ABAC Air Compres 125-275 Receiver Mounted with Dryer Installation Guide

ABAC Air Compres 125-275 Receiver Mounted with Dryer

Specifications

• Model: COOL 125-275 (C7 – C7,5 – C8 – C9 – C10)
• Edition: 08/2018
• General Characteristics: Chilling machine with direct expansion and dry evaporator

Product Usage Instructions

General Characteristics

• The dryer functions as a chilling machine with direct expansion and a dry evaporator.
• The air to be dried is processed in the heat exchanger, where water vapor is condensed, collected in the separator, and discharged outside through a steam trap.

Intended Use

The dryer is designed for drying air by condensing water vapor.
It is essential to follow all safety precautions and guidelines provided in the manual before operating the dryer.

Operation

The operation of the dryer involves the following components.

• Refrigerant Compressor
• Condenser
• Motor Fan
• Evaporator
• Demister Condensate Separator
• Impurity Trap
• Expansion Capillary Tube

FAQ

Q: What should I do in case of a breakdown or malfunction?

• A: In the event of a breakdown or malfunction, switch off the dryer and do not attempt to repair it yourself.
• Contact a technical assistance center approved by the manufacturer for repairs using original spare parts.

Q: Can the dryer be used for external installation?

A: No, the machine is not suitable for external installation as per the manufacturer’s instructions.

Q: How should I dispose of lubricating liquids and other fluids from the dryer?

A: The lubricating liquids and other fluids must not be discharged into the environment. They should be disposed of by authorized and specialized firms according to the product’s typology.

• ATTENTION: THERE IS A COPY OF THE WIRING DIAGRAM INSIDE THE ELECTRIC PANEL

ADDRESSES OF ASSISTANCE CENTRES

• In the event of a breakdown or malfunction of the dryer, switch it off and do not tamper with it. If repairs are needed, apply only to a technical assistance center approved by the manufacturer and insist on the use of original spare parts.
• Failure to comply with the above may endanger the safety of the machine.

INTRODUCTION

• Keep this manual with care for future consultation; the use and maintenance manual is an integral part of the dryer. Read this manual carefully before carrying out any operations on the dryer.
• The installation of the dryer and all operations involving it must be performed in conformity with the regulations in force concerning electric plants and personal safety.

CHARACTERISTICS AND SAFETY PRECAUTIONS

• BEFORE REMOVING THE PROTECTIVE GUARDS TO CARRY OUT ANY MAINTENANCE ON THE MACHINE, SWITCH OFF THE ELECTRIC POWER SUPPLY AND DISCHARGE THE RESIDUAL PRESSURE INSIDE THE UNIT.
• ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL.
• The manufacturer does not accept responsibility for damage caused as a result of negligence or failure to abide by the instructions given above.
• THIS MACHINE IS NOT SUITABLE FOR EXTERNAL INSTALLATION THIS MACHINE CORRESPONDS TO THE ESSENTIAL SAFETY REQUIREMENTS FORESEEN FROM THE EUROPEAN STANDARD (2006/42 CE).
• THE LUBRICATING LIQUIDS AND OTHER EVENTUAL FLUIDS MUST NOT BE DISCHARGED IN THE ENVIRONMENT.
• THESE POLLUTING AND HAZARDOUS PRODUCTS MUST BE DISPOSED OF BY CHARGING AUTHORISED AND SPECIALISED FIRMS ACCORDING TO THE DIFFERENT TYPOLOGIES OF PRODUCTS.
• DIFFERENTIATE THE COMPRESSOR COMPONENTS ACCORDING TO THE DIFFERENT CONSTRUCTION MATERIALS (PLASTIC, COPPER, IRON, OIL FILTER, AIR FILTER ECC…)

GENERAL CHARACTERISTICS

• The dryer is a chilling machine with direct expansion and a dry evaporator.
• The air to be dried is sent to the heat exchanger in which the water vapor present is condensed: the condensate gathers in the separator and is discharged outside through a steam trap.

INTENDED USE

• The dryer has been built to dry the compressed air for industrial use.
• The dryer cannot be used on premises where there is a risk of fire or explosion or where work is carried out that releases substances into the environment that are dangerous to safety (for example: solvents, inflammable vapors, alcohol, etc.).
• In particular, the appliance cannot be used to produce air to be breathed by humans or used in direct contact with foodstuffs.
• These uses are allowed if the compressed air produced is filtered through a suitable filtering system (Consult the manufacturer for these special uses.)
• This appliance must be used only for the purpose for which it was specifically designed. All other uses are to be considered incorrect and therefore unreasonable.
• The Manufacturer cannot be held responsible for any damage resulting from improper, incorrect, or unreasonable use.

