Ultrafilter BOREAS DSM SD 1200-60 Specifications
I14 1001 0US
07.03
Operators Instruction
and
Maintenance Manual
BOREAS DSM
SD 1200-60 - SD 3000 W-60
SD 4000-60 - SD 5000 W-60
207.03
Type Code
BOREAS DSM
Model Type-No. Material-no.
SD 1200-60 457A L0457001000
SD 1400-60 458A L0458001000
SD 1600-60 459A L0459001000
SD 2000-60 460A L0460001000
SD 2400-60 461A L0461001000
SD 3000-60 462A L0462001000
SD 4000 W-60 593W L0593001000
SD 5000 W-60 594W L0594001000
SD 1200 W-60 457W L04570010005000
SD 1400 W-60 458W L04580010005000
SD 1600 W-60 459W L04590010005000
SD 2000 W-60 460W L04600010005000
SD 2400 W-60 461W L04610010005000
SD 3000 W-60 462W L04620010005000
SD 4000 A-60 593A L05930010006000
SD 5000 A-60 594A L05940010006000
Construction
Series
Type code
Version
aircooled
Version
watercooled
Version
watercooled
Version
aircooled
3
07.03
Type Code
Part 1 Important user infor-
mation
Part 2 Installation
Part 3 Description
Part 4 Operation
Part 5 Maintenance
Appendix
Page
2
1.1 General Notes 4
1.2 Safety regulations 5
1.3 Handling with refrigerant 6
1.4 First aid 7
1.5 Disposal 7
2.1 Transportation 8
2.2 Requirements on the place
of installation 8
2.3 Installation (Mounting) 8
2.4 Compressed air connection 9
2.5 Electric Connection 10
2.6 Connection condensate drain 10
2.7 Connection cooling water 10
3.1 Designation 11
3.2 Purpose 11
3.3 Unit layout 11
3.4 Nominal power of CA-dryer 12
3.5 Principle of operation 13
3.6 Mode of operation 13
3.7 SAB-processor 15
3.8 Condensate draining 17
4.1 Commissioning 18
4.2 Starting 18
4.3 Operation 18
4.4 Stopping 18
5.1 Maintenance 19
5.2 Trouble shooting 19
Technical data
Table of constancy
Wiring diagrams
Spare parts lists
Additional sheets for options
Table of contents
All safety notes in this operating instruction which may cause harm to personnel
or equipment, when ignored, are marked by the following symbols:
General danger symbol Electrical danger symbol
!
407.03
Part 1 Important User Information
1.1 General notes • This refrigerated compressed air-dryer is referred to
below as CA-dryer.
• The Company does not accept responsibility if safety
regulations are not met during handling, operation,
maintenance and repair, even though these are not
strictly stated in these operating instructions.
• We recommend the notice of these operating instruc-
tions verified by the operating personnel in writing (per-
sonnel file).
• We recommend translation of these operating instruc-
tion into native language of foreign workers.
• The usability and the life cycle of the compressed air-
dryer as well as the avoidance of premature repairs
depends on proper operation, maintenance, care and
competent repair under consideration of these oper-
ating instructions.
• Hints to figures and locations are in brackets, e.g.
(Fig. 5/2)
• Due to our position as suppliers of components we do
not always know the final usage and total range of
products' applications.We constantly improve our prod-
ucts to the latest state of science and technology and
therefore, we assume that our products are free from
defects in the sense of product liability. However, it
cannot be excluded that during faulty operation in criti-
cal areas of application especially at danger to life and
limb of persons involved, additionally safety measures
may be necessary. Therefore, we request the user of
our components / units, to ensure in his own interest,
to inform us about the application of our products in
order to initiate additional safety measures, if neces-
sary.
5
07.03
!
Part 1 Important user Information
Attention!
The operator has to observe the national working-, op-
erating- and safety regulations.Also existing internal fac-
tory regulations must be met.
Maintenance and repair work must only be carried out
by specially trained personnel and, if necessary, under
supervision of a person qualified for this work.
• Protective or safety devices must not be removed,
modified or readjusted.
• During operation of the CA-dryer none of the protec-
tive of safety devices must be removed, modified or
readjusted temporarily or permanently.
• Use proper tools for maintenance and repair work only.
• Use original spare parts only.
• All maintenance and repair works must only be ex-
ecuted at stopped machine, disconnected power sup-
ply and pulled mains plug. Ensure that the CA-dryer
cannot be switched on by mistake.
• Prior to dismounting a part under pressure discon-
nect the CA-dryer from all pressure sources and de-
pressurize the CA-dryer.
• Do not use inflammable solvents for cleaning.
• Keep the environment absolutely clean during main-
tenance and repair works. Keep free of dirt by cover-
ing the parts and free openings with clean cloth, pa-
per or adhesive tape.
• Never weld at the pressure vessel or modify it in any
way.
• Ensure that no tools, loose parts or similar are left in
the system.
1.2 Safety regulations
607.03
• Wear eye protection and protective gloves
• Avoid contact of liquid refrigerants with your skin (frost-
bite).
• Do not inhale refrigerant vapours.
• To avoid higher concentrations, all work rooms must
be ventilated very well. The opening of windows and
doors may not be sufficient, so an exhausting system
must be used directly at the supply point or near the
floor.
• Do not smoke, because fire might decompose the
refrigerant. The resulting substances are toxic and
must not be inhaled.
• Do not have refrigerants escaped during filling or re-
pair work. Cover with tape.
• Leave the room immediately and only enter after the
room has been sufficiently ventilated when refrigerant
concentrations (e.g. pipe line leakages) appear sud-
denly.
