instruction manual ked150

Non-Cycling Refrigerated Compressed Air Dryers

KED-A

Operation & Maintenance Manual

Models : 150 - 200 - 250 – 300 400 - 500 - 600 - 700 - 750

(According to PED 97/23/CE)

-GB- TABLE OF CONTENTS 1.0 GENERAL INFORMATION 3 1.1 How to use this manual 1.2 Symbols 1.3 Warranty 1.4 Standard equipment 1.5 Description 1.6 Use

2.0 SAFETY INFORMATION 4 2.1 General safety instructions 2.2 Equipment nameplate values 2.3 Information about remaining risks of the equipment

3.0 MACHINE UNPACKING AND HANDLING 6 3.1 Unpacking and handling 3.2 Package disposal 3.3 Returned equipment

4.0 SET UP 6 4.1 Machine positioning 4.2 Installation 4.3 Start - up

5.0 MAINTENANCE 7 5.1 Weekly 5.2 Monthly 5.3 After 6 months

6.0 CONTROL PANEL 7 6.1.1 Icons display visualization 6.1.2 Keys function 6.1.3 Display visualization 6.1.4 Parameter programming 6.1.5 Alarms visualization 6.2 Before start up 6.3 Start up

7.0 TROUBLESHOOTING 16

8.0 ELECTRONIC CONDENSATE DRAIN 17

9.0 DRYER’S DISPOSAL 17

10.0 SAFETY REQUIREMENTS 17

11.0 DAILY REGISTER 17

12.0 EQUIPMENT DATA 18

13.0 ELECTRIC WIRING DIAGRAMS 20

14.0 REFRIGERANT CIRCUIT DIAGRAMS 27

15.0 INSTALLATION LAYOUT 30

16.0 BASIC SPARE PART KED150-750A 31

17.0 KED150-750A ASSEMBLY 33

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- GB -

1.0 GENERAL

1.1 How to use this manual All features of this machine, all information on safety, machine installation, operation, adjusting and maintenance are described in this manual. This manual is integral part of this machine and should absolutely be read and understood by any person operating and maintaining this machine. Should this machine be sold again, this manual should be given to the new machine owner. Should this manual be lost, please ask for a new copy to your authorized dealer.

1.2 Symbols Symbols included in the below frames refer to safety instructions to be followed during the machine operation and maintenance. The other symbols refer to machine features and are either on the machine or on explanation screens.

Air inlet

Condensate drain outlet

Air outlet

Electric shock danger!

1.3 Warranty This product is supplied after being regularly tested. It is guaranteed for 12 months from the delivery date. This warranty applies provided the customer has complied with contract and administrative rules and the machine is installed and used under the instructions of this manual. The manufacturer agrees in fixing or replacing all parts proved to be worn and faulty at the factory free of charge. Final decision is left to our “authorized service” technicians. Labor costs are not covered by this warranty and the customer will therefore be charged with the relative amount. Any liability for direct or indirect damages caused to people due to misuse and improper maintenance of this product is not included in this warranty. It is limited to operation and manufacture defects. All parts subject to wear due to their specific use are not covered by this warranty. All transport, on-site, disassembly and reassembly costs due to our technician’s intervention are not covered by this warranty and the customer will therefore be charged with the relative amount if defects are not under our liability.

1.4 Standard equipment

Instruction and maintenance manual.

Wiring diagram.

Condensate drain unit (where not already fitted).

1.5 Description The frigorific circuit dryers in this serie have been developed in order to eliminate without further expenses and overall dimensions all humidity contained in compressed air by lowering its temperature at about +3°C. These dryers take advantage of frigorific circuit’s features by utilizing freon gas. The air which is obtained is without humidity, while all condensate that accumulated in the condensate separator is discharged on the outside through an electronic programmable discharger, in order to avoid air consumption. The installation’s overload, within the maximum use’s limits, causes a worsening of dryer’s performances (higher dew point), but doesn’t prejudice its safety. The electrical circuit has an IP42 protection degree.

ATTENTION: the machine is equipped with a power supply - sectioning device (1S1).

The Authorized Installer must care for the dryer’s correct connection to the power system, according

to the EN60204 regulation, chapt. 5.3.2. A start and stop device (ON/OFF) allows the dryer to be turned on and it permits its normal working. An amperometrical and a thermometrical protection (an automatic re-establishment on the compressor) prevent from electric and frigorific circuit’s damages.

1.6 Use The use of a dryer is recommended in the treatment of compressed air if a low content of impurities and a high drying is required, such as in the pharmaceutical and food industry or in medical applications.

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2.0 SAFETY INFORMATION

2.1 General safety instruction

SAFETY INFORMATION

This dryer has been designed and manufactured in accordance to the European safety directive

98/37/CE Machine Directive

73/23/CEE Low tension Directive

89/336/CEE Electromagnetical compatibility Directive

97/23/CE PED Directive

According to PED Directive, this plant is supplied with safety devices on the frigorific circuit, calibrated according to the under mentioned

specifications.

The working life of such equipments is expected between 10 and 20 years.

Any installation, use and maintenance operations must be done according to the instructions contained in this manual and in accordance

to the national rules.

Any cleaning/maintenance operation which needs access to the dryer must be carried out by qualified and export personnel who must be

aware of all necessary precautions.

The machine has been designed and manufactured to be used in conformity to the following specifications.

In case of different use of the machine or not in conformity to this manual, the Manufacturer can’t be accused of any responsibility.

