Denco C14-1 Manuale utente

Contents

DescriptionPage

Introduction3

Warranty3

Health and Safety4

Machine Card4

GeneralSafety Instructions5

Refrigerant R134a Safety Data6

Installation8

Installation – Electrical9

Installation – Mechanical9

Installation Recommendations9

Commissioning10

Start-Up Procedure10

Description ofOperation10

Schematic FlowDiagram11

GeneralArrangement Drawings12

TechnicalDescription ofComponents17

TechnicalData Tables18

ElectricalDescription20

Wiring Diagrams22

ControlofRefrigerant Discharge26

Log Book26

Routine Maintenance27

Fault Finding28

Notes31

Information

Thisproduct hasbeen manufactured for: Denco Limited

Dolphin House

Moreton Business Park

Moreton-on-Lugg

Hereford

HR4 8DS

Telephone: +44 (0) 1432 277277

Facsimile: +44 (0) 1432 377364

Important

The refrigerant availableon the CseriesofCompressed AirDryersis Refrigerant R134a or Refrigerant

R407C.It isimperativethat refrigerantsare not mixed. Alabelisfixed to each compressor, which identifiesthe

refrigerant being used withinthe unit, and that refrigerant ONLY shouldbe used inthe dryer. R134a &R407C

are ozone benign refrigerantsand meet the requirementsofthe revised “MontrealProtocol”. Theserefrigerants

require the useofESTER oil withinthe systemand not MINERAL oil asused with R22 systems,and therefore

again these oilsmust NOT be mixed.

Introduction

The Denco CseriesofCompressed AirDryersare used to removeentrained moisture fromcompressed air

supplysystemsand thusprotect the variouscomponentsand are designed such that routine maintenance is

kept to a minimum.

Mostpartsare fieldreplaceablebut shouldmajor maintenance or repairbe required pleaserefer to Denco

Limited or an authorised distributor.

NOTE: This manual applies ONLY to the Cseries of Compressed Air Dryers.For actual model refer to serial

plate fitted to the unit. For other ranges refer to the respective manuals.

Warning

TheseDryersare onlydesigned for usewith compressed airat or belowthe design maximumpressure (see

TechnicalData sheet(s) for maximumworking pressuresapplicable). These Dryersmust NOT be used for drying

any other gasesor fluidsat other pressures.Operation oftheseDryersusing compressed airofagreater

temperature than that specified will causeexcessivelyhigh pressuresinthe refrigeration system,which may be

dangerous.

The air supplied to the dryer must be free ofany corrosive or combustible gasesor impurities.

Warranty

The warranty will onlybe considered validifthe equipment supplied isinstalled, commissioned and maintained

inaccordance with the instructionsissued by Denco Limited. Furthermore the Company will not accept any

liability whatsoever shouldthe Dryer be installed incorrectlyor operated outside itsstated design dutiesand

operating conditionsor improper use be made ofthe equipment.

Health and Safety

Due regard shall be given to observing safeprocedureswhen working with or on the equipment. It isthe

responsibility ofthe Installer /Operator /Customer to ensure that the “Health and Safety at Work Act (1974)”

and NormalSafe Working Proceduresare adhered to at all times.

With reference to the "ControlofSubstancesHazardousto Health Regulations1988 (COSHH)” the following

paragraphshave been extracted fromDenco’sletter responding to information requested

“However, certainsubstancescontained withinmaterialsused inthe manufacture ofour unitscouldbe

hazardouswhen released, ifthe unit ismisused, abused or maintained by unskilled labour.

Fumeswouldbe released ifpipework or slab foaminsulation (Armaflexor similar), electricalinsulation or vinyl

coatingswere exposed to naked flame. It will be, therefore, that no naked flameshouldbe applied to any ofthe

above mentioned substances, nor to print, rubber or plastic parts.

Light oil isapplied to somebare metalpartsasaprotectivecoating and thiscouldcausedermaticreaction to

sensitive skin.

Refrigerantscontainhydrofluorocarbons(HFC’s). Glycol/water mix isused during manufacture but drained

before delivery. The quantitiesin use are minimalbut care should be taken in disposal.

