This document describes the DXR1600N-DXR3000N series of dry air machines, which are refrigeration dryers designed for industrial air treatment.
Function Description
The DXR series dry air machines function as refrigeration dryers, designed to remove moisture from compressed air. The process involves directing the hot, humid compressed air into a direct expansion heat exchanger (evaporator). Here, the air is cooled by a refrigerant, causing the water vapor to condense into liquid. This condensate is then separated and discharged through an electronic level sensing drain. The cooled, dry air then passes through a heat exchanger, where it is reheated by the incoming hot compressed air. This reheating prevents further condensation in the downstream piping. A hot gas bypass system (HGBP) regulates the refrigerant, ensuring stable cooling capacity and preventing the temperature from dropping below 32°F (0°C).
Important Technical Specifications
The DXR series includes models DXR1600N, DXR1800N, DXR2200N, DXR2400N, and DXR3000N.
Dimensions (L x W x H):
- DXR1600N: 40.1 x 44.2 x 60.07 inches (1020 x 1123 x 1526 mm)
- DXR1800N-3000N: 40.1 x 82.6 x 60.4 inches (1020 x 2099 x 1535 mm)
Net Weight:
- DXR1600N: 837 lb (380 kg)
- DXR1800N: 1212 lb (550 kg)
- DXR2200N: 1323 lb (600 kg)
- DXR2400N: 1323 lb (600 kg)
- DXR3000N: 1433 lb (650 kg)
Refrigerant:
- Type: R404A
- GWP 100: 3922
Refrigerant Charge (R404A):
- DXR1600N: 14.6 lb (6.6 kg)
- DXR1800N: 23.1 lb (10.5 kg)
- DXR2200N: 24.3 lb (11.0 kg)
- DXR2400N: 24.3 lb (11.0 kg)
- DXR3000N: 33.1 lb (15.0 kg)
Nominal Power (HP/W) - Compressor (60 Hz):
- DXR1600N: 13.1 HP (9740 W)
- DXR1800N: 11.3 HP (9600 W)
- DXR2200N: 16.7 HP (12500 W)
- DXR2400N: 23.1 HP (17270 W)
- DXR3000N: 23.1 HP (17270 W)
Nominal Power (HP/W) - Fan (60 Hz):
- DXR1600N: 1.7 HP (1250 W)
- DXR1800N: 3.4 HP (2500 W)
- DXR2200N: 3.4 HP (2500 W)
- DXR2400N: 3.2 HP (2400 W)
- DXR3000N: 3.2 HP (2400 W)
Maximum Working Pressure: 203 psi (14 bar)
Reference Conditions:
- Ambient temperature: 77°F (25°C)
- Inlet air temperature: 95°F (35°C)
- Working pressure: 101 psi (7 bar)
Limit Conditions:
- Max. ambient temperature: 113°F (45°C)
- Min. ambient temperature: 41°F (5°C)
- Max. inlet air temperature: 131°F (55°C)
- Max. working pressure: 203 psi (14 bar)
Safety Requirements: The machine corresponds to the essential safety requirements of the European Standard (2006/42 CE). It is not suitable for outdoor installation.
Usage Features
Installation:
- The machine must be placed on a level floor capable of supporting its total weight.
- Sufficient space around the machine is required for maintenance.
- The installation room should be spacious, dry, well-ventilated, and free from dust.
- Environmental conditions (temperature and humidity) should be stable to prevent refrigerant compressor/fan overload and maintain dryer performance.
- The air composition in the machine room must be clean, free of damaging contaminants (dust, fibers, sand), explosive or chemically unstable gases/vapors, and acid/alkaline forming substances (ammonia, chlorine, hydrogen sulfide).
- Ducting for cooling air is not recommended.
- Isolation valves (not supplied) must be installed between the machine and the compressed air network for maintenance.
- A proper pre-filter should be installed at the dryer air inlet and replaced annually or sooner in high contamination environments.
- The condensate auto-drain must be plumbed to a location where it can be treated before disposal, adhering to local rules and regulations.
