Documentation

for pressure reducing module

Art.-No. NK: 1172746

Commission-No. NK: NK 9326

Revision Date: 21.02.2022

Neuenhauser Kompressorenbau GmbH

Hans–Voshaar–Straße 5
D - 49828 Neuenhaus
Germany

Tel.: +49 (0) 5944 – 9301-200

Fax: +49 (0) 5944 – 9301-202
E-Mail: [email protected]
Internet: www.nk-air.de
 1 2 3 4 5 6 7 8 9 10 11 12

754 5 76.5

A A

162.5
Auslass/ Outlet ø25mm Einlass/ Inlet ø25mm
B EO 24° Anschluss/ cone end EO 24° Anschluss/ cone end B
DIN EN ISO 8434-1 DIN EN ISO 8434-1
max. 10 bar max. 40 bar

509.5
ca. 614.5
18

C C

D D

180 170 150 160 70 50 30 40 90 100 80 110 20 200 190

2 2 2 2 2 2 2 2 2 2 2 8 2 2 2

E E

200 2 Überwurfmutter nut 1069712

190 2 Progressiv Stop Ring progressiv stop ring 1069711
180 2 Gerade Reduzierung straight reducer 0112589
170 2 Gerade Reduz. mit Dichtkegel swivel union reducer 1069678
160 2 Gerader Aufschraubstutzen EO Female connector 1033719

F 150 2 T-Verschraubung mit Schaft EVT EO standpipe branch tee EVT 0104086
F
140 2 Einstellb. Winkelverschraubung Adustable male stud elbow 0069754
130 2 Verschraubung EVL EO standpipe run tee EVL 0058601
120 8 Gerader Einschraubstutzen EGE adapter 1/2'' male / DN18 0227750
110 8 Gerader Einschraubstutzen GE 0321592
100 2 Dichtkantring DKI EO edge sealing ring for MAVE DKI 0058739
90 2 Manometerverschr. m. Dichtkegel MAVE EO Pressure gauge swivel connector 0233753
80 2 Verschraubung GE EO male stud collector 0053947
70 2 Dichtring Form A gasket ring 0059125
60 4 Kugelhahn PN 40 G1/2 " ball valve PN 40 G1/2" 0071638
50 2 Eck-Sicherheitsventil D10C - 10,0 bar Edge-Safety-Valve 10 bar 1069720
40 2 Manometer d=63 0-16 bar pressure gauge 0058389
30 2 Druckminderventil D22- 1/2" A, Pressure regulator D22-1/2"A, 0-40 bar 0243411

G 20
10
2
2
Schmutzfänger
ZSB Rohrleitung
Y-Strainer
asm pipe
0206866
1172801
G
Pos. Stk. Benennung description Art. Nr.
pos. piece art. no.

Index Änderung Datum Name

Datum Name Werkstoff-Daten Bez. (alt):
Gez. 13.09.2021 Köhnke Nr.: Bez. (EN):
NEUENHAUSER
Gepr. KOMPRESSORENBAU
16.09.2021 Köhnke Halbzeug-Daten Halbzeug-Nr.:
D-49824 Ringe/Neugnadenfeld
Status Freigegeben Halbzeug: / TELEFON (+49) 5944 9301-200
H DIN-Norm: EN-Norm: http://www.nk-air.de
H
Schutzvermerk nach e-mail [email protected]
ISO 16016 beachten! Oberfläche:
Artikel-Nr.1172746
Allgemein- Maßstab
toleranzen 2x Regelstrecke 30 auf 10 bar, 50m³/h Zeichng.-Nr. Zu_34637
ISO 2768-mK 2x regulation line 30 to 10bar, 50m³/h
3:10 Stahl/Messing G1'' Index: 0 2
Blatt-Nr.: von: 2
Ersatz für:
steel / brass, G1''
PC 46 Ersetzt durch:

ZU_34637-0-0 2 3 4 5 6 7 8 9 10 11 12 A2
 D 22
Pressure reducing valve with piston balanced seat
Standard pattern for compressed air
Product specification sheet
Application
D 22 pressure reducing valves protect installations against
excessive pressure from the supply. They can be used for
industrial or commercial applications within the range of their
specification. Because pressure reducing valves are subject
to wear, they cannot be used as the only means of protection
and if the downstream system needs to be protected against
excessive pressure to prevent leakage, then a suitable safety
valve must be fitted.

Special Features
l Screw with knob for setting pressure
l The adjustment spring is not in contact with the medium
l Compact construction
l Internal threaded connection
l Reliable and proven
l Short installed length
l Light weight
l – Servicing and maintenance without
removal from pipework
l Inlet pressure balancing – fluctuating inlet pressure does
Construction not influence outlet pressure
The pressure reducing valve comprises:
l Housing
Range of Application

l Valve piston
Medium: Compressed air, non-toxic and
non-flammable gases
l Piston guide with G 1/4" pressure gauge connection
Inlet pressure: Maximum 40.0 bar
l Diaphragm
Outlet pressure: 1.0 – 10.0 bar
l Adjustment spring
l Spring bonnet with adjuster Technical Data
l Pressure gauge not included (see accessories) Operating temperature: Maximum 70 °C
Pressure rating: PN 40
Materials
Minimum pressure drop: 1 bar
l Brass housing
Connection sizes: 1 4
/ " to 2"
l Brass valve piston
l Brass piston guide
l High quality synthetic material spring bonnet
l NBR Diaphragm
l NBR sealing washer
l NBR O-rings
l Spring steel adjustment spring

