IDX-OM-K012-C
Initial issue August, 2006
3
rd
edition : Nobember,2010
Operation Manual
PRODUCTNAME
Refrigerated Air Dryer
MODEL/ Series
IDU22E-30
IDU37E-30
IDU55E-30
IDU75E-30
Please read this manu al prio r of using the air dryer. Keep the manual r eadil y available fo r
reference.
© 2010 SMC CORPORATION All Rights Reserved.
To Customers
Thanks for purchasing SMC Refrigerated Air Dryer.
This opertion manual must be read and understood throughoutly before handling. It provides all essential
information for maximizing product operating efficiency, as well as, for safe and longer life span operation.
For safety operation of SMC Refrigerated Air Dryer, read thoroughly and follow stated safety instructions, as well
as regulation stated within ISO 4414
*1
& JIS B 8370*2.
*1) ISO 4414: Pneumatic fluid power – Recommendations for the application of equipment to transmission
and control systems.
*2) JIS B 8370: Pneumatic fluid power – General rules relating to systems
This manual explains about installation and operation of the product. Only those who have thorough
understanding of the fundamental operating procedure or have basic knowledge and skills of handling industrial
product for the installation and operation of the product are qualified to perform installation and operation.
The contents of the operation manual and the other documents attached to the product cannot become a part of
the contract clause or cannot change and modify existing agreements, promises, and relationship.
Any statements contained in the operation manual cannot be newly guaranteed and modify existing guarantee
certificate.
You are not allowed to copy any part of this operation manual for usage of third person without informing it to us
beforehand.
Caution: Please understand that the contents of this operation manual are subject to
changed without previous notice.
Air Dryer Table of Contents
Table of Contents - 1
Table of Con tents
To Customers
Chapter i Safety Instructions
i
- 1 Warning: Before Using Air Dryer.......................................................................... i - 1
i - 1 - 1 Meanings of signs: Caution, Warning, Danger..........................................................i - 1
i - 2 Danger Classifications / Position of Danger warning label............................i - 3
i - 2 - 1 Danger Classifications.............................................................................................i - 3
i - 2 - 2 Danger of Electricity................................................................................................. i - 4
i - 2 - 3 Danger of high Heat................................................................................................. i - 4
i - 2 - 4 Danger of Rotor.......................................................................................................i - 4
i - 2 - 5 Danger of Compressed Air Circuit ...........................................................................i - 4
i - 2 - 6 Positions of Danger Warn ing L abel.......................................................................... i - 5
i - 2 - 7 Danger of Refrigerant...............................................................................................i - 6
i - 2 - 8 Cautions about Usage..............................................................................................i - 7
i - 2 - 9 Other Label.............................................................................................................. i - 7
i - 3 Disposal .................................................................................................................... i – 8
i - 4 Limited warranty and Disclaimer / Compliance Requirements..................... i – 9
Chapter 1 Parts Name and Functions
1 - 1 Parts Names and Functions
..................................................................................1 - 1
Chapter 2 Transportation / Installation
2 - 1 Transportation
..........................................................................................................2 - 1
2 - 2 Installation ................................................................................................................2 - 2
2 - 2 - 1 Locati o n..................................................................................................................2 - 2
2 - 2 - 2 Anchora ge.............................................................................................................. 2 - 2
2 - 2 - 3 Air pipi ng.................................................................................................................2 - 2
2 - 2 - 4 Drain Tube..............................................................................................................2 - 3
2 - 2 - 5 Electric wiri n g...................................................................................................... ....2 - 3
2 - 3 Cautions about reinstallation...............................................................................2 - 4
Chapter 3 Operation / Shutdown
3
- 1 Check points before operation............................................................................. 3 - 1
3 - 2 Operation ..................................................................................................................3 - 1
3 - 3 Shutdown.................................................................................................................. 3 - 2
3 - 4 Cautions about restart...........................................................................................3 - 2
3 - 5 Check points before restart ..................................................................................3 - 2
3 - 6 Precautions for long-term non-operation..........................................................3 - 2
Chapter 4 Maintenance
4
- 1 Daily inspection.......................................................................................................4 - 1
4 - 2 Periodical maintenance.........................................................................................4 - 1
4 - 2 - 1Cleani n g o f vent i l a tion gri lle (su c t ion gri l l e )..................................................................4 - 1
4 - 2 - 2 Service parts..............................................................................................................4 - 1
4 - 2 - 3 Cleaning of the case assembly...................................................................................4 - 1
Chapter 5 Troubleshooting............................................................................................................5 - 1
5 - 1 Cause and countermeasure of errors.................................................................5 - 1
5 - 2 How to reset the thermal relay and high pressure switch
.............................5 - 3
Chapter 6. References
6 - 1 Specifications
..........................................................................................................6 - 1
6 - 2 Dimensions...............................................................................................................6 - 2
6 - 3 Electrical Circuit......................................................................................................6 - 3
6 - 4 Compressed Air and Refrigerant Circuit / Operation Principles...................6 - 4
Air Dryer i Safety Instructions
Safety Instructions
Before use, read and comprehend important cautionary
notification well on this operattion manual.
i – 1 Warni ng: Before Useing Air Dryer
In this chapter, the stated contents are especially about safety way to use the product. for customer.
An Air Dryer is installed on the downstream of the air compressor to remove moisture. We, manufacturer,
cannot take any responsibility if you use it for any other purpose.
An Air Dryer works with high voltage and has some parts that gets hot or rotates during operation. Ask vendor
if you need component replacement and servicing.
Not only people handle the air dryer but every people who perform maintenance on or do works related to it
should read safety instructions on this operation manual before handling.
This operation manual is not a general safety manual which is practiced by safety training representatives.
People who handle this product or work around it need to take training to comprehand inherent risks of it and
master measures for safety.
It is usually responsible for super visor to follow the safety instructions, but each operator or maintemance
representative should do daily operations on their own head.
Operators and maintemance representatives should take the safety of working place and work environment
into account.
It is necessary to think of the safety of working place and work environment for each task
Take enough safety training before the operation training. It is very dangerous to do operation training without
any safety training. Operation training must be paid attention to its safety.
