Fini RD 185-810 User manual

7425MUM041_EN_2008-06

- EN -

USER’S,

MAINTENANCE MANUAL

RD RD

RD 185

185185

185

810

810810

810

ISSUE

2008

Targhetta Dati

REFRIGERATED AIR DRYER

Fini S.p.a.

Via F.lli Vignoli,3 40069 Zola Predosa – Bologna – ITALY

IT - Dichiara sotto la sua esclusiva responsabilità,che il

prodotto qui di seguito descritto è conforme alle prescrizioni

di sicurezza delle direttive: 98/37/CE, 97/23/CE,

73/23/CEE, 89/336/CEE

FI - vakuuttaa, että seuraavassa esitelty tuote vastaa alla

lueteltujen direktiivien turvallisuusvaatimuksia:

98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC

EN - Declares under its sole responsibility that the

product described below complies with the safety

requirements of directives:

98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC

EL - ∆ηλώνει µε αποκλειστικά δική του ευθύνη ότι το προϊόν

που περιγράφεται παρακάτω ανταποκρίνεται στις

προδιαγραφές ασφαλείας των οδηγιών: 98/37/EE, 97/23/EE,

73/23/EEC, 89/336/EEC

FR - Déclare sous son entière responsabilité que le produit

décrit ci-après est conforme aux prescriptions de sécurité

des directives :

98/37/CE, 97/23/CE, 73/23/CEE, 89/336/CEE

PL - oświadcza pod wyłącznąwłasnąodpowiedzialnością, e

opisany poni ej wyrób odpowiada wymaganiom dotyczącym

bezpieczeństwa zawartym w Dyrektywach 98/37/EC,

97/23/EC, 73/23/EC, 89/336/EC

DE - erklärt unter ihrer alleinigen Verantwortung, dass das

in Folge beschriebene Produkt den Sicherheitsvorschriften

der folgenden Richtlinien entspricht:

98/37/EG, 97/23/EG, 73/23/EWG, 89/336/EWG

CS - prohlašuje s plnou odpovědností, že uvedený výrobek

vyhovuje bezpečnostním požadavkům směrnic:

98/37/ЕS, 97/23/ЕS,73/23/ЕHS, 89/336/ЕHS

ES - Declara bajo su exclusiva responsabilidad que el

producto descrito a continuación responde a las

prescripciones de seguridad de las directivas :

98/37/CE, 97/23/CE, 73/23/CEE, 89/336/CEE

SK - Zodpovedne vyhlásuje, že uvedený výrobok zodpovedá

bezpečnostným požiadavkám smerníc:

98/37/ES, 97/23/ES, 73/23/EES, 89/336/EES

NE - Verklaart onder zijn eigen verantwoordelijkheid dat het

hieronder beschreven product in overeenstemming is met

de veiligheidsvoorschriften van de richtlijnen:

98/37/EG, 97/23/EG, 73/23/EEG, 89/336/EEG

HU - teljes felelısségének tudatában tanúsítja, hogy az

alábbiakban jellemzett termék a 98/37/ЕС, 97/23/ЕС,

73/23/ЕЭС és 89/336/ЕЭС sz. irányelvek biztonsági

követelményeinek megfelel.

N0 -

Erklærer under eget ansvar at produktet her beskrevet

er i overensstemmelse med sikkerhetsforskriftene i

direktivene:

98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC

LT - Su visa atsakomybe pareiškia, kad žemiau aprašytas

gaminys atitinka direktyvų98/37/ES, 97/23/ES, 73/23/EES ir

89/336/EES saugumo reikalavimams.

SV - Försäkrar under eget ansvar att den produkt som

beskrivs följande är i överensstämmelse med

säkerhetsföreskrifterna i EU-direktiv:

98/37/EG, 97/23/EG, 73/23/EEG, 89/336/EEG

LV - Apliecina, uzĦemoties pilnu atbildību, ka zemāk

aprakstītais produkts atbilst direktīvu 98/37/ЕС, 97/23/ЕС,

73/23/ЕEСun 89/336/ЕEСdrošības noteikumiem.

