Parker PRD125, PRD150, PRD175 User Manual

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User manual

Refrigeration Dryer

PRD125 PRD150 PRD175

DATE：2012.06.20 －Rev.2 CODE：272896

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SPL040 ---060 (60Hz)

English

Index

1. Safety

2. Introduction

3. Installation

4. Commissioning

5. Control

6. Maintenance

7. Troubleshooting

8. Appendix

, 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

1.1 Importance of the manual

S Keep it for the entire life of the machine. S Read it before any operation. S It is subject to changes: for updated information see the ver-

sion on the unit.

1.2 Warning signals

Instruction for avoiding danger to persons.

Instruction for avoiding damage to the equipment.

The presence of a skilled or authorized technician is required.

There are symb ols whose meaning is given in the para.8.

1.3 Safety instructions

! Always disconnect the appliance from the main power sup-

ply before starting maintenance work.

! The manual is intended for the end---user, only for opera-

tions performable with closed panels: operations requiring opening with tools must be carried out by skilled and qualified personnel.

Y Do not exceed the design limits given on the dataplate. ! Y 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.

!The safety devices on the compressedair 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 unauthorisedpersonnel 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 regarding safety of the system.

The manufacturer declines any liability for damage due to alterations 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 and/or options are fully comprehensive for the correct or foreseeable use of the machine itself or its components.

! IMPORTANT: The manufacturer reserves the right to mo-

dify 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 situation. 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 pointed 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

burns contact

avoid contact, wear protective gloves

inside the unit:

metal parts and electrical wires

intoxication, electrical shock, serious burns

defects in the insulation of the p ower supply lines upstream of the electrical panel; live metal parts

adequate electrical protection of the power supply line; ensure metal parts are properly connected to earth

outside the unit:

area surrounding the unit

intoxication, serious burns

fire due to sho rt circuit or overheating of the supp ly line upstream of the unit’s electrical panel

ensure conductor cross---sectional areas and the supply line protection system conform to applicable regulations

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.

Always disconnect the dryer from the main power sup-

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SPL040 ---060 (60Hz)

English

2.3 Inspection

a) All units 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, in a clean area protected from direct atmospheric agents (including sunlight).

Y Correctly connect the dryer to the compressed air inlet/out-

let connections.

Y For correct installation, follow 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.

Y Pre---filter element (for 3 micron filtration or better) must

be replaced at least once a year, or sooner as per manufacturer recommendations.

3.2 Operating space

YLeave adequateclearancearoundthedrier for maintenance

operations. On the condenser side, leave at least 3.94 inches (10 cm) clearance to ensure correct air flow.

3.3 Tips

To prevent damage to the internal parts of the dryer and air compressor, avoid installations where the surrounding air contains solid and/or gaseous pollutants (e.g. sulphur, ammonia, chlorine and installations in marine environments). Theductingof extractedair is not recommendedfor versions with axial fans.

3.4 Electrical connection

Use approved cable in conformity with the local laws and regulations (for minimum cable section, see par. 8.3). Install a differential thermal magnetic circuit breaker with contact opening distance ² 0.12 inches (3 mm) ahead of the system (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 an 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 suppliedwiththedryerforspecific detailsconcerningthecondensate drain.

Y 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 environmental regulations.

4 Commissioning

4.1 Preliminary checks

Before commissioning the dryer, make sure: a) installationwas carried out according that givenin the section

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 (QS); 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 dryer operates in automatic mode,thereforefieldsettings

are not required;

c) in the event of unforeseen 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 (QS). The power light

goes out and the compressor stops.

5 Control

Main power switch

Dewpoint indicator

The dewpoint indicator can show one of three conditions:

blue: dewpoint too low green: dewpoint ideal red: dewpoint too high

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SPL040 ---060 (60Hz)

English

6 Maintenance

a) The machine is designed and built to guarantee continuous

operation;however, the life of its componentsdepends on the maintenance performed;

b) when requesting assistance or spare parts, identify the ma-

chine (model and serial number) by reading the dataplate located on the unit.

6.1 General instructions

! Before any maintenance, make sure:

S the pneumatic circuit is no longer pressurized; S the dryer is disconnected from the main power supply.

Y Always use the Manufacturer’s original spare parts: other-

wise the Manufacturer is relieved of all liability regarding machine malfunctioning.