Reset the protective circuit referring to “5-2 How to reset the thermal relay”.
i – 1 – 1 Meaning of Signs: Caution, Warning, Danger
These safety instructions are intended to prevent hazardous situation and/or product damage.
These instructions indicate the level of potentia l hazard by signs “Caution”, “Warning” or
“Danger”. Contents with these signs state about important instructions concerning safety.
Confirm where those s igns ar e, an d read a nd c o mprehend notices and ca utio nary notices well
before handling.
“Caution”, “Warning” or “Danger” is the order of importance (Danger>Warning>Caution).
Followings are the meanings of those signs.
Danger
Statements with the “Danger” sign explain about conditions in which there is a
possible result of serious injury or loss of life if someone handles wrongly during
operation or maintenance and did not follow the procedure to avoid danger.
i - 1
Air Dryer i Safety Instructions
Warning
Statements with the “Danger” sign explain about possibilities that can result in
serious injury or loss of life if someone handle wrongly during operation or
maintenance and did not follow the procedure to avoid danger.
Caution
Statements with the “Danger” sign explain about possibilities that can result in injury
or product damage if someone handles wrongly during operation or maintenance and
did not follow the procedure to avoid danger.
i - 2
Air Dryer i Safety Instructions
i – 2 Danger Classifications / Position of Danger Warning Label
To protect operator’s sefety, we group danger into some types uniquely and attached labels indicating those types.
Comfirm the contents of the danger types and positions of the labels before operation.
Warning
No one but professionals should operate an air dryer.
Transportation, installation, and maintenance involve risks. These should be done by
someone who have enough knowledge and experience about this product and incidental
devices.
No one but our service personnel or qualified person should open the cover panel of this
product.
Warning
Should any problem occur, address it according to statements on this manual.
• Identify problems according to “Chapter 5 Troubleshooting.”
• Ask repair and maintenance.
Warning
The product should not be operated in the event of any problems.
When the product gets out of order, shutdown it immediatery, and contact our service
person or qualified person.
i – 2 – 2 Danger Classifications
Specific danger classification of this product is as follows.
Danger of Electricity
Since this product run s at hign v oltage, ther e is the danger of electric shoc k. So, w e display a
symbol with indications,
“Caution”, “Warning” or “Danger,” on the product and this
manual.
Danger of Heat
Since this product becomes hot while driving, there is the danger of burn injury. So, we
display a symbol with indications, “Caution”, “Warning” or “Danger,” on the product
and this manual.
Danger of Rotor
Since this product has parts that rotate while driving, there is the danger of catching your
fingers in or injury. So, we display a symbol with indications, “Caution”, “Warning” or
“Danger,”
on the product and this manual.
i - 3
Air Dryer i Safety Instructions
i – 2 – 2 Danger of Electricity
Inside of this product, there is power-supplying section with high voltage separated by the
cover panel. Do not operate the product without the cover panel.
No one but trained qualified person should operate or inspect in the power transmission
sections.
Warning
Read with caution and pay attention to the notations on danger warning labels.
Do not remove or rub danger warning labels.
Confirm the positions of danger warning labels.
i – 2 – 3 Danger of High Heat
Warning
Since this equipmant has parts that become hot during operation, there is the danger of burn
injury resulting from contact with them. What is more, there is also the danger of burn injury due to
remaining heat after the power supply is cut. Th erefore, wait until the temperature of hot parts become
50
o
C and below.
i – 2 – 4 Danger of Rotor
Warning
Since this product has parts that rotate during operation, there is the danger of burn injury
resulting from contact with them. Though sometimes those parts can temporarily stop the rotation,
they will rotate again, and so do not work with them while driving.
i – 2 – 5 Danger of Compressed Air Circuit
Warning
Before replacing or cleaning parts, be sure to bleed compressed air remain inside of the
product untill the gauge indicates “0”. If you do not do this air-bleeding,
there would be the
great danger of unexpected accident, such as shooting out of parts when they are being unscrewed.
i - 4
Air Dryer i Safety Instructions
i – 2 – 6 Positions of Danger Warning Label
Warning
Read with caution and pay attention to the notations of danger warning labels.
Do not remove or rub danger warning labels.
Confirm the positions of danger warning labels.
Front
Front
IDU22E, 37E IDU55E, 75E
WARNING 警告
!
1 Remove panels for maintenance only.
2 Never insert anything into product to ensure
safety.
3 Cut power prior to maintenance to prevent
electric shock.
4 Settle product to room temp.before main tenance toprevent burn or frostbite.
5 Ensure zero air pr essu re b efore replacing parts.
1 点検以外はﾊﾟﾈﾙを取り外さないこと。
2 回転物があるので指、棒状の物を差し
込まないこと。
3 感電の恐れがあるので、点検の前には電源を
切ること。
4 火傷の恐れがあるので、点検の前には装置を
常温にすること。
5 部品交換の前には必ず、空気圧力を"0"に
すること。
!
i - 5
Air Dryer i Safety Instructions
i – 2 – 7 Danger of Refrigerant
Caution
This product uses Fluorocarbon (HFC) as a refrigerant.
This product is specified by “Class 1 Fluorocarbon Collection and Destruction Law in Japan.”
It is strictly forbitten to emit Fluorocarbon to the atmosphere. Before you repair this product,
you should collect the refrigerant with “Refrigerant collector.” Then, ask a destruction agency
to dispose of collected refrigerant. No one but someone have enough knowledge and
experience about the product and incidental device should do the collection of the refrigerant.
No one but service person or qualified person should remove the cover panel of the product.
The quantity and the sort of the Fluorocarbon are mentioned on the specification label that are
explained on Page i - 7.
Front Front
Fluorocarbon Collection an d Destruction La w in Japan
フロン回収破壊法第一種特定製品
This product uses
Fluorocarbon (HFC) as a refrigerant.
1 It is strictly forbidden to emit Fluorocarbon
to the atmosphere.
2 When disposing this product, Fluorocarbon
must be collected in an appropriate manner.
3 The kind of Fluorocarbon and the amount used
in this product is prited on the name label.
