PLH130 en
PLH130 en
PLH130 en
7425MUM019_2009_12
-EN-
EN- PLH 130 AF
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 PLH 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.
IDENTIFICATION PLATE
The product identification plate,
on the back of the dryer, shows
all the primary data of the
machine. Upon installation, fill in Model Model
the table copying the data Serial No. Serial No.
shown on the identification Code Code
plate. These data must always Nominal Flow Rate Nominal Flow Rate Nl/min
be referred to the manufacturer Max Air Pressure Max Air Pressure barg
or to the dealer when Max Inlet Air Temp. Max Inlet Air Temp. °C
information or spares are Ambient Temp. °C
Ambient Temp.
needed, even during the
Refrigerant (Type and qty) Refrigerant type/kg
warranty period.
The removal or the alteration of Refrig. Design Pres. HP/LP Refrig. Design Pres. HP/LP barg
the identification plate will void Electric Supply Electric Supply ph/V/Hz
the warranty rights. Electric Nominal Power Electric Nominal Power W/A
Fuse Max. Fuse Max. A
Manufactured Manufactured
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.
PLH 130 AF -EN-
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1. SAFETY RULES
1.1. Definition of the Conventional Signs Used in This Manual
1.2. Warnings
1.3. Proper use of the dryer
1.4. Instructions for the use of pressure equipment according to ped directive 97/23/EC
2. INSTALLATION
2.1. Transport
2.2. Storange
2.3. Installation site
2.4. Installation layout
2.5. Correction factors
2.6. Connection to the compressed air system
2.7. Connection to the cooling water network (Water-Cooled)
2.8. Electrical connections
2.9. Condensate drain
3. START UP
3.1. Preliminary operation
3.2. First start-up
3.3. Start-up and shut down
4. TECHNICAL SPECIFICATIONS
4.1. Technical specifications PLH 130 AF
5. TECHNICAL DESCRIPTION
5.1. Control panel
5.2. Operation
5.3. Flow diagram (Water-Cooled)
5.4. Refrigerating compressor
5.5. Condenser (Water-Cooled)
5.6. Condenser Water regulating valve (Water-Cooled)
5.7. Filter drier
5.8. Capillary tube
5.9. Air-to-air heat exchanger
5.10. Evaporator
5.11. Condensate separator
5.12. Refrigerant relief valve
5.13. Hot gas by-pass valve
5.14. Refrigerant pressure switches PA- PB
5.15. Safety thermo-switc TS
5.16. Compressor crankcase heater
5.17. DMC14 Electronic instrument (Air Dryer Controller)
5.18. Electronic level controlled condensate drain
7. LIST OF ATTACHMENTS
7.1. Dryers dimensions
7.2. Exploded view
7.3. Electic diagrams
-EN-
EN- PLH 130 AF
1. SAFETY RULES
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. Part or system under pressure.
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
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.
PLH 130 AF -EN-
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1.2. WARNINGS
Compressed air is a highly hazardous energy source. Never work on the dryer with parts under
pressure. Never point the compressed air or the condensate drain jet towards anybody. The user is
responsible for the installation of the dryer, which has to be executed on the basis of the
instructions given in the “Installation” chapter. Otherwise, the warranty will be voided and
dangerous situations for the personnel and/or damages to the machine could occur.
Only qualified personnel can use and service electrically powered devices. Before attempting any
maintenance action, the following conditions must be satisfied:
• Ensure that any part of the machine is under voltage and that it cannot be connected to the
mains.
• Ensure that any part of the dryer is under pressure and that it cannot be connected to the
compressed air system.
These refrigerating air dryers contain R134a or R404A HFC type refrigerant fluid. Refer to the
specific paragraph - maintenance operation on the refrigerating circuit.
Any change to the machine or to the relevant operating parameters, if not previously verified and
authorised by the Manufacturer, in addition to create the possibility of dangerous conditions will
void the warranty.
Don’t use water to extinguish fire on the dryer or in the surrounding area.
2. INSTALLATION
2.1. 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.
• 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.
• Store machine in a clean, dry environment, do not expose to severe weather environments.
• Handle with care. Heavy blows could cause irreparable damage.