2.2 Equipment nameplate values (Nameplate values extracted from Calculation data sheet)

Fluid Circuit Side Press. Max. Amm. Safety devices set Work. Temp Design Temp

MAWP

"PS" (bar rel) (bar rel) (°C) (°C)

Freon HFC (R507, R407c, R134a, R404a) R134a R407c

R404a, R507

R134a R407c R407c

R404a, R507

Low press. -LP 20 20 18* 18* 18* min -10° min -15°

High Press. -HP 28 30,8 18* 27,9* 29* max +100° max +100°

Compressed air (Dryers) Compress. Air Side min 0

(Customer care)

min 0° min 0°

max. 12 (aluminium) max +45° max +45°

max. 16 (copper)

Refrigerant Liquid (Chiller) Liquid side min 0 (Customer care)

min -10° min -15°

max 8 max +45° max. +45°

Ambient air Ventilation side Atm. ( Not Appl.) min 5° min -15°

max +40° max. +40°

* - Safety Pressure switch Cat IV PED, Manual reset

Welding Joints Coefficient Z 0,7 (Table 5.6-1)

Tickness allowance C 0,1 mm ( Per rame - For copper )

(Not required for surfaces in contact with freon - EN 14276-1) C 1 mm ( Per acciaio - For carbon steel )

Ammissibile pressure drop compressed air side P max. 4 bar

Thermodynamic design temperatures (air-air heat-exchanger)

Hot side inlet temperature Tci 45 °C

Hot side outlet temperature Tcu 25 °C

Cold side inlet temperature Tfi 0 °C

Cold side outlet temperature Tfu 25 °C

Thermodynamic design temperatures (evaporator)

Hot side inlet temperature Tci 25 °C

Hot side outlet temperature Tcu 0 °C

Cold side inlet temperature Tfi -21 °C

Cold side outlet temperature Tfu 0 °C

Manufacturer design code 717.0012.01.00 Rev.02 Essential Safety Requirements ON10.0010.02 Rev.01 Manufacturer Working Procedure PO 08.2 Rev.01 Assembly classification according PED 97/23 Cat. II Evaluation Module according PED 97/23 Mod. A1 PED Notified Body number 0474

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WHAT SHOULD BE DONE:

Be familiar with all controls.

Respect all working limits indicated in this Manual

Before performing any maintenance be sure that the dryer is isolated from the compressed air network (inlet and outlet cut-off valves

closed) and that internal pressure has been released.

Before removing the protection panels disconnect electrical power and allow 15 minutes for the inner parts to cool down.

Before removing the cooling fan protection grid be sure to disconnect the electrical power.

Be sure that all protection panels are properly attached during the operation and after any maintenance operation.

Be sure not to operate the unit in the presence of flammable fumes or vapours which might cause either explosion or fire risk.

WHAT SHOULD NEVER BE DONE:

No maintenance operation under pressure except Chapt. 5 can be carried out by any personnel without the Manufacturer’s written

approval.

Do not modify the pressure equipment, including the uncalibration of control and safety devices.

Never place flammable objects near the dryer.

Never use the dryer if the power cable is faulty or the connection is not safe.

Never allow anyone to operate the dryer without giving him/her proper instructions.

Never make any alteration to safety parts.

Never strike or use excessive force on internal parts.

Never touch any part of the cooling circuit when the machine is running. They are very hot!

Never drain the condensate directly into the sewage system.

2.3 Information about remaining risks of the equipment

Fire: This equipment, in accordance to EN-378-2, isn’t supplied with freon drain safety valve. In case of fire it is preferable to use fire extinguishers or extinction systems basically composed of powder or foam or carbon dioxide: it is possible to cool the equipment thanks to nebulized water. Avoid the massive use of water because, in case of freon gas leak, the chemical reaction can cause caustic effects, even if small. In any case it is necessary to cool down the ambient and/or the equipment’s temperature and before any intervention wait unti l the temperature has been reduced. Therefore it is preferable to insert this equipment into the Fire Prevention and Factory Safety Plan. Arrange adequate actions capable to prevent and fight the possible risk.

Dispersion of freon gas in the ambient: the refrigerant means is toxic only if inhaled at high concentration: it is necessary to provide an adequate ventilation in the room where the equipment is installed. In any case check the scheme showing the values and the risk sentences.

Excessive pressure on the compressed air side: this equipment isn’t supplied with safety devices on the compressed air side. The safety devices on the compressed air side must be carried out by the installer. Such devices will have to be carried out according to the applicable National Norms and to the limits mentioned in this Manual.

Ozone layer deterioration: The adoption of HFC freon reduce to the minimum ozone layer deterioration and greenhouse effect.

EN378-1:2000

FREON GROUP

L safety COMPOSITION

AUTO IGNITION

TEMPERATURE (°C) GWP ODP

R-134a 1 A1 1,1,1,2-tetrafluoroethane 743 1300 0

R-507 1 A1 R-125/R-143 a (50/50) - 3800 0

R-404a 1 A1 R-125/143a/134 a (44/52/4) 728 3800 0

R-407c 1 A1 R-32/125/134 a (23/25/52) 704 1600 0

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3.0 MACHINE UNPACKING AND HANDLING

3.1 Unpacking and Handling When supplied the dryer is packed into a suitable cardboard box to be always handled in an upright position using a means with a suitable lifting power (see technical data). After cutting straps (always wear safety gloves and eye protection and cut either with scissors or cutting nippers), removing the carton from the top and moving the dryer from the wooden pallet to the chosen position.

3.2 Package Disposal It is recommend to keep the package so that it can be used again in case the dryer should be moved. Keep it for the warranty period at least. If needed, it will be easier and safer to pack it and send it to the service center. If you decide not to keep the package, it should be delivered to the authorized organization for its disposal.

3.3 Returned Equipment Repack the dryer in its original carton or with one of the same dimensions.

The dryer must be kept vertical and packed as supplied from the manufacturer.

Do not transport the dryer without proper packing, shipment damage remains the responsibility of the sender. Materials returned without proper packing and authorization documents will not be accepted.

4.0 SET-UP

4.1 Machine positioning The dryer should be placed in a suitable room with the following features:

fully flat floor;

protected against weather conditions and direct sun light;

properly ventilated, so to keep temperature within 5°C and 40°C even when the dryer is running. It should also be large enough so to have at least one free meter in front of the dryer for a proper machine cooling;

properly ventilated since the dryer heats the room up while working.

4.2 Installation

Air by-pass piping is recommended to allow uninterrupted air service during instances of maintenance of repair.

Prior to installation check to insure that the compressed air piping is free of debris or other contaminants.

Connect the dryer to the compressed air line in accordance with one of the diagrams shown in section 11 and per unit labeling.

Always use a back-up wrench to prevent damage to the connections during piping of the air inlet and outlet.

Make sure that line power agrees with the unit data plate and the service complies with local electrical codes.