OPERATION

• The gaseous refrigerant coming from the evaporator (4) is sucked by the refrigeration compressor (1) and it is pumped into the condenser (2).
• This one allows its condensation, eventually with the help of the fan (3); the condensed refrigerant passes through the dewatering filter (8) expands through the capillary tube (7), and goes back to the evaporator where it produces the refrigerating effect.
• Due to the heat exchange with the compressed air which passes through the evaporator against the stream, the refrigerant evaporates and goes back to the compressor for a new cycle.
• The circuit is equipped with a bypass system for the refrigerant; this intervenes to adjust the available refrigerating capacity to the actual cooling load. This is achieved by injecting hot gas under the control of the valve (9): this valve keeps constant the pressure of the refrigerant in the evaporator and therefore also the dew point never decreases below 0 °C (32 °F) to prevent the condensate from freezing inside the evaporator. The dryer runs completely automatically.

DRYER FLOW DIAGRAM

1. REFRIGERANT COMPRESSOR	8) REFRIGERANT FILTER

2. CONDENSER| 9) HOT GAS BYPASS VALVE
3. MOTOR FAN| 10) AIR-TO-AIR EXCHANGER
4. EVAPORATOR| 11) DEW POINT THERMOMETER
5. DEMISTER CONDENSATE SEPARATOR| 12) FAN CONTROL PRESSURE SWITCH
6. IMPURITY TRAP| 13) CONDENSATE DRAIN
7. EXPANSION CAPILLARY TUBE|

GENERAL SAFETY STANDARD

• The appliance may be used only by specially trained and authorized personnel.
• Any tampering with the machine or alterations not approved beforehand by the Manufacturer relieve the latter of responsibility for any damage resulting from the above actions.
• The removal of or tampering with the safety devices constitutes a violation of the European Standards on safety.
• ALL WORK ON THE ELECTRIC PLANT, HOWEVER SLIGHT, MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL.

DESCRIPTION OF DANGER SIGNALS

DANGER ZONES

SAFETY DEVICES

1. Cooling fan shield
2. Shield
3. Earth

POSITION OF PLATES

POSITION OF THE DANGER PLATES (Fig. 4)

The plates fitted on the compressor unit are part of the machine; they have been applied for safety purposes and must not be removed or spoiled for any reason.

Ref.1 – Spare plate Code 1079 9903 48

POSITION OF THE DATA PLATES (Fig. 4)

• Ref. 2) “IN”
• Ref. 3) “ OUT”
• Ref. 4) Identification plate

DRYERS ROOM

FLOOR

• The floor must be even and of industrial type; the total weight of the machine is shown in Fig. 5
• Remember the total weight of the machine when positioning it.

VENTILATION

• The choice of an appropriate room will prolong the life of your dryer; the room must be spacious, dry, well-ventilated, and free from dust.
• The operating conditions to be complied with are the following.

Min. room temperature: + 5 °C (41 °F) compulsory| Min. temperature of incoming air: 10 °C (50 °F)
---|---
Max. room temperature: + 40 °C (104 °F) compulsory| Max. working pressure: 13 bar (188 psi) for C7,5-C8-C9-C10
Max. temperature of incoming air: 50 °C (122 °F)| Max. working pressure: 16 bar (232 psi) for C7

TRANSPORT AND HANDLING

The machine must be transported as shown in the following figures.

UNPACKING

CUTTING THE METAL STRAPPING IS A DANGEROUS OPERATION, DO NOT ABANDON THE CUT PIECES IN THE ENVIRONMENT.

• After removing the packing, ensure that the machine is unbroken and that there are no visibly damaged parts.
• If you are in doubt, do not use the machine but apply to the manufacturer’s technical assistance service or your dealer.
• The packing material (plastic bags, polystyrene foam, nails, screws, wood, metal strapping, etc.) must not be left within the reach of children or abandoned in the environment, as they are a potential source of danger and pollution.
• Dispose of these materials in the approved collection centers.