DA - Forsikrer på eget ansvar, at produktet, der beskrives

nedenfor, er i overensstemmelse med

sikkerhedsforskrifterne i direktiverne:

98/37/EC, 97/23/EC, 73/23/EEC, 89/336/EEC

ET - Deklareerib omal vastutusel, et allpool kirjeldatud toode

vastab direktiivide 98/37/EÜ, 97/23/EÜ, 73/23/EMÜ ja

89/336/EMÜ ohutusnõuetele.

PT - Declara sob a sua exclusiva responsabilidade que o

produto descrito a seguir está em conformidade com as

prescrições de segurança das directivas:

98/37/CE, 97/23/CE, 73/23/CEE, 89/336/CEE

SL - Na lastno odgovornost izjavlja, da je spodaj opisani

izdelek v skladu z varnostnimi predpisi, ki veljajo za stroje

98/37/EU, 97/23/EU, 73/23/EEU in 89/336/EEU.

Amministratore delegato Toimitusjohtaja

CEO Dieuqu/nwn Su/mbouloj

PdG Dyrektor Zarządzający

Geschäftsführer Generální ředitel

Administrador delegado Generálny riaditeľ

President-directeur Vezérigazgató

Daglig leder Generalinis direktorius

Verkställande direktör Āenerāldirektor

Administrerende direktør Pea direktor

Administrador delegado Generalni direktor

Enrico Santoro

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

Dear Customer,

thank you for choosing our product. In order to get the best performances out of this product, please read

this manual carefully.

To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and

strictly follow the instructions contained in this manual.

Note, these instructions are in addition to the safety rules that apply in the country where the dryer is

installed. Before packing for shipment each RD series refrigerated air dryer undergoes a rigorous test to

ensure the absence of any manufacturing faults and to demonstrate that the device can perform all the

functions for which it has been designed.

Once the dryer has been properly installed according to the instructions in this manual, it will be ready for

use without any further adjustment. The operation is fully automatic, and the maintenance is limited to few

controls and some cleaning operations, as detailed in the following chapters.

This manual must be maintained available in any moment for future references and it has to be intended as

inherent part of the relevant dryer.

Due to the continuous technical evolution, we reserve the right to introduce any necessary change without

giving previous notice.

Should you experience any trouble, or for further information, please do not hesitate to contact us.

DATA NAMEPLATE

Model



Serial No.



Code



Nominal Flow Rate



Max Air Pressure



Max Inlet Air Temp.



Ambient Temp.



Refrigerant (Type and qty)



Refrig. Design Pres. HP/LP



Electric Supply



Electric Nominal Power



Fuse Max.



Manufactured



The data nameplate is located on

the back of the dryer and shows

all the primary data of the

machine. Upon installation, fill in

the table on the previous page

with all the data shown on the

data nameplate. This data should

always be referred to when

calling the manufacturer or

distributor.

The removal or alteration of the

data nameplate will void the

warranty rights.

Model

Serial No.

Nominal Flow Rate

Max Air Pressure

Max Inlet Air Temp.

Ambient Temp.

Refrigerant

Refrig. Design Pres.

HP/LP

Electric Supply

Electric Nominal Power

Fuse Max.

Manufactured

Nl/min

barg

°C

type/kg

barg

ph/V/Hz

W/A

www.finicompressors.com

BOLOGNA - ITALY

40069 - ZOLA PREDOSA

FINI S.p.A.

Fini

COMPRESSORS

WARRANTY CONDITIONS

For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty

covers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and

restaurant expenses of our engineer.

The warranty doesn’t cover any responsibility for direct or indirect damages to persons, animals or

equipment caused by improper usage or maintenance, and it’s limited to manufacturing faults only.