Subject to change EN0H-1011GE23 R0900 55

D 22 Pressure reducing valve

Method of Operation
Spring loaded pressure reducing valves operate by means of a
force equalising system. The force of a diaphragm operates
against the force of an adjustment spring. If the outlet pressure
and therefore diaphragm force fall because water is drawn, the
then greater force of the spring causes the valve to open. The
outlet pressure then increases until the forces between the
s diaphragm and the spring are equal again.
The inlet pressure has no influence in either opening or closing
h
s t of the valve. Because of this, inlet pressure fluctuation does not
s R influence the outlet pressure, thus providing inlet pressure
s balancing.

Options
H D 22 - . . . A = Standard pattern

Connection size

s Special versions available on request

s

L
s

Connection size R 1/4" 3/8" 1/2" 3/4" 1" 11/4" 11/2" 2"
Nominal size DN 8 10 15 20 25 32 40 50
Weight approx. (kg) 0.3 0.3 0.45 0.6 1.35 1.8 2.9 3.8
Dimensions (mm)
L 50 50 65 80 95 105 115 130
H 90 90 105 105 150 160 200 210
h 34 34 36 42 57 57 72 72

Accessories
M 39 K Pressure gauge
Housing diameter 63 mm, bottom connection
thread G 1/4".
Ranges: 0 - 4, 0 - 10, 0 - 16 or 0 - 40 bar.
Please indicate upper value of pressure range
when ordering.

M 39 K FY 30 Strainer
With double mesh strainer, brass housing
A = Mesh size approx. 0,35 mm

FY 30

56 Subject to change EN0H-1011GE23 R0900

 D 22 Pressure reducing valve

Installation Example

10
5

0 bar 15
16

Connection size R 1/4" 3/8" 1/2" 3/4" 1" 11/4" 11/2" 2"
W* (mm) 45 45 50 50 55 60 60 70
* Minimum distance from wall to centre line of pipework

Installation Guidelines Typical Applications

l If possible install in horizontal pipework with the spring D 22 pressure reducing valves are suitable for all types of
bonnet downwards compressed air installations. They can be used for industrial
m This is the most effective position for cleaning and commercial applications within the range of their
l Fit shut off valves specifications.
m This permits – servicing and main- Pressure reducing valves should be installed:
tenance without removal from pipework l If the static pressure exceeds the maximum
l Ensure good accessibility permissible value for the system
m So that the pressure gauge can be easily seen l If pressure fluctuations in the downstream system must
m Simplifies maintenance and inspection be avoided
l Install downstream of the filter or strainer
m The pressure reducing valve then has maximum
protection against dirt

Inspection and Maintenance

Under normal operating conditions no specific maintenance
is required. However all worn parts can be replaced as may
become necessary.

Subject to change EN0H-1011GE23 R0900 57

D 22 Pressure reducing valve

Spare Parts for D 22 Pressure Reducing Valves

(From 1968 onwards)

Description Nominal size Part number

¬ Valve cone complete 1

/4" + 3/8" 0903223
1
/2" 0903224
¬ 3
/4" 0903225
1" 0903226
11/4" 0903227
11/2" 0903228
2" 0903229

­ Diaphragm 1
/4" + 3/8" 2202500
1
/2" + 3/4" 2202700
1" + 11/4" 2203300
11/2" + 2" 2204100

® Spring bonnet complete 1

/4" + 3/8" 0900272
1
/2" + 3/4" 0900273
1" + 11/4" 0900274
11/2" + 2" 0900275
­

Home and Building Control

Honeywell AG
Hardhofweg · D-74821 Mosbach, Germany
Phone (49) 6261 81-0 · Fax (49) 6261 81-309 http://europe.hbc.honeywell.com

Subject to change EN0H-1011GE23 R0900 58

 Mounting and Installation Manual
Strainer

END-Armaturen GmbH & Co. KG

Postfach (PLZ 32503) 100 341 · Oberbecksener Str. 78 · D-32547 Bad Oeynhausen · Telefon (05731) 7900-0 · Telefax (05731) 7900-199 · http://www.end.de
Impressum

© by END-Armaturen GmbH & Co. KG

All rights reserved.

END-Armaturen GmbH & Co. KG claims copyright over this documentation.
This documentation may neither be altered, expanded , reproduced nor passed to third parties without the
written agreement of END-Armaturen GmbH & Co. KG. This restriction also applies to the corresponding draw-
ings.
END-Armaturen GmbH & Co. KG has the right or change parts of the valves and armatures at any time without
prior or direct notice to the client. The contents of this publication are subject to change without notice.

This publication has been written with great care. However, END-Armaturen GmbH & Co.KG cannot be held
responsible, either for any errors occuring in this publication or for their consequences.

The products are specified by the statements in this documentation; no assurance or the properties is given.