Y In case of refrigerant leakage, contact qualified and author-

ized personnel.

Y The Schrader valve must only be used in case of machine

malfunction:otherwise any damage caused by incorrect refrigerant charging will not be covered by the warranty.

6.2 Refrigerant

Charging: any damage caused by incorrect refrigerant replacement carried out by unauthorized personnel will not be covered by the warranty.

Y 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.

! In case of refrigerant leakage, ventilate the room.

6.3 Preventive Maintenance Programme

To guarantee lasting maximum dryer efficiency and reliability:

Maintenance

Activity Description

Maintenance Interval

(standard operating conditions)

Activity

Daily

Weekly

4 Months

12 Months

Check POWER ON indicator is lit.

Check control panel indicators.

Check condensate drain.

Clean condenser fins.

Check electrical absorption.

Depressurize the dryer. Complete drain maintenance.

Depressurize the dryer. Repalce pre--- and post ---filter elements.

check service

The following are available (see par. 8.4): a) service kits

1. compressor kits;

2. fan kits;

3. automatic expansion valve kits;

4. hot gas valve kits;

b) individual spare parts.

6.4 Dismantling

The refrigerant and the lubricating oil contained in the circuit must be recovered in conformity with current local environmental regulations.

Recycling

Disposal

structural work steel/epoxy---polyester resins

exchanger aluminium

pipes aluminium/copper

drain polyamide

exchanger insulation EPS (sintered polystyrene)

pipe insulation synthetic rubber

compressor steel/copper/aluminium/oil

condenser steel/copper/aluminium

refrigerant R134a

valves brass

electrical cables copper/PVC

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SPL040 ---060 (60Hz)

English

7 Troubleshooting Z

Condenser dirty

Ambient temperature

over 1 22˚F (50˚C)

Compressor

components

perished

Repair or

replace

compressor

Seek external

assistance

Compressor

winding insulation

partially perished

(compressor

too hot)

Heat exchanger

fouled with

debris

Reduce compressed

air quantity or air

temperature

Compressor

noisy

Excessive

current

consumption

High pressure

drop on air side

High refrigerant

discharge pressure:

HT trip.

Fan pressure/

thermostat

switch (PV)

calibration error

or damaged.

Condenser

dirty

Ice formation on evaporator

(low

evaporation

pressure)

Clean heat

exchanger (blow

compressed air in

opposite direc-

tion to operating

air flow). Fit/

renew prefilter

By---pass air flow keeping air inlet open. Open con-

densate drain

valve manually. Restart, checking the calibration of

the expansion

valve or hot gas

valve.

High dew

point

High refrigerant

temperature.

HT trip.

Fan does not work

Excessive thermal load

(compressor head too hot)

Low current consumption

Clean

condenser

Reduce

temperature

Replace fan

Insufficient refrigerant: repair any leaks and recharge the

circuit

Clean

condenser

Fan does not work

Replace fan

Replace

pressure switch

Condenser

dirty

Clean

condenser

Fan does not work

Replace fan

FAULT

CAUSE REMEDY

Yes

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5

8 Appendix

8.1 Legend



Meaning



Meaning

ķMC

Compressor

ԤHT

High temperature safety thermostat

ĸ

Refrigerant condenser

ԥ

Expansion capillary

ĹEV1-2

Fan motor

ԦHP

High pressure switch

ĺ

Evaporator

CN

Electronic condensate drain power supply

Ļ

Separator

SK

Overload protector

ļ

Power cable

KA

Starting relay

ĽAEV

Expansion automatic valve

C/Cs

Compressor starting capacitor

ľ

Refrigerant filter

QF

Residual---current automatic circuit breaker

Ŀ HGV

Hot gas valve

QS

Main power switch

ŀ

Air---air exchanger

Compressor run capacitor

Ԣ

Dewpoint indicator

Power light

ԣPV

Fan pressure switch

Cover

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6

8.2 Installation diagram

8 8 8

8 8



Safety valves for not exceeding dryer design pressure



Hoses for air connections if the system undergoes vibrations



Suitable dampers if the system undergoes pulsations

1 Air compressor

2 Dryer

3 By---pass unit

4 Filter (3 micron filtration or better) near dryer air inlet

5 Tank in position A or in B

6 Outlet filter

7 Oil---Water separator

8 Condensate drain

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SPL040 ---060 (60Hz)

8.3 Technical data / Caractéristiques techniques / Datos técnicos

Weight Refrigerant

MIN.---MAX.