2.2. STORANGE
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 maximum
temperature of 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. Each single material must be properly disposed in
a manner complying with the rules in force in the destination country.
PLH 130 AF -EN-
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1m (200-330)
2m (400-500)
Minimal installation requirements :
• Select a clean room dry, free from dust, and protected
from atmospheric disturbances.
• The supporting area must be smooth, horizontal and
able to hold the weight of the dryer.
• Minimum ambient temperature +1 °C.
• Maximum ambient temperature +50°C.
• Allow at least a clearance of 1 m on each side of the 2m
1m
1m
(400
dryer, for proper ventilation and to facilitate eventual -500
)
1 Air compressor
-A- 7
3 4 8 2 Aftercooler
1
3 Condensate separator
9 4 Pre-Filter (min. 5 micron)
2 9 9
9
5 By-pass group
6 Dryer
7 Compressed air tank
-B- 7 8 Final filter
3 4
9 Condensate drain
1
9
2 9
9
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).
-EN-
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2902 l/min This is the maximum flow rate that the dryer can accept under these operating conditions.
CAUTION:
PIPING THE DRYER, INLET/OUTLET CONNECTIONS MUST BE SUPPORTED AS SHOW IN
THE DIAGRAM.
FAILING WILL RESULT IN DAMAGE
Before connecting the unit to the electric power, verify that the voltage and the frequency available on the
mains correspond to the data reported on the data plate of the dryer. In terms of voltage, a ±5% tolerance is
allowed.
The dryers PLH 130 AF come with an electric box for the connection to the mains.
The mains socket must be provided with a mains magneto-thermal differential breaker (I∆n=0.03A),
adjusted on the basis of the consumption of the dryer (see the nominal values on the data plate of the
dryer).
The cross section of the power supply cables must comply with the consumption of the dryer, while keeping
into account also the ambient temperature, the conditions of the mains installation, the length of the cables,
and the requirements enforced by the local Power Provider.
It is mandatory to ensure the connection to the ground terminal.
Don’t use adapters on the mains socket.
If necessary, have the plug replaced by qualified personnel.
-EN-
EN- PLH 130 AF
3. START UP
Before delivery, each dryer is submitted to accurate tests and controlled simulating real operating
conditions. Nevertheless, the unit could be damaged during transportation. We therefore suggest to check
the integrity of the dryer upon arrival and to keep it under control during the first hours of operation.
The start-up must be performed by qualified personnel.
It’s mandatory that the engineer in charge adopt safety operational conditions complying with the
local safety and accident prevention requirements.
The same engineer will be responsible for the proper and safe operation of the dryer.
Never operate the dryer if the panels are not in place.
PLH 130 AF -EN-
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NOTE : A DewPoint within 0°C and +10°C displayed on 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 refrigeration 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.
The number of starts must be no more than 6 per hour. The dryer must stop running for at
least 5 minutes before being started up again.
The user is responsible for compliance with these rules. Frequent starts may cause
irreparable damage.
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EN- PLH 130 AF
4. TECHNICAL SPECIFICATIONS
5. TECHNICAL DESCRIPTION
°C DMC14 I
ON
°F
set esc
3
K
PQS0017
5.2. OPERATION
Operating principal - The dryer models described in this manual operate all on the same principal. 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 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.
-EN-
EN- PLH 130 AF
2 3 4 T7 12.1
T3 T2
PB TS PA
12.1 12.1
31
T4
6 T5
12.1 12.1
25
7 18
1a 1b
1
19 T8 12.1
T6
12.1
12
T1
11 10 20
1c
DGF0031
15
13 Standard 14 16
ELD
EC 17
Optional 21
5.10. EVAPORATOR
Also called an air-refrigerant exchanger. The liquid formed in the condenser is evaporated in this part of the
circuit. In the evaporation phase the refrigerator tends to absorb the heat from the compressed air present
in the other side of the exchanger.
Refrigerant and air are in counter flow, thus contributing to limit pressure drop and to provide efficient
thermal exchange.
1
Manually reset the thermo-switch only after the nominal operating
conditions have been restored. Unscrew the relative cap (see pos.1 in the
figure) and press the reset button (see pos.2 in the figure).