The right to warranty repairs is subordinated to the strict compliance with the installation, use and

maintenance instructions contained in this manual.

The warranty will be immediately voided in case of even small changes or alterations to the dryer. To

require repairs during the warranty period, the data reported on the identification plate must be notified.

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

1. SAFETY RULES

1.1 Definition of the Conventional Signs Used in This Manual

1.2 Warnings

1.3 Proper Use of the Dryer

1.4 Instructions for the use of pressure equipment according to PED Directive 97/23/EC

2. INSTALLATION

2.1 Transport

2.2 Storage

2.3 Installation site

2.4 Installation layout

2.5 Correction factors

2.6 Connection to the Compressed Air System

2.7 Connection to the Cooling Water Network (Water-Cooled)

2.8 Electrical connections

2.9 Condensate Drain

3. START UP

3.1 Preliminary Operations

3.2 First Start Up

3.3 Start-up and shut down

4. TECHNICAL CHARACTERISTICS

4.1 Technical Specifications RD 185-810 /AC (Air-Cooled)

4.2 Technical Specifications RD 185-810 /WC (Water-Cooled)

5. TECHNICAL DESCRIPTION

5.1 Control panel

5.2 Operation

5.3 Flow Diagram (Air-Cooled)

5.4 Flow Diagram (Water-Cooled)

5.5 Refrigerating compressor

5.6 Condenser (Air-Cooled)

5.7 Condenser (Water-Cooled)

5.8 Condenser water regulating valve (Water-Cooled)

5.9 Filter Drier

5.10 Capillary tube

5.11 Alu-Dry Module

5.12 Hot gas by-pass valve

5.13 Refrigerant Pressure Switches P

-P

5.14 Safety thermo-switch Ts

5.15 Compressor crankcase heater

5.16 DMC14 Electronic Instrument

5.17 DMC20 Electronic Instrument

5.18 Electronic level drain

6. MAINTENANCE, TROUBLESHOOTING AND DISMANTLING

6.1 Controls and Maintenance

6.2 Troubleshooting

6.3 Maintenance operation on the refrigeration circuit.

6.4 Dismantling of the Dryer

7. LIST OF ATTACHMENTS

7.1 Dryers Dimensions

7.2 Exploded View

7.3 Electrical Diagram

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

1.1 DEFINITION OF THE CONVENTIONAL SIGNS USED IN THIS MANUAL

Carefully read instruction manual before attempting any service or maintenance procedures on the

dryer.

Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not

followed properly.

Electrical hazard. Warning message indicates practices or procedures that could result in personal

injury or fatality if not followed correctly.

Danger hazard. Part or system under pressure.

Danger hazard. High temperature conditions exist during operation of system. Avoid contact until

system or component has dissipated heat.

Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may

result if precautions are not followed.

Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptable

means in cases of fire.

Danger hazard. Do not operate equipment with panels removed.

Maintenance or control operation to be performed by qualified personnel only 1.

ARIA

AIR

LUFT

AIR

Compressed air inlet connection point.

ARIA

AIR

LUFT

AIR

Compressed air outlet connection point.

Condensate drain connection point.

Cooling water inlet connection point (Water-Cooled).

Cooling water outlet connection point (Water-Cooled).

Operations which can be worked out by the operator of the machine, if qualified

NOTE : Text that specifies items of note to be taken into account does not involve safety precautions.

In designing this unit a lot of care has been devoted to the environment protection:

•CFC free refrigerants

•CFC free insulation parts

•Energy saving design

•Limited acoustic emission

•Dryer and relevant packaging composed of recyclable materials

Not to spoil our commitment, the user should follow the few ecological suggestions marked with

this sign.

1Experienced and trained personnel acquainted with the relevant rules and laws, capable to perform the needed activities and to identify and

avoid possible dangerous situations while handling, installing, using and servicing the machine.