Wetrustthat thisinformation issufficient but shouldyou require further information regarding our productsor

maintenance service, please contact our salesdepartment.”

Machine Card

In order to complywith BS EN 378-2:2000 “Refrigeration Systemsand Heat Pumps–Safety and Environmental

Requirements”, an adequatelyprotected card shall be situated near the operating site and mustbe clearly

readable. The card shall at least contain the following information:

1) Name, address and telephone number ofthe installer, hisservice department, or the person responsible

for the refrigeration and the addressesand telephone numbersofthe Fire Department, Police, Hospitals

and BurnsCentres

2) The refrigerant isR134a or R407C (refer to TechnicalData Table)

3) To shut downthe Compressed AirDryer inan emergency, switch off the unitusing the ON/OFF isolating

switch on the front panel. The mainssupply to the Dryer should be isolated at the mainsisolator.

4) MaximumAllowable Pressures

Compressed Air13 barg

5) Flammability Limitsin Air

NONE

General SafetyInstructions

IMPORTANT:THE FOLLOWING SAFETYPRECAUTIONS MUST BE READAND UNDERSTOOD BEFORE

REPAIR OR MAINTENANCE WORK IS ATTEMPTED.

General

Beware ofthe following danger areaswithin the dryer :

a) Any rotating components(fan etc.)

b) Sharp edges(coil fins, etc.)

c) Hot refrigeration pipework

d) Possible live electricalcomponentsor terminals

The refrigeration and compressed aircircuitscan operate at high pressuresand unauthorised tampering

may cause injury or damage.

Discharge fromthe condensate drain will contain oil, and therefore should be disposed ofsafely.

Do not place either temporary or permanent loadson or against the unit.

Mechanical

The dryer shall be fully disconnected or isolated fromthe compressed air supply and any remaining pressure

released safely.

The refrigeration circuitshall be fullyemptied ofgassafelyBEFORE work isattempted on any associated

components.Refrigerant gasmay be toxicand/or harmful(burns-both hot and cold), therefore usethe

necessary protective equipment (such asgogglesand gloves) at all timeswhen emptying the system,

Ifany heat or flameisto be used on or near the unitcare shall be taken to avoidcontact with combustible

surfaces.Furthermore, itshouldbe noted that the insulation materialsand refrigerant might giveoff toxic

fumeswhen heated. Whenever heat or flameisused the working area shall be thoroughlyventilated

BEFORE and DURING thisoperation. Proper fire precautionsshall be observed and the necessary fire

safety equipment on hand, typicalfor electrical, oil and foamfires,

The refrigerant used isrefrigerant R134a or R407C. No other type ofrefrigerant or mixture shall be used.

Ifrecharging or adding refrigerant to the unitensure correct refrigerant and oil are used, check labelson

compressor identifying refrigerant being used.

Ester oilsused insystemswith R134a &R407C are very hygroscopic(adsorb moisture very quickly),

therefore care shouldbe taken to ensure that the systemsand any ester oil containersare not leftopen to

atmosphere for any length oftime.

Ifany oil isremoved fromthe systemitshall be disposed ofsafely. Do not re-useor usefor any other

purpose.

When working on the dryersbeware ofany rotating componentsand any hot refrigerant pipework.

Observe any safety labelsfitted to variouspartsofthe dryer.

Electrical

The dryersare designed to operate onlyon a220/240 volt, 1phase, 50-60 Hz liveneutraland earth supply.

THE EARTH CONNECTION MUST NEVER BE OMITTED. The voltage tolerance for each modelisshown

on the respective wiring diagramin thisManual.

The dryer must be fully isolated fromthe supply BEFORE maintenance work isstarted.

The dryer MUST NOT be used on other supplieswithout prior approvalfromthe manufacturer.

The dryer should only be used in a SAFE (i.e. non- hazardous) area.

Observe any electricalsafety labelsfitted to variouspartsofthe dryer.

Solenoid coilsshould not be removed fromvalve stemuntil they have been electrically disconnected.

