FS-Curtis RNP35 User manual

3227447

Rev. A

AUGUST 2012

RNP SERIES

REFRIGERATED COMPRESSED AIR DRYERS

OPERATOR

MANUAL

RNP25 RNP35 RNP50

GENERAL SAFETY INFORMATION

1. PRESSURIZED DEVICES:

This equipment is a pressure containing

device.

• Donotexceedmaximumoperating

pressure as shown on equipment

serial number tag.

• Makesureequipmentisdepressurizedbefore

workingonordisassemblingitforservice.

2. ELECTRICAL:

This equipment requires electricity to

operate.

• Installequipmentincompliancewith

all applicable electrical codes.

• Standardequipmentissuppliedwithelectrical

enclosuresnotintendedforinstallationinhazardous

environments.

• Disconnectpowersupplytoequipmentwhen

performinganyelectricalservicework.

3. BREATHING AIR:

• Airtreatedbythisequipmentmay

notbesuitableforbreathingwithout

furtherpurication.

 Refertoapplicablestandardsand

specicationsfortherequirements

forbreathingqualityair.

RECEIVING, MOVING, AND UNPACKING

A. RECEIVING

Thisshipmenthasbeenthoroughlychecked,packedand

inspectedbeforeleavingourplant.Itwasreceivedin

goodconditionbythecarrierandwassoacknowledged.

CheckforVisibleLossorDamage.Ifthisshipmentshows

evidenceoflossordamageattimeofdeliverytoyou,

insistthatanotationofthislossordamagebemadeon

the delivery receipt by the carrier’s agent.

B. UNPACKING

Checkforconcealedlossordamage.Whenashipment

hasbeendeliveredtoyouinapparentgoodorder,but

concealeddamageisfounduponunpacking,notifythe

carrier immediately and insist on his agent inspecting

the shipment. Concealed damage claims are not our

responsibilityasourtermsareF.O.B.pointofshipment.

C. MOVING

Inmovingortransportingdryer,donottipdryerontoits

side.

D. STORAGE

IMPORTANT:Donotstoredryerintemperaturesabove

130°F (54.4°C).

Compressor

Oil Removal

Filter

Aftercooler

Automatic Drain

Dryer

Separator

Receiver

TYPICAL COMPRESSED AIR SYSTEM

INSTALLATION

Ambient Air Temperature

Locatethedryerindoorswheretheambientairtemperature

willbebetween40°Fand100°F.Intermittentoperationat

ambient temperatures up to 113°F will not damage the dryer

but may result in a higher dew point or dryer shutdown

duetohighrefrigerantdischargepressure(seeFieldService

Guide).

Donotoperateair-cooleddryersatambientairtemperatures

below40°F.Suchoperationmayresultinlowsuction

pressure,causingfreeze-up.

Callyourlocaldistributorifprolongedoperationatambient

temperatures above 100°F or below 40°F is unavoidable.

Location and Clearance

Mountthedryeronalevelbase.Installthedryerinaclean,

well-ventilatedareatoreducefoulingofthecondensercoils

with dirt and dust.

Vaporsandcontaminantscorrosivetocopperandaluminum

mustnotbeintheareaofthedryeroraircompressorintake.

Allowatleast6inchesclearancefromthefrontandfromthe

condensercoilserviceaccess.Installthedryerwiththeframe

level.Anchorboltsarenotrequired.

System Arrangement

Liquidwaterintheinletairwilladverselyaffectthe

performanceofthedryer.Installthedryerdownstreamofan

aftercoolerorseparatorsothatthetemperatureofthedryer

inletairdoesnotexceed120°Fandtheinletairdoesnot

contain any liquid water.

Mostcompressedairsystemsrequireltersforremoval

ofsolidandliquidcontaminants.Whenanoil-removal

lterisused,itshouldbeinstalleddownstreamofthe

refrigerateddryer.Thedryerwillremovesomeentraineddirt,

extendingthelifeofthereplaceablelterelement.Outlet

air temperature may be 10 to 30 degrees higher than inlet

airtemperature.Thisisnormal.Consultyourdistributorifa

lower outlet air temperature is required.

Piping and Connections

Pipingmustbefurnishedbytheuserunlessotherwise

specied.Connectionsandttingsmustberatedforthe

maximumoperatingpressuregivenonthedryerdataplate

andmustbeinaccordancewithapplicablecodes.Support

allpiping;donotallowtheweightofanypipingtostressthe

dryerorlters.Inletandoutletshutoffvalvesandabypass

valvearerecommended.Pipingshouldbeatleastthesizeof

theinletandoutletconnectionstominimizepressuredrop

intheairsystem.SeeEngineeringDatasectionfordryerinlet

and outlet connections.