Always include a fused safety switch in the line power supply (refer to data plate amperage for proper selection).

A particulate filter is recommended at the air inlet to avoid any deposit of solid particles into the dryer.

Position the dryer so that all controls can be easily read and so that all maintenance operations are easily performed.

Attach the fittings & tubing (supplied) to the reservoir overflow connections located on the rear panel of the dryer.

Connect the condensate drain tube in compliance with local regulations. The condensate is a pollutant and cannot be drained directly into the sewage system. A water-oil separator of suitable capacity is recommended.

4.3 Start-up

Make sure that intake and outtake valves are closed, switch on the devices (1S1) and (ON/OFF) and check that the pilot light on the control panel.

Allow some minutes for the dryer to run at full speed, i.e. until the displayed value on the temperature display is into the field of good operation (about 3°C).

Now open the outlet air valve and then open gradually the intake air valve. In this way, the plant is gradually pressurized.

If the plant is overloaded over the max. use limits (see technical data), its performance will be remarkably lower but safety will not be in danger.

Before disconnecting the dryer from electrical power supply, use ON/OFF key to stop the dryer.

Otherwise wait 10 minutes before switching the dryer on again, in order to allow freon pression re-

balance.

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5.0 MAINTENANCE

5.1 Weekly Check visually if the condensate is properly drained.

5.2 Monthly Clean prefilter to remove any possible dirt on the inner filtering element. Perform the following after stopping the compressed air blow by closing the intake and outtake cocks.

5.3 After 6 months Unplug the machine before performing the following. According to the room temperature quality and when summertime begins, clean the condenser with an air jet and clean the finned unit to remove possible scales or deposits the might decrease its performance. Check that the compressor consumption values fall within the range mentioned on the machine plate (see compressor product label).

6. CONTROL PANEL

General Advices

Please read this manual before using

This manual is part of the product and should be kept near the instrument for easy and quick reference.

The instrument shall not be used for purposes different from those described hereunder. It cannot be used as a safety device.

Check the application limits before proceeding.

Safety Precaution

Check the supply voltage is correct before connecting the instrument.

Do not expose to water or moisture: use the controller only within the operating limits avoiding sudden temperature changes with high atmospheric humidity to prevent formation of condensation

Warning: disconnect all electrical connections before any kind of maintenance.

Fit the probe where it is not accessible by the End User. The instrument must not be opened.

In case of failure or faulty operation send the instrument back to the distributor or to “Dixell s.r.l.” with a detailed desc ription of the fault.

Consider the maximum current which can be applied to each relay (see Technical Data).

Ensure that the wires for probes, loads and the power supply are separated and far enough from each other, without crossing or intertwining.

In case of applications in industrial environments, the use of mains filters (our mod. FT1) in parallel with inductive loads could be useful.

Dixell Srl reserves the right to change the composition of its products, even without notice, ensuring the same and unchanged functionality.

PIC. 1

Start / Stop Air Dryer

Press key for 3 seconds:

the unit starts or stops the Air Dryer.

The icon or flashes for 3 seconds when the controller is waiting to turn on/off.

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6.1.1 ICON DISPLAY VISUALIZATION

Icon Meaning °C -°F

bar-PSI ON when the display visualizes a temperature or a pressure

On flashing in case of alarm

On if the Energy Saving, dynamic set-point or function for units without water storage tank are active. OFF if a function above is enabled but not active.

On during menù visualization

On flashing during drain delay time. On during drain

On if a compressor is on. On flashing during the delay time for compressor activation.

On if open collector output is active

On in case of Low pressure alarm or High pressure alarm

6.1.2KEYS FUNCTION

1. Push to enter in the Menu 2. Push and hold (about 3 seconds) to set the clock

1. Push to visualize the set point. 2. Push and hold to modify the set point 3. Push during parameter programming:

- to enter in parameter modification - to confirm the changes of the parameter

5. Menù AlrM: push to reset the alarms

1. Push and release to visualize all the temperatures 2. In programming mode it scrolls the parameter list 3. In programming mode increases the value of the

parameters.

1. Push and release to visualize all the temperatures 2. In programming mode it scrolls the parameter list 3. In programming mode decreases the value of the

parameters

1. Push 3 seconds to activate the drain valve

1. Push and old to switch on/off the machine

+ Push and hold to enter on the parameters programming

+ 1. Push to exit to the programming parameters

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6.1.3 Display visualization

Upper digits (red color): configurable by parameter CF36 (PB1, PB2, PB4, Set-point (parameter value)*, working set-point (real set-point modified from dinamic set-point,

Lower digits (yellow color): configurable by parameter CF43 (PB1, PB2, PB3, PB4, Set-point (parameter value)*, working set-point (real set-point modified from dinamic set-point,

6.1.4 Parameters Programming

“Pr1” Programming Level (User Level)

How to access the “Pr1” User Level:

1) Push + key for some seconds; the upper display shows “ALL” (first family of parameters).

and icons are flashing.

2) Using and arrows scroll the other family labels.

3) Push to enter and see all the parameter belonging to that family. The display shows the first parameter label and its value.

Scroll the parameter list with and arrows

“Pr2” Programming Level (Factory Level)

“Pr2” parameters level is accessible through password:

1. Enter the “Pr1” level

2. Search parameter “Pr2”; “PAS” label appears on the upper side.

3. Push “SET”: the lower display shows “Pas” and the upper display shows “0” flashing.

4. Set the password using and keys.

5. Push key to confirm the value.

1. Parameter Table

Regulation Parameters :

Parameter Description Unit STANDARD

VALUE

ST01 Summer Set point °C / °F -2

ST02 Summer differential °C /°F 6.0

ST05 Minimum set point limit for ST01 (summer) °C /°F -2.0

ST06 Maximum set point limit for ST01 (summer) °C /°F 1.0

ST09 Regulation band °C /°F 4.0

Configuration Parameters :


VALUE

CF03 Regulation probe 0= Pb1 regulation (Dew point)

