MDX Non-Cycling Refrigerated Compressed Air Dryers with Intellidrain Condensate Drain Trap Operation & Maintenance Manual MODELS MDX 1500 1800 2400 3000 TABLE OF CONTENTS 1.0 GENERAL 2 1.1 How to use this manual 1.2 Symbols 1.3 Warranty 1.4 Standard equipment 1.5 Description 1.6 Use 1.7 Saftey instructions 2.0 MACHINE UNPACKING AND HANDLING 3 2.1 Unpacking and handling 2.2 Package disposal 3.0 SET UP 4 3.1 Machine positioning 3.2 Installation 3.3 Start-up 3.4 Decommissioning 3.5 Control panel 4.0 TIMED CONDENSATE DRAIN TRAP 6 4.1 Operation 4.2 Controls 4.3 Maintenance 5.0 MAINTENANCE 7 5.1 Each week 5.2 Each month 5.3 Each 6 months 6.0 TROUBLESHOOTING 7 7.0 TECHNICAL FEATURES 8 7.1 Data sheet 7.2 Electric Wiring diagrams 7.2 Refrigeration diagrams 8.0 INSTALLATION LAYOUT 18 1/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
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 drainage Air outlet Direction of rotation of ventilator motor 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 series 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 / 37,4 F. 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. 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 Country current norms. A start and stop device (ON/OFF) allows the dryer to be turned on and it permits its normal working. This units are equipped with a frigorific circuit safety system to prevent damages. A cartridge pressure control opens the compressor s contacts at a preset pressure and remains in this position until the reset button is activated. The reset button remains enabled until the line pressure returns to the factory setted safe level. An ammeterical and a thermometrical protection (an authomatic re-establishment on the compressor) prevent from electric and frigorific circuit s damages. 2/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
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. 1.7 General safety instruction Read this manual carefully before performing any operation. This machine has been designed and realized to be used as described below. Any other use is not allowed. Any maintenance or cleaning operation of inner parts has to be performed by specialized staff only. The Suppier is not responsable for any use other than the intended use or not in compliance with the instructions mentioned in this manual. WHAT SHOULD BE DONE: Be familiar with all controls. Before performing any maintenance make sure that the dryer is not connected to the compressed air network (intake and outtake cut-off cocks closed) and no pressure is inside the machine Before removing the protection panels unplug the machine and allow 15 minutes for the inner parts to cool down. Before removing the cooling fan protection grid make sure the dryer is unplugged. Make sure that all protection panels are properly fitted while the machine is working and after any maintenance operation. Make sure that the intake air is free from inflammable fumes or vapours which might cause either explosion or fire risk. WHAT SHOULD NEVER BE DONE: Never place inflammable 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 operation on safety parts. Never hit inner pipes with objects. 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. This plant has been designed and realized in compliance with European safety regulations EC 98/37, EEC 73/23 and EEC 89/336. All installation, use and maintenance operations should therefore be perfomed according to the instruction of this manual. Any cleaning/maintenance operation on the dryer should be performed by a qualified and specialized personnel only, fully familiar with precautions to be taken. 2.0 MACHINE UNPACKING AND HANDLING 2.1 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 cut them either with scissors or cutting nippers), take the dryer out. Withdraw the package from the top remove the wooden pallet and place the dryer in the choosen position. 2.2 Package disposal We 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. 3/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
3.0 SET-UP 3.1 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 41 F and 104 F 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. 3.2 Installation - Before any operation check that the pipes to be connected to the dryer are properly clean inside and do not contain any dirt. Install the machine in compliance with the following instructions: Connect the dryer to the air compressed line in compliance with one of the diagrams shown in the fig. 6 and the instructions on labels stuck to the machine and described on page 2. A by-pass structure able to cut the dryer off (disconnection) from the air compressed line is recommended. It will avoid any break in the air supply in case of problems during routine maintenance. Connect the condensate drain tube in compliance with local regulations. The condensate cannot be drained directly into the sewage system since it is a pollutant. A water-oil separator of suitable capacity is therefore recommended. Make sure that voltage and frequency of the electric network are steady and in compliance with data on the machine plate and local regulations of the country in which the dryer is used. Always fit a safety switch in the line. It is up to the customer to decide for its capacity (refer to technical data on the plate). To avoid any deposit of solid particles into the dryer and of oil into the heat exchanger a ceramic filter (QF) before the dryer is always recommended. Aim the dryer so that all controls can be easily read and all maintenance operation easily performed. 