Removing Condensate

Aseparatorwithanautomaticdrainvalveissuppliedwith

each dryer. The user must install a separate discharge line

atthedrainconnectiontocarryoffcondensatetoan

environmentally approved condensate collection/disposal

system.Securelyanchordrainlinetopreventwhipping.

Ifcloggingoftheautomaticdrainisaproblem,installa

particulatelterbeforethedryertokeepsolidparticlesfrom

enteringthedryer.Contactyourlocaldistributorforthe

appropriateparticulatelter.

Electrical Connections (See Figure 1)

Dryerisdesignedtooperateonthevoltage,phaseand

frequencylistedontheserialnumbertag.Referencetag

priortomakingelectricalconnection.Dryersaresupplied

withacordandplug.Installinreceptacleofpropervoltage.

Operationofdryerswithimproperlinevoltage

constitutesabuseandcouldaffectthedryerwarranty.

INSTRUMENTATION

ON/OFF Switch

ThedryerisequippedwithanON/OFFswitchonthefront

panel.Alightsignalswhenthedryerison.

Color Indicator

Alldryersareequippedwithacolorindicatorwhichindicates

dryerconditionsasfollows:

Itisnormalfortheindicatorcolortobeintheredzonewhen

thedryerisrstturnedonandthenmovetothegreenzone

whenthedryerreachesitsnormaloperatingtemperature.If

thisindicatorisintheredzoneduringnormaloperation,turn

thedryerofftoavoidcompressordamage.RefertotheField

ServiceGuideforadditionalinformation,orcallyourlocal

distributor.

DRAIN VALVES

Anelectronicdrainvalveissuppliedtoautomatically

dischargecondensatefromthedryer.Thedrainvalveand

itscontrolsareaccessiblefromtherearofthedryer.The

electronic drain valve has two indicators and a test button to

helpverifyoperation.Pushingthetestbuttoncausesthe

drainporttoclickopen.Ifeitherindicatorfailstoturnon

atthepropertime,refertothemaintenancesectionofthis

manual.Drainvalveoperationiscontrolledbyanelectronic

timer.Thedrainopeningcanbesetfrom0.5secto10sec.

Thedraincyclecanbesetfrom0.5minto45min.

Drain Valve Adjustment

Tominimizeairlosses,thedraintimershouldbeadjusted

toopenthedrainportjustlongenoughtodischarge

accumulatedcondensate.Setthetimersothatonlyair

dischargesattheendoftheopenperiod.

Recommended Drain Settings

Time

ModelSCFM Open(Sec) Closed(Min)

25 2 10

35 2 10

50 2 10

NOTE:Ifliquiddischargesastheportisclosing,setthetimerfora

shortercycleoralongeropening.Theamountofcondensatewill

vary as ambient conditions and inlet ﬂow rates change.

START-UP/OPERATION

Follow the procedure below to start your dryer. Failure

tofollowtheprescribedstart-upprocedurewillinvalidate

thewarranty.Ifproblemsariseduringstart-up,callyour

distributor.

RefertoSerialNumberTagfordryeroperating

capacity.Donotexceedrecommendedcapacity.

Drainconnectionsmustbemadebeforethedryercanbe

operated.Thedryersarefullyautomaticandrequireno

auxiliarycontrols.

1. Connectinletandoutletlinestothedryer.Reference

dryerindentationsandinstructiontagforappropriate

inlet and outlet connections.

2. Routedrainconnectionstoacondensateseparatoror

approved collection point.

3. Turntheon/offswitchtoon.Doublecheckconnections.

4. Afterthedryerhasbeenrunningfor30minutes:

a. Checkthaton/offlightedswitchisglowing.Iflight

isnotglowing,unplugunitandrefertoFieldService

Guideforadditionalinformationorcallyourlocal

distributor.

b. ChecktheColorIndicator.IftheIndicatorisinthe

redzone,unplugthedryer.RefertotheField

ServiceGuideforadditionalinformation,orcallyour

local distributor.

c. Conrmthatcondensateisdischargingfromthe

drain. This can only be done when there is air ﬂow

through the dryer.

ReferenceSerialNumberTagforappropriate

powerrequirement/connectionrating.Makeotherdryer

connections prior to connecting power source.

Thedryerisdesignedtoruncontinuously.Letthedryerrun

evenwhenthedemandforcompressedairisinterrupted;

thedryerwillnotfreezeup.