PQS0005
In any moment it is possible to exit the programming mode by pressing the buttons esc and at the
same time. In case no operations are made during 30 seconds, the system exits automatically the set-up
condition.
PLH 130 AF -EN-
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TROUBLE SHOOTING
Only qualified personnel should perform troubleshooting and or maintenance operations.
Prior to performing any maintenance or service, be sure that:
• no part of the machine is powered and that it cannot be connected to the mains supply.
• no part of the machine is under pressure and that it cannot be connected to the
compressed air system.
• Maintenance personnel have read and understand the safety and operation instructions
in this manual.
SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION
No led lighting up. Verify that the system is powered.
Verify the electric wiring (internal and/or external).
Check internal printed circuit board for possible damage.
Pressing of Test button, The service valve located before the drain is closed - open it.
but no condensate The dryer is not under pressure - restore nominal condition.
discharge. Solenoid valve defective - replace the drain.
The internal printed circuit board is damaged - replace the drain.
Condensate discharge The capacitive sensor is too dirty - open the drain and clean the sensor plastic
only when Test button tube.
is pressed.
Drain keeps blowing off The diaphragm valve is dirty - open the drain and clean it.
air. The capacitive sensor is too dirty - open the drain and clean the sensor plastic
tube.
Drain in alarm The capacitive sensor is too dirty - open the drain and clean the sensor plastic
condition. tube.
The service valve located before the drain is closed - open it.
The dryer is not under pressure - restore nominal condition.
Solenoid valve defective - replace the drain.
NOTE : When the drain is in alarm condition, the diaphragm solenoid valve will open 7.5 sec every 4 min.
-EN-
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• Close the isolation valve for the condensate drain, remove the mechanical filter and clean it with
compressed air and a brush. Reinstall the filter, make sure it is secure, and open the isolation valve.
• At the end, check the operation of the machine.
EVERY 1000 HOURS OR YEARLY
• Verify for tightness all the screws of the electric system and that all the “Faston” type
connections are in their proper position, inspect unit for broken, cracked or bare wires.
• Inspect refrigerating circuit for signs of oil and refrigerant leakage.
• Measure and record amperage. Verify that readings are within acceptable parameters as listed
in specification table.
• Inspect condensate drain flexible hoses, and replace if necessary.
• At the end, check the operation of the machine.
PLH 130 AF -EN-
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6.2. TROUBLESHOOTING
Only qualified personnel should perform troubleshooting and or maintenance operations.
Prior to performing any maintenance or service, be sure that:
• no part of the machine is powered and that it cannot be connected to the mains supply.
• no part of the machine is under pressure and that it cannot be connected to the
compressed air system.
• Maintenance personnel have read and understand the safety and operation instructions
in this manual.
Before attempting any maintenance operation on the dryer, shut it down and wait at least 30
minutes.
Some components can reach high temperature during operation. Avoid contact until system or
component has dissipated heat.
SYMPTOM POSSIBLE CAUSE - SUGGESTED ACTION
The dryer doesn't Verify that the system is powered.
start. Verify the electric wiring.
The compressor Activation of the compressor internal thermal protection - wait for 30 minutes,
doesn’t work. then retry.
Verify the electric wiring.
Where installed- Replace the internal thermal protection and/or the start-up
relay and/or the start-up capacitor and/or the working capacitor.
The pressure switch PA has been activated - see specific point.
Where installed- The pressure switch PB has been activated - see specific
point.
Where installed- The safety thermo-switch TS has been activated - see
specific point.
If the compressor still doesn’t work, replace it.
DewPoint too high. The dryer doesn't start - see specific point.
The T1 DewPoint probe doesn’t correctly detect the temperature - ensure the
sensor is pushed into the bottom of copper tube immersion well.
The refrigerating compressor doesn’t work - see specific point.
The inlet air is too hot - restore the nominal conditions.
The inlet air pressure is too low - restore the nominal conditions.
The inlet air flow rate is higher than the rate of the dryer - reduce the flow rate -
restore the normal conditions.
The cooling water is too hot - restore the nominal condition.