Refrigerant SafetyData

Reactivity Data

UnstableStability StableYES Conditions to Avoid

Use in presence ofnaked flames, red-hot surfaces. High moisture levels

Incompatibility (Materials and Conditions to Avoid)

May react violently with sodium, potassium, bariumor other alkali or alkaline earth materials.

Magnesiumand alloyscontaining more than 2% magnesium. All finely divided metals.

Hazardous Decomposition Products

Halogen acidsformed by thermaldecomposition.

Fire and Explosion Hazard Data

Flash Point (oC) Method

------ Auto-ignition Temperature (oC)

---

Flammable Limits (%by Vol. in Air) Lower Upper

Non Flammable--- ---

Would any materialsaturated Materials:

with thisproduct be subject to

spontaneouscombustion? No

Fire Extinguishing Data

Non flammable, not combustible.

Special Fire Fighting Procedures

Fire exposed containersshould be kept coolwith water sprays.

Usual Fire and Explosion Hazards

Will decompose in contact with high temperature sources, i.e. flames, electric arcs, etc. to produce irritating

and highly toxic acidic products. Breathing apparatusshould be worn ifrefrigerant isexposed to fire

conditions. Containersmay burst ifoverheated.

Precautions in Handling and Use

General Precautions

Atmospheric levelsshould be minimised and kept aslowasreasonably practicable belowhygiene standard.

Avoid inhalation ofhigh concentrationsofvapour. Heavy vapour collectsat lowlevels. Ventilate by extraction

at lowest level. Decomposesin flames, arcsand at red heat to toxic acid by-products. Avoid contact between

liquid and skin or eyes.

Ventilation Requirements

Ventilation may be required to achieve a sufficiently

lowexposure level. Extract at lowest level. Vapour

collectsin pits, trenches, basements, sewersand in

confined spacesand vessels.

Respiratory Protection

Where doubt existson atmospheric concentration and

particularly in confined spaces, self-contained

breathing apparatusshould be considered. Breathing

apparatusshould alwaysbe worn in a fire situation.

Protective Clothes

Where liquid splash isa possibility glovessuitable

for use in lowtemperaturesshould be worn e.g.

chlorobutylrubber with cotton liners.

Overalls.

Eye Protection

Goggles.

Storage

Containersshould be stored in a cooldry place away fromfire risk and sourcesofheat. They should not be

exposed to direct radiation fromsourcesofheat such assteamor electric radiators. Do not heat containers

beyond 45oC.

Health Hazard Data and First Aid

Short term effects of over exposure when:

In contact with skin: Liquid splashesmay cause freeze burns. No information found on irritancy or

sensitisation. There isno known hazard due to absorption through the skin.

In contact with eyes:Liquid splashesor vapour spray may result in freezing oftissue or eye fluids.

Inhaled: Very high concentrationsmay produce anaesthetic effectsand can act asan

asphyxiant by limiting available oxygen. They also may prove suddenly fatal

(cardiac sensitisation).

10 mineffective concentration 50 28% (Rat)

15 minlethalconcentration 50 >80% (Rat)

4 hr lethalconcentration 50 >50% (Rat)

Threshold for cardiac sensitisation 7.5% 5 min(Dog)

Ingested: Extremely unlikely to occur under normalindustrialuse.

Should thisoccur freeze burnswill result.

Long term effects of over exposure:

No effectshave been seen in ratsexposed to up to 50,000 ppmfor 90 days. It isnot teratogenic in ratsor

rabbits. Short-termscreening testsfor carcinogenicity have proved negative. No long-termeffectswere noted

when administered by gavage to ratsat a dose of300 mg/kg/day for one year and the ratsheld for the

remainder oftheir life span.

Occupational Exposure Limit (OEL):

1000 ppmv/v– 8 hr TWA value.

Emergency and First Aid Procedures:

Skin: Thawaffected areaswith water, remove contaminated clothing carefully, wash affected areas

ofskin thoroughly with copiousamountsofwarmwater. Ifsymptomsoccur, obtain medical

attention.

Eyes:Irrigate with eyewash solution or clean water for at least 10 minutes. Obtain immediate

medicalattention.