Operating Check Points

1. Powerlightison,lightisilluminated.

2. Condensateisdischargingproperly.

3. ColorIndicatorisintheGreenZone.

SHUTDOWN

Whenthedryermustbeshutdownformaintenanceorother

reasons,usethefollowingprocedure:

1. Turnthepoweron/offswitchtooff.

2. Disconnectthemainpowersupply.

Ifmechanicalrepairsaretobemadeorserviceisperformed,

venttheinternalpressureofthedryertoatmospheric

pressure.Restartthedryeraccordingtothestart-up

instructions.

Disconnectpowersupplyanddepressurize

dryerbeforeservicing.Dismantlingorworkingonany

componentofthecompressedairsystemunderpressure

maycauseequipmentfailureandseriouspersonalinjury.

MAINTENANCE

Thedryersrequirelittlemaintenanceforsatisfactory

operation.Gooddryerperformancecanbeexpectedifthe

followingroutinemaintenancestepsaretaken.

Disconnectpowersupplyanddepressurize

dryerbeforeperforminganymaintenance.

General

Forcontinuedgoodperformanceofyourrefrigerateddryer,

allrefrigerationsystemmaintenanceshouldbeperformedby

acompetentrefrigerationmechanic.

NOTE:Beforecorrectivemaintenanceisdoneduringthe

warrantyperiod,callyourlocaldistributorandproceed

accordingtoinstructions.Refertothewarrantyforlimitsof

your coverage.

Daily Maintenance

Checktheseparatorforcondensatedischarge.Ifno

dischargeisevident,depressurizeandperformthefollowing:

1. ElectricDrain-Cleanstrainerand/orclean/replace

solenoid valve.

Monthly Maintenance

Inspectthecondensercoils.Removeaccumulateddustand

dirtwithasoftbrushorwithairfromanOSHAapproved

compressedairnozzlethatlimitsthedischargepressureto

30 psig.

Electronic Drain Valve Disassembly and Servicing

Donotdisassembledrainvalvetimerorattempt

torepairelectricalparts.Replacetimerifdefective.

Thedrainvalvedischargecondensatethroughafull-port

drain opening. The valve body may need to be cleaned under

conditionsofgrossparticulatecontamination.

Todisassemblethedrainvalvebodyforcleaningandother

maintenance:

1. Turnpowerswitchoff.

2. Disconnectmainpowersupplytodryer.

3. Depressurizeunit.

4. LockoutandtagpowersupplyinaccordancewithOSHA

requirements.

Ifpowersupplyisnotconnectedandunitis

notdepressurizedbeforedisassembly,seriouspersonalinjury

and valve damage may result.

5. Removescrewandwasherfromfrontofthedrainvalve.

6. Removethepowersupplyconnectorandgasket(with

thetimerassemblyifattached)fromthesolenoidcoil

housing.Donotdamageorlosethegasket.

7. Removecoilxingnutandspringwasherfromtopof

solenoid coil housing.

8. Liftsolenoidcoilhousingoffsolenoidcoreinvalvebody.

9. Unscrewsolenoidcorefromvalvebody.

Oncethedrainvalveisdisassembled,thefollowing

maintenancecanbeperformed.

1. Inspectinternalpartsofvalvebody;cleanorreplaceas

required.

 NOTE:Replacesolenoidvalveifcomponentdamageis

observed.

2. Removedebrisfromvalvebody.

3. Wipesolenoidcorecomponentswithacleanclothor

blowoutdebriswithcompressedairfromanOSHA-

approvedairnozzlethatlimitsitsdischargepressureto

30 psig.

4. Checkthattheplungerassemblyiscleanandmoves

freelyinhousing.

5. Iftimerisattachedtovalvebody,checkelectrical

continuity across timer assembly.

Toreassemblethedrainvalve,reversethesequence

oftheprecedingsteps.Afterthedrainvalveis

reassembled,connectthemainpowersupplytothe

dryer.Whenthedryerisreturnedtoservice,check

thedrainvalveforairorcondensateleaks;tighten

connectionsasrequiredtocorrectleaks.Checkthedrain

cycle;adjustthetimeraccordingtotheprocedureinthe

drainvalveadjustmentsection.

Returns to Manufacturer

Ifthedryeroracomponentofthedryermustbereturnedto

themanufacturer,rstcallyourlocaldistributorforareturn

authorizationnumberandshippingaddress.Yourdistributor

willinformyouwhetherthedryeroronlyacomponentmust

bereturned.Markthepackagewiththereturnauthorization

numberandshipfreightprepaidasdirectedbyyourlocal

distributor.

FIELD SERVICE GUIDE

Problemsmostfrequentlyencounteredwithrefrigerated

dryersarewaterdownstreamofthedryerandexcessive

pressuredrop.Mostcausescanbeidentiedandremedied

byfollowingthisguide.