INSTALLATION

POSITIONING

• After unpacking the equipment and preparing the dryer room, put the machine into position, checking the following items: ensure that there is sufficient space around the machine to allow maintenance (see Fig. 6).
• ENSURE THAT THE OPERATOR CAN SEE THE WHOLE MACHINE FROM THE CONTROL PANEL AND CHECK THE PRESENCE OF ANY UNAUTHORIZED PERSONS IN THE VICINITY OF THE MACHINE.

ELECTRICAL CONNECTION

• Check that the supply voltage is the same as the value indicated on the machine data plate.
• Check the condition of the line leads and ensure that there is an efficient earth lead.
• Ensure that there is an automatic cut-out device upstream for the machine against overcurrents, with a differential device ( Ref. 1 Fig. 6 ), wiring diagram.
• ONLY PROFESSIONALLY SKILLED PERSONNEL MAY HAVE ACCESS TO THE ELECTRIC PANEL. SWITCH OFF THE POWER BEFORE OPENING THE DOOR OF THE ELECTRIC PANEL. COMPLIANCE WITH THE REGULATIONS IN FORCE CONCERNING ELECTRIC PLANTS IS FUNDAMENTAL FOR OPERATOR SAFETY AND FOR THE PROTECTION OF THE MACHINE.

CONNECTION TO THE COMPRESSED AIR NETWORK

• Fit a manual interception valve Ref. 1 between the machine and the compressed air network so that the dryer may be isolated during maintenance operations (see Figure 7 ).
• Drainage of condensate Rif. 2 Fig. 7 (automatic) is led outside the machine with a flexible pipe that may be inspected.
• Drainage must comply with the local regulations in force.
• ALL DAMAGE DUE TO THE FAILURE TO COMPLY WITH THESE MEDICATIONS CANNOT BE ATTRIBUTED TO THE MANUFACTURER AND MAY CAUSE INVALIDITY OF THE GUARANTEE CONDITIONS.

STARTING UP

• See part B of this manual, Chapter 18.0

DIMENSIONS AND TECHNICAL DATA

1” GAS F. (CE)

| 1” NPT F. (cULus)

1” GAS F. (CE)

150(C7,5)| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

200(C8)| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

250(C9)| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

275(C10)| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

| 1”1/2 NPT F. (cULus)

1”1/2 GAS F. (CE)

MACHINE ILLUSTRATION

GENERAL LAYOUT

COMMAND AND CONTROL PANEL

BEFORE CARRYING OUT THE OPERATION TEST, READ CAREFULLY AND ACQUIRE A GOOD KNOWLEDGE OF THE COMMAND FUNCTIONS.

1. Ref. 1) Dew point indicator
2. Ref.   2) Stop – Running button

PARTIAL ROUTINE MAINTENANCE

• BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS AND THE COMPRESSED AIR DISTRIBUTION NETWORK.

MAINTENANCE SCHEDULE

• These maintenance intervals are recommended for work environments that are not dusty and are well-ventilated. For particularly dusty environments, double the frequency of controls.

Each Week

• Condensate drain: Clean the filter of the steam trap

Each Monthly

• Condenser: Clean the condenser fins to remove eventual dust.

CLEANING OF THE AUTOMATIC CONDENSWATER DISCARGER FILTER (Fig. 10)

• Clean the filter of the steam trap.

Proceed as follows:

• Close the cock Ref. 1 Fig. 10
• Release the pressure in the dryer by pressing the condensate drain “TEST” pushbutton located on the steam trap Ref. 2 Fig. 10.
• Switch off the machine by pressing the STOP button Ref. 3 Fig. 10
• Turn on the supply automatic differential switch Ref. 4 Fig. 10

HOT PARTS INSIDE

• Remove the panels’ Ref. 5
• Remove the stopper Ref. 6
• Remove the filter Ref. 7
• Clean the filter Ref. 5 with a jet of air, working from inside to outside
• Install the filter, fix the plug Ref. 7 – 6
• Close the panels’ Ref. 5

CLEANING THE CONDENSER (Fig. 10)

• The condenser must be cleaned every month.

Proceed as follows:

• Switch off the machine by pressing the STOP button Ref. 3 Fig. 10
• Turn on the supply automatic differential switch Ref. 4 Fig. 10
• Remove the panel’s Ref. 5 Fig. 10
• Clean the condenser fins Ref. 1 with compressed air (Fig. 10) DO NOT USE WATER OR SOLVENTS
• Close the panel’s Ref. 5 Fig. 10

SCRAPPING THE UNIT

• If the machine is to be scrapped, it must be dismantled into parts of the same material, to be disposed of according to the local regulations in force.
• ALWAYS RESPECT THE REGULATIONS IN FORCE FOR DISPOSING OF OLD OIL AND OTHER POLLUTING MATERIALS SUCH AS INSULATING FOAM, ETC.