この製品には冷媒として、
フロン類（ＨＦＣ）が使われています。
1 フロン類をみだりに大気中に放出することは
禁じられています。
2 この製品を廃棄する場合には、フロン類の回収が
必要です。
3 フロン類の種類及び数量は、型式銘板に記載
されています。
IDU22E, 37E IDU55E, 75E
i - 6
Air Dryer i Safety Instructions
i – 2 – 8 Cautions about Usage
Warning
Read with caution and pay attention to the notations on danger warning labels.
Do not remove or rub danger warning labels.
Cimfirm the positions of danger warning labels.
i – 2 – 9 Other Label
Comfirm the model, contents of specifications on the label.
Front
S
p
ecification Label
Contents
MODEL: Model
VOLTAGE: Power supply voltage (frequency)
RUNNING CURRENT: Running current
REFRIGERANT: Type of refrigerant (amount)
WEIGHT: W eightMAX.PRESS: Maximum
operating pressure
SERIAL No.: Serial No.
MANUFACTURING DATE: Manufacturing Date
MADE IN: Country of manufacture
Front
CAUTION 注意
!
12 Read m an u al b efore op er a tion.
Ensure vantilation and maintenance
space.
p water away from the product.
ecure In / Out connector with spanner
during piping.
Wait 3 m in u tes b efore r esta r t.
Ensure Running Condition / Evaporating
Temp . in g r e en z one.
3 Kee
4 S
5
6
1
2 通
ご使用前に必ず取扱説明書を読んでください。
風、メンテ ナンス スペースを 確保して
ください 。
雨や水滴がかからないようにしてください。
ＩＮ／ＯＵＴポートをスパナで固定して
配管 して ください 。
再起動は運転停止３分後に行ってください。
Ｒ ＵＮ ＮＩＮ Ｇ ＣＯ ＮＤ ＩＴＩＯ Ｎ・ 蒸発 温 度 計は
ーン帯で使用してください。
3
4
5
6
グリ
Front
IDU22E, 37E IDU55E, 75E
AIR DRYER
MODEL
VOLTAGE
RUNNING CURRENT
REFRIGERANT
WEIGHT MAX.PRESS.
SERIAL No.
MAKER
MADE IN
i - 7
Air Dryer i Safety Instructions
i – 3 Disposal
When you dispose of the product, you shoud collect the refrigerant and the r ef rigerat oil enclosed in th e
refrigerant circuit.
Caurion
A sort of Fluorocarbon (HFC) is used for this product as refrigerant.
This product is specified by “Class1 Fluorocarbon Collection Destruction Law in Japan.”
It is strictly forbitten by the law to emit the refrigerant to the atmosphere. Before you repair
this product, you should collect the refrigirant with “Refrigerant collector.” Then, ask a
destruction agency to dispo s e of co llected refrigerant.
No one but someone have ebough knowledge and experience about the product and
incidental devices should do the collection of the refrigerant.
No one but service person or qualified person shoud remove the cover panel of the product.
The quantity and the sort of the Fluorocarbon are printed on the specification label.
Caution
Dispose of the refrigerant and refrigerant oil according to the bylaw or regulation of local
government.
Do not dispose of refrigerant oil together with domestic garbage. And do not burn it in
unauthorized incinerators.
No one but someone have enough knowledge and experience about the product and
incidental devices should do the collection of the refrigerant oil.
No one but service person or qualified person shoud remove the cover panel of the product.
If there are something not clear, please contact our service office.
i - 8
Air Dryer i Safety Instructions
i – 4 Limited warranty and Disclaimer / Compliance Requirements
The product used subject to the following “Limited warranty and Disclaimer“ and “Compliance Requirements.
Read and accept them before using the product.
Limited warranty and Di scl aimer
1. The warrant y per i od of t he pro d uc t is 1 yea r i n s er v ice or 1.5 years after th e product is del i vered.
Also, the product may have specified durability, running distance or replacement parts. Please consult
your neares t sa l es branch.
2. For any failure or damage reported within the warranty period which is clearly our responsibility, a
replacement product or necessary parts will be provided.
This limited warranty applies only to our product independently, and not to any other damage incurred
due to the failure of the product.
3. Prior to using SMC products, please read and understand the warranty terms and disclaimers noted in
the specified catalog for the particular products.
Compliance Requirements
1. The use of SMC products with production equipment for the manufacture of weapons of mass
destruction (WMD) or other wea p on is st r ictly prohibited.
2. The exports of S MC pr odu cts or tec hno lo g y from one cou ntr y to anot her are go vem ed b y the r ele van t
security laws and regulation of the countries involved in the transaction. Prior to the shipment of a SMC
product of a SMC produ ct to ano ther country, assure that all local rules gov eming tha t expor t a re know n
and followed.
Caution
The Product is provided use in manuf actu rin g ind ust rie s.
The product herein described is basically provided for peaceful use in manufacturing industries.
If considering using the product in other industries, c onsult SMC beforehand a nd exchange
specifications or a contact if necessary.
If anything is u nc l ear, contact your nearest sale s b r an ch .
i - 8
Air Dryer 1 Name and Functions Parts
1
Parts Name and Functions
1-1 Parts Name and Functions
・IDU22E,37E
Front
Terminal block
You can see the terminal block when you
remove front panel. Connect the power
cable through the rubber grommet.
(3 phase AC200V)
Aut o Dr ain
Check if drained
correctly once a day.
Compressed Air (IN
)
Ball Valve
Thermal relay
(The thermal relay is
placed at the inside of
a front panel.) Refer to
page 5-2 to reset the
thermal relay.
L1 L2 L3
PE
（ ）
Switch with Lamp
(ON/OFF Switch)
The lamp is continuously ON
during normal operation. Use it
for ON/OFF operations.
Evaporation
thermometer
(Evaporating Temp)
Indicates the temperature
of refrigerant of
low-pressure side.
During normal driving, it
indicates in the green
zone.
Drain Tube
Discharges drain.
not block with wall and so on.
Customer Connection Side
Terminal Connecting Screw: M3
Applied Pressure Terminal: 1.25-3
(Width 6.5mm and below)
Front panel mounting screw
I can be found at left side (4 pcs in total).