Closedrefrigerationsystemsarepotentially

dangerous.Workontherefrigerationsystemmustbedone

onlybyacompetentrefrigerationmechanic.Donotrelease

uorocarbonrefrigerantstotheatmosphere.Allrefrigerants

mustberecoveredperEPArequirements.Donotsmoke

whenarefrigerationleakissuspected.Burningmaterials

maydecomposerefrigerants,formingatoxicgasoracids

thatmaycauseseriousinjuryandpropertydamage.Before

dismantlinganypartofthedryerorcompressedairsystem,

completely vent the internal pressure to the atmosphere.

PROBLEM SYMPTOM POSSIBLE CAUSE REMEDY

Water Downstream of

Dryer

Refrigerantcompressornot

running.

Leakinrefrigerationsystem. Contact your local distributor.

Compressor overheated. Turndryeroff,wait30minutes;turndryeron.

(Motorthermostatself-starting)

Compressor burned out. Contact your local distributor.

Nocondensatedischargingfrom

dryer.

Failureofdrain. Dismantleandcleanstrainer.Repairorreplace

solenoid valve.

Dryerinletairtemperaturetoo

high.

Aftercoolermalfunction. Checkaftercoolerdischargetemperatureand

reducetodryerdesigncondition(120°Fmax)

Excessive Pressure

Drop Across Dryer

Lowoutletpressure. Dryerundersized(mayalsocause

waterdownstreamofdryer)

Checkairowanddryercapacity.Reduceairowor

resizeandreplacedryer.

Dryericingup.(checkatseparator) Contact your local distributor.

Color Indicator Out of

Green Zone

Indicatorinredzone. Inletairtemperaturetoohigh. Reduceaftercoolerdischargetemperaturetodesign

conditions(SeeEngineeringData).

Condenserfouledorclogged. Clean or replace condenser.

Inletairtemperaturetoohigh. Reduceaftercoolerdischargetemperaturetodesign

conditions.(SeeEngineeringData)

Highambienttemperature. Ventilatearea.

Improperadjustmentofexpansion

valve.

Removecapfromtheexpansionvalveandturnthe

screwuntiltheindicatorisinthegreenzone.

Indicatorinbluezone. Improperadjustmentofexpansion

valve.

Adjusttheexpansionvalveuntiltheindicatorisin

thegreenzone.

Lowambienttemperature. Increaseambienttemperaturetodesignconditions.

ENGINEERING DATA

MODEL 25 35 50

SPECIFICATIONS

Rated Capacity

-(scfm) 25 35 50

Inlet/OutletConnections-(inches) 3/4 3/4 3/4

Dimensions

Height-(inches) 22.2 22.2 22.2

Length-(inches) 15.5 15.5 19.7

Width-(inches) 14.5 14.5 19.7

PowerSupply-(V/Ph/Hz) 115/1/60 115/1/60 115/1/60

RefrigerantCompressorRating-(hp) 1/4 1/4 1/3

InputPower-(kW) 0.47 0.47 0.63

RefrigerantType

R-134a R-134a R-134a

Rating conditionsare100°Finlettemperature,100psiginletpressure,100%inletrelativehumidity,100°Fambienttemperature@60Hz.PerCAGIADF-100.

Refertodryerdataplateforrefrigerantcharge.

MODEL 25, 35, 50

MINIMUM - MAXIMUM OPERATING CONDITIONS

Min.-Max.InletAirPressure(compressedairatinlettodryer) 30-250psig

Min.-Max.InletAirTemperature(compressedairatinlettodryer) 40°F-120°F

Min.-Max.AmbientTemperature 40°F-110°F

NOTE:Continuousoperationintheabovemaximumandminimumoperationconditionsisnotallowable.

ELECTRICAL SCHEMATICS

ON/OFF SWITCH

WITH RUNNING LAMP

PTC STARTER

COMP.

1PH

OVERLOAD

PROTECTOR

DRAIN SOL.

VALVE TIMER

Figure 1

25-50 scfm models

AIR AND REFRIGERANT FLOW SCHEMATICS

Figure 2

25-50 scfm models

HEAT EXCHANGER

REHEATER

AIR OUTLET

AUX. CONDENSER

CONDENSER

REF. COMPRESSOR

ELECTRONIC

DRAIN

VALVE

LIQUID RECEIVER

FILTER DRYER

CONSTANT PRESSURE

EXPANSION VALVE

DRAIN OUTLET

COLOR INDICATOR

C.I.