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

1.2 WARNINGS

Compressed air is a highly hazardous energy source. Never work on the dryer with parts under

pressure. Never point the compressed air or the condensate drain jet towards anybody. The user is

responsible for the installation of the dryer, which has to be executed on the basis of the instructions

given in the “Installation” chapter. Otherwise, the warranty will be voided and dangerous situations

for the personnel and/or damages to the machine could occur.

Only qualified personnel are authorized to service electrically powered devices. Before attempting

maintenance, the following conditions must be satisfied:

•Ensure that main power is off, machine is locked out, tagged for service and power cannot be

restored during service operations.

•Ensure that valves are shut and the air circuit is at atmospheric pressure. De-pressurize the dryer.

These refrigeration air dryers contain R134a or R404A HFC type refrigerant fluid. Refer to the

specific paragraph for maintenance operation on the refrigeration circuit – maintenance operation

on the refrigeration circuit.

Warranty does not apply to any unit damaged by accident, modification, misuse, negligence or

misapplication. Unauthorized alterations will immediately void the warranty.

In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of

electrical fire.

1.3 PROPER USE OF THE DRYER

This dryer has been designed, manufactured and tested for the purpose of separating the humidity normally

contained in compressed air. Any other use has to be considered improper.

The Manufacturer will not be responsible for any problem arising from improper use; the user will bear

responsibility for any resulting damage.

Moreover, the correct use requires the adherence to the installation instructions, specifically:

•Voltage and frequency of the main power.

•Pressure, temperature and flow-rate of the inlet air.

•Pressure, temperature and cooling water capacity (Water-Cooled).

•Ambient temperature.

This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to the

plant in compliance with the instructions given in the following chapters.

The purpose of the machine is the separation of water and eventual oil particles present in

compressed air. The dried air cannot be used for breathing purposes or for operations leading to

direct contact with foodstuff.

This dryer is not suitable for the treatment of dirty air or of air containing solid particles.

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

1.4 INSTRUCTIONS FOR THE USE OF PRESSURE EQUIPMENT ACCORDING TO

PED DIRECTIVE 97/23/EC

To ensure the safe operation of pressure equipments, the user must conform strictly to the above directive

and the following :

1. The equipment must only be operated within the temperature and pressure limits stated on the

manufacturer’s data nameplate.

2. Welding on heat-exchanger is not recommended.

3. The equipment must not be stored in badly ventilated spaces, near a heat source or inflammable

substances.

4. Vibration must be eliminated from the equipment to prevent fatigue failure.

5. Automatic condensate drains should be checked for operation every day to prevent a build up of

condensate in the pressure equipment.

6. The maximum working pressure stated on the manufacturer’s data nameplate must not be exceeded.

Prior to use, the user must fit safety / pressure relief devices.

7. All documentation supplied with the equipment (manual, declaration of conformity etc.) must be kept for

future reference.

8. Do not apply weights or external loads on the vessel or its connecting piping.

Users of the equipment must comply with all local and national pressure equipment

legislation in the country of installation.

2.1 TRANSPORT

Check for visible loss or damage, if no visible damage is found place the unit near to the installation point

and unpack the contents.

•Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid

on its side or if placed upside down.

•Store machine in a clean, dry environment, do not expose to severe weather environments.

•Handle with care. Heavy blows could cause irreparable damage.

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

2.2 STORAGE

SCC0001

Even when packaged, keep the machine

protected from severity of the weather.

Keep the dryer in vertical position, also when

stored. Turning it upside down some parts could

be irreparably damaged.

If not in use, the dryer can be stored in its

packaging in a dust free and protected site at a

maximum temperature of 45 °C, and a specific

humidity not exceeding 90%. Should the

stocking time exceed 12 months, please contact

the manufacturer.

The packaging materials are recyclable. Dispose of material in compliance with the rules

and regulations in force in the destination country.

2.3 INSTALLATION SITE

Failure to install dryer in the proper ambient conditions will affect the dryer’s ability to condense

refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and

performance, overheated condenser fan motors, electrical component failure and dryer failure due

to the following: compressor loss, fan motor failure and electrical component failure. Failures of

this type will affect warranty considerations.

Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous

gasses; steam heat, areas of high ambient conditions or extreme dust and dirt.

In case of fire, use an approved fire

extinguisher, water is not an acceptable

means in cases of fire.

Minimal installation requirements :

•Select a clean dry area, free from dust, and

protected from atmospheric disturbances.

•The supporting area must be smooth, horizontal

and able to hold the weight of the dryer.

•Minimum ambient temperature +1 °C.

•Maximum ambient temperature +45°C.

•Allow at least a clearance of 1 m on each side of

the dryer (2 m RD 480-810 dryers, Air-Cooled

models), for proper ventilation and to facilitate

eventual maintenance operations.

The dryer doesn't require to be fixed to the

supporting surface. The dryer needs to be fixed to

the supporting surface only with particular installation

procedures (dryer on brackets, hanging units, etc.)

(480-810)

LGT0003

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

2.4 INSTALLATION LAYOUT

Air compressor

Aftercooler

Condensate separator

Pre-Filter (min. 5 micron)

By-pass group

Dryer

Compressed air tank

Final filter

Condensate drain

3 4

OUT

- A -

- B -

3 4

OUT

In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend the

additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the heat

exchanger.

Type A installation is suggested when the compressor operates at reduced intermittence and the total

consumption equals the compressor flow rate.

Type B installation is suggested when the air consumption can consistently change with peak values highly

exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensate

eventual instantaneous demanding conditions (peak air consumption).

40069 Zola Predosa (BO) - ITALY

[email protected]

- EN -

2.5 CORRECTION FACTORS

Correction factor for operating pressure changes :

Inlet air pressure barg 4 5 7 8 10 12 14

Factor (F1) 0.77 0.85 1.00 1.06 1.15 1.21 1.25

Correction factor for ambient temperature changes (Air-Cooled):

Ambient temperature ºC < 25 30 35 40 45

Factor (F2) 1.00 0.98 0.95 0.90 0.80

Correction factor for inlet air temperature changes:

Air temperature ºC < 30 35 40 45 50 55

Factor (F3) 1.20 1.00 0.85 0.75 0.61 0.49

Correction factor for DewPoint changes:

DewPoint ºC 3 5 7 10

Factor (F4) 1.00 1.09 1.18 1.38

How to find the air flow capacity: How to select a suitable dryer for a given duty:

Air flow

capacity =XFactor

(F1)

Factor

(F2)

XFactor

(F3)

X X Factor

(F4)

Nominal

duty

= ÷

Factor

(F1)

Factor

(F2)

Factor

(F3)

÷ ÷

Factor

(F4)

Design

air flow

Std. air

flow rate

Minimum

Example: Example:

An RD 185 has a nominal duty of 18500

l/min. What is the maximum allowable flow

through the dryer under the following operating

conditions:

−Inlet air pressure = 8 barg

−Ambient temperature = 45°C

−Inlet air temperature = 50°C

−Pressure DewPoint = 10°C

Each item of data has a corresponding numerical

factor which multiplied by the design air flow is as

follows:

The procedure here is to list the operating

conditions and then to locate the

corresponding numerical factors:

−Design air flow = 16200 l/min

−Inlet air pressure = 8 barg

−Ambient temperature = 45°C

−Inlet air temperature = 50°C

−Pressure DewPoint = 10°C

In order to select the correct dryer model the

required flow rate is to be divided by the correction

factors relating to above mentioned parameters:

= 13206 l/min →This is the maximum

flow rate that the dryer can accept under these

operating conditions.

= 22693 l/min →Therefore the model

suitable for the conditions above is RD 250 (25000

l/min - nominal duty).

1.06

18500

0.80

1.38

0.61

capacity

Air flow

1.06

16200

0.80

1.38

0.61

flow rate

Minimum

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