• Execute welding and soldering works on refrigerating
systems in well ventilated rooms only. Refrigerants
will be decomposed in flames as well as in electrical
arcs.
• The resulting decomposition products are toxic.
• Before welding and soldering at refrigerating systems,
the refrigerant must be removed.
• A stinking smell points to decomposition of refrigerant
due to overheating:
- leave room immediately
- ventilate room very well.
Part 1 Important user Information
1.3 Handling with
refrigerant
7
07.03
!
Part 1 Important user Information
• Take victim immediately into the fresh air or into a
very well ventilated room.
• Splashes of refrigerant in the eyes must be blown out
with the mouth. Then rinse eyes with plenty of water.
Do not wipe with cloth!
• If the victim does not breathe, perform a mouth-to-
mouth resuscitation or use a respirator until the doc-
tors arrival.
•Call the doctor and inform him that accident has
been caused by refrigerants, for refrigerant type
see identification plate!
• Never leave the victim unattended!
• When disposing of used devices, pay attention to oil
and refrigerant in the hermetically sealed refrigerating
circuit of the CA-dryers. Therefore, before dismount-
ing, these operation media must be disposed by a
special company.
• The used materials are listed on the recycling label
inside the CA-dryer.
Attention!
Do not dispose waste oil into the environment. Do not
mix with household rubbish and do not burn in unauthor-
ized plants.
• The escape of refrigerant into the atmosphere must
be prevented by appropriate measures.
1.4 First aid
1.5 Disposal
807.03
2.1 Transportation
Fig. 1 Mounting of lifting
eyes (M20)
2.2 Requirements on
the place of in-
stallation
2.3 Installation (mount-
ing)
Part 2 Installation
The CA-dryer can be transported for a short time in an
inclined position of up to 45 °. For transportation or lifting
by means of a crane it is possible to use lifting eyes on
the upper side of the frame (fig. 1).
Attention!
When using lifting eyes the load limitations must be ob-
served!
The lifting eyes must only be loaded vertically (use
traverse)!
The CA-dryer may be transported by a fork lift truck or
stacker lift truck.
Transportation has to be carried out in the normal oper-
ating position of the CA-dryer.
At the site of installation, the CA-dryer can be installed
without anchorage or special foundation at the location
desired.
The CA-dryer is designed for an ambient temperature of
100 °F.
Attention!
At different ambient conditions pay attention to the lay-
out data!
To prevent the condensate from freezing the room tem-
perature must not drop below 35 °F.
Install the CA-dryer with access to the front panel to
reach the integrated switches and indicators. Further-
more leave space for service purpose on both sides of
the CA-dryer (fig. 2).
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!
9
07.03
The cooling air for the refrigerant condenser will be sucked
in at the front panel (fig. 2). This area must be kept free
and not be obstructed.
If necessary, the cooling air may be led to the CA-dryer
from outside through wall openings.
The cooling air outlet is positioned at the top of the unit
(fig. 2). Ensure a free air outlet and do not obstruct the
outlet of the cooling air.
If the CA-dryer is connected to an exhaust trunk, an
additional fan must be installed, depending on the di-
mensions of the trunk.
The connection must be executed acc. to marking at the
CA-dryer (fig. 2).
For service purposes the installation of a bypass line is
recommended (additional equipment).
Attention!
Before mounting the CA-dryer, welding residual, rust or
other pollution must be removed from the pipelines to be
connected. If pollution cannot be excluded, proper filter
system must be installed
The compressed air pipes must be installed stress-free.
Expansion joints are recommended in case of vibrations
and pulsations.
Part 2 Installation
2.3.1 Version air cooled
Fig. 2: Installation of the
CA-dryer (air cooled)
2.4 Compressed air con-
nection
min. 32 in
Direction of suc-
tion cooling air
min. 32 in
Outlet
cooling air
ö
ö
CA-outlet
CA-inlet
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10 07.03
!
The CA-dryers are completely equipped and wired.They
merely have to be connected to a power supply.The CA-
dryers are to be protected by slow-blow fuses as defined
in the wiring diagram.
Voltage: acc. to name plate or wiring diagram resp.
The power supply is provided in the switch cabinet.
Attention!
The proper phasing as given in the wiring diagram must
absolutely be fulfilled!
At correct direction of rotation the cooling air is sucked
through the condenser!
The CA-dryer separates water as well as oil from the
compressed air. The water/oil mixture must not be led
into the sewage. Water and oil must be separated by
suitable separators (additional equipment).
Attention!
Route outflow so that persons or objects will not be struck
by condensate (condensate escapes under operating
pressure)!
A minimum operation pressure of 30 psig is required for
safe operation. The condensate drain pipe (fig. 3.2) may
be fixed to the wall with a rising slope of maximum 15 ft.
Thereby the minimum operation pressure increases for
1/2 psi per ft.The collecting pipe (fig. 3/3) should be laid
throughout its whole length at least as the cross-section
of the condensate outlet.
A minimum cooling water differential pressure of 30 psig
is required.The cooling water pressure must not exceed
145 psig.
Attention!
It is essential to adhere to the limit values regarding
cooling water quality described in the appendix. In
case of deviating conditions please contact the
manufacturer. This note applies for all machines with
stainless steel plate condensers.
Part 2 Installation
2.5 Electric connection
2.6 Connection conden-
sate drain
Fig. 3 Connection conden-
sate drain
2.7 Connection cooling
water
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3
2
to treatment
1
This manual suits for next models
3
Table of contents
