FR005A FR010A FR020A FR030A FR050A FR075A FR100A FR150A

Ver.071203

z This Air Dryer is designed for

industrial use. Handle with care.

z Please read this manual carefully

and operate this equipment accordingly.

z Retain this manual for future

Reference.

Page 2

Thank you for your purchase.

Thank you for purchasing this Fu Sheng Co., Ltd product. To ensure safe and efficient use, please install and operate this equipment in accordance with the instructions provided in this manual. Product specifications are subject to change without notice. Please be aware that recent changes to product specifications may not be reflected in the content of this manual.

ＣＯＮＴＥＮＴＳ

Important Notes........................... ........................... 1(1)

Names of Parts and Functions.......................................... 2(1)

1．Appearance..................................................

2(1)

2．Control panel................................................

2(1)

3．Switch board.................................................

3(1)

Installation Notes..................................................... 4(1)

1．Checking Model............................ ..................

4(1)

2．Space for Installation..........................................

5(1)

3．Forbidden places............................. .................

5(1)

Preparation for Operation............................................. 6(1)

1．Piping.......................................................

6(1)

2．Installation of Accessories.......................................

7(1)

3．Wiring.................................................... ....

9(1)

Operation............................................................ 10(1)

1．How to Start..................................................

10(1)

2．How to Stop..................................................

11(1)

Safety Devices.........................................................

12(1)

Daily Maintenance and Checks...........................................

13(1)

1．Daily Checks...................................................

13(1)

2．Maintenance...................... .............................

13(1)

1）Cleaning of Condenser......................................

13(1)

2）Cleaning of Auto Drain Trap(ET3000 4000)....................

14(1)

3）Cleaning of Auto Drain Trap(AD-5).............. ............

15(1)

Troubleshooting................................ .......................

16(1)

After－Sale Service....................................................

16(1)

Before Long Disuse....................................... .............

17(1)

Table of Specifications..................................................

Specification............................... ...........................

Part list.................................. ...........................

Page 3

Important Notes.

1(1)

1. Do not carry the dryer turned aslant or upside down．

3. Do not modify the wiring in the switchboard．

‧Do not modify the wiring except at the

primary-side power terminals.

5．Never turn the operation switch on and off

frequently.

2. Be sure to ground the unit to prevent electric shock.

4．Before inspection, be sure to stop the air

compressor and turn off power to the air dryer.

Make sure that pressure is reliefed in the

air dryer.

Page 4

Names of Parts and Functions

Illustrations used are those of FR020A

2 ( 1 )

1. Appearance

2. Control Panel

■ FR005A、FR005AP、FR010A、FR010AP

■ FR020A~075A、FR075AP~100AP

Air inlet

Wet compressed air inlet

Control Panel

Air Outlet

Dry compressed air outlet.

Power Cord Hole

Lead the power cord out from here.

Leg

Use the aperture to fix this device in place.

FR005A、FR005AP

FR010A、FR010AP

EVAP. Pressure Gauge Indicates the EVAP. Pressure of the

Operation Switch (with lamp) Press ON, and the lamp lights up, the dryer starts operating. Press OFF, and the lamp goes out, the dr

er stops

○6 AIR PRESSURE GAUGE

○4 START SWITCH (WHITE)

○5 REMOTE/LOCAL SWITCH

○2 RUNNING LAMP

○7 EVAP. PRESSURE GAUGE ○8 COND.PRESSURE GAUGE

○3 STOP SWITCH（RED

○1 ALARM LAMP

○1 ○2 ○3 ○4

○5

○6

○7

○8

○2

○3 ○4

○6

○7

Page 5

3(1)

3.Switchboard

Terminal Earth

FR020AP~050AP FR030A~075A

Terminal Earth

FR010AP FR020A

FR100A 075AP FR150A 100AP

Terminal Earth Earth Terminal

Page 6

Installation Notes

4(1)

1. Checking Model

After unpacking the dryer, check the Specifications Plate to make sure that you have received the system that you ordered..

■ Accessories

Auto drain trap Ball valve FR005AP 010AP 020AP 30AP050AP

FR005A 010A 020A FR030A 050A 075A

Float type 1pc 1/2B 1pc

FR075AP 100APFR FR100A 150A

Discus type 1pc

1/2B 1pc

Also confirm that the unit has not suffered any shipping-relating damage. In the event of a problem, please contact your dealer

Page 7

5(1)

2. Space for Installation

Locate the dryer with enough free space around. To ensure a sufficient ventilation and accessibility, keep adequate distances

between the dryer and objects in its surrounding

3. Forbidden places

■ Do not install in the place where unit will

be exposed to direct sunlight, rain, or external heat. Such exposure may reduce the ability of the condenser to release heat, resulting in poor performance.