Right Side Ventilation Grille
(Outlet)
Waste heat will be exhausted
as hot air by the fan motor. Do
Compressed Air (OUT)
1 - 1
Air Dryer 1 Name and Functions Parts
Fixing Screw for Front Panel
Another one is on the right side.
Left Side Ventilation Grille (Inlet)
Breathe in cooling air from this grill.
Do not bung up with wall and so on.
Rubber Grommet
Power cord outlet
Front
1 - 2
Air Dryer 1 Name and Functions Parts
・IDU55E,75E
Front
Terminal block
You can see the terminal block when you
remove front panel. Connect the power
cable through the rubber grommet.
(3 phase AC200V)
Aut o Dr ain
Check if drained
correctly once a day.
Compressed Air (IN
)
Ball Valve
Thermal relay
(The thermal relay is
placed at the inside of
a front panel.) Refer to
page 5-2 to reset the
thermal relay.
L1 L2 L3
PE （ ）
Switch with Lamp
(ON/OFF Switch)
The lamp is continuously ON
during normal operation. Use it
for ON/OFF operations.
Evaporation
thermometer
(Evaporating Temp)
Indicates the temperature
of refrigerant of
low-pressure side.
During normal driving, it
indicates in the green
zone.
Drain Tube
Discharges drain.
Right Side Ventilation Grille
(Outlet)
Waste heat will be exhausted
as hot air by the fan motor. Do
not block with wall and so on.
Customer Connection Side
Terminal Connecting Screw: M3
Applied Pressure Terminal: 1.25-3
(Width 6.5mm and below)
Front panel mounting screw
I can be found at left side (6 pcs in total).
High Pressure Switch
(The high pressure switch is placed at
the inside of a front panel.) Refer to page
5-2 to reset the high pressure switch.
Compressed Air (OUT)
1 - 3
Air Dryer 1 Name and Functions Parts
Fixing Screw for Front Panel
Another one is on the right side.
Left Side Ventilation Grille (Inlet)
Breathe in cooling air from this grill.
Do not bung up with wall and so on.
Rubber Grommet
Power cord outlet
Front
1 - 4
Air Dryer
2 Transportation / Installation
2
Transportation / Installation
Warning
Use the product in the right way. During Installation, operation, maintenance, and check,
you should be careful in keeping the safety of human body.
Caution
Transportation, installation, and maintenance including dangerous work must be done by
a personnel who has enough knowledge and experience about the product and the
sysytem.
2-1 Transportation
When you transport the product, you should follow these instructions below.
• You should uplift the produ ct from the ba se surface
with careful attention to prev ent falling si deways and
drop.
• Do not bring the product lying sideways. If you lay it sideways, it will be broken.
• Do not hang up the product.
• Do not transport the product with any part such as an air filter mounted on the fittings at the air inlet or
outlet port of the product. If it is unavoi dab le to tra nsp ort the product with such a part mounted, su pport
the mounted part with a bracket to prevent the product from being affected by vibration during
transportation
Warning
Those instructions above must be followed because the product is so heavy that it carries
a great risk to transport.
IDU22~75E are 90~170kg or more. They must be transported by forklift of IDU22E~IDU75E.
2 - 1
Air Dryer
2 Transportation / Installation
2-2 Installation
2-2-1 Location
The product should not be used or stored in the circumstances as follows.
Those circumstances will cause not only malfunction but also failures.
• Environment where the product is
exposed to rainwater,
moisture vapor,
salty water, oil and so on.
• Locations where dust or particles are.
• Locations where inflammable or
explosive gas are.
• Locations where corrosive gas, solvent,
combustible gas are.
•
Locations that rece iv e d irec t s unli ght or
where radiant heat is generated.
• Locations where ambient temperature
is beyond following range:
On-stream: 2 ~ 40
o
C
Storage: 0 ~ 50
o
C (when there is no
drain water inside of the piping)
• Locations where temperature changes
ra
pidly.
• Locations where strong
• electromagnetic noise is generated
(locations where electromagnetic field,
strong magnetic field, surge is
generated)
• Circumstances where static electricity
is produced or discharged through the
body of the product.
•
Locations where strong high frequency
wave is generated.
• Locations where danger of thunder is
apparent.
• Locations by loading on vehicles,
marine vessels, and so on.
• Locations whose altitude is higher than
2,000 meters.
• Circumstances where strong vibration
or impact are transmitted.
• Circumstances where
too much force
and weight are put on the body of the
product that causes it to deform.
• Circumstances where enough spaces
cannot be taken to do maintenance (in
the plant where the product is
operated).
Spaces needed for maintenance
Front : 600 mm
Rear : 600 mm
Top : 600 mm
Right : 600 mm
Left : 600 mm
• Locations the ventilation grille of the
product can be blocked.
• Place where rejection style air of air
compressor or other driers (hot w ind) is
inhaled.
Warning
Do not use and store in environment having compressed air or ambinet atmosphere which
includes the following substances. It could result in failure of the product and damage of
components, which leads to injury.
- Corrosive gas, Organic solvent, Chemicals
2-2-2 Anchorage
• The air dryer should be installed on a vibration-free, stable, horizontal flat surface.
•
Refer to “Chapter6 6-2 Dimensions” for the dimensions.
• Fix by bolts to prevent falling down. The bolts can be prepared separately as an accessory.
Model No. Name Quantity Applicable Model
IDF-AB501 Anchor bolt set 1 (4 pcs／1 set） IDU22E,IDU37E,IDU55E,IDU75E
2-2-3 Air piping
• Connection to the inlet and outlet of compressed air should be made removable by using union and so
on.
• Pressing the hexagonal fitting with screw wrench and so on, connect the air piping fittings to the body.
• W hen mounting any part such as an air filter on the fitting at the compressed air inlet or outlet port,
support the part to prevent excessive force from being applied to the product.
2 - 2
Air Dryer
2 Transportation / Installation
• Be careful not to let the vibration of the air compressor transmit.
• If the temperature of c omp res s ed air on the inlet side is higher than 80oC, place an aftercooler after th e
air compressor. Or, make th e temperature of the place where the air compressor is installed lower than
80
o
C.