Electrical Connection:
- Verify that the supply voltage matches the machine data plate.
- Ensure the line leads are in good condition and there is a sufficient grounding line.
- A fused disconnect or appropriately sized breaker (not supplied) is required to protect against over-currents.
- Only professionally licensed personnel should access the electric panel, and power must be switched off before opening it.
Starting Up:
- Remove protective caps from the dryer inlet and outlet.
- Connect to the compressed air piping and condensate drainage system.
- Ensure the power supply matches the dryer nameplate.
- The dryer is equipped with a crankcase heater to prevent refrigerant and oil mixing. It is strongly recommended to energize the heater for at least 6 hours before switching on the dryer.
- The selector switch must be in "HEATER ON" position initially, then moved to "DRYER ON" after 6 hours.
- The system should be started before the air compressor and stopped after the air compressor has been stopped to ensure condensate-free piping. A 5-minute wait is required before restarting the dryer to allow pressure to balance.
Command and Control Panel:
- Features a digital controller with icons for alarms, refrigerant compressor, fan, dryer ON, and PDP indicator.
- Buttons for snooze/reset alarm, SET, UP, and DOWN.
- Alarm functions include probe failure, high/low temperature, service alarm, dewpoint too low, and high discharge temperature of the refrigerant compressor.
- The controller allows remote alarm functionality via a free NC (Normally Closed) contact.
Maintenance Features
Routine Maintenance Schedule:
- Every week: Brush/blow off the finned surface of the condenser.
- Every 2000 hours / 1 year: Clean the filter of the automatic condensate drain.
- Every 4000 hours / 2 years: Replace the filter of the automatic condensate drain (2902016102) and replace the drain kit (2200902017).
- These intervals are for non-dusty, well-ventilated environments; frequency should be doubled for dusty conditions.
Cleaning the Automatic Condenswater Discharger Filter:
- Isolate the unit from the compressed air network.
- Remove the panel.
- Release pressure by pressing the condensate drain "TEST" button.
- Switch off the machine and lock-out/tag-out at the fuse/breaker box.
- Remove and clean the Y-strainer plug and filter with a jet of air (from inside to outside).
- Re-install the filter and plug, then close the panel.
Cleaning the Condenser:
- The condenser must be cleaned every month.
- Switch off the machine and lock-out/tag-out at the fuse/breaker box.
- Remove the panel.
- Clean the condenser fins with compressed air; do not use water or solvents.
- Close the panel.
Trouble-shooting and Emergency Remedies:
- All work must be carried out by professionally skilled personnel.
- Before any maintenance, stop the machine and disconnect it from the power mains.
- The manual provides a table of fault messages (e.g., Dewpoint temperature probe failure, Pressure dewpoint too high/low, Refrigerant compressor discharge temperature too high, Internal EPROM error, Maintenance required) with corresponding descriptions and remedies.
Resetting Maintenance Warning (SE Alarm):
- After 6000 hours, the controller issues an "SE" warning.
- The procedure involves pressing and holding "SET" and "DOWN" buttons to enter the menu, navigating through messages ("rS", "n", "y"), and finally pressing "SET" to reset the service alarm.
Setting Service Interval on PDP Device:
- The service interval can be configured (e.g., 4000h, 5500h, 8000h).
- This involves entering the menu, selecting the desired interval using "UP" or "DOWN", and confirming with "SET".
Freeze Protection Function:
- The digital controller switches off the refrigerant compressor if the dewpoint temperature drops below -28.4°F (-2°C) for more than 2 minutes (L2 Alarm).
- To reset, press button 7. The dryer restarts when the dewpoint is above -2°C and 30 seconds have passed since the compressor stop.
Silent Alarm Function:
- Press button 7 to snooze the alarm.
Disposing of the Dryers:
- If the machine is scrapped, it must be dismantled into parts of the same material and disposed of according to local regulations.
- Old oil, polluting materials, and insulating foam must be disposed of properly.
- Refrigerant within the unit must be reclaimed by a properly certified refrigerant technician before scrapping.
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