END-Armaturen GmbH & Co. KG

Oberbecksener Straße 78
D-32547 Bad Oeynhausen
Telefon: 05731 / 7900 - 0
Telefax: 05731 / 7900 - 199
Internet: http://www.end.de
E-Mail: [email protected]

Edition: 11/02

2 http://www.end.de 13.11.02
 Contents

Inhalt

1 Foreword 4

2 General advice 5
2.1 Validity 5
2.2 Inward monitoring 5
2.3 Complaints 5
2.4 Guarantee 5
2.5 Symbole und ihre Bedeutung 6

3 Safety Advice 7
3.1 Personal safety 7
3.1.1 Safety advices for mounting 7
3.1.2 Safety advice for adjustment / starting 7
3.1.3 Safety advice for maintaining / repairing 8
3.2 Device safety 9

4 Name-plate 10

5 Y-Strainer 11
5.1 General 11
5.2 Corresponding use 11
5.3 Operation 11
5.4 Mounting / Disassembly 11
5.4.1 Mounting with threaded connection 12
5.4.2 Mounting with welded connection 12
5.4.2.1 Disassemble of the bonnet 13
5.4.2.2 Welding the body between pipes 13
5.4.2.3 Mounting of the body 14
5.4.3 Mounting with flanged connection 15
5.5. Maintenance 15
5.5.1 Cleaning of the mesh 16

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Foreword

1 Foreword

Dear customer,
Dear assembler / user,

these operation and installation manuals are intended to give you the knowledge, which is
necessary for you to be able to carry out the mounting and adjustment of the valves and armatures
rapaidly and correctly.

Please read these instructions carefully and pay particular attention to the advice and warning
notes.

Only instructed and qualified mechanician should mount, adjust or maintain the valves and arma-
tures

If you have any questions in relation to the valves and armatures we shall be pleased to answer
them.
The telephone number will be found on the inside cover of these operation and installation
manual.

Yours
END-Armaturen GmbH & Co. KG

4 http://www.end.de 13.11.02
 General Advice

2 General advice

2.1 Validity

These mounting and installation manual is valid for the standard version of the valves and arma-
tures.

2.2 Inward monitoring

Please check
• directly after delivery the valves and armatures for any transport damages and defi-
ciencies.
• with reference to the accompanying delivery note the number of parts.

Do not leave any parts in the package.

2.3 Complaints

Claims for replacement or goods which relate to transport damage can only be considered valid if
the delivery company is notified without delay.

In case of returns (because of transport damage / repairs), please make a damage protocol and
send the parts back to the manufacturer, if possible in the original packaging.

In case of a return, please mention the following:

• Name and address of the consignee
• Stock-/ ordering-/ article-number
• Description of the defect

2.4 Warranty

For our valves and armatures we give a guarantee period in accordance with the sales contract.
The end of the normal duration of life of the wearing parts represents no defect.

The warranty and guarantee rules of END-Armaturen GmbH & Co. KG are applicable.

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Symbols and their signification

2.5 Symbols and their signification

Paragraphs which are identified with this symbol contain very important advices; this also includes
advices for averting health risks. Observe these paragraphs without fail!

Paragraphs which are identified with this symbol contain very important advices, this also includes
how to avoid damage to property. Observe these paragraphs without fail!

This symbol indicates paragraphs which contain comments / advices or tips.

This spanner identifies the description of actions which you should carry out.

6 http://www.end.de 13.11.02
 Safety Advice

3 Safety Advice

Depending on the technical circumstances and the time under and at which the armatures and
valves are mounted, adjusted and commissioned, you must take into account particular safety
aspects in each case!

If, for example, a pneumatic actuator works a slide in an operational chemical plant, the potential
hazards of commissioning have another dimension from that when this is only being carried out for
test purposes an a „dry“ part of the plant in the assembly room!

Since we do not know the circumstances at the time of the mounting/adjustment/commissioning,

you may find advices on hazards in the following descriptions which are not relevant to you.

Please observe (only) the advices which applies to your situation!

3.1 Personal safety

3.1.1 Safety advices for mounting

We wish to point out expressly that the mounting, adjusting and at accessories the pneumatical
and electrical installation of the armatures and valves must be carried out by trained specialist
personnel having mechanical, pneumatical and electrical knowledge!

Secure that the machine / plant come up to the Machinery Directive after the mounting and
installing of the armatures and valves.

Switch off all the devices / machines / plant affected by mounting or repair.
If appropriate, isolate the devices / machines / plant from the mains.

Check (for example in chemical plants) whether the switching off of devices / machines / plant
will cause potential danger.

If appropriate, in the event of a fault in the armature / valve (in a plant which is in operation)
inform the shift foreman / safety engineer or the works manager without delay about the fault, in
order, for example, to avoid an outflow / overflow of chemicals or the discharge of gases in good
time by means of suitable measures!

Before mounting or repairing, remove the pressure from pneumatic / hydraulic devices / machines
/ plant.

If necessary, set up warning signs in order to prevent the inadvertent starting up of the devices /
machines / plant.

Observe the respective relevant professional safety and accident prevention regulations when
carrying out the mounting / repair work.

