Air Dryer Maintenance Guide
Air Dryer Maintenance Guide
EGRD
010 – 500
EGRDUL10TO500ENR01
7425MUM296UL_EN_04.0
Dear Customer,
thank you for choosing our product. In order to get the best performances out of this product, please read
this manual carefully.
To avoid incorrect operation of the equipment and possible physical risk to the operator, please read and
strictly follow the instructions contained in this manual.
Note, these instructions are in addition to the safety rules that apply in the country where the dryer is
installed.
Before packing for shipment each EGRD series refrigerated air dryer undergoes a rigorous test to ensure
the absence of any manufacturing faults and to demonstrate that the device can perform all the functions for
which it has been designed.
Once the dryer has been properly installed according to the instructions in this manual, it will be ready for
use without any further adjustment. The operation is fully automatic, and the maintenance is limited to few
controls and some cleaning operations, as detailed in the following chapters.
This manual must be maintained available in any moment for future references and it has to be
intended as inherent part of the relevant dryer.
Due to the continuous technical evolution, we reserve the right to introduce any necessary change without
giving previous notice.
Should you experience any trouble, or for further information, please do not hesitate to contact us.
2 Warranty conditions
For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty
covers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and
restaurant expenses of our engineer.
The warranty doesn’t cover any responsibility for direct or indirect damages to persons, animals or
equipment caused by improper usage or maintenance, and it’s limited to manufacturing faults only.
The right to warranty repairs is subordinated to the strict compliance with the installation, use and
maintenance instructions contained in this manual.
The warranty will be immediately voided in case of even small changes or alterations to the dryer. To require
repairs during the warranty period, the data reported on the identification plate must be notified.
Carefully read instruction manual before attempting any service or maintenance procedures on the
dryer.
Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not
followed properly.
Electrical hazard. Warning message indicates practices or procedures that could result in personal
injury or fatality if not followed correctly.
Danger hazard. High temperature conditions exist during operation of system. Avoid contact until
system or component has dissipated heat.
Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may
result if precautions are not followed.
Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptable
means in cases of fire.
ARIA
AIR
LUFT Compressed air inlet connection point
AIR
ARIA
AIR
LUFT Compressed air outlet connection point
AIR
Operations which can be performed by the operator of the machine, if qualified [1].
NOTE: Text that specifies items of note to be taken into account does not involve safety precautions.
In designing this unit a lot of care has been devoted to environmental protection:
CFC free refrigerants
CFC free insulation parts
Energy saving design
Limited acoustic emission
Dryer and relevant packaging composed of recyclable materials
This symbol requests that the user heed environmental considerations and abide with suggestions
annotated with this symbol.
[1] Experienced and trained personnel familiar with national and local codes, capable to perform the needed activities, identify and
avoid possible dangerous situations while handling, installing, using and servicing the machine. Ensuring compliance to all statutory
regulations.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of
electrical fire.
The purpose of the machine is the separation of water and eventual oil particles present in
compressed air.
The dried air cannot be used for breathing purposes or for operations leading to direct contact with
foodstuff.
This dryer is not suitable for the treatment of dirty air or of air containing solid particles.
4 Installation
4.1 Transport
Check for visible loss or damage, if no visible damage is found place the unit near to the installation point
and unpack the contents.
To move the packaged unit we recommend using a suitable trolley or forklift truck. Hand carrying is not
recommended.
Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid on
its side or if placed upside down.
Handle with care. Heavy blows could cause irreparable damage.
4.2 Storage
Even when packaged, keep the machine
protected from severity of the weather.
Keep the dryer in vertical position, also when
stored. Turning it upside down some parts could
be irreparably damaged.
If not in use, the dryer can be stored in its
packaging in a dust free and protected site at a
temperature of 32°F (0°C) … 122°F (50°C), and
a specific humidity not exceeding 90%. Should
the stocking time exceed 12 months, please
contact the manufacturer.
SCC0001
The packaging materials are recyclable. Dispose of material in compliance with the rules
and regulations in force in the destination country.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of fire.
1 Air compressor
2 Aftercooler
3 Condensate separator
4 Pre-Filter (min. 5 micron)
5 By-pass group
6 Dryer
7 Compressed air tank
8 Final filter
9 Condensate drain
In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend
the additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the
heat exchanger.