TROUBLESHOOTING AND EMERGENCY REMEDIES

• ALL WORK MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL. BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS.
• N.B. OPERATIONS MARKED ◼ ◼ MUST BE CARRIED OUT BY PROFESSIONALLY SKILLED PERSONNEL APPROVED THE MANUFACTURER

calibration

◼ ◼-The room temperature is too low and the evaporator piping is obstructed with ice

2) Presence of condensate in the pipings.| 2A) The condensate separator does not work correctly

**2B)** The dryer is working outside its rating

**2C)** The dryer is working under bad conditions of condensation

| -Clean the filter from the condensate drain

Check the condensate drain

**** -Check the flow rate of treated air

-Check the room temperature

-Check the air temperature at the drier inlet.

Clean the condenser.

◼ ◼Check the operation and the calibration of the press. switch

◼ ◼Check the good operation of the fan.

3) The compressor head is very hot (> 55 °C) (131 °F)| Refer to 2B

Refer to 2C

3A) The cooling circuit is not working with the right gas charge

| ◼ ◼Check if there are leaks of refrigerating gas.

◼ ◼Charge it again.

4) Motor cuts out on overload| Make reference to 2B

Make reference to 2C

Make reference to 3A

|
5) The motor hums and does not start.| The line voltage is too low.

You switched the machine off and on again without leaving enough time for the pressure balancing.

The starting system of the motor is defective.

| -Contact the electric power company

-Wait a few minutes before starting the machine again.

**** ◼ ◼Check the running and starting relays and condensers (if any)

6) The machine has stopped and does not restart even after a few minutes.| The overload protection has intervened: refer to 2B-2C-3A.

**** The motor has burnt out.

|
7) The compressor is very noisy.| Troubles with the internal mechanical parts or with the valves|

PART “B” OF THE INSTRUCTIONS MANUAL IS RESERVED FOR PROFESSIONALLY SKILLED PERSONNEL APPROVED BY THE MANUFACTURER.

STARTING UP

BEFORE CARRYING OUT ANY OPERATION ON THE MACHINE, ENSURE THAT THE ELECTRIC POWER SUPPLY HAS BEEN DISCONNECTED

PRELIMINARY CONTROLS

Before starting the dryer, check:

• The correct connection to the compressed air piping: remember to remove eventual caps on the drier inlet and outlet.
• The correct connection to the condensate drainage system.
• That the power supply is right.

STARTING AND STOP

• Start the system before the air compressor starts running and stop it after the air compressor has been stopped. The compressed air piping will be free of condensate only by doing so.
• The drier must be kept running during all the time the air compressor is running.
• WARNING: if the drier is switched off, before starting it again, wait at least 5 minutes to allow the pressure to balance.
• BEFORE CARRYING OUT ANY MAINTENANCE JOBS IT IS OBLIGATORY TO STOP THE MACHINE AND DISCONNECT IT FROM THE POWER MAINS AND THE COMPRESSED AIR DISTRIBUTION NETWORK.
• PRESSURE DISCHARGE PROCEDURE

Proceed as follows:

• Close the taps Ref. 1 Fig. 11
• Release the pressure in the dryer by pressing the condensate drain “TEST” pushbutton located on the steam trap Ref. 1 Fig. 11
• Switch off the machine by pressing the STOP button Ref. 3 Fig. 11
• Turn on the supply automatic differential switch Ref. 4 Fig. 11

CALIBRATIONS

BYPASS VALVE FOR HOT GAS

• N.B.These valves have already been calibrated and they do not require any adjustment.
• A dew point different from the rated one generally depends on causes that are not attributable to their operation.

1. Ref. 1) Closing cap
2. Ref. 2) Adjusting screw

WORKING PRESSURES AND TEMPERATURES OF R404A

| SUCTION SIDE OF REFRIGERATION COMPRESSOR
---|---
| Evaporate. Temperature. °C (°F)| Evaporating Pressure bar (psi)
**** RATED VALUES

(Temperat. 20°C – 68°F)

| **** 1 ÷ 2

(33,8 ÷ 35,6)

| **R404A**

4,3 ÷ 4,5

(62,3 ÷ 65,2)

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