3.3 Start-Up Make sure that intake and outtake valves are closed. Turn the door blocking switch (S1) on position 1, in this way the heating system will be activated. Push the (ON/OFF) button on the control panel. Wait for at least 15 minutes until the dryer is steady. Now open the outtake 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. 3.4 Decommissioning - In the case there is the need to move the dryer, proceed as follows: 1. insulate the unit from the compressed air line; 2. if necessary, depressurize the dryer s air circuit by using the condensate drainer (TEST button); 3. insulate the dryer from electricity; 4. disconnect the dryer from electrical feeding; Packing and transport of faulty machines - Repack the dryer in its original box or with a similar one of the same dimensions. The dryer must be kept vertically and packed as supplied from the manufacturer. Do not transport the dryer without its packing, you may damage it irreparably. MATERIALS WITHOUT PACKING AND DOCUMENTS WILL NOT BE ACCEPTED. 4/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
3.5 Control Panel These dryers are equipped with an electronic controller. Please note that the SET POINT & other control parameters have been optimized and factory set. Altough the set point value can be displayed, the ability to alter these factory settings via the digital interface on the front panel has been removed to eliminate the possiblity of unit damage caused by improper settings. A description of the operation of the digital interface is provided below however, to facilitate factory-authorized adjustments. The control panel shown in fig. 2 consists of 5 buttons (ON/OFF, TEST, SET, DOWN and UP) and a three-figure display with three warning LED s shown as 1, 2, 3 and two manometers for low and high refrigerant pressure. DEW POINT fig. 2 Control Panel Status LEDs 1 On = Compressor energized 2 On = Drain valve(s) energized 3 On = Dx solenoid energized Button Functions TEST SET Performs a test of the condensate discharge valve when pressed for more than 3 seconds during the normal operation. Displays the set point value when pressed during normal operation. Stores all changes when pressed after changing set point. DOWN Decreases the displayed value when pressed during set point programming. UP Increases the displayed value when pressed during set point programming. ON/OFF Activates or deactivates unit operation when pressed for 3 seconds. When deactivated, the OFF message is displayed. Set Point Modification Press the SET button (the current set point value is displayed). Modify the displayed set point value by using the UP or DOWN button (if modification is not performed in 15 seconds the controller automatically returns to the normal operating display indicating the DEW POINT value). Confirm the new set value by pushing the SET button within 10 seconds of the modification, the flashing of the set point value confirms acceptance of the new data. If the modified data is not confirmed within 10 seconds, the new data will not be stored and the controller will revert to the previous set point. Please note that changes to the set point WILL adversely effect dryer operation and therefore should only be done by authorized technical service personnel. 5/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
Digital Display Message Numeric Value Description Dewpoint Temperature Error Codes The controller recognizes specific types of operational errors. When an error occurs the display shows a flashing alarm message alternating with the current dewpoint value, as described below: Message (flashing) HtA LtA PF1 Cause High Dewpoint Temperature Low temperature alarm Temperature Sensor failure All the alarms except for PF1 are automatically reset when the cause is removed. PF1 must be cleared by switching the unit off and then re-started. PF1 has a priority over all the other displayed messages. 4.0 INTELLIDRAIN ZERO-LOSS DRAIN TRAP 4.1 Operation The IntelliDrain is designed to remove condensate from any compressed air application without air loss. It is completely automatic, and requires no external settings or adjustments. A two-stage condensate level sensor installed in the trap s internal cavity signals both the beginning and the end of the discharge cycle so the trap discharges only liquid and no air is wasted regardless of load. At start-up, purge any air from the trap s inlet connection by pushing the TEST button several times. The factory-installed inlet filter should be examined and cleaned daily for the first week of operation, and monthly thereafter. 4.2 Controls Green LED: Red LED: Pushbutton: Electrical Power ON Discharge Solenoid Energized (valve open) Discharge TEST (Open Valve Manually) 4.3 Maintenance Close the ball valve located on the filter/stop installed at the drain trap inlet. Depressurize the trap by by pushing the TEST button. Unscrew the plug in the end of the filter/stop to access the filter screen. Clean the filter screen with a compressed air jet. Reassemble and open filter/stop valve. 6/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