0

CF04 Pb1 configuration 1= NTC temperature of Dew point

1

CF05 Pb2 configuration 1= NTC temperature of Ambient

1

CF06 Pb3 configuration 1= NTC temperature of Air inlet

1

CF07

Pb4 configuration

7= NTC temperature probe of Suction

tube

7

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CF08 ID1 configuration 0= 1

st compressor thermal protection

0

CF09 ID2 configuration 3= Remote On/off

3

CF10 ID5 configuration 1= Condenser fan thermal protection

1

CF11 Pb4 configuration in digital input mode 15= not used

15

CF12 ID1 input polarity 0= active for closed contact 1= active for open contact

1


1


1


0


1

CF17 Pb1 input polarity 0= active for closed contact 1= active for open contact

0


0


0


VALUE

CF20 RL4 configuration of the relay 4

11= draining valve

11

CF21 RL5 configuration of the relay 5 0 = Alarm relay

0

CF22 4mA / 0,5V corresponding to the pressure value of the transducer

Bar Psi

0

CF23 20mA / 5V corresponding to the pressure value of the transducer

Bar Psi

30

CF24 Pb1 Offset °C

°F -2

CF25 Pb2 Offset °C

°F 0

CF26

Pb3 Offset °C °F

Bar Psi

0

CF27 Pb4 Offset °C

°F 0

CF31

Chiller or Heat pump key configuration

0= drain valve

0

CF32 Celsius or Fahrenheit selection 0= °C / °BAR 1= °F / °psi

0

CF33

Power supply frequency 0= 50 Hz 1= 60 Hz 2 = DC power supply (PWM configrured as output for an external alarm relay)

0

CF34 Serial Address for monitoring 1

CF36

Default viewing of upper display of the controller

0 = PB1 visualization

0

CF37

Firmware Release

CF38 Eeprom – Parameter mapping 30

CF39

RL2 configuration 12= not used

12

CF40 RL3 configuration

12= not used

12

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CF43

Default viewing of lower display of the controller

7 = No visualization

7

CF46 Controller: visualization in Std-by mode 1 = the display visualizes “OFF”

1

CF48 Analog output configuration 0 = 4..20mA 1 = 0..10V

0

CF49 Buzzer enable 0= disabled 1= enabled

0

CF50 Dry valve operation mode 0= always ON 1= cyclic operation

1

CF51 Dry valve ON time sec 3

CF52 Dry valve OFF time sec 60

CF53 Air Dryer enable 0= not enabled 1= enabled

1

Compressor parameters :


VALUE

CO01

Minimum ON time Sec 180

CO02 Minimum OFF time Sec 180

CO03 ON delay time between two compressors or Comp. and valve

Sec 1

CO04 OFF delay time between two compressors or Comp. and valve

Sec 1

CO05 Output time delay after power supply start-up

Sec 0

CO06 Compressor On delay time after Pump/”Supply fan” activation

Sec 1

CO07 Compressor OFF delay time after Pump/”Supply fan” de-activation

Sec 0

CO08 Compressor rotating control 0= Enabled 1= Fixed sequence

0

C

O11

Water pump / Supply fan operating mode 0= Not used 0

CO12 Compressor 1 0 = Enabled 1 = OFF

0

CO13 Compressor 2 / Stage valve. 0 = Enabled 1= OFF

1

CO14 Hour counter setpoint for 1st compressor Hr 0

CO15 Hour counter setpoint for 2nd compressor Hr 0

CO16 Hour counter setpoint for pump/”Supply fan” Hr 0

CO29 Maximum continuous operating time of a compressor

Min 250

Alarm Parameter :


VALUE

AL01

Low pressure alarm delay time Sec 180

AL02 Maximum low pressure alarm events in 1 hour

5

AL03 Low pressure alarm with off compressor 0= Not enabled when compressor Off 1= Enabled when compressor Off

1

AL08 Thermal protection alarm delay after starting the compressor

Sec 1

AL09 Number of maximum thermal protection alarm

events. 5

AL10 Maximum number of high temperature / condenser pressure alarm interventions per hour

0

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6.1.5 Alarm visualization

When the instrument detects an alarm, the lower display shows the alarm code alternated to probe value. The alarm icon ( ) is on flashing. In case of HIGH PRESSURE alarm (HP), LOW PRESSURE alarm (LP) dedicated icons are on.

How to Display the Alarm Events

Enter the “menu”:

1. Use or keys to find “ALrM” label

2. Push and release the key

3. Use or keys to scroll the alarm list

To exit the function “menu” push and release the “menu” key or wait the time-out. The “menu” icon disappears.

How to Reset a Manual Alarm

1) Enter the function “menu”.

2) Use or keys to find the “ALrM” label.

3) Push and release the key the lower display shows the alarm code. 4) Lower display shows the alarm code.

Upper display shows “rSt” label if the alarm can be reset, “NO” label if it is not possible.

Use or keys to scroll the alarm list.

5) Push key when “rSt” is lighted to reset the alarm; after a while the read-out move to next alarm.

6) To exit the function menu push and release the “menu” key or wait the time-out. The “menu” icon disappears.

Alarm Code and Events

Code Meaning Cause / Origin Instrument behaviour

Reset

P1 Pb1 probe alarm

Probe Pb1 faulty or disconnected

Open collector / alarm relay ON. Buzzer ON. General alarm icon lighted. Alarm code on display.

Automatic if the probe value recovers

P2 Pb2 probe alarm



Automatic if the probe value recover

P3 Pb3 probe alarm




P4 Pb4 probe alarm




A01 High pressure switch alarm

Digital input for high pressure activated

Open collector / alarm relay ON. Buzzer ON. General alarm icon lighted. High pressure icon lighted. Alarm code on display.

Automatic It turns to manual after AL10 intervention

Manual: after the alarm event expires, proceed with manual reset.

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A02 Low pressure switch alarm

Digital input for low pressure activated

Open collector / alarm relay ON. Buzzer ON. General alarm icon lighted. Low pressure icon lighted. Alarm code on display.

Automatic. It turns to manual after AL02 events in 1 hour.

Manual: after the alarm event expires, proceed with manual reset.

A04

Low temperature alarm of the outlet air from evaporator.

If CF01=0,1 and Pb2< AR03 for AR05 seconds


Automatic. It turns to manual after Ar06 events in 1 hour. Manual: the event expires if Pb2 > (AR03+ AR04), then proceed with manual reset.