■ Ambient temperature should be between 2 ℃ and 40℃. Ambient temperatures above

40℃. can impede heat release from the condenser, resulting in safety-device

activation and equipment shutdown. If you need to install the unit in an area where ambient temperature may exceed 40 , set up ductwork as necessary to supply outside air directly to the air intake area on the cabinet, or construct an outdoor exhaust port to discharge the inside exhaust air (warm air). Be sure that the design does not result in a drop in the fan airflow.

■ Do not install in a dusty location.

Dust accumulation on the condenser may reduce the unit’s performance

Space for ventilatio

60cm or more

Side space 60cm or more

Space for ventilatio

60cm or more

Side space 60cm or more

Page 8

Preparation for Operation

6(1)

1. Piping

■Air inlet∕outlet connection dimension

Model

FR005AP

FR010AP、015AP

020AP

FR030AP、

050AP

FR075AP FR100AP

Model

FR005A、FR010A FR020A、030A FR050A、075A FR100A FR150A

Pipesize

1/2B 1B 1-1/2B 2B 21/2B

■ Piping notes

1）Do not confuse the inlet and outlet of the air dryer. 2）Do not use any riser in the piping from air compressor to air dryer．

However, if it is inevitable, install a valve or a drain trap so that water can be purged． 3）Provide a by-pass circuit between the inlet and the outlet of the air dryer． 4）Do not allow the piping weight to bear on the air dryer． 5）In a cold place, cover the outdoor piping, if any, with heat insulator．

Even indoors, use heat insulator if the air dryer outlet piping develops condensation. 6）In piping, prevent dust and other foreign materials from entering the air circuit．

AIRINLET AIROUTLET

Suspend By-pass circuit Check valve Heat Insulato

Inclination

Compressor Chamber

Inside

Valve or drain trap

When providing a riser in piping

Page 9

7(1)

2. Installation of Accessories

1) FR005AP、010AP、020AP、030A、050AP

FR005A、010A、020A、030A、050A、075A

■ Accessories

Auto drain trap Floattype 1pc Ball valve 1/2B 1pc Auto drain trap Floattype 1pc

1) As shown, install the ball valve and auto drain trap on the drain pipe with the marking DRAIN .

2) After the installation, open the ball valve.

3) Install the auto drain trap so that the drain outlet is positioned below.

4) Use the following vinyl hose when the drainage is to be led out of the auto drain trap.

Hose inside diam.:16 mm

5) When connecting a pipe, screw it on the threaded part of the drain trap outlet.

Drain trap outlet thread diam: Rc 1/4

● Important

To remove the drain trap (when you need to replace it), proceed as follows: (1) Close the ball valve; (2) Release the pressurized air from the trap; (3) Hold on to the ball valve so that it cannot turn, and rotate (unscrew) the trap to remove.

● Important

If attaching a pipe to the drain outlet, note that the pipe should not be too long and should not move upward. Reverse pressure caused by excessive pipe length or upward flow may prevent

draining.

Page 10

8(1)

2) FR050AP、075AP、100AP FR050A、075A、100A、150A

■ Accessories

Auto drain trap

Discus type 1 pc

Ball valve 1/2B 1 pc

● Important

To remove the drain trap (when you need to replace it), proceed as follows:

1) Close the ball valve;

2) Release the pressurized air from the trap;

3) Hold on to the ball valve so that it cannot turn, and rotate (unscrew) the trap to remove.

● Important

If attaching a pipe to the drain outlet, note that the pipe should not be too long and should not move upward. Reverse pressure caused by excessive pipe length or upward flow may prevent draining.

Page 11

9(1)

3. Electrical Wiring

1) Power-cord capacities are as follows.

Model

FR005AP、010AP、020AP FR030AP FR050AP FR075AP、100AP

FR005A、010A、020A、030A FR050A FR075A FR100A、150A

Power source (standard type)

Single phase 220V

50/60Hz

3 phase 220V 50/60Hz

Power cord (mm2) 1.25 or more 2.0 or more Breaker capacity (A) 10A 20A Ground line (mm2) 1.25 or more 2.0 or more

2) Install an overload leakage breaker (overload-protect function plus current leakage function). The breaker must be dedicated to the air dryer. (Use high-speed type with 30mA current sensitivity.)

3) Connect up the power cord.

For single-phase models, connect the wires to terminals 1 and 2. For three-phase models, connect to terminals R,S and T

4) Connect the ground.