Ambient temperature

Minimum

Compressed

air inlet/outlet

Amb

Compressed

air inlet

Air---side

max. working

F.L.A. [A]

Minimum

section

validated cable

Sound pressure

level

134a (Kg)

During transport

and stockage

After

installation

temperature

pressure

for eletrical connection

level

(lb) (kg)

(oz) (kg)

Max

115V±10%

1ph/60Hz

230V±10%

1ph/60Hz

Ø NPT

[dB(A)]

SPL040

115 52 19.4 0.55 13.44 7.3

SPL050

128 58 29.6 0.84

32---122 ˚F

0---50˚C

41---122 ˚F

5---50˚C

149˚F

65˚C

232 PSIg

16 bar

15.35 8.41

AWG

NPT

(compatible)

1”1/2

SPL060

132 60 31.7 0.90

050C550C65C16ba

--- 8.34

1611/

Calibration values Expansion automatic valve Hot gas valve Fan pressure switch

High temperature

safety thermostat

High pressure switch

7 AEV 9 HGV 12 PV 13 H T 15 HP

SPL040

32 PSIg

2.2 barg

---

ON: 160 PSIg

OFF: 116 PSIg

185˚F

85˚C

---

SPL050---060

---

32 PSIg

2.2 barg

ON: 11 bar OFF: 8 bar

266˚F

130˚C

406 PSIg

28 bar

PRD125

PRD175

PRD150

PRD125

PRD150--175

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8.4 Spare parts list

(See paragraph 8.5)

PRD125 PRD150 PRD175

Compressor kit

(115V/1Ph/60Hz)

① ⑧

SP-147341 SP-147738

——

(230V/1Ph/60Hz)

SP-147398 SP-147737 SP-147740

Fan kit

(115V/1Ph/60Hz)

③

SP-381616

——

(230V/1Ph/60Hz)

SP-381794

Automatic expansion valve kit

⑦ ⑧

SP-473109

——

Hot gas valve kit

⑧ ⑨

——

SP-474433

Refrigerant condenser

②

SP-114808 SP-114809 SP-114810

Evaporator/Separetor/Air-air heat-exchanger

④ ⑤ ⑩

SP-472143

Power cable

⑥

SP-256347

——

Refrigerant filter

⑧

SP-206218

Dewpoint indicator

⑪

SP-354317

Fan pressure switch

⑫

SP-354110CX

High temperature safety thermostat

⑬

SP-473399 SP-474434

High pressure switch

⑮

——

SP-354160

Main power switch

SP-255132 SP-255042

Power light

(115V/1Ph/60Hz)

——

SP-271011

——

(230V/1Ph/60Hz)

——

SP-255229

Compressor relay

(115V/1Ph/60Hz)

——

SP-255943

——

(230V/1Ph/60Hz)

——

SP-255944

Cover

SP-139151 SP-139152

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SPL040 ---060 (60Hz)

8.5 Exploded drawing / Vues éclatées / Dibujos de vista despiezada

SPL040

SPL050--060

KA1 KT

T01

KA1 KT

T01

PRD125

PRD150--175

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SPL040 ---060 (60Hz)

8.6 Dimensional drawing / Cotes / Dibujos de dimensiones

[ inches ]

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SPL040 ---060 (60Hz)

8.7 Refrigerant circuit / Circuits de fluide frigorigène / Circuitos de refrigerante

SPL040 SPL050--060

PRD125 PRD150--175

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SPL040 ---060 (60Hz)

8.8 Wiring diagram / Schéma électrique / Esquema eléctrico SPL040

PRD125

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SPL040 ---060 (60Hz)

Wiring diagram / Schéma électrique / Esquema eléctrico SPL050

PRD150

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SPL040 ---060 (60Hz)

Wiring diagram / Schéma électrique / Esquema eléctrico SPL060

PRD175

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Parker Hannifin Corporation

Finite Airtek Filtration Division 4087 Walden Avenue Lancaster, NY 14086 phone 716 686 6400 www.parker.com/faf

c 2012 Parker Hannifin Corporation. Product names are trademarks

or registered trademarks of their respective companies