Type A installation is suggested when the compressor operates at reduced intermittence and the total
consumption equals the compressor flow rate.
Type B installation is suggested when the air consumption can consistently change with peak values highly
exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensate
eventual instantaneous demanding conditions (peak air consumption).
61 scfm (104 m³/h) This is the maximum flow rate that the dryer can accept under these operating
conditions.
The dryer comes already fitted with a timed condensate drainer (solenoid valve controlled by electronic
instrument).
Connect and properly fasten the condensate drain to a collecting plant or container.
The drain cannot be connected to pressurized systems.
Don’t dispose the condensate in the environment.
The condensate collected in the dryer contains oil particles released in the air by the compressor.
Dispose the condensate in compliance with the local rules.
We recommend to install a water-oil separator where to convey all the condensate drain coming
from compressors, dryers, tanks, filters, etc.
Ensure that all the steps of the “Installation” chapter have been observed.
Ensure that the connection to the compressed air system is correct and that the piping is suitably fixed
and supported.
Ensure that the condensate drain pipe is properly fastened and connected to a collection system or
container.
Ensure that the by-pass system (if installed) is closed and the dryer is isolated.
Ensure that the manual valve of the condensate drain circuit is open.
Remove any packaging and other material which could obstruct the area around the dryer.
Activate the mains switch.
Turn ON the switch - pos. 1 on the control panel.
Ensure that electronic instrument is ON.
Ensure the consumption matches with the values of the data plate.
Ensure the fan works properly – wait for its first interventions.
Allow the dryer temperature to stabilise at the pre-set value.
Slowly open the air inlet valve.
Slowly open the air outlet valve.
Slowly close the central by-pass valve of the system (if installed).
Check the piping for air leakage.
Ensure the drain is regularly cycling - wait for its first interventions.
Check that the DewPoint temperature indicated on the electronic instrument is within range.
Shut down the air compressor.
After a few minutes, turn OFF the switch - pos. 1 on the control panel.
NOTE : A DewPoint included in the green operating area of the electronic controller is correct according to
the possible working conditions (flow-rate, temperature of the incoming air, ambient temperature, etc.)
During the operation, the refrigerant compressor will run continuously. The dryer must remain on during the
full usage period of the compressed air, even if the air compressor works intermittently.
1
ON DMC15
0
sec - min
Set
1
PQS0008
2 3
I K
ON
ON DMC15
sec - min
Set
PQS0024
1 2 3
1 ON-OFF Switch
2 Electronic instrument
3 Air and refrigerant flow diagram
7.2 Operation
Operating principle - The dryer models described in this manual operate all on the same principle. The hot
moisture laden air enters an air to air heat exchanger. The air then goes through the evaporator, also known
as the air to refrigerant heat exchanger. The temperature of the air is reduced to approximately 36°F (2°C),
causing water vapor to condense to liquid. The liquid is continuously coalesced and collected in the
separator for removal by the condensate drain. The cool moisture free air then passes back through the air
to air heat exchanger to be reheated to within 8 degrees of the incoming air temperature as it exits the dryer.
Refrigerant circuit - Refrigerant gas is cycled through the compressor and exits at high pressure to a
condenser where heat is removed causing the refrigerant to condense to a high-pressure liquid state. The
liquid is forced through a capillary tube where the resulting pressure drop allows the refrigerant to boil off at
a predetermined temperature. Low-pressure liquid refrigerant enters the heat exchanger where heat from
the incoming air is transferred causing the refrigerant to boil; the resulting phase change produces a low
pressure, low temperature gas. The low-pressure gas is returned to the compressor, where it is re-
compressed and begins the cycle again. During those periods when the compressed air load is reduced the
excess refrigerant is by-passed automatically back to the compressor via the hot gas by-pass valve circuit.
2 3 4 5
P< TS P> PV
1a
7
1 9 8
1b
17 EC M
12.1
T1
12.2
1c
11 10 T2
DGF0110
15
Standard 13 14 16
EC
ELD
21
Optional
7.5 Condenser
The condenser is the component in which the gas coming from the compressor is cooled down and
condensed becoming a liquid. Mechanically, a serpentine copper tubing circuit (with the gas flowing inside)
is encapsulated in an aluminum fin package.