Check the correct functioning of the safety equipment (for example the emergency push off but-
tons/ safety valves, etc)!

3.1.2 Safety advice for adjustment / starting

As a result of the starting (pneumatic, electric or by hand) of the armatures and valves the flow
of gases, steam, liquids, etc. may be enabled or interrupted! Satisfy yourself that, as a result of
the starting or the test adjustment no potential hazards will be produced for the personnel or the
environment!

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Safety advice

If necessary, set up warning signs in order to prevent the inadvertent starting up or shutting down
of the device / machine / plant.!

By ending the adjustment check the correct function and should the occasion arise the position
of the slide / valve / flap.

Check the function of the limit switches (option)!

Check, whether the slide / valve / flap will be closed totally, if the control signals the appropriate
limit stop!

Through suitable measures, prevent links being trapped by moving actuating elements!

Check the right function of all safety devices (for example emergency push off buttons / safety
valves)!

Carry out the starting and the adjustments only in accordance with the instructions described in
this documentation!

Adjusting switch on armatures and valves with options (e.g. actuators, solenoid valves, limit
switches) there is the risk that live parts (230 V AC~) can be touched!
Therefore the adjustments must be carried out only by the electrician or a person having adequate
training, who is aware of the potential hazard!

3.1.3 Safety advice for maintaining / repairing

Do not carry out any maintenances / repairs if the armature / valve will be under pressure.

Before disassembling or a armature or valve some essential points should be clarified!

• Will the armature/valve to be disassembled be replaced by another immediately?
• If appropriate, does the production process of the plant needed to be stopped?
• Is it necessary to inform specific personnel about the disassembly?

If necessary, inform the shift foreman/ safety engineer or the manager about the maintenance
or repair without delay in order, for example, to avoid an outflow/ overflow of chemicals or a
discharge of gases in good time by means of suitable measures!

Observe that some valves / armatures are able to enclose the pressured medium e.g. the ball
in the ball valve. You have to relieve the pressure in the pipes in which the armature/valve is
mounted.

Switch off pilot pressure and the power supply and relieve the pressure in the pipes.

If necessary set up warning signs in order to prevent

• the inadvertent starting up of the devices/machines/plants in which the armature/
valve is mounted
• the switching on of pilot medium supply, pilot power supply and/or the power supply
of actuators and accessories.

In case of defect in the armature/valve make contact to the supplier. The telephone number will
be found on the back cover of these mounting and installation manual.

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 Safety advice

If you ascertain a damage of the armature/valve, isolate the device from the mains. Please
observe the safety advices.

Do not mount, start or adjust the armature/valve if itself, the pipes or a mounted actuator will be
damaged.

After the maintenance or repair check the right function of the armature/valve and the tightness
of the pipe connections.

Also check the function of the accessories e.g. actuators, limit switches, etc.

3.2 Device safety

The armatures/valves
• are quality products which are produced in accordance to the recognized industrial
regulations.
• left the manufacturer`s work in a perfect safety condition.

In order to maintain this condition, as installer / user you must carry out your task in accordance
with the description in these instructions, technically correctly and with the greatest possible
precision .

We assume, as a trained specialist you are having mechanical and electrical knowledge!

Satisfy yourself that the armatures/vales will only be used within their admissible limiting value
(see the technical data) .

The armatures/valves must be used only for a purpose corresponding to their construction!

The armatures/valves must be used within the values specified in the technical data!

The operating of the armature/valve outside the nominal temperature range could destroy the
seals and the bearings.

The operating of the armatures/valves outside the nominal pressure range could destroy the inner
parts and the body.

Never remove a cap or a other component part if the armature/valve will be under pressure.

Do not mount, start or adjust the armature/valve if itself, the pipes or a mounted actuator will be
damaged.

After the maintenance or repair check the right function of the armature/valve and the tightness
of the pipe connections.

Also check the function of the accessories e.g. actuators, limit switches, etc.

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Name-plate

4 Name-plate

In some cases the armatures/valves will be provided with a name- plate, which permits a definite identification
of the armatures/valves and shows the most important technical data to you. The name-plate should not be
displaced or changed.

END-Armaturen
END-ArmaturenGmbH GmbH &&Co.Co.
KGKG
D-32547
D-32547BadBadOeynhausen
Oeynhausen
+49
+49 (0)5731
(0)5731- -7900-0
7900-0• www.end.de
www.end.de
Art.Nr.:
Art.Nr.: ZA310028-ED620632
ZA310028-ED620632
Serial: 313857
Serie: ARMAU813857
Pressure range (PS): 16 bar
Betriebsdruck (PS): 16 bar
Pilot pressure: 6-8 bar
Steuerdruck: 6...8 bar G/DN: 2”
Temperature
Volt: rangeHz:
(TS): -30°C ... +180°C
Fluidgruppe 1
Size (DN): (TS):
Temperatur -30...+180°C 50 / G2"
Testing
Prüfdruckpressure
(PT): (PT):
60 bar 60 bar
Fluidgroup:
Herstellungsdatum: 25.11.2009 1 0062
Date of manufacturing: 11.2002

0062

Fig. 4.1 - name-plate

Art.No. article number of the valve / armature

Serial order- or production- number
Pressure range (PS) max. admisable working pressure of the valve / armature [bar]
Pilot pressure recommend pilot pressure for correct function of the valve / armature [bar]
(only at pneumatic actuated valves / armatures)
Size (DN) connecting size of the valve / armature
Testing pressure (PT) testing pressure of the body of the valve / armature
Fluidgroup allowed fluidgroup of the valve / armature
Date of manufacturing month and year of manufacturing of the valve / armature

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 Strainer

5 Strainer

5.1 General

Before you are mount, adjust, start, operate or disassemble a strainer you must
have read the

Safety advice

If you have not read the safety advices until now please read these important advices now and
turn back to this point.