Inhalation: Remove patient to fresh air, keep warmand at rest, administer oxygen ifnecessary. Apply

artificialrespiration ifbreathing hasceased. Apply externalcardiac massage in the event of

cardiac arrest. The use of adrenaline or similar sympathomimetic drug should be

avoided. Obtain immediate medicalattention.

Ingestion: Highly unlikely. Should thisoccur freeze burnswill result.

Further Medical Advice

Symptomatic and supportive therapy asindicated. Cardiac sensitisation hasbeen described which may, in

the presence ofcirculating catecholaminessuch asadrenaline, give rise to cardiac arrythmiasand

subsequent arrest following exposure to high concentrationsofvapour. Therefore, adrenaline and similar

sympathomimetic drugsshould be avoided.

Spill or Leak Procedures

Steps to be taken in event of Spill or Release

Shut off leak ifwithout risk. Allowspilled liquid to evaporate. Contain spillage with sand or earth, prevent

liquid entering sewers, basementsand pitssince vapour may create suffocating atmosphere.

Neutralising Chemicals

None necessary.

Disposal Procedures

Best to recover and recycle. Ifthisisnot possible, destruction isto be in an approved facility, which is

equipped to absorb and neutralise acidsand other toxic processing products.

Installation - General

Storage

The equipment shouldbe stored inasecure frostfree area with amaximumambient of55°C and maximum

humidity of90% non-condensing.

Unpacking

Carefully remove the unit fromitspacking and examine it for obviousdefectsor damage including:

Paint damage.

Case deformation.

Integrity ofelectricalcable.

Breakage ofgauge glass (where applicable).

Ifany ofthe abovefaultsare noted, or any other defect or damage isobserved and itbecomesnecessary to

return the unit for rectification, thisshould be done in accordance with the procedure agreed with the supplier.

Moving

Due care shall be taken when moving the dryer not to causeinjury to personnelthrough improper safety

precautions.

NOTE: The dryer must be kept in the upright position at all timesto avoid damaging the compressor.

Lifting

The unitsare designed for fork lifting fromthe base. The baseisuneven –ensure that the forksare extended

fully through.

Do NOT use convenient pipes, boltsor aperturesin the dryer aslifting points.

Positionof Unit

The dryer should be placed on a firm, levelload bearing surface of adequate strength and asuitablearea be left

clear ofobstruction at the inlet and outlet grillesand the access panels(see note reference ambient

temperatures). To prevent airrecirculation the condenser coil mustbe situated at least500 mm fromawall,

partition etc. Sufficient space must be left for service access around the unit.

The C seriesunit are NOT suitable for direct wall mounting.

Ambient Temperatures

Care shouldbe taken to ensure that there isadequate aircirculation and the Dryersshouldnot be placed in

areaswhere the ambient temperature islikelyto exceed the recommended design maximum (refer to Technical

Data tables).

Removal of Covers

Generalaccess for installation or maintenance isviathe coverswhich are removableby removing the screws

around the panels.

Corrosion

Aircooled unitsare designed for operation innormalambient air. Any corrosiveagent inthe airsuch as

ammonia, sea water spray etc. will causecorrosion and wouldrequire specialprotectivemeasures.Corrosion

can result in release ofpressure and refrigerant.

Installation - Electrical

The C seriesDryersrequire a 220/240 Volt 1 phaseand neutral50-60 Hz supply. Aflying lead isinstalled on the

dryer for convenience. The cable core coloursare:

BrownLive

BlueNeutral

Green / YellowEarth

Ifthe unitisconnected to ajunction box,receiving itssupplyfromanother source (e.g., auxiliary contactsofa

mainstarter, or arelay), then itisimportant that electricalprotection isprovided by meansofasuitablyrated

H.R.C. fuselocated inthe line. Installation mustcomplywith the latestedition of IEE Wiring Regulations,Safety

Standardsand any LocalCodesofPractice that apply.

Installation - Mechanical

Connect the compressed airpipework to the Dryer using approved pipe and fittingsofthe correct rating and

type. To ensure damage doesnot occur to internalpipework and componentsduring the connection process,

removeaccess cover(s)and ifnecessary support the internalpipework /components.Pleaseensure that ALL

shut off valvesare fully open before starting unit.