A05

High

temperature

High pressure

Pb3 o Pb4 > AL11

Open collector / alarm relay ON. Buzzer ON. High alarm icon lighted.

Alarm code on display.

Automatic. It turns to manual after AL10 events in 1 hour. Manual: the event expires if Pb3 or Pb4 < (AL11-AL12), then proceed with manual reset.

A06 Low temperature Low pressure

Pb3 o Pb4 < AL14

Open collector / alarm relay ON. Buzzer ON. General alarm icon lighted. Low alarm icon lighted. Alarm code on display.

Automatic. It turns to manual after AL06 events in 1 hour. Manual:

the event expires if Pb3

or Pb4 > (AL14+AL15),

then proceed with

manual reset.

A09

Compressor 1 overload protection alarm

Digital input active; bypassed for AL08 upon start-up of compressor


Manual: the event expires, then proceed with manual reset.

A10

Compressor 2 thermal protection alarm

Digital input active


Manual:

the event expires, then

proceed with manual

reset.

A11

Condenser fan thermal protection alarm

Digital input active

Open collector / alarm relay ON. Buzzer ON. General alarm icon lighted. Alarm code on display

Manual:

the event expires, then

proceed with manual

reset.

A13 Compressor maintenance warning

Running hour > CO14


Manual:

Proceed with the hour

reset procedure 13.6

A14 Compressor 2 maintenance warning

Running hour > CO15


Manual:

Proceed with the hour

reset procedure 13.6

EE EEPROM error alarm

Possible data losing

Open collector / alarm relay ON Buzzer ON General alarm icon lighted Alarm code on display

Manual:

Proceed with manual

reset., if nothing

happens the controller

is locked, no regulation

available.

ACF2 Configuration alarm

Air/air or H2O/air unit and:

Fa020 and ventilation probe

not configured

Chiller parameters

configuration differents from

FA13<FA14 and

FA10+FA12+FA13<FA11

Heat Pump parameters

configuration differents from

FA22<FA23 and

FA20+FA21+FA22<FA19

If Ar18=2 or 3 and CF073 If Ar31=2 or 3 and CF07=3

If CF01=3 and CF076


Automatic

After parameter proper

debug.

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ACF3 Configuration alarm

Two digital inputs having the same function; two relays having the same function


Automatic

After parameter proper

debug.

ALOC

General alarm for machine block

Digital input activated for continuous time > AL21. Alarm enabled only if AL23=1

Alarm relay/ open collector ON. Buzzer ON Flashing flow regulator alarm icon Code on display

Automatic

Becomes manual after

AL20 intervention

Manual

De-activation: digital

input not enabled for

continuous time > AL22

and manual reset

procedure.

bLOC

General alarm, signal only

Digital input activated for continuous time > AL21. Alarm enabled only if AL23=0

Alarm relay/ open collector ON. Buzzer ON. Flashing flow regulator alarm icon Code on display

Automatic

The alarm is reset

automatically and does

not depend on AL20

A21 Pre alarm low temperature Pb1

PB1 < AL35. Active also in std-by.


Automatic

If Pb1 > AL35 + AL36.

Manual

Becomes manual if the

number of alarms per

hour > AL37.

De-activation: Pb1 >

AL35 + AL36 and after

the manual reset.

A22 Pre alarm low temperature Pb2



Automatic

If Pb2 > AL38 + AL39.

Manual



hour > AL40.

Reset: Pb2 > AL38 +

AL39 and after the

manual reset.

A23 Low temperature Pb1 alarm



Manual

If Pb1 > AL41 + AL42

and after the manual

reset.

A24 Low temperature Pb2 alarm



Manual

If Pb2 > AL43 + AL44

and after the manual

reset.

A25 High temperature Pb1 alarm

PB1 > AL45 after AL34 time starting from compressor activation. Not active in std-by.


Automatic

If Pb1 < AL45 - AL46 Manual



hour > AL47.

Reset: Pb1 > AL45 –

AL46 and after the

manual reset.

A26 High temperature Pb2 alarm

PB1 > AL48 after AL51 time starting from compressor activation. Not active in std-by.


Automatic

If Pb1 < AL48 - AL49 Manual



hour > AL50.

Reset: Pb1 > AL48 –

AL49 and after the

manual reset.

6.2 BEFORE START UP

Before starting the machine, make sure that all operating parameters correspond to the nominal data.

The dryer is supplied already tested and preset for normal operation, and it doesn’t require any calibration. Nevertheless, it’s necessary to check the operating performances during the first working hours.

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6.3 START UP

The operations specified below must be performed after the first start up and at each start up after a prolonged inactive period of time due to maintenance operations, or any other reason.

1. Make sure that all instructions contained in chapters INSTALLATION SITE and INSTALLATION have been respected.

2. Check if by-pass is locked properly (if existent).

3. Activate current supply and press the ON/OFF switch on the control panel for at least 1 second.

4. Wait 5 to 10 minutes until machine has achieved its standard operating parameters.

5. Slowly open the air outlet valve and successively open the air inlet valve.

6. If existent, close the by-pass.

7. Check if the condensate drainer is working properly.

8. Check if all connecting pipes are properly tightened and fixed.

Before disconnecting the dryer from electrical power supply, use ON/OFF key to stop the dryer. Otherwise wait 10 minutes before switching the dryer on again, in order to allow freon pression re-balance.

7.0 TROUBLESHOOTING

SYMPTOM

POSSIBLE ORIGIN

SOLUTION

A) Temperature shown in display higher than preset value.

High compressed air inlet temperature.

High compressed air flow.

High ambient temperature.

Fouler refrigerant condenser.

Low refrigerant charge.

Faulty refrigerant compressor.

Faulty fan.

Faulty fan pressure switch or thermostat.

Faulty electronic controller

Reduce air temperature to within design limits.

Reduce air flow to within design limits.

Increase ventilation rate of installation area.

Clean condenser.

Locate and repair leak and re-charge.

Replace item.

Replace item.

Replace item.

Replace item.

B) Excessive air pressure drop across dryer.

Inlet / outlet piping reversed.