5.2 Corresponding use

Strainer are used to strain pollution out of the media. The efficiency dependents on the diameter
of the mesh.
It should only be used media on which the material of the y-strainer will be resistant. Using outside
the nominal pressure range and/or the nominal temperature range should causes damages on the
armature especially on the seals.

5.3 Operation

Y-strainer need no special operation. Only the mesh have to been clean in periodical terms, respec-
tively the mesh have to been exchange (please refer to chapter 5.5 “Maintenance“).

5.4 Mounting / Disassembly

The mechanical mounting is identical in all variants. It differs only by the type of connection.

Observe the flow direction which is specified on the valve body. The installation of the screw joint
should take place downwards, that the pollution will fall out of the body by the cleaning of the y-
strainer.

We recommend the installation of a gate valve in front and behind the y-strainer, to clean the mesh
without emtyning of the divice.

Remove all transport safety devices (e.g. plugs or caps). Observe that there won`t be any parts of
the package or other pollution in the armature.

Before mounting the y-strainer clean up the pipes. Pollution will reduce the safety and the duration
of life of the valve.

Avoid stress on the body by non align pipes.

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Strainer

5.4.1 Mounting with threaded connection

Before lay on sealing compounds, check the hardly screwing of the pipes into the valve body.

Lay on the correct sealing compounds on the pipes end. By using PTFE- ribbon or hemp seal-
ings observe the screw direction. Don`t use sealing compounds which are not prescribed for your
employment.

Screw the pipes into the connection ends of valve.

Strike up the pipes with pressure after that time the manufacturer of the sealing compounds pre-
tends for harden it.

Check the tightness of all connections.

sealing compound
harden !

o.k.

flow direction

Fig. 5.1 - Y-strainer, mounting with threaded connection (Fig. shows Art. BG100025). Option: Gate valve TC101025, hexagon nipple A111010

5.4.2 Mounting with welded connection

Before welding the strainer between the pipes you have to disassemble the bonnet of the strainer
first, to prevent the damage of the seals.

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 Strainer

5.4.2.1 Disassemble of the bonnet

Clamp the strainer between a vice carefully. By using guard plates you can prevent the damage of
the ends of the body.

Loosen the bonnet by using a fit spanner.

Screw the bonnet out of the valve body and put it aside.

Fig. 5.2 - Y-strainer, disassemble of the bonnet (Fig. : Art. EA300064)

5.4.2.2 Welding the body between pipes

By welding the valve body with the pipes observe the appropriate demands and guide lines.

The safety demands be welding are depending on the place and the position of the point of weld.
Welding the parts in a serviceable device/machine/plant the potential of danger is as higher as
welding the parts in a welding room.

If appropriate inform the shift foreman / safety engineer or the works manager and the fire brigade
of your factory.

By welding observe your own national guide lines about safety and the prevention of accidents.

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Strainer

o.k.

flow direction

Fig. 5.3 - Y-strainer, welding of the body (Fig.: body of Art. EA300064)

5.4.2.3 Mounting of the body

Befor mounting the bonnet let the body cool down.

Screw the bonnet into the body. Observe the correct placement of the seals in the bonnet and take
care that there will be no pollution on the seals or the seat.

Tighten the bonnet with a fit spanner.

Check the tightness of all connections.

cool down!

Fig. 5.4 - y-strainer, mounting of the bonnet (Fig.: Art. EA310064)

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 Strainer

5.4.3 Mounting with flanged connection

In the following discription we assume that you have mounted the flanges at the end of the pipes
and the strainer (welded flanges) and they are cooled down..

Push the strainer between the flanges by using the appropriate seals. This process must happen
easily to avoid the damage of the seals.

Align the borings of the flanges and put some fit screws through the holes. Screw the fit nuts onto
the screws and tighten them up crosswise.

Fasten all screws crosswise and check the function of the y-strainer. Observe the maximum torque
of the screws.

Check the tightness of all connections.

o.k.

flow direction

Fig. 5.5 - y-strainer, mounting with flanged connections (Fig.: Art. KU3000xx)

5.5. Maintenance

Before you maintain or shut down the strainer you have to read the

Safety advice

If you have not read the safety advices until now, read this important advices now and turn back
to this page.

Depending on the used media and the employment of the y-strainer you have to do the following

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Strainer

maintenance:

• Cleaning of the mesh

In case of a defect of the y-strainer make a contact to the supplier. The telephone number will be
found on the back of these operation and installation manual.

If you determinate that there is a damage to the y-strainer switch off the device/ machine/ plant!
However doing this, it is essential to refer to the

Safety advice.