The drainconnection shouldbe connected to asuitablysized drainline and piped to asuitableoil /water

separator prior to drain.

Installation Recommendations

The compressed airpipework shouldincorporate sufficient shut-off valvesto enablethe dryer to be by-passed

and/or disconnected in the event ofrepair or replacement.

Apurge valveshouldalsobe fitted at aconvenient point to enablethe airpressure to be released safelyand

gradually before undoing any connections.

Asuitablysized pressure safety device shouldbe fitted to prevent over-pressurisation ofthe compressed air

dryer.

Ifthe compressor pumpsintermittently, or the totalairdemand doesnot exceed the totalflowrate ofthe

compressor, the dryer MUST be installed downstreamofthe receiver.

Ifthe receiver issized to permitwide fluctuationson airdemand or ifpeak demand exceed compressor

maximumflowrate, the dryer SHOULD be installed upstreamofthe receiver.

Aminimum of 5micron (Denco recommend 1micron) pre-filter mustbe fitted to removeimpuritiesfromthe air

prior to itentering the dryer. Additionalfiltration may be required downstreamofthe dryer subject to the site

requirements.

1Air Compressor

2Receiver

3SafetyValve

4Shut off valve

5Pre-filter (1 micron)

6Refrigerant Dryer

7 After-filter

(0.01 micron, dust filter &

activated carbon asrequired)

Commissioning

The unitsare factory pre-set and commissioned and shouldnot need any fieldadjustment. However, ifafter a

period oftimethe unitisfound to be operating poorlyor incorrectly, thismay be due to arange offaultsor

problemswhich may be analysed by reference to the Fault Finding section ofthismanual.

Start-up Procedure

Important

Do not allow the compressed air to flow through the unit until the following checks have been made

AND THE UNITSWITCHED ON.

1. Switch the on-off switch /isolator to the "ON" (I)position. The following observationswill indicate correct

operation:

The fan will start

An airflowwill be felt fromthe condenser discharge grille

After 2minutes,the compressor will start and alow-levelnoisewill be heard similar to that ofa

domestic refrigerator.

2. After a further 5 minutes, slowly allowthe compressed air supply into the dryer.

3. Press the VALVE button to check the operation ofthe condensate discharge valve.

Note:

Somesafety cut outsare auto reset, and unless isolated fromthe mainsthe unitcan be re-started without

warning.

Pressure switchesshould be adjusted with the power off.

Any work done to the Compressed AirDryer involving entry into the controlpanel,fitting gauges,adjusting

controls, charging the system,evacuating the system or opening the system inany way, mustbe carried out

by aFULLY QUALIFIED REFRIGERATION ENGINEER. ACity and Guilds2078 or equivalent certificate is

strongly advised and will soon be mandatory.

Description of Operation

The saturated compressed airentersthe evaporator and ispre-cooled by the outgoing cooler air. The internal

refrigerant circuitisthen used to further coolthe airto itsrequired dewpoint. Once dewpoint isachieved, the

moisture condenses,and the water dropletsare ejected viathe condensate drainsystem.The cold, dry airis

then warmed by the incoming warmair and discharged, dry, to the downstreampipework.

The refrigerant circuitisofconventionaldesign operating on ozone benign Refrigerant R134a ofR407c and

incorporatesan hermeticcompressor, combined air/airand evaporator type heat exchanger, an aircooled

condenser, an expansion device (capillary tube or thermostaticexpansion valve), afilter/dryer, ahot gasby-

pass valve. The refrigeration circuit iscontrolled by meansofa simple but effective panelmounted controller

Schematic Flowand General Arrangement Drawings

Model NumbersSchematic Flow

Diagram Number Outline Arrangement

Drawing Number

C9-1, C14-1, C19-1PS1061-C-021PS1061-C-001

C31-2, C39-2, C58-2PS1061-C-021PS1061-C-002

C92-3, C120-3PS1061-C-021PS1061-C-003

C147-3PS1061-C-021PS1061-C-004

C175-4, C238-4PS1061-C-021PS1061-C-005

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