Temperature probe out of well.

Faulty refrigerant solenoid valve coil.

Ambient temperature below freezing.

Obstruction in air circuit.

Air by – pass valve close.

Connect properly.

Re-install.

Replace item.

Install dryer in heated space.

Locate and remove blockage.

Open valve.

C) Water present in air downstream of dryer.

Condensate drain strainer fouled.

Faulty condensate drainer.

Faulty electronic controller.

High dew – point temperature.

Air by – pass valve open.

Clean strainer.

Replace item.

Replace item.

See Symptom #A above.

Close valve.

IMPORTANT:

The temperature control probe is extremely delicate. Do not remove the probe from its position. In

case of any kind of problem, please contact your “Service Centre”

17-36

8.0 ELECTRONIC CONDENSATE DRAIN

8.1 Maintenance

Close the ball valve located on the filter/stop installed at the drain trap inlet.

Depressurize the trap by pushing the TEST button on the control panel.

Unscrew the plug in the end of the filter/stop to access the filter screen (F) and clean it with a compressed air jet.

Reassemble and open filter/stop valve.

Cleaning of the drain solenoid valve

9.0 DRYER’S DISPOSAL The equipment’s disposal must be carried out according to the National Norms in force. These dryers contain cooling media HFC type and lubrication oils that cannot be dispersed in the atmosphere. Before scrapping the dryer, it’s necessary to recover all the gas contained in it using specific gas cylinders and send them for recycle. This operation must be done by OMI’s qualified Personnel, who has all the proper equipment (consult our Technical Service Centre for additional information about recovery procedure). The recovered fluid must be disposed in accordance to the National Sanitary Norms.

10.0 SAFETY REQUIREMENTS In case of Freon gas leak, it’s important to keep in mind the following phrases to diminish risks/damages to goods and peop le.

FREON DANGERS FIRST AID

R134a

R407C

High concentration can cause asphyxia , lose of consciousness and lose of mobility. Low concentration can cause narcotic effects

Move the victim to an uncontaminated zone, keep him/her warm and call the doctor.

R507 Contact with skin and eyes. Swallowing is an improbable cause of risk.

Rinse immediately the eyes with water for 15 minutes. In case of low temperature Freon gas spray burn sprinkle water for 15 minutes.

11.0 DAILY REGISTER According to EN 378-1 specification, it’s necessary to keep an updated daily register of the cooling system. The register, freely chosen and filled in by the dryer’s user, must contain the following information:

All repairing and maintenance interventions;

Freon consumption (new, re-utilized, recycled) and Freon quantities loaded for each maintenance intervention;

Test results on Freon gas;

Freon origin;

Modifications and replacements of system components.

Periodical tests results;

Significant working periods. Keep the register in the engine room and/or in other rooms, just to have it put in an accessible place to the person in charge of its maintenance.

18-36

12.0 EQUIPMENT DATA

Model UNITS KED 150A KED 200A KED 250A KED 300A

Construction CE CE PED 97/23 CE PED 97/23 CE

Air flow rate l/min 20048 28317 36667 45000

Air flow rate SCM 708 1000 1295 1589

Power consumption* KW 3,40 3,40 5,3 6,80

Nominal Current* A 7.1 7.1 9,29 11,6

Full Load Current A 8,90 8,90 11,2 14,3

Locked Rotor Current A 44 44 63 101

Power supply V/Ph/Hz 400/3/50 400/3/50 400/3/50 400/3/50

Air connections IN / OUT Rp 3“ Rp 3“ Rp 3“ DN 100

Refrigerant type R407c R407c R407c R407c

Weight Kg 260 270 300 330

Inlet Air Temp. Min / Max. °C +0 / +55 +0 / +55 +0 / +55 +0 / +55

Ambient Temperature min / Max °C +5 / +45 +5 / +45 +5 / +45 +5 / +45

Maximum Inlet Air Pressure bar 14 14 14 14

* @ rating conditions of: 45°C & 7 bar air inlet, 35°C ambient, 3°C leaving dew point.

KED150-200-250A

KED300

19-36

12.0EQUIPMENT DATA

Model UNITS KED 400 A KED 500 A KED 600 A KED 700 A KED 750 A

Construction CE CE PED 97/23 CE PED 97/23 CE PED 97/23 CE

Air flow rate l/min 60000 70000 88333 100000 110000

Air flow rate SCM 2118 2472 3120 3530 3882

Power consumption* KW 9,68 14,23 16,44 16,44 16,44

Nominal Current* A 13,3 18,3 20,6 20,6 20,6

Full Load Current A 15,8 22,4 25,7 25,7 25,7

Locked Rotor Current A 78,5 115 130 130 130

Power supply V/Ph/Hz 400/3/50 400/3/50 400/3/50 400/3/50 400/3/50

Air connections IN / OUT DN125 DN125 DN150 DN150 DN 150

Refrigerant type R407c R407c R407c R404a R404a

Weight Kg 420 520 620 720 750

Inlet Air Temp. Min / Max. °C +0 / +45 +0 / +45 +0 / +45 +0 / +45 +0 / +45

Ambient Temperature min / Max °C +5 / +35 +5 / +35 +5 / +35 +5 / +35 +5 / +35

Maximum Inlet Air Pressure bar 14 14 14 14 14

* @ rating conditions of: 45°C & 7 bar air inlet, 35°C ambient, 3°C leaving dew point.