• Flash the piping sufficiently in order to avoid any foreign substances such as dust, sealing tape, liquid
gasket, etc. when piping before piping connection.Foreign substances in the piping can cause cooling
failure or drainage failure.
• Use pipes and fittings that have enough endurance against the operating pressure and temperature.
And connect it firmly to prevent air leakage.
• Provide bypass piping to make it possible to do maintenance without stopping the air compressor.
We recommend the bypass piping sets that
we are selling separately as accessories.
Model No. Name Q.t
Applicable
Model
IDU-BP336 1 IDU22E
IDU-BP337 1 IDU37E
1 IDU55E
IDU-BP338
Bypass
piping
sets
1 IDU75E
Bypass
Valve
Union Joint
Union Joint
Valve (OUT)
Valve (IN)
Compressed Air (IN)
Compressed Air (OUT)
2-2-4 Drain Tube
• A polyurethane tube of 10mm ex ternal diameter i s attac hed t o the drain tu be. The outlet e nd of t he tube
is released to atmosphere. And let drain flow through the tube into a scupper and so on.
• Using the pressure of the com pressed a ir, drain w ill be disc harged p eriodic ally. Fix the outl et end of the
tube so as not to swing during discharge.
• Prevent the drain tube from riser piping.
• Prevent the drain tube fr om being fo lded or flatted. Si nce the d rain tube i s coming from the bo ttom of the
body, be careful to avoid the body from stomping over the tube during installation.
2-2-5 Electric Wiring
Warning
No one but qualified person should do the wiring work.
・Before wiring, you must cut the power off for safety. Do not work under any
energized conditions.
・Supply power from a stable place, which is free from the effect of surge.
Ensure that an Ground Fault Circuit Interrupter(GFCI) with appropriate capacity for
earth leakage and load is used in the power supply of the product to prevent
electrical shock and burnout of the compressor motor. See “6-1 List of
specifications” for details.
・Supply power for the product should meet the specifications.
・The product should be grounded for safety.
・Do not connect the earth to a water pipe, a gas pipe, or a lightening.
・Do not plug too many leads into a single socket. That causes exothenmic heat or fire.
・Do not convert the wiring to use.
・In European countries, a circuit breaker that meets the IEC standard should
・be used for the supply power.
How to connect wiring
・Take off the front panel in front of the product and connect the power supply (AC200V) to the
terminal base.
・Install an Ground Fault Circuit Interrupter(GFCI) to the power supply
(Prepare by yourself)
[ Sensed current: 30mA and below, Rated current 10A (IDU75E…Rated curre nt 15A) ]
2 - 3
Air Dryer
2 Transportation / Installation
Specification of power cable
Prepare following power cable.
Power cable: 1.25mm
2
(16AWG), External diameter: about 8 ~ 12mm
IDU22E ~ 75E-30 (3 phase power supply) …4 cores (including grounding)
Additional length of about 0.2m is needed to wire inside of the product.
Length of the power cable
The length of the power cable should extend less than 30m from the product.
Connecting to the power supply
Connect the power cable and t he earth to the terminal b lock. M3 screw is used for the conne ction part. Make sur e
to use round crimped terminal.
Applicable crimped terminal: 1.25-3 (Width: 6.5mm and below)
Wiring procedure
・Remove the front panel.
・Insert the cord through the r ubber gro mmet an d conne ct it to the ter minal b lock (r efer t o the la bel on the term inal
block). M3 screw tightening torque: 0.6~1Nm
During wiring work, do not touch other sections except terminal block.
・Attach the front panel as it we re.
2-3 Cautions about Reinstallation
Caution
No one but someone who has enough knowledge about the product and incidental
devices should reinstall in another place. And following instructions must be executed.
If you move the product and reinstall it into another place after some operations (including trial running),
instructions that are not only following ones but also all of those in the chapter 2 should be followed.
Disassembly of the power cable
Cut off the power source when you disassemble the power cable.
Warning
No one but qualified personnel should do the electric wiring.
Cut off the power supply for safety before the wiring. Do not work under energized
condition.
Disassembly of the air piping
Warning
No one but qualified personnel should do the air piping.
Separate the compressor from the product for safety before removing the iping. Do not
remove any piping when there is remaining compressed air pressure inside of it.
・Remove the seal tape completely after detaching th e piping. Remained tape will cause imperfect
cooling and failure by entering into the body of the product.
Residual compressed air pressure release procedure
・Even while the dryer is removed, only when co mpressed air i s
needed, open the bypass piping valve.
･Close the compressed air inlet and outlet valve.
･Make sure the ball valve located next to the auto drain opened.
Case Assembly
The ramainder de pressure cock.
※It opens when turning in the
drection og the arrow of figure.
・Open the auto drain residual pressure rel ease valve
to release air pressure inside the product. Refer to
the figure at right.
2 - 4
Air Dryer 3 Operation / Shutdown
3
Operation / Shutdown
Caution
No one but someone who has enough knowledge and experience about the product and
incidental devices should operate or shut down the product.
3-1 Check points before operation
Before a trial running, check following points.
• Installed Condition
By visual inspection check that the product is installed horizontally.
Make sure the product is fixed enough with anchor bolts.
Do not place heavy obstacles on the product and add unreasonable loading by piping and so on.
• Wiring Connections
Power cord, and the earth should be connected firmly.
• Drain Tube
Drain tube should be connected correct ly .
• Air Piping
Make sure the piping for compressed air is connected correctly. Those valves of IN / OUT side and bypass
piping of the product and of the bypass piping should be completely fasten.
• Ball valve
Make sure the ball valve located next to the auto drain opened.
3-2 Operation
Start operation according to the procedure below.
• Turn on the breaker of the main power supply. Then, turn on the Switch with Lamp.
• The lamp will light up. Few minutes later, the cooling fan will rotate and hot air will be exhausted from the
ventilation grille.
Place of the ventilation grille: Right Side Ventilation Grille
• Open the IN / OUT side v alve slow ly. M ake sur e the by pass valv e is comp let ely cl osed. M ake sur e th e bypa ss
valve is completely closed. Confirm there is no air leakage.