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. Proceed as described on 4.0. 5.3 Every 6 months Unplug the machine before performing the following: According to room s temperature, quality of the ambient air and at the beginning of summertime, remove the left side panel and clean the condenser with some compressed air and clean the aluminium fins in order to remove possible dust or deposits which might decrease its performance. Check out compressor s power consumption with reference to dryer s back label or the data sheet on this manual (see chapter 7.1). 6.0 TROUBLESHOOTING SYMPTOM POSSIBLE ORIGIN SOLUTION Temperature shown in display is higher than preset value High compressed air inlet temperature High compressed air flow High ambient air temperature Fouled refrigerant condenser Low refrigerant charge Faulty refrigerant compressor Faulty refrigerant solenoid valve Faulty fan thermostat Faulty control relay Refrigerant high pressure switch open Reduce air temperature to within design limits Reduce air flow to within design limits Increase ventilation rate of installation area Clean condenser Locate & repair leak & re-charge Repair or replace Repair or replace Repair or replace Repair or replace Eliminate cause & reset switch Excessive air pressure drop across dryer Inlet/outlet piping reversed Thermostat sensor out of well Faulty thermostat Ambient temperature below freezing Obstruction in air circuit Connect properly Re-install Repair or replace Install dryer in heated space Locate & remove blockage Water present in air downstream of dryer Air by-pass valve open Condensate drain strainer fouled Faulty condensate drain High dew point temperature Close valve Clean strainer Repair or replace See Symptom #1 above Fan doesn't start and/or stop. Faulty fan thermostat / pressostat Low refrigerant charge Low load with low ambient temperature Repair or replace Locate & repair leak & re-charge Install dryer in heated space 7/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
7.0 TECHNICAL FEATURES 7.1 Data Sheet Model UNITS MDX 1500 MDX 1800 MDX 2400 MDX 3000 Air flow rate SCFM 1500 1800 2400 3000 Compressor Power HP 8-1/2 10 12 14 Power Consumption KW 6,37 8,21 10,51 11,78 Nominal Current* A 9,53 12,4 14,2 19,1 Full Load Current A 13,4 17,1 22 28,6 Locked Rotor Current A 105 115 105 115 Power supply V/Ph/Hz 460/3/60 460/3/60 460/3/60 460/3/60 Air connections FLG ANSI 4 ANSI 4 ANSI 4 ANSI 6 Refrigerant type R134a R134a R22 R22 Weight lbs 1214 1744 1943 2318 Maximum Air Inlet F 113 113 113 113 Maximum Ambient F 104 104 104 104 Maximum Pressure psig 232 232 232 232 * @ rating conditions of: 100 F & 100 psig air inlet, 100 F ambient, & 38 F leaving dew point 8/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
7.2 Electric Wiring Diagrams MDX 1500-1800 - POWER WIRING DIAGRAM Cod. 714.026.01.00 Rev. 01 01.03.02 MDX 1500 1800 - CONTROL WIRING DIAGRAM 9/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 1500 1800 - TERMINAL BLOCKS DIAGRAM MDX 1500 1800 - COMPONENTS DIPOSITION 10/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 1500 1800 PARTS LIST MDX 2400 - POWER WIRING DIAGRAM Cod. 714.027.01.00 Rev. 01 01.03.02 11/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 2400 - CONTROL WIRING DIAGRAM MDX 2400 - TERMINAL BLOCKS DIAGRAM 12/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 2400 - COMPONENTS DIPOSITION MDX 2400 PARTS LIST 13/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 3000 - POWER WIRING DIAGRAM Cod. 714.031.01.00 Rev. 01 01.03.02 MDX 3000 - CONTROL WIRING DIAGRAM 14/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 3000 - TERMINAL BLOCKS DIAGRAM 15/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 3000 - COMPONENTS DIPOSITION MDX 3000 PARTS LIST 7.3 Refrigerat Circuit Diagram 16/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 1500-1800 - Cod. 713.029.01.00 Rev. 01 02.05.02 MDX 2400 - Cod. 713.029.02.00 Rev. 01 02.05.02 17/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
MDX 3000 - Cod. 713.029.04.00 Rev. 01 02.05.02 8.0 INSTALLATION LAYOUT 1 Air Compressor 2 Aftercooler 3 Condensate Separator 4 Receiver Tank 5 Automatic Drain 6 Particulate Prefilter 7 Dryer 8 Solenoid Drain Valve 9 Filter 1.0 micron 10 Filter 0.01micron 11 Activated Carbon Filter 12 Water/Oil Separator 18/19 Cod. 710.063.04.00 Rev. 01 10.07.2002
19/19 Cod. 710.063.04.00 Rev. 01 10.07.2002