FS-Curtis RNP50 User manual

Type
User manual

This manual is also suitable for

3227447
Rev. A
AUGUST 2012
RNP SERIES
REFRIGERATED COMPRESSED AIR DRYERS
OPERATOR
MANUAL
RNP25 RNP35 RNP50
2
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).
3
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.
4
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.
5
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.
6
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.
7
ENGINEERING DATA
MODEL 25 35 50
SPECIFICATIONS
Rated Capacity
a
-(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
b
R-134a R-134a R-134a
a
Rating conditionsare100°Finlettemperature,100psiginletpressure,100%inletrelativehumidity,100°Fambienttemperature@60Hz.PerCAGIADF-100.
b
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.
8
ELECTRICAL SCHEMATICS
ON/OFF SWITCH
WITH RUNNING LAMP
R
25
6
PTC STARTER
S
M
COMP.
1PH
C
OVERLOAD
PROTECTOR
DRAIN SOL.
VALVE TIMER
T
Figure 1
25-50 scfm models
9
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
10
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]
WWW.FSCURTIS.COM
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FS-Curtis RNP50 User manual

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