• Depending on the condition of compressed air or ambient temperature, the cooling fan sometimes alternates
between rotation and stop at th e beginning. T hen, the refriger ator will go i nto continuo us run and the poi nter of
the evaporation thermometer will indicate in the green zone. If the pointer of the evaporation thermometer
indicates higher than the green zone, refer to “Chapter5 Troubleshooting.”
• After a while from the start of flowing the compressed air, drain will be discharged from the drain tube
automatically.
• Keep the condition of continuous run to use.
3 - 1
Air Dryer 3 Operation / Shutdown
Caution
Avoid frequent ON / OFF operation, which can cause troubles.
The auto drain used for the product has a structre that closes the valve with air pressure higher
than 0.15MPa. Therefore, until the pressure increase, air will be emitted form the drain outlet at
the begining of opening the IN side valve. Keep in mind that sometime the pressure cannot
increase enough with air compressor that has low dischage flow rate.
3-3 Shutdown
• Turn off the Switch with Lamp.
• The lamp will go out and then, the operation will be stopped. Depending on the condition of operation, hot air
continues to be emitted from the ventilation grille by the cooling fan for a while after turning off the switch,
which is not an abnormality but a process for safety shutdown.
3-4 Cautions about restart
• One must wait for at least 3 minutes before restarting air dryer after it has been shut down. Failure to do this
may cause safety devices to trip due to over load.
If it is not possible to restart, refer to “Chapter 5 Troubleshooting.”
3-5 Check points before restart
Check following points before you start operation. If any abnormalities occur, immediately stop the operation. Turn off
the Switch with Lamp of the product and then the breaker to the power supply.
• There is no leakage of compresse d air .
• Compressed air pressure, temperature, flow rate, and ambient temperature meet the specifications.
• Drain is being discharged from the drain tube.
• The pointer of evaporation thermom eter is ind ica ting in the green zone .
• There are no
abnormal sound, vibration, or smelling.
3-6 Precautions for long-term-non-operation
• If the product will not be op erated for 24 h ours, for ex ample at the w eekend, t urn off the RUN sw itch or power
supply, for energy saving and safety. It is also recommended to release the pressure inside the compressed
air piping.
3 - 2
Air Dryer
4 Maintenance
4
Maintenance
4-1 Daily Inspection
Check following points during usual operations. If you find some problems, immediately stop the operation and refer to
“Chapter 5 Troubleshooting” as soon as possible.
• There is no air leakage
• The running lamp is lighting during operation
• Drain is being discharged from drain tube
• The pointer of the evaporation thermometer indicates in the green zone when it is running with pressurized air
supply.
• The pointer of the evaporated thermo meter indi cates about 3 ~10
o
C lower than that of ambie nt temperature w hen
the product is suspended with no pressurized air supply.
• There is no abnormal sound or vibration coming up from the product.
• There are no abnormal smell or smoke coming up from the product.
4-2 Periodical Maintenance
4-2-1 Cleaning of ventilation grille (suction grille)
Clean dust and other foreign particles from the ventilation area with vacuum cleaner or air blow nozzle once a
month.
Caution
During air blowing, put on protective glass and mask to prevent dusts from coming into
hroat or eyes.
t
4-2-2 Service parts
It is recommended to replace the f ollo win g parts regul ar ly. The interval alues shown in t his o peration
manual depend on the operating conditions (ambient tem perature, installation environment, etc.), so
that they are for referens.
• Table 1. List of parts to be replaced regularly
Description Recommended replacement period *Note}
Pressure switch One Million times.
Fan motor 20,000 hours
Magnetic Contactor, Magnetic Switch One Million times.
*Note）If it is m ounte d b y o ptio n ”T” (With term inal b lo ck for power supply , ru n , alar m signal and remote
operation) or special order.
4-2-3 Cleaning of the case assembly
Remove the dust deposited in t he auto drain c ase assembly e very month. Use neu tral detergent for cleaning. If t he
degree of dirt is heavy and operating failure still continues even after cleaning, replace the product. Also, shorten
cleaning interval from the next time.
• Part No. of case assembly
Part No. Name Quantity Applicable Model
AD48
Case Assembly
1
IDU22E, IDU37E
IDU55E, IDU75E
4 - 1
Air Dryer
4 Maintenance
・ Maintenance of the a ir dryer should only be carr ied out by someone with sufficient knowledge and
experience of air dryers and related equipment.
・ Before carrying o ut maintenance, the important warnings in this manual must be thor ou ghly read and
understood.
Warnin
g
・ When replacing or cleaning parts of the air dryer, be sure to remove the compressed air pressure inside
the air dryer to “0”. Never rem ove the case assem bly when the air dryer is opera ted or air pressure
remains inside. It is ex tremely dangero us if com pressed air pres sure rem ains inside the air dr yer, as
parts may come flying off at speed when loosened, or other unexpected accidents.
・ This product has parts that become hot during operation and a power supply with high voltage applied.
There is a risk of burns due to heat or electrification by high voltage. Even when operation is shut down
after switching off the air dryer’s illuminated lig ht, t her e are als o c h argi ng li nes . When working on the
charged sections, be sure to switch off the earth leakage breaker installed before starting work.
・ As some parts of the air dryer will r emain hot, there is a risk of burns due to residual heat after the
power is switched off. So do n ot carr y out re placem ent work until th e tem peratur e of thes e parts has
fallen to 50℃ or less. Wait for about 10 to 15 minutes as a guide.
・ When carrying out maintenance work on the auto drain strainer and auto drain, there is a risk of
touching the drain fluid during work. Please follow the safety procedure for operators specified by
customer.（Example: carry out work wearing safety glasses, apron and gloves to prevent discharged
fluid from touching the human body.）
・ Use neutral detergent solution to clean parts such as the auto drain strainer and auto drain. Never
use solvent such as thinner.
・ When removing the outer casing panel or case assembly of the auto drain, wear gloves to prevent
injuries.
Dange
r
4 - 2
Air Dryer
4 Maintenance
Ball valve
Float assembly
Turn to 45°
（
right or left)
Aut o drain s t raine
r
Bl eed valve
SO
Drain tube
release bus h
Lock but ton
Drrain t u be
Ball valve
Bleed valve
・ Close the ball valve.
