Ultrafilter BOREAS DSM SD 1200-60 - User Manual

I14 1001 0US
07.03
Operators Instruction
and
Maintenance Manual
BOREAS DSM
SD 1200-60 - SD 3000 W-60
SD 4000-60 - SD 5000 W-60

Summary

Part 1 Important User Information

General notes

General notes about the CA-dryer, company responsibility, and user recommendations.

Safety regulations

Safety regulations for operating, maintaining, and repairing the CA-dryer.

Handling with refrigerant

Precautions and safety measures when handling refrigerants.

First aid

First aid procedures in case of accidents involving refrigerants.

Disposal

Guidelines for the proper disposal of the CA-dryer and its components.

Part 2 Installation

Transportation

Instructions for transporting the CA-dryer safely.

Requirements on the place of installation

Conditions and requirements for the installation location.

Installation (mounting)

Steps and considerations for mounting the CA-dryer.

Version air cooled

Specific installation details for the air-cooled version of the CA-dryer.

Compressed air connection

Instructions for connecting the compressed air supply to the CA-dryer.

Electric connection

Guidelines for connecting the CA-dryer to the electrical power supply.

Connection condensate drain

How to connect the condensate drain outlet.

Connection cooling water

Instructions for connecting the cooling water supply.

Part 3 Description

Designation

Identifies the unit as a Refrigerated compressed air-dryer (CA-dryer).

Purpose

Explains the function of the CA-dryer in dehumidifying compressed air.

Unit Layout

Details accessible external components of the CA-dryer with a diagram.

Switch cabinet

Description of the switch cabinet and its components.

Nominal power of CA-dryer

Explains nominal power ratings and operating conditions.

Principle of operation

Explains how the CA-dryer cools air and removes condensate.

Mode of operation

Details how the CA-dryer operates on the compressed air and refrigerant sides.

Compressed air side

Describes the path and cooling stages of compressed air.

Refrigerant side

Explains the refrigerant injection and capacity control system.

Pressure dew point control

How the system maintains the pressure dew point.

Capacity levels

Explains how capacity levels are managed with two compressors.

Types 593 A, 593 W, 594 A, 594 W

Specifics on capacity management for certain models.

Siemens Logo

Information about the Siemens Logo control system.

SAB-Processor

Describes the SAB-Processor for measuring and storing data.

Display

Details the display interface of the SAB-Processor.

Temperature measuring

Lists the temperature inputs monitored by the SAB-Processor.

Plausibility and average value

Explains how measured values are processed and checked.

Limit values

Describes limit values for normal operation and error conditions.

Pressure dew point report

How to adapt and set pressure dew point values.

Temperature - History

How temperature data is stored and can be reviewed.

Operating status - normal operation

How to interpret the display during normal operation.

Operating status - alarm; failure

How alarms and failure reports are triggered and indicated.

SAB-service unit (additional equipment)

Functionality of the SAB-service unit for data management.

Condensate draining

Explanation of the automatic condensate draining system.

Condensate drain

Details the operation of the condensate drain mechanism.

Drain valve

Describes the function of the solenoid drain valve.

Part 4 Operation

Commissioning

Steps for initial setup and powering up the CA-dryer.

Starting

Procedures for starting the CA-dryer and initiating compressed air flow.

Operation

How to monitor and understand the CA-dryer's operation.

Stopping

Instructions for safely stopping the CA-dryer.

Part 5 Maintenance

Maintenance

General guidelines and safety for maintenance tasks.

Daily maintenance

Recommended daily checks for the condensate drain and temperatures.

Weekly maintenance

Recommended weekly checks for the condensate draining system.

Troubleshooting

General troubleshooting steps for common issues.

Function: Cause

Basic troubleshooting for 'No function' issue.

Reports of the SAB-processor

Explains alarm and failure indications from the SAB-processor.

Alarm indications

Details alarm conditions related to critical operating ranges.

Failure indications

Details failure conditions like temperature deviations.

Failure reports with stopping the refrigerant compressor

Lists failures that cause the compressor to stop.

Failure acknowledgement

How to acknowledge and reset certain failures.

Reports of the condensat drain

Troubleshooting common issues with the condensate drain.

No reports

Troubleshooting when the condensate drain shows no activity.

Failure reports

Troubleshooting specific failure reports from the condensate drain.

No condensate, blocked pipe, low pressure

Troubleshooting blocked pipes or low pressure in condensate drain.

Level- or temperature sensor defect

Troubleshooting sensor defects in the condensate drain.

Water in compressed air system

Troubleshooting water presence in the compressed air.

Temporary overload of the CA-dryer due to non-uniform compr. air consumption

Diagnosing water issues due to dryer overload.

Overload due to high volume flow, or to high compressed air inlet temperature

Diagnosing water issues due to high flow or inlet temperature.

Bypass valve of bypass line opened

Troubleshooting bypass valve issues leading to water.

Bypass valve of bypass line leaking

Troubleshooting leaking bypass valves.

Stopping CA-dryer during operation

Reasons and remedies for the dryer stopping during operation.

CA-volume flow too high

Troubleshooting high volume flow causing shutdown.

CA-inlet temperature too high

Troubleshooting high inlet temperature causing shutdown.

Room temperature too high

Troubleshooting high room temperature causing shutdown.

Defective fan or cooling water regulator resp. (water-cooled version)

Troubleshooting fan or regulator issues causing shutdown.

Condenser polluted

Troubleshooting a polluted condenser causing shutdown.

Operating pressure too low

Troubleshooting low operating pressure causing shutdown.

High differential pressure at CA-side

Diagnosing and resolving high differential pressure issues.

CA-volume flow too high

Troubleshooting high volume flow causing high differential pressure.

Operating pressure too low

Troubleshooting low operating pressure causing high differential pressure.

Icing of CA-dryer

Explains icing characteristics and troubleshooting steps.

Ultrafilter BOREAS DSM SD 1200-60 Specifications

General

Brand	Ultrafilter
Model	BOREAS DSM SD 1200-60
Category	Dehumidifier
Language	English