CHILLER

EVAPORATOR

AIR INLET

REPLACEMENT PARTS

Item 25 35 50

RefrigerantCompressor 3149273 3146980 3149274

Condenser 3149275 3149275 3149275

LiquidReceiver/FilterDryer 1283369 1283369 1283369

ConstantPress.ExpansionValve 3041489 3041489 3041489

ElectronicDrainValve 3149293 3149293 3149293

ColorIndicator 3041493 3041493 3041493

On/OffSwitch 3041494 3041494 3041494

HeatExchanger 3149278 3149279 3149280

MaintenanceKits RNPJMK2 RNPJMK2 RNPJMK2

AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL IS

RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.

WARRANTY

Themanufacturerwarrantstheproductmanufacturedbyit,whenproperlyinstalled,operated,applied,andmaintainedinaccordancewithproce-

duresandrecommendationsoutlinedinmanufacturer’sinstructionmanuals,tobefreefromdefectsinmaterialorworkmanshipforaperiodas

speciedbelow,providedsuchdefectisdiscoveredandbroughttothemanufacturer’sattentionwithintheaforesaidwarrantyperiod.

Themanufacturerwillrepairorreplaceanyproductorpartdeterminedtobedefectivebythemanufacturerwithinthewarrantyperiod,provided

suchdefectoccurredinnormalserviceandnotasaresultofmisuse,abuse,neglectoraccident.Normalmaintenanceitemsrequiringroutinereplace-

mentarenotwarranted.Thewarrantycoverspartsandlaborforthewarrantyperiodunlessotherwisespecied.Repairorreplacementshallbemade

atthefactoryortheinstallationsite,atthesoleoptionofthemanufacturer.Anyserviceperformedontheproductbyanyoneotherthanthemanu-

facturermustrstbeauthorizedbythemanufacturer.

Unauthorizedservicevoidsthewarrantyandanyresultingchargeorsubsequentclaimwillnotbepaid.Productsrepairedorreplacedunderwarranty

shallbewarrantedfortheunexpiredportionofthewarrantyapplyingtotheoriginalproduct.

Theforegoingistheexclusiveremedyofanybuyerofthemanufacturer’sproduct.Themaximumdamagesliabilityofthemanufactureristheoriginal

purchasepriceoftheproductorpart.

THEFOREGOINGWARRANTYISEXCLUSIVEANDINLIEUOFALLOTHERWARRANTIES,WHETHERWRITTEN,ORAL,ORSTATUTORY,ANDISEXPRESSLYINLIEU

OFTHEIMPLIEDWARRANTYOFMERCHANTABILITYANDTHEIMPLIEDWARRANTYOFFITNESSFORAPARTICULARPURPOSE.THEMANUFACTURERSHALL

NOTBELIABLEFORLOSSORDAMAGEBYREASONOFSTRICTLIABILITYINTORTORITSNEGLIGENCEINWHATEVERMANNERINCLUDINGDESIGN,MANUFAC-

TUREORINSPECTIONOFTHEEQUIPMENTORITSFAILURETODISCOVER,REPORT,REPAIR,ORMODIFYLATENTDEFECTSINHERENTTHEREIN.

THEMANUFACTURER,HISREPRESENTATIVEORDISTRIBUTORSHALLNOTBELIABLEFORLOSSOFUSEOFTHEPRODUCTOROTHERINCIDENTALORCONSE-

QUENTIALCOSTS,EXPENSES,ORDAMAGESINCURREDBYTHEBUYER,WHETHERARISINGFROMBREACHOFWARRANTY,NEGLIGENCEORSTRICTLIABILITY

INTORT.

Themanufacturerdoesnotwarrantanyproduct,part,material,component,oraccessorymanufacturedbyothersandsoldorsuppliedinconnection

withthesaleofmanufacturer’sproducts.

Warranty Period

Partsandlaborfortwo(2)yearsfromthedateofshipmentfromthefactory;heatexchangersarecovered(partsonly)foranadditionalthree(3)

years(totalofve[5]).Onunitsthatmanufacturerrequestsbereturnedtothefactory,aonetimeremoval/reinstallationlaborallowanceasnotedin

theServiceWarrantyPoliciesandProceduresHandbookwillapply.Freighttothefactoryfromtheinstallationsiteandtotheinstallationsitefromthe

factorywillbepaidbythemanufacturer;meansoftransportationtobespeciedbymanufacturer.

SERVICE DEPARTMENT: (724) 746-1100

Curtis-Toledo, Inc.

1905 Kienlen Avenue, St. Louis Missouri 63133

phone: 314-383-1300 fax: 314-381-1439 email: [email protected]