・ Open the bleed valve by turning it anticlockwise to release
air left in the product.
Pull down the case
assembly slowly
・ Remove the drain tube from the case assembly.
・
Hold the case assembly lightly and pull down the lock button with
thumb. Then, turn the case assembly to the left (or right) to 45°to
align the marks,
Release your thumb from the lock button a nd slow ly pull dow n the
case assembly (vertically) to remove it.
・
Pour solution of neutral detergent into the case assembly and
shake it well to clean.
・ Check the case O-ring for damage such as scratches, twisting or
foreign particles attached to it. Then, apply grease thinly and fit it
in the groove in the case assembly.
・
Fit the case assembly to the auto drain bo dy. Turn it untill t he lock
button clicks
S
O
Case assembly
“O”ring
・ Try to turn the case assembly li ghtly and chec k that it does not
turn. If it turns, start with fi tting the ca se assembly to t he body
again.
・ Close the bleed valve by turning it clockwise and fit the
drain tube as it was.
・ Open the ball valve.
・ If the case assem bly is damaged or very dirty, replace it
with a new one.
4 - 3
Air Dryer 5 Troubleshooting
Troubleshooting
5
5-1 Cause and countermeasure of errors
Should any problem occur, inspect the following table, and if the problem cannot be solved, shut off the power supply
and then contact one of our sales offices for further instructions.
Problem Probable Causes Remedy
Power cord or plug is in loosening
state or completely pulling out.
Perform proper connection on the power cord and plug.
Circuit breaker is OFF. Confirm whether the proper capacity of the circuit
breaker is used.
It is not possible to restart the air dryer within 3
minutes after shutdown. Wait for 3 m inutes before
restarting.
Resume the operation after resetting the circuit
breaker to ON. If the circuit breaker still trips to OFF,
failure of electrical insulation may have occurred.
Remove the power supply and contact one of our
agents for further instructions.
Air dryer does not
operate and running
lamp does not light
on, even switch is
ON.
Connect the 3-phase power supply
incorrectly. (Applicable to products
using the 3-phase power supply.)
Replace 2 wires (R phase a nd T phase) a mong 3 ea ch
other.
Installation place is poorly
ventilated. Ambient temperature
is too high.
Improve the ventilation s ystem to lower the ambient
temperature.
Reset the protective circuit refe rring to “5-2 How to reset
the thermal rela
y
and high pressu re swi t ch”.
The ventilation grilles are
obstructed by wall or clogged
with dust.
Install the air dryer more than 40cm away from the
wall.
Clean the ventilation grilles onc e a month.
Reset the protective circuit refe rring to “5-2 How to reset
the thermal rela
y
and high pressure sw itch ”.
Temperature of the compressed
air is too high.
Improve the ventilation system around air
compressor or make ambient temperature around air
compressor low to lower the temperature of
discharge from compressor.
Reduce the temperature of the compressed air by
installing an additional after-cooler after air dryer.
Reset the protective circuit refe rring to “5-2 How to reset
the thermal rela
y
and high pressure sw itch ”.
Running lamp
extinguishes and
compressor stops
during operation but
resumes normal
operation
illuminating the
lamp after a
period of time.
The power supply voltage changes
largely .
Install a power supply transfor mer and review the p ower
supply to keep the voltage a dequate val ue.
Allowable fluctuation of the power supply voltage is
+-/10% at max. of the rated voltage.
eset the pr otective c ircuit refe rring to “5- 2 How to res et
the thermal relay and high pressu re switch”.
Installation place is poorly
ventilated. Ambient temperature
is too high.
Improve the ventilation s ystem to lower the ambient
temperature.
The ventilation grilles are
obstructed by wall or clogged
with dust.
Install the air dryer more than 40cm away from the
wall.
Clean the ventilation grilles onc e a month.
Evaporation
thermometer points
the value exceeding
a green range under
the condition where
no hot wind blows out
from the ventilation
port (exhaust port) at
right side face.
(Refrigerating
compressor stops
with light on.)
Temperature of the compressed
air is too high.
・Improve the ventilation system around air
compressor or make ambient temperature around air
compressor low to lower the temperature of
discharge from compressor.
Reduce the temperature of the compressed air by
installing an additional after-cooler after air dryer.
5 - 1
Air Dryer 5 Troubleshooting
Installation place is poorly
ventilated. Ambient temperature
is too high.
Improve the ventilation s ystem to lower the ambient
temperature.
The ventilation grilles are
obstructed by wall or clogged
with dust.
Install the air dryer more than 40c m away from the
wall.
Clean the ventilation grilles onc e a month.
Evaporation
thermometer points the
value exceeding a
green range under the
condition where no hot
wind blows out from the
ventilation port (exhaust
port) at right side face.
Temperature of the compressed
air is too high.
Improve the ventilation system around air
compressor or make ambient temperature around air
compressor low to lower the temperature of
discharge from compressor.
Reduce the temperature of the compressed air by
installing an additional after-cooler after air dryer.
Bypass valve of air dryer is not
fully closed.
Close the valve completely.
Drain is not discharged from auto
drain properly.
Check if the drain pipe has been raisen up or bent.
Check auto drain.
Check auto drain strainer.
Moisture occurs
downstream of the
compressed air
lines.
Confluence of piping with anoth er
unit without air dry er.
Install air dryer on the lin e that does not h ave it.
Separate two lines not to converge.
IN / OUT valve on the air dryer
side is not fully opened.
Open IN/OUT valve thoroughly. Large pressure drop
Filter that is installed separately
in compressed air line is clogged.
Replace the filter element.
(Follow the instruction manual of each individual
device.)
5 - 2
Air Dryer 5 Troubleshooting
5-2 How to reset the thermal relay and high pressure switch
If light goes off during operation and refrigerating compressor stops, the thermal relay or high pressure switch
(for only the IDU55E and IDU75E) to protect the refrigerating compressor starts operating and needs to be
reset manually. For the position of the thermal relay and high pressure switch, refer to page 1-1.
Remove causes to start the thermal relay or high pressure switch referring to “5-1 Cause and countermeasure
for errors”.
Danger
Be sure to turn off the switch with light of the body.