Ground (earth) connection must be set up by a qualified electrician. The ground line must be connected to the earth terminal. The line diameter must be at least 2mm2.

5) Power voltage should remain within 5% of the rated value while the dryer is operating.

Page 12

Operation

＊Before starting operation, make certain that the power breaker is ON．

10(1)

1．How to start

c Press the operation switchON The operation lamp lights up and operation starts．

FR005AP FR010AP above

FR005A、010A FR020AP

d 3 minutes later, start supplying compressed air．

About three minutes after the start of the dryer, supply compressed air by operating the air compressor．

。

Caution At this time, be sure to close the by-pass valve in the piping。

By-pass valve

Open

Page 13

11(1)

e Check the indications on the gauges.

Soon after the flow of compressed air, EVAP. pressure gauge will normally start indicating within the green-colored range．

● EVAP. pressure gauge：

The air dryer may not easily develop trouble even when it is operated with the EVAP. pressure gauge indicating a little beyond the green range. Yet, take care to use it within the green range so that the dryer can perform at its maximum efficiency．

【Note】 When the ambient temperature drops, the fan may repeat stop and run operation．This is

to prevent the freezing inside the heat exchanger．

2．How to Stop

c Stop the air compressor．

d Press the stop switch OFF．

The operation lamp goes out and operation stops．

Green range

Page 14

Safety Devices

ÚThe dryer is provided with safety devices to ensure operational safety for you

12(1)

The air dryer will stop automatically at the operation of any safety device．

■ Refrigerant circuit safety device ) High-pressure switch

The high-pressure switch operates when the condensation pressure reaches:

3.0±0.1MPa (30±1kgf/cm2G) (R407CRefrigerant)

2.0 ±0.1MPa (20±1kgf/cm2G) (R134aRefrigerant) and stops the dryer．

■ Electric circuit ) Motor protector

The motor protector will operate to stop the air dryer if the temperature of the compressor gets high or an over current flows in the circuit.

How to reset

1．Remove the cause of stoppage.（See Troubleshooting．） 2．Press the operation switch ON on the control panel.

Page 15

Daily Maintenance and Checks

13(1)

Dust or dirt accumulated on the condenser will reduce the heat exchange efficiency． At the worst，the dryer may stop with the safety device operating．

1. Daily Checks

Checking of auto drain trap Check the auto drain trap everyday.

2. Maintenance

1）Cleaning of condenser

Clean the condenser periodically, using a brush or air gun．

Caution In cleaning, exercise care so as not to deform the condenser fins．

Check items

● Air leakage

● Normal operation

(water draining)

Water

draining

No air

leakage

Page 16

14(1)

2) Cleaning of auto drain trap (Float type)

. Overhaul the auto drain trap periodically (every week) so that it can always operate normally.

NO. PARTS NAME

Plat cover

Body

O-ring

Filter

Bowl

Bowl guard

Float

Orifice

Float level arm

Spring

Packing

Valve

Orifice spring

■ How to clean

(1) Close the ball valve. (2) Remove the dirt and dust from the filter element, which is fit in the lower part of the auto

drain unit, using an air gun or like means.

(3) Wash the separated parts with a neutral detergent. (4) Check for damaged parts. Make a particularly careful check of O-ring.

(2) Caution

Neverdisassembletheauto drainunit.Otherwise troubleswillresult

(3)

(4)

● The drain should not be exposed to direct sunlight, as such exposure may damage the drain

bowl.

● The following substances can damage the drain bowl. These substances should never be

present within the drain or in the atmosphere around the drain.

○ Oils based on phosphoric acid esters. ○ Organic solvents (aromatic, chloride, and hydrocarbon compounds)

─Benzene, toluene, phenol, trichloroethylene, gasoline, paint thinner, etc.

○ Sulfurous acid gas, chorine gas, CFC gas.

○ Acids: hydrochloric acid, sulfuric acid, acetic acid, etc.

Page 17

15(1)

3) Cleaning of auto drain trap ( Discus type )

Overhaul the auto drain trap periodically (every week) so that it can always operate normally.