KED 400 – 500 – 600 – 700 – 750 A

20-36

13.0 ELECTRICAL WIRING DIAGRAMS

KED 150-250A

Power Circuit diagram

KED 300A


21-36

Control Circuit diagram KED150-300A

22-36

Terminal blocks diagram KED150-300A

Components layout KED150-300A

23-36

Electric parts list KED 150-750A

13.0 ELECTRICAL WIRING DIAGRAMS

KED 400-750A


24-36

Control Circuit diagram KED400-750A


25-36


Components layout KED400-750A

26-36

Electric Parts list KED400-750A

27-36

14.0 REFRIGERATION CIRCUIT DIAGRAM

KED 150A

28-36

KED 200-250A

KED 300A

29-36

14.0 REFRIGERATION CIRCUIT DIAGRAM

KED 400 – 500A

KED600A

30-36

KED 700-750 A

15.0 INSTALLATION LAYOUT

1 Compressore Compressor

2 Refrigeratore Aftercooler

3 Separatore di Condensa Condensate separator

4 Serbatoio Tank

5 Scaricatore Automatico Automatic Drain

6 Prefiltro ceramico DF 25μ Ceramic Prefilter DF 25μ

7 Prefiltro antipolvere – QF 5μ Dust Filter QF 5μ

8 Essiccatore Dryer

9 Scaricatore Elettronico Solenoid Drain Valve

10 Filtro Disoleatore 1 - PF Filter 1 - PF

11 Filtro Disoleatore 0,01 - HF Filter 0,01 - HF

12 Filtro a Carbone Attivo - CF Carbon Filter - CF

13 Separatore Acqua/Olio Water / Oil Separator

31-36

16.0 BASIC SPARE PARTS KED 150-300A

Model

KED 150A KED 200A KED 250A KED 300A Pos Element

1A1 Electronic Controller 305.0058.01.00-00 305.0058.01.00-00 305.0058.01.00-00 305.0058.01.00-00

RT1 Temperature probe L3MT 243.0029.00.00-00 243.0029.00.00-00 243.0029.00.00-00 243.0029.00.00-00

RT4 Temperature probe L1.5MT 243.0030.00.00-00 243.0030.00.00-00 243.0030.00.00-00 243.0030.00.00-00

1M1 Refrigerant compressor 201.T110.00.00-00 201.T110.00.00-00 201.T111.00.00-00 201.T112.00.00-00

1M2 Fan motor 210.0139.00.00-0N 210.0139.00.00-0N 210.0139.00.00-0N 210.0139.00.00-0N

1P1 High pressure Switch 245.0076.00.00-00 245.0076.00.00-00 245.0078.00.00-00 245.0078.00.00-00

1P2 Fan pressure Switch 245.0077.00.00-00 245.0077.00.00-00 245.0077.00.00-00 245.0077.00.00-00

1V1 Coil CS728 24v 50Hz/60Hz 240.T100.24.01-00 240.T100.24.01-00 240.T100.24.01-00 240.T100.24.01-00

1B1 Solenoid CS728 Con ½” 6mm 240.T100.24.02-00 240.T100.24.02-00 240.T100.24.02-00 240.T100.24.02-00

RBF Strainer CS728 Con ½” 6mm 240.T100.24.03-00 240.T100.24.03-00 240.T100.24.03-00 240.T100.24.03-00

CND Condenser 921.1934.00.00-03 921.1934.00.00-03 921.1935.00.00-03 921.1935.00.00-03

FF Filter dryer 630.0076.00.00-CH 630.0076.00.00-CH 630.0077.00.00-00 630.0077.00.00-00

SC Heat exchanger base 920.0062.01.00-00 920.0066.01.00-00 920.0062.01.00-00 920.0066.01.00-00

VB By-pass hot gas valve 142.0074.00.00-00 142.0074.00.00-00 142.0113.00.00-00 142.0113.00.00-00

SLI Liquid separator 910.0951.00.00-00 910.0951.00.00-00 910.0951.00.00-00 910.0951.00.00-00

IM Moisture indicator 143.0048.00.00-00 143.0048.00.00-00 143.0049.00.00-00 143.0049.00.00-00

VG Freon filling valve 910.0050.00.00-00 910.0050.00.00-00 910.0050.00.00-00 910.0050.00.00-00

TH Thermostat 242.0072.00.00-00 242.0072.00.00-00 242.0072.00.00-00 242.0072.00.00-00

FML Low pressure Freon manometer 143.0037.00.00-CH 143.0037.00.00-CH 143.0037.00.00-CH 143.0037.00.00-CH

FMH High pressure Freon manometer 143.0038.00.00-CH 143.0038.00.00-CH 143.0038.00.00-CH 143.0038.00.00-CH

1T1 Transformer 241.0048.00.00-00 241.0048.00.00-00 241.0048.00.00-00 241.0049.00.00-00

1T2 Board transformer 241.0054.00.00-00 241.0054.00.00-00 241.0054.00.00-00 241.0054.00.00-00

F1 Primary fuse 331.T001.00.50-00 331.T001.00.50-00 331.T001.00.50-00 331.T001.00.50-00

F2 24V secondary circuit fuse 331.T001.06.00-00 331.T001.06.00-00 331.T001.06.00-00 331.T001.06.00-00

PFU Fuse holder 332.TFUSE.00.00-3P 332.TFUSE.00.00-3P 332.TFUSE.00.00-3P 332.TFUSE.00.00-3P

1Q1 Compressor overload switch 332.TMCB.05.50-00 332.TAUX.01.01-01

332.TMCB.05.50-00 332.TAUX.01.01-01

332.TMCB.07.50-00 332.TAUX.01.01-01

332.TMCB.15.00-00 332.TAUX.01.01-01

1Q2 Fan overload switch 332.TMCB.01.50-00 332.TAUX.01.01-01

332.TMCB.01.50-00 332.TAUX.01.01-01

332.TMCB.01.50-00 332.TAUX.01.01-01

332.TMCB.01.50-00 332.TAUX.01.01-01

K1 Compressor contactor switch 332.TMAG.15.00-B7 332.TMAG.15.00-B7 332.TMAG.15.00-B7 332.TMAG.15.00-B7

K2 Fan contactor switch 332.TMAG.04.00-B7 332.TMAG.04.00-B7 332.TMAG.04.00-B7 332.TMAG.04.00-B7

PD Phase detector 224.0001.00.00-00 224.0001.00.00-00 224.0001.00.00-00 224.0001.00.00-00

32-36

16.0 BASIC SPARE PARTS KED 400-750A

Model

KED 400A KED 500A KED 600A KED 700A KED 750A Pos Element

1A1 Electronic Controller 305.0058.01.00-00 305.0058.01.00-00 305.0058.01.00-00 305.0058.01.00-00 305.0058.01.00-00

RT1 Temperature probe L3MT 243.0029.00.00-00 243.0029.00.00-00 243.0029.00.00-00 243.0029.00.00-00 243.0029.00.00-00