How to reset a thermal relay
①Turn off the switch with lamp of the body.
②Take off the front panel. The thermal relay as shown on
right figure can be found on the power supply terminal base.
＋＋
＋
＋
③Confirm that a green indication does not appear at an
indication window of thermal relay.
If the green indication appears, there are other possible causes
and contact SMC with remaining the power supply on.
④Press the blue reset button and confirm that the green
indication comes to appear at the indication window.
⑤Put back the front panel.
⑥When the switch with lamp is turned on, the product will restart
Indication
window
Reset
button (Blue)
【IDU22E〜55E】
Reset
button (Blue)
【IDU75E】
operation.
How to reset a high pressure switch
①Turn off the switch with lamp of the body.
②Take off the front panel. The high pressure switch can
be found at upper right part of power supply terminal
base.
③Press the red rest button.
④Put back the front panel.
⑤When the switch with lamp is turned on, the product will
Thermal relay
High pressure switch
Rest button
(Red)
High pressure
switch bracket
restart operation.
5 - 3
Air Dryer
6 References
References
6
6-1
Specifications
Model
Specification
IDU22E-30 IDU37E-30 IDU55E-30 IDU75E-30
50Hz 3.9 5.7 8.4 11
Air Flow Rate
m
3
/min (ANR)(Note 1)
60Hz 4.3 6.1 9.8 12.5
Operating PressureMPa
0.7
Inlet Air Temperature ℃
55
Ambient Temperature℃
32
Rated Condition
Pressurized Dew Point ℃
10
Working Fluid
Compressed Air
Inlet Air Temperature ℃
5〜80
Inle t Ai r P res sure MPa
0.15〜1.0
Operating
Range
Ambient Temperature ℃
2〜40 (Relative Humidity of 85% or less)
Phase Three
Power source
(Note 4)
Voltage V AC200(50Hz) / AC200,220(60Hz)
Operating current(Note 2) A
4.2 / 4.8 6.3 / 6.8 8.2 / 9.3
Power consumption(Note 2) W
1100 / 1450 1530 / 2000 2200 / 2850
Electrical
Specification
C ir cu it B re a ke r( N ot e 3 ) A
10
Condenser
Air cooling
Refrigerant
R407C (HFC)
Refrigerant Charge g 470±10 830±10 550±10 745±10
Air IN/OUT Connection
R1
R1･1/2
R2
Drain Connection mm 10
Coating Color
Panel：Urbanwhite 1
Base：Urbangray 2
Weight kg 90 130 160 166
Applicable Compressor(Standard) kW 22 37 55 75
Note1: The data for m3/h (ANR) is referring to the conditions of 20°C, 1atm . pressure & relative humidity of
65%.
Note 2: The value is that of under specified condition.
Note 3: Install GFCI breaker with sensivity of 30mA.
Note 4: When short period power shortage (including instantly recovered shortage) is recovered, it
may take a longer starting period than usual starting or may not start due to the protective
devices.
6 - 1
Air Dryer
6 References
6-2 External Dimentions
IDU22E〜75E
BALL VALVE
AUTO DRAIN
DRAIN TUBE
LENGTH:1m)
(O.D.10,
VENTILATION
SWITCH
EVAPORATION
TERMINAL
PORT SIZE
AIR OUTLET
PORT SIZE
AIR INLET
DRAFT
13φ4xPOWER SUPPLY ENTRY
9～11)[OPPOSITON]
φ
(WIRE
(F)
J
H
C
(G)
B
(D)
E
M
A
P
KL±2 N±1
THERMOMETER
VENTILATION
BLOCK
AIR OUTLET
WITH LAMP
measure：mm
Model
Port
size
A B C D E F G H J K L M N P
IDU22E R1 325 775 1153 93 445 1235 279 353 600 379
IDU37E
R1･1/2
360 1258 64 550 1350 290
46
388
85
680 414
IDU55E 1345 1440
50
IDU75E
R2 470
855
1480
53 530
1575
360 30
70
13
500 75 700 526
6 - 2
Air Dryer
6 References
6-3 Electrical Circuit
IDU22E, 37E-30 (3 phase AC200V) IDU55E-30 (3 phase AC200V)
θθ
θ
PEL1
L3
TB
CM
FM1
P
L2
PRR
THR
THR
MC1
THP1
THS
MC1
ILS
PRR
PRS2
P
THP2
MC2
PSR1
FM1
MC2
IDU75E-30 (3 phase AC200V)
SYMBOL DESCRIPTION
CM Compressor Motor
FM1,FM2 Fan Motor For Condensor
MC1,MC2 Magnetic Contactor
PRS,PRS1 Pressure Switch
PRS2 High Pressure Switch
ILS Switch with Lamp
THR Thermal Relay
TB Terminal Block
θθ
PE
L3
L1
TB
CM
FM2
FM1
P
L2
PRR
PRR
THR
MC1
MC2
THP
THS
THR
MC2
MC1
PRS
C11
ILS
θ
θ
PE
L3
L1
TB
CM
FM1
P
L2
PRR
THR
THR
MC1
THP1
MC1
ILS
PRR
PRS2
P
THP2
FM2
OLR
MC2
MC2
PSR1
6 - 3
Air Dryer
6 References
6-4 Compressed Air and Refrigerant Circuit / Operation Principles
Compressed Air Circuit
Hot and humid air which has come in an air dryer firstly enters air-cooled aftercooler part, and is
cooled. Then, it enters reheating part and exchanges its heat with dehumidified cold air and
becomes cooler. Then, it enters cooling part and gives its heat to cold fleon, which cools and
dehumidifies further, and separates its moisture. Finally, it exchanges its heat with hot and
humid air which comes in the air dryer and it goes out from the air dryer as warm and dry air.
Refrigeran t Ci rcui t
The fluorocarbon charged in the refrigerant circuit is compressed by the compressor and cooled
by the condenser to become liquid. Then, going through the capillary tube, it is decreased the
pressure to reach a low temperature. Passing through the cooler part, it
draws heat from
compressed air and intensely boils. Finally it is inhaled into the compressor again. The capacity
control valve opens to prevent dew drops from freezing when compressed air is cooled enough.
6 - 4
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