5.5.1 Cleaning of the mesh

Cut off the media flow and relieve the media pressure.

Keep ready some fit tanks to catch up leaking liquids.

Loosen the bonnet of the strainer. Catch up the running out liquid. Take the bonnet aside and pull
the mesh out of the body.

Clean the body and the mesh or exchange the mesh for a new one.

Insert the mesh into the body of the y-strainer.

Screw the bonnet into the body. Observe the correct placement of the seals in the bonnet and take
care that there will be no pollution on the seals or the seat.

Tighten the bonnet with a fit spanner.

Check the tightness of all connections.

o.k.

Fig. 5.6 - y-strainer, cleaning of the mesh (Fig.: Art. BG100025). Option: Gate valve TC101025, Hexagon nipple A111010

16 http://www.end.de 13.11.02
 Notice

13.11.02 http://www.end.de 17
 6 Declaration in conformity as defined by Pressure-Equipment-Directive 97/23/EC

(1)
Declaration in conformity
(2)
as defined by Pressure-Equipment-Directive 97/23/EC
(3) This declaration apply to the article groups with the nominal sizes:
Articles Nominal size Articles Nominal size Articles Nominal size Articles Nominal size
Butterfly valves NG DN32 ... DN100 VO DN32 ... DN200 Non-return valves
HA DN50 ... DN300 Ball valves VS DN32 ... DN200 AR 1¼" ... 2"
TA DN40 ... DN300 AG 1¼" ... 2" VT DN32 ... DN100 CK3003 DN65 ... DN200
WA DN50 ... DN300 BK DN32 ... DN100 VU 4" CK5003 DN32 ... DN200
WM DN50 ... DN300 IK 1¼" ... 2" ZA 1¼" ... 4" CK5100 DN65 ... DN250
Gate valves IL 1¼" ... 4" ZA DN32 ... DN100 CK5200 DN65 ... DN250
AB 1¼" ... 2" IW 1¼" ... 2" ZB 1¼" ... 2" CW5400 DN65 ... DN250
AE 1¼" ... 3" KA 1¼" ... 3" ZB DN32 ... DN50 EB 1¼" ... 3"
AE DN32 ... DN80 PD 1¼" ... 2" ZD 1¼" ... 4" EB DN32 ... DN80
CA5014 DN100 ... DN300 TB 1¼" ... 4“ ZD DN32 ... DN100 RG1300 DN32 ... DN100
CA5015 DN65 ... DN300 TF DN32 ... DN200 ZE 1¼" ... 4" RG33xx DN32 ... DN200
CA5214 DN40 ... DN200 TH 1¼" ZE DN32 ... DN100 RK DN32 ... DN400
CD5010 DN32 ... DN200 VD 1¼" ... 4" ZF 1¼" ... 4" TD 4"
CV3010 DN32 ... DN150 VD DN32 ... DN100 ZG 1¼" ... 2" Strainer
CV5010 DN32 ... DN200 VH 1¼" ... 2" ZH 1¼" ... 2" AS 1¼” ... 3”
CV5020 DN32 ... DN200 VH3100 1¼" ... 2" ZK DN32 ... DN100 AS DN32 ... DN200
Pressure reducer VK DN32 ... DN200 ZL 1¼" ... 3" EA 1¼" ... 3"
SD Ǫ" ... 2" VK/PN40 DN32 ... DN200 ZM 1¼" ... 2" EA DN32 ... DN80
Pressure relief valves VL 1¼" ...2", 3" ZP DN32 ... DN200
NG 1¼" ... 1½" VN 1¼" ... 2" ZU 1¼" ... 3"

and all variations of these articles

(4) of the company END-Armaturen GmbH & Co. KG

D-32547 Bad Oeynhausen
Germany

(5) Herewith we declare that the above-mentioned articles in the conditions of our delivery are in conformity with the regula-
tions of the Pressure Equipment Directive 97/23/EG.

(6) Applied conformity assessment procedure: Modul H.

(7) Noti¿ed body for conformity assessment PED an Quality-Management-System:

Bureau Veritas S.A.

Paris / Frankreich
Kennzeichen 0062

(8) Certi¿cate numbers: Quality Management System: INT110198DE

Certi¿cate of System approval PED: 2011/70.10.1777/P

(9) Applied harmonized standards, in particular:

DIN EN 12516:2005 Industriearmaturen - Gehäusefestigkeit

(10) On behalf Bad bH & Co. KG Oeynhausen, 07. July 2011

END-Armaturen Gm . 78
Oberbecksener Str en · Germany
32547 Bad Oeynhaus 1 - 7900-0
Telefon: +49 (0)5731 - 7900-199
Telefax: +49 (0)573· [email protected]
http://www.end.de
Friedhelm König Michael End
Technical Manager Quality Manager

Declaration without signature or company stamp shall not be valid. The declaration may be circulated only without alternation.
Extracts or alternations are subject to approval by END-Armaturen GmbH & Co. KG.