RT4 Temperature probe L1.5MT 243.0030.00.00-00 243.0030.00.00-00 243.0030.00.00-00 243.0030.00.00-00 243.0030.00.00-00

1M1 Refrigerant compressor 201.T113.00.00-00 201.T114.00.00-CP 201.T115.00.00-CP 201.T117.00.00-CP 201.T117.00.00-CP

1M2 Fan motor 210.0139.00.00-0N 210.0139.00.00-0N 210.0139.00.00-0N 210.0139.00.00-0N 210.0139.00.00-0N

1P1 High pressure Switch 245.0078.00.00-00 245.0078.00.00-00 245.0078.00.00-00 245.0078.00.00-00 245.0078.00.00-00

1P2 Fan pressure Switch 245.0077.00.00-00 245.0077.00.00-00 245.0077.00.00-00 245.0077.00.00-00 245.0077.00.00-00

1V1 Coil CS728 24v 50Hz/60Hz 240.T100.24.01-00 240.T100.24.01-00 240.T100.24.01-00 240.T100.24.01-00 240.T100.24.01-00

1B1 Solenoid CS728 Con ½” 6mm 240.T100.24.02-00 240.T100.24.02-00 240.T100.24.02-00 240.T100.24.02-00 240.T100.24.02-00

RBF Strainer CS728 Con ½” 6mm 240.T100.24.03-00 240.T100.24.03-00 240.T100.24.03-00 240.T100.24.03-00 240.T100.24.03-00

CND Condenser 921.1934.00.00-03 921.1935.00.00-03 921.1935.00.00-03 921.1935.00.00-03 921.1935.00.00-03

FF Filter dryer 630.0077.00.00-00 630.0077.00.00-00 630.0077.00.00-00 630.0077.00.00-00 630.0077.00.00-00

SC Heat exchanger base 920.0066.01.00-00 920.0066.01.00-00 920.0066.01.00-00 920.0066.01.00-00 920.0066.01.00-00

VB By-pass hot gas valve 142.0089.00.00-00 142.0089.00.00-00 142.0089.00.00-00 142.0089.00.00-00 142.0089.00.00-00

SLI Liquid separator 910.0957.00.00-00 910.0957.00.00-00 910.0955.00.00-00 910.0955.00.00-00 910.0955.00.00-00

IM Moisture indicator 143.0049.00.00-00 143.0049.00.00-00 143.0049.00.00-00 143.0049.00.00-00 143.0049.00.00-00

VG Freon filling valve 910.0050.00.00-00 910.0050.00.00-00 910.0050.00.00-00 910.0050.00.00-00 910.0050.00.00-00

TH Thermostat 242.0072.00.00-00 242.0072.00.00-00 242.0072.00.00-00 242.0072.00.00-00 242.0072.00.00-00

FML Low pressure Freon manometer 143.0037.00.00-CH 143.0037.00.00-CH 143.0037.00.00-CH 143.0037.00.00-CH 143.0037.00.00-CH

FMH High pressure Freon manometer 143.0038.00.00-CH 143.0038.00.00-CH 143.0038.00.00-CH 143.0038.00.00-CH 143.0038.00.00-CH

1T1 Transformer 241.0050.00.00-00 241.0050.00.00-00 241.0050.00.00-00 241.0050.00.00-00 241.0050.00.00-00

F1 Primary fuse 331.T001.00.50-00 331.T001.00.50-00 331.T001.00.50-00 331.T001.00.50-00 331.T001.00.50-00

F2 24V secondary circuit fuse 331.T001.06.00-00 331.T001.06.00-00 331.T001.06.00-00 331.T001.06.00-00 331.T001.06.00-00

PFU Fuse holder 332.TFUSE.00.00-3P 332.TFUSE.00.00-3P 332.TFUSE.00.00-3P 332.TFUSE.00.00-3P 332.TFUSE.00.00-3P

1Q1 Compressor overload switch 332.TMCB.07.50-00 332.TMAG.15.00-B7 332.TMAG.15.00-B7 332.TMAG.15.00-B7 332.TMAG.15.00-B7

1Q2 Fan overload switch 332.TMCB.01.50-00 332.TMCB.01.50-00 332.TMCB.01.50-00 332.TMCB.01.50-00 332.TMCB.01.50-00

K1 Compressor contactor switch 332.TMAG.07.50-B7 332.TMAG.09.00-00 332.TMAG.09.00-00 332.TMAG.09.00-00 332.TMAG.09.00-00

K2 Fan contactor switch 332.TMAG.04.00-B7 332.TMAG.04.00-B7 332.TMAG.04.00-B7 332.TMAG.04.00-B7 332.TMAG.04.00-B7

PD Phase detector 224.0001.00.00-00 224.0001.00.00-00 224.0001.00.00-00 224.0001.00.00-00 224.0001.00.00-00

33-36

17.0 KED 150A ASSEMBLY

34-36

17.0 KED 200-300A ASSEMBLY

35-36

17.0 EXPLODE VIEW KED400A-KED750A

Pos Element Pos Element

1A1 Electronic Controller IM Moisture indicator

RT1 Temperature probe L3MT VG Freon filling valve

RT4 Temperature probe L1.5MT TH Thermostat

1M1 Refrigerant compressor FML Low pressure Freon manometer

1M2 Fan motor FMH High pressure Freon manometer

1P1 High pressure Switch 1T1 Transformer

1P2 Fan pressure Switch 1T2 Board transformer

1V1 Coil CS728 24v 50Hz/60Hz F1 Primary fuse

1B1 Solenoid CS728 Con ½” 6mm F2 24V secondary circuit fuse

RBF Strainer CS728 Con ½” 6mm PFU Fuse holder

CND Condenser 1Q1 Compressor overload switch

FF Filter dryer 1Q2 Fan overload switch

SC Heat exchanger base K1 Compressor contactor switch

VB By-pass hot gas valve K2 Fan contactor switch

SLI Liquid separator PD Phase detector

instruction manual ked150

Documents

machine operation

machine installation

machine unpacking

machine features

machine positioning

new machine owner

safety information

symbols symbols