■ Parts name

■ Draining

Discharge the drainage once a week by turning the drain plug clockwise．During a cold season, perform the drainage after every operation to prevent freezing．

■ Draining before a long suspension of operation．

Be sure to discharge the water from the bowl by turning "clockwise" the drain plug at the bottom of the drain trap．

■ Adjustment of drainage discharge

The operating interval of this drain trap varies with the load, pressure，etc． Turning the needle valve in the "＋"direc tion will shorten the interval and increase the drainage discharge．Adjust the interval in such a way that water will not accumulate in the bowl．

■ Disassembly

If some abnormality, such as excessive dirt on the screen or longer interval, is found, overhaul the drain trap as follows：

　 Turn the cap counterclockwise and remove it ．　 Blow the dust off from the filter, using compressed air．　 Clean the disc cap and disc．　 Turn the ring counterclockwise and remove it. 　 Remove the screen．　 Blow the dust off the screen．　 Wash the bowl with a neutral detergent. Never use any organic solvent．　 Check all the parts for damage. Never fail to check the O-rings, packings and washer

Page 18

Troubleshooting

16(1)

■ Should any trouble arise during operation of the dryer, correct it using the troubleshooting chart below

Problem Possible Cause Solution Dryer does not operate with

operation switch ON pressed．

(RUN lamp does not light up.)

‧Lamp disconnected ‧Switch faulty ‧Low power supply voltage ‧Magnetic contactor faulty ‧Protector faulty ‧High pressure switch faulty

‧Replace. ‧Replace. ‧Use specified voltage. ‧Replace． ‧Replace． ‧Replace.

Dryer does not operate with operation switch ON pressed (RUN lamp lights up.)

‧Magnetic contactor faulty ‧Protector fault

‧Replace． ‧Replace

Dew point is normal but water or oil drops occur．

‧Drainage hindered by foreign

material in auto drain trap

‧Drainage in auto drain trap frozen

‧Disassemble and clean

auto drain trap．

‧Take proper measures to

prevent freezing．

Dew point is high and water or oil drops occur．

‧ Too high air processing rate

‧Lowered cooling capacity ‧Condenser clogged up ‧Too high ambient temperature

‧Fan motor faulty

‧Correct air processing

rate．

‧Check for gas leak． ‧Clean． ‧Lower ambient

temperature.(below 40 ℃)

‧Replace．

Machine stops suddenly during operation．

‧Magnetic contactor faulty ‧Too high air processing rate

‧Condenser clogged up ‧Too high ambient temperature ‧Abnormal voltage

‧Fan control pressure switch faulty

‧Replace． ‧Correct air processing

rate．

‧Clean ‧Lower ambient

temperature. (below 40 ℃)

‧Use rated voltage． ‧Replace．

After -Sale Service

■ Should any trouble arise, correct it according to the troubleshooting chart． If you can not correct it, contact your dealer and ask for the repair. When you request an after-sale service on the dryer, give information on the following particulars：

● Application for repair (1) Model and Serial No．of the air dryer (2) Defective part and trouble (3) Date of purchase (4) Sketch map of your location

● Application for parts (1) Model and Serial No．of the dryer (2) Number, name and quantity of part(s)

Page 19

Before Long Disuse

17(1)

1. Turn off the power

Turn off the main power supply（power supply breaker）．

2. Purge drainage out

Discharge the drainage inside the air dryer completely through the auto drain trap.

3. Store

Store the air dryer in a place free from dirt, dust, rain, water, snow, etc．

■ For operation after a long disuse Perform checks of the parts of the air dryer. Then resume operation according to the

instructions on preparation and operation in this manual．

Page 20

Table of Specifications

規格表

Model機型 FR 005A 010A 020A 030A 050A 075A 100A 150A

Measurement conditions on air processing 處理空氣條件

Air processing capacity 空氣處理量

m3/ min 0.6 1.2 2.4 4.4 7.0 11.0 14.0 23.5

Inlet air pressure 入口空氣壓力

MPa 0.69

Inlet air temperature 入口空氣溫度

℃ 35

Dew point of outlet air 出口空氣露點

℃

-17 at atmosphere 大氣壓下 17

Ambient temperature 環境溫度

℃ 32

Allowable conditions 使用範圍

Maximum inlet air temperature 最高使用溫度

℃ 10 ～ 50

Ambient temperature 環境溫度

℃ 2 ～ 40

Maximum air pressure 最高使用壓力

MPa 0.2 ～ 0.98

External dimensions 本體外形尺寸

Height 高度

mm 478 542 705 705 966 1166 1220 1260

Depth 深度

mm 490 423 423 440 490 490 984 1022

Width 寬度

mm 377 722 797 797 944 944 696 792

Net weight 淨重

kg 22 34 42 42 70 88 105/95 180

Air pipe connection 空氣配管尺寸

B R 1/2 R 1 R 1-1/2 R 2 R 2-1/2

Electric rating

電氣規格

Power source 使用電源

1ø220V 50/60Hz

單相 220V 50/60Hz

3ø220V50/60Hz

三相 220V50/60Hz Power consumption 消耗電力

kW 0.25/0.3 0.4/0.5 0.6/0.7 0.8/0.9 1.6/1.7 1.6/1.7 2.2/1.7 3.4/4.1

Electric current 電流

1.3/1.5 2.0/2.3 2.7/3.3 4.1/4.5 6.0/6.7 6.3/7.5 8.0/6.8 12.0/12.5

Equipment details 裝置細目

Evaporator 熱交換器

Cross - wave fin type (Shell : SUS304)