END-Armaturen GmbH & Co. KG

Postfach (PLZ 32503) 100 341 · Oberbecksener Str. 78 · D-32547 Bad Oeynhausen (Germany) ·Telefon +49 - 5731 - 7900-0 ·Telefax +49 - 5731 - 7900-199 · http://www.end.de
 (1)
Declaration in conformity
(2)
as defined by Pressure-Equipment-Directive 97/23/EC
(3) This declaration apply to the article groups with the nominal sizes:
Articles Nominal size Articles Nominal size Articles Nominal size Articles Nominal size
Gate valves BT ½" ... 1" VN ¼" ... 1" CK3003 DN15 ... DN50
AA ½" ... 2" BV ¼“ ... ¾“ VO DN25 CK5000 DN40 ... DN250
AB ¼" ... 1" CB ¼" ... 2½" VS DN15 ... DN25 CK5003 DN40 ... DN25
AC ǩ" ... 2" CO-CO ½" ... 2" VT DN15 ... DN25 CK5100 DN40 ... DN50
AD ½" ... 2" HF ¼" ... 1" ZA ¼" ... 1", DN10 ... DN25 CK5200 DN40 ... DN50
AE ½" ... 1", DN15 ... DN25 HO DN10 ... DN15 ZB ¼" ... 1", DN15 ... DN25 CW5400 DN40 ... DN50
AV ¼" ... 1" IB ¼" ... 2" ZD ½" ... 1", DN15 ... DN25 DR DN50 ... DN300
BE Ǫ" ... 3" IK ¼" ... 1" ZE ¼" ... 1", DN10 ... DN25 EB ½" ... 1", DN15 ... DN25
BF ¼" ... 3" IL ¼" ... 1" ZF ¼" ... 1" MR ¼" ... 3"
BS ½" ... 1¼" IW ¼" ... 1" ZG ¼" ... 1" RG DN15 ... DN25
CA5014 DN40 ... DN80 KA ½" ... 1" ZH ½" ... 1" TD Ǫ" ... 3"
CA5015 DN40 ... DN50 KFE Ǫ" ... ¾" ZK DN15 ... DN25 TG ½" ... 2"
CA5214 DN40 ... DN32 NK Ǫ“ ... 4", DN10 ... DN100 ZL ¼" ... 1" TR Ǫ“ ... 4"
CD5010 DN15 ... DN25 PB ǩ ... 2" ZM ¼" ... 1" VB ¼“ ... 2“
CV3010 DN15 ... DN25 PD ½" ... 1" ZP DN15 ... DN25 ZR DN15 ... DN200
CV5010 DN15 ... DN25 SK ½" ... 3", DN10 ... DN80 ZU ¼" ... 1" Sight glasses
CV5020 DN15 ... DN25 TB ¼" ... 1" Pipe fittings SG ¼" ... 2", DN15 ... DN150
IC ¼" ... 4" TE ½" ... 2" FG ǩ" ... 4" Strainer
MV ½" TF DN20 ... DN25 FS DN15 ... DN150 AS ¼“ ... 1“
TC ¼" ... 4" TH ½" ... 1" GE Ø6 ... Ø20 AS DN15 ... DN25
Pressure reducer TT Ǫ" ... 1" GR Ø8 ... Ø28 BG Ǫ" ... 2"
ID Ǫ" ... ¾" TV Ǫ" ... 1" GV Ø6 ... Ø20 CU DN15 ... DN250
MB ½" ... 2" VD ¼" ... 1" TE Ø6 ... Ø25 EA ½" ... 1", DN15 ... DN25
MC ½" ... 2" VD DN10 ... DN25 TV Ø6 ... Ø20 IG ¼" ... 4"
Pressure relief valves VE ¼" ... 1" WE Ø6 ... Ø38 KU DN15 ... DN100
NG Ǫ" ... 1", DN15 ... DN25 VF ǩ“ ... ½" WV Ø6 ... Ø20 Water-shock damper
Ball valves VH ǩ“ ... 1" Non-return valves TS ½"
AG ¼" ... 1" VH3100 ½" ... 1" AH ¼" ... 1½"
BC ǩ“ ... ¾" VK DN15 ... DN25 AR ½" ... 1"
BK DN15 ... DN25 VL ¼" ... 1" BH Ǫ" ... 3"

and all variations of these articles

(4) of the company END-Armaturen GmbH & Co. KG

D-32547 Bad Oeynhausen
Germany

(5) Herewith we declare that the above-mentioned articles in the conditions of our delivery are in conformity with the regula-
tions of Article 3 Part 3 of the directive 97/23/EG. These products bear no CE mark, but are in line to the good engineering
practice designed and manufactured.

(6) Applied harmonized standards, in particular:

ren GmbH & Co. KG

DIN EN 12516:2005 Industriearmaturen - Gehäusefestigkeit
END-Armatu . 78
Oberbecksener Str en · Germany
(7) On behalf Bad 32547 Bad Oeynhaus Oeynhausen, 04. July 2011
1 - 7900-0
Telefon: +49 (0)5731 - 7900-199
Telefax: +49 (0)573· [email protected]
http://www.end.de

Friedhelm König Michael End

Technical Manager Quality Manager

Declaration without signature or company stamp shall not be valid. The declaration may be circulated only without alternation.
Extracts or alternations are subject to approval by END-Armaturen GmbH & Co. KG.