The cooling water flow is insufficient - restore the nominal condition.
The condenser is dirty - clean it.
The dryer doesn’t drain the condensate - see specific point.
The hot gas by-pass valve is out of setting - contact a refrigeration engineer to
restore the nominal setting.
There is a leak in the refrigerating fluid circuit - contact a refrigeration engineer.
DewPoint too low. Ambient temperature is too low - restore de nominal condition.
The hot gas by-pass valve is out of setting - contact a refrigeration engineer to
restore the nominal setting.
Excessive pressure The dryer doesn’t drain the condensate - see specific point.
drop within the dryer. The DewPoint is too low - the condensate is frost and blocks the air - see
specific point.
Check for throttling the flexible connection hoses.
-EN-
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The dryer doesn’t The condensate drain service valve is closed - open it.
drain the condensate. The condensate drain strainer is clogged - remove and clean it.
The drain solenoid valve is jammed - remove and clean it.
Verify the electric wiring.
The coil of the condensate drain solenoid valve burned out - replace it.
The DewPoint is too low - the condensate is frozen - see specific point.
The coil of the condensate drain solenoid valve burned out - replace it.
The dryer The drain solenoid valve is jammed - remove and clean it.
continuously drains Try to remove the electric connector on the solenoid valve - if drain stops verify
condensate. the electric wiring or the electronic instrument is faulty - replace it.
Water within the line. The dryer doesn't start - see specific point.
Where installed - Untreated air flows through the by-pass unit - close the by-
pass.
The dryer doesn’t drain the condensate - see specific point.
DewPoint too high - see specific point.
PA high-pressure Check which of the following has caused the activation :
switch has been 1. The cooling water is too hot - restore the nominal condition.
activated. 2. The cooling water flow is insufficient - restore the nominal condition.
3. The condenser is dirty - clean it.
Reset the pressure-switch pressing the button on the controller itself - verify
the dryer for correct operation.
The PA pressure switch is faulty - contact a refrigeration engineer to replace it.
The PB low-pressure There is a leak in the refrigerating fluid circuit - contact a refrigeration
switch has been engineer.
activated. The pressure switch restores automatically when normal conditions are
restored - check the proper operation of the dryer.
The TS safety thermo- Check which of the following has caused the activation :
switch has been 1. Eccessive thermal load – restore the standard operating conditions.
activated. 2. The inlet air is too hot - restore the nominal conditions.
3. The ambient temperature is too high or the room aeration is insufficient -
provide proper ventilation.
4. The condenser unit is dirty - clean it.
5. There is a leak in the refrigerating fluid circuit - contact a refrigeration
engineer.
Reset the thermo-switch by pressing the button on the thermo-switch itself –
verify the correct operation of the dryer.
The TS thermo-switch is faulty - replace it.
DMC14- The LED The LED flashes because the DewPoint is too high – see specific point.
of the The LED flashes because the DewPoint is too low - see specific point.
instrument is on or
The LED flashes because the probe is faulty or interrupted, the
flashes to indicate
instrument displays the message “PF” (Probe Failure) – replace the probe.
alarm situations.
PLH 130 AF -EN-
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7. LIST OF ATTACHMENTS
Bn
3
T1
2 4 5 8 9 11 12
DEW-POINT ALARM
max 250V 1A
Bu
Bn
2
C
KT
C
R S
CS
PLH 130 AF -EN-
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COSTRUTTORE / MANUFACTURER :
FRIULAIR S.r.l.
Sede Legale:
34077 - Ronchi dei Legionari (GO) – ITALY
Via Joze Srebernic, 10
Cap.Soc. € 12.480 i.v.
P.IVA 00430110312
Export MGO001913
COD.ID.CEE IT 00430110312
R.E.A.GO n.51691
Cod.Fisc.e Reg.Impr. 00430110312
Sede Operativa:
33050 - Cervignano del Friuli (UD) – ITALY
Via Cisis, 36 - S.S.352 Km 21 Fraz. Strassoldo
www.friulair.com
7425MUM019_EN_2009-12
Subject to technical changes without prior notice; errors not excluded.
Original instructions are in ENGLISH.