交錯氣流鰭片 (外殼材質:SUS304) Condenser 冷凝器

Fin and tube, forced air cooling

鰭管式，強迫通風

Parallel flow condenser ,forced air cooling

平行流風扇強制通風

Fin and tube

鰭管式

Fan motor for condenser 冷凝器用風扇馬達

φ/W 120/40 230/40 250/40 300/40 350/100 400/250 500/400

Refrigerant controller 冷媒控制

Capillary tube system

毛細管 Capacity controller 容量控制

Capacity control valve

容量控制閥 Refrigerant 冷媒

R134a R407C

Auto drain trap 自動排水器

Float type

浮球式

Discus type

碟式

Protecting devices 保護裝置

Over current relay

過電流保護繼電器

─

Opposite phase relay

反相繼電器

Compressor 壓縮機

─

Thermostat

過熱繼電器 Fan motor for condenser 冷凝器用風扇馬達

─

Fan motor over temp. switch

風扇馬達過熱保護開關

Refrigerant circuit 冷媒回路

─

High pressure switch

高壓壓力開關

Cooling fan control switch

風扇控制壓力開關

Page 21

Table of Specifications

規格表

Model 機型

FR 005AP 010AP 020AP 030AP 050AP 075AP 100AP

Measurement conditions on air processing 處理空氣條件

Air processing capacity 空氣處理量

m3/ min 0.6 1.2 2.4 4.4 7.0 11.0 14.0

Inlet air pressure 入口空氣壓力

MPa 0.69

Inlet air temperature 入口空氣溫度

℃ 55

Dew point of outlet air 出口空氣露點

℃

-17 at atmosphere 大氣壓下 17

Ambient temperature 環境溫度

℃ 32

Allowable conditions 使用範圍

Maximum inlet air temperature 最高使用溫度

℃ 10 ～ 80

Ambient temperature 環境溫度

℃ 2 ～ 40

Maximum air pressure 最高使用壓力

MPa 0.2 ～ 0.98

External dimensions 本體外形尺寸

Height 高度

mm 542 705 705 966 1166 1214/1220 1260

Depth 深度

mm 423 423 440 490 490 1022/973 1022

Width 寬度

mm 722 797 797 944 944 792/670 792

Net weight 淨重

kg 34 42 42 70 88 175/105 180

Air pipe connection 空氣配管尺寸

B R1/2 R1 R1-1/2 R2 R2-1/2

Electric rating

電氣規格

Power source 使用電源

1 phase 220V 50/60Hz

單相 220V 50/60Hz

3phase220V50/60Hz

三相 220V50/60Hz Power consumption 消耗電力

kW 0.4/0.5 0.6/0.7 0.8/0.9 1.6/1.7 1.6/1.7 3.4/2.6 3.8/4.1

Electric current 電流

2.0/2.3 2.7/3.3 4.1/4.5 6.7/7.0 6.7/7.7 12/7.5 12.0/12.5

Equipment details 裝置細目

Evaporator 熱交換器

Cross - wave fin type (Shell : SUS304)

交錯氣流鰭片 (外殼材質:SUS304) Condenser 冷凝器

Fin and tube, forced air cooling

鰭管式，強迫通風

Parallel flow condenser ,forced air cooling

平行流風扇強制通風

Fin and tube

鰭管式 Fan motor for condenser 冷凝器用風扇馬達

φ/W 230/40 250/40 300/40 350/100

500/400 400/250

500/400

Refrigerant controller 冷媒控制

Capillary tube system

毛細管 Capacity controller 容量控制

Capacity control valve

容量控制閥 Refrigerant 冷媒

R134a R407C

Auto drain trap 自動排水器

Float type

浮球式

Discus type

蝶式

Protecting devices 保護裝置

Over current relay

過電流保護繼電器

─

Opposite phase relay

反相繼電器

Compressor 壓縮機

─

Thermostat

過熱繼電器 Fan motor for condenser 冷凝器用風扇馬達

─

Fan motor over temp. switch

風扇馬達過熱保護開關

Refrigerant circuit 冷媒回路

─

High pressure switch

高壓壓力開關

Cooling fan control switch

風扇控制壓力開關

Page 22