END-Armaturen GmbH & Co. KG

Postfach (PLZ 32503) 100 341 · Oberbecksener Str. 78 · D-32547 Bad Oeynhausen (Germany) ·Telefon +49 - 5731 - 7900-0 ·Telefax +49 - 5731 - 7900-199 · http://www.end.de
 watergates
knife-gate-valves - Stoffschieber

END-Armaturen GmbH & Co. KG END-Automation GmbH & Co. KG Watergates GmbH & Co. KG
Oberbecksener Str.78 Oberbecksener Str.78 Oberbecksener Str.70
D-32547 Bad Oeynhausen D-32547 Bad Oeynhausen D-32547 Bad Oeynhausen
Postfach (PLZ 32503) 100 341 Postfach (PLZ 32503) 100 342 Postfach (PLZ 32503) 100 321
Telefon +49 (0) 5731 / 7900-0 Telefon +49 (0) 5731 / 7901-0 Telefon +49 (0) 5731 / 7900-0
Telefax +49 (0) 5731 / 7900-199 Telefax +49 (0) 5731 / 7901-999 Telefax +49 (0) 5731 / 7900-199
Internet http://www.end.de Internet http://www.end.de Internet http://www.watergates.de
E-Mail [email protected] E-Mail [email protected] E-Mail [email protected]
Installation, Operation &
Maintenance Manual

RS-PRO

English Version V 06 / 2016

Please read carefully before commissioning and follow

instructions. Keep in a safe place for future use.

RENNER GmbH Kompressoren

Emil-Weber Str. 32
D-74363 Gueglingen
Tel: +49 (0)7135 931 93 0
Fax: +49 (0)7135 931 93 50
[email protected]
www.renner-kompressoren.de
EN
Table of contents

Chapter 0 Nr. Subject page

General
information 0.1 General information 0-2

0.2 Structure and use of this manual 0-4

0.3 Intended usage / misuse 0-6

0.4 Requirement of the user 0-7

0.5 Personnel responsibilities 0-8

Chapter 1 Nr. Subject page

Safety advice
1.1 Symbols 1-2

1.2 Basic safety advice 1-3

1.3 Accident conduct 1-6

Chapter 2 Nr Subject page

Machine
description 2.1 Authorized access points 2-2

2.2 Safety devices 2-4

2.3 Compressor unit 2-5

2.4 Instrumentation panel RENNERlogic 2-10

2.5 RENNERtronic control (optional) 2-11

2.6 RENNERtronic plus control (optional) 2-12

2.7 Frequency control (optional) 2-13

2.8 Refrigeration air dryer (optional) 2-14

Table of contents Content-I

Table of contents (continuation)

Chapter 3 Nr. Subject page

Installation &
putting into 3.1 Compressor installation 3-2
operation
3.2 Connections 3-3

3.3 Putting into operation 3-5

Kapitel 4 Nr. Subject page

Operating / normal
use 4.1 Control instrumentation RENNERlogic 4-2

4.2 Control instrumentation RENNERtronic 4-3

4.3 Control instrumentation RENNERtronic plus 4-5

4.4 Compressor startup / normal use 4-6

4.5 To stop the compressor 4-8

4.6 Failures during operation 4-10

Table of contents Content-II

Chapter 5 Nr. Subject page
Maintenance
5.1 What to take into account 5-2

5.2 Remove faults 5-4

5.3 Venting the compressor system 5-5

5.4 Cleaning work 5-6

5.5 Checking oil level 5-7

5.6 Change of oil filter 5-8

5.7 Changing oil 5-9

5.8 Cleaning oil level sight glass 5-10

5.9 Cleaning oil cooler 5-10

5.10 Checking safety valve 5-11

5.11 Tensioning and changing drive belts 5-12

Chapter 6 Nr. Subject page

Decommissioning
and disposal 6.1 Decommissioning of plant 6-2

6.2 Re-commissioning after storage 6-4

6.3 Shut-down and disposal 6-5

Table of contents Content-III

Appendixes Nr. Subject

AT Data sheet

AEC EC Conformity Declaration

AW1 Maintenance check

AW2 Motor bearings

AW3 Maintenance work

ADS Pressure switch

AFU Frequency converter (optional)

AKT Refrigeration dryer (optional)

AD Air receiver (optional)

Table of contents Content-IV

Chapter 0
General Information

Contents Hereunder you will find general information relating to the

following subjects:
Utilisation of the INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Compressor Operation and Usage
Personnel responsibilities

Survey This chapter relates to the following subjects:

No. Subject Page

0.1 General information 0-2

0.2 Structure and use of the manual 0-4

0.3 Intended Usage 0-5

0.4 Requirement of the user 0-6

0.5 Personnel responsibilities 0-7

0 General Information 0-1

0.1 General Information

Contents General information regarding this manual.

Validity This manual is applicable to the following compressor:

Compressor Detail Classification

Type Screw compressor

Year of construction

Serial number

Model

Location

Manufacturer RENNER GmbH compressors

Emil-Weber-Strasse 32
D-74363 Gueglingen

Date of issue June 2016

Safe-keeping and This manual should be kept in a clean