The cooling operation occurs via a high efficiency fan, creating airflow within the dryer, moving air through
the fin package. It’s mandatory that the ambient air temperature does not exceed the nominal values. It is
also important to keep the condenser unit free from dust and other impurities.
VLY0001
+
connected, a part of refrigerant is exhausted.
Without compressed air flow through the dryer, rotate the adjusting
screw (position A on the drawing) until the following value is reached:
Hot gas setting :
R134.a pressure 29.0 psig (+ 1.45 / -0 psi) [2.0 barg (+0.1 / -0 bar)]
R407C pressure 65.3 psig (+1.45 / -0 psi) [4.5 barg (+0.1 / -0 bar)]
LPS : Low-pressure protection device on the suction side of the compressor, trips if the pressure drops
below the pre-set value. The values are automatically reset when the nominal conditions are
restored.
Calibrated pressure : R 134.a Stop 10.2 psig (0.7 barg) - Restart 24.7 psig (1.7 barg)
R 407 C Stop 24.7 psig (1.7 barg) - Restart 39.2 psig (2.7 barg)
HPS : This high-pressure controller device, located on the discharge side on the compressor, is activated
when the pressure exceeds the pre-set value. It features a manual-resetting button mounted on the
controller itself.
Calibrated pressure : R 134.a Stop 290 psig (20 barg) - Manual reset P<203 psi (P<14 bar)
R 407 C Stop 435 psig (30 barg) - Manual reset P<334 psi (P<23 bar)
PV : Fan control pressure switch located at the discharge side of compressor. It keeps the condensing
temperature/pressure constant within preset limits.
Calibrated pressure : R 134.a Start 160 psig (+7.25 / -0 psi) [11 barg (+0.5 / -0 bar)]
Stop 116 psig (+0 / -7.25 psi) [8 barg (+0 / -0.5 bar)]
R 407 C Start 261 psig (+7.25 / -0 psi) [18 barg (+0.5 / -0 bar)]
Stop 203 psig (+0 / -7.25 psi) [14 barg (+0 / -0.5 bar)]
ON Led – Power ON
ON DMC15
Led - Drain ON
DISPLAY
Button – Increase / Drain test
The DMC15 displays DewPoint temperature, controls the condenser fan activation and the timed drainer.
Display 1st (left) and 10th (right) led are flashing Failure T1 (DewPoint) temperature probe.
(EGRD 010-100)
Led is flashing Failure T2 (fan control) temperature probe.
NOTE : fan is forced always ON.
Set
With dryer ON press button for at least 3 seconds to enter the setup menu.
Access to the menu is confirmed by led ON and flashing (first parameter of menu).
Set Set
Keep pressed and use arrows to change the value. Release the button to confirm
Set
the value. Press shortly to skip to following parameter.
Press to exit setup menu (if no button is pressed after 2 minutes the menu is exited automatically).
Standard
Display Description Limits Resolution
setup
Synchronous flashing (EGRD 010-100) 31 … 40 °C 1 °C 35
FANon : condenser fan activation or or or
led ON + led
(ON) temperature 88 … 104 °F 2 °F 96
Synchronous flashing Ton – drain time ON : time ON 1 … 10 sec 1 sec 2
led ON + led condensate drain valve
Non-Synchronous flashing ToF - drain time OFF : pause
1 … 20 min 1 min 1
led ON + led time for condensate drain valve
NOTE : parameter values are displayed on the 10 led display where 1st (left) led is the lowest limit and 10th
(right) is the highest limit.
Daily
Verify that the DewPoint displayed on the electronic instrument is correct.
Check the proper operation of the condensate drain systems.
Verify the condenser for cleanliness.
Close the manual condensate drain valve, unscrew the strainer (if installed) and clean it with
compressed air and brush. Reinstall the strainer properly tight, and then open the manual valve.
At the end, check the operation of the machine
Part Material
Refrigerant fluid R407C, R134a, Oil
Canopy and Supports Carbon steel, Epoxy paint
Refrigerating compressor Steel, Copper, Aluminium, Oil
Alu-Dry Module Aluminium
Condenser Unit Aluminium, Copper, Carbon steel
Pipe Copper
Fan Aluminium, Copper, Steel
Valve Brass, Steel
Electronic Level Drain PVC, Aluminium, Steel
Insulation Material Synthetic rubber without CFC, Polystyrene, Polyurethane
Electric cable Copper, PVC
Electric Parts PVC, Copper, Brass
We recommend to comply with the safety rules in force for the disposal of each type of material.
Refrigerant contains droplets of lubrication oil released by the refrigerating compressor.
Do not dispose this fluid in the environment. Is has to be discharged from the dryer with a suitable
device and then delivered to a collection centre where it will be processed to make it reusable.
BN Brown OR Orange
BU Blue RD Red
BK Black WH White
YG Yellow / Green WH/BK White / Black
48 – EN
L1 BN-1 1 2 2
N BU-2 4 5 4
PE
DMC15 - Air Dryer Controller
PE
Electric diagrams
EGRD 010 – 100
10 10
T1 T2
9 6 7 8 4 2 1
BN-1
BU-2
BU-2
BN-1
BU-2
BN-1
Attachments
BT1 BT2
MC1
KT ELD EVD
C X1.1 X1.2
MV1
NTC 2k
M M
S 1~ R
1~
KR
CS
L1 BN-1 1 2 2
PE
DMC15 - Air Dryer Controller
PE
DMC15 - Sécheur d'Air Contrôleur
EGRD 150 – 200
ON
sec - min
11 11
10 10
T1 T2
9 6 7 8 4 2 1
PV
4 2
2k7
1
BN-1
BU-2
BU-2
BN-1
Attachments
BT1
MC1
KT ELD EVD
MV1
C X1.1 X1.2 NTC 2k
M M
S 1~ R 1~
CV
KR
CS
49 – EN
01 of / de 01
9.3.3
0 1 2 3 4 5 6 7 8 9
50 – EN
L1 BN-1 1 2 2
N BU-2 3 4 4
EGRD 250
PE
DMC15 - Air Dryer Controller
PE
DMC15 - Sécheur d'Air Contrôleur
ON
sec - min
11 11
10 10
T1 T2
9 6 7 8 4 2 1
TS PV
C 4 2
2k7
1 1
BN-1
BU-2
BU-2
BN-1
Attachments
BT1
MC1
KT ELD EVD
MV1
C X1.1 X1.2 NTC 2k
M M
S 1~ R 1~
CV
KR
CS
L1 BN-1 1 2 2
PE
DMC15 - Air Dryer Controller
PE
DMC15 - Sécheur d'Air Contrôleur
ON
sec - min
11 11
10 10
T1 T2
9 6 7 8 4 2 1
HPS PV
4 2 4 2
2k7
1 1
TS
BN-1
BU-2
BU-2
BN-1
1
Attachments
BT1
MC1
KT ELD EVD
MV1
C X1.1 X1.2 NTC 2k
M M
S 1~ R 1~
CV
KR
CS
51 – EN
Sheet / feuille 01 of / de 01
5
9.3.5
0 1 2 3 4 6 7 8 9
52 – EN
L1 BN-1 1 2 2
N BU-2 3 4 4
EGRD 400
PE
DMC15 - Air Dryer Controller
PE
DMC15 - Sécheur d'Air Contrôleur
ON
sec - min
11 11
10 10
T1 T2
9 6 7 8 4 2 1
HPS PV
4 2 4 2
2k7
1 1
TS
BN-1
BU-2
BU-2
BN-1
1
Attachments
BT1
MC1
KT ELD EVD
MV1
C X1.1 X1.2
X2.3 NTC 2k
M M
S 1~ R 1~ X2.2
CV
X2.1
KR
CS
L1 BN-1 1 2 2
PE
DMC15 - Air Dryer Controller
PE
DMC15 - Sécheur d'Air Contrôleur
ON
sec - min
11 11
10 10
T1 T2
9 6 7 8 4 2 1
HPS PV
4 2 4 2
2k7
1 1
LPS
BN-1
BU-2
BU-2
BN-1
2 4
TS
C
Attachments
BT1
MC1
KT ELD EVD
MV1
C X1.1 X1.2
X2.3 NTC 2k
M M
S 1~ R 1~ X2.2
CV
X2.1
KR
CS
53 – EN
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10 Blank pages
Original instructions are in ENGLISH - Subject to technical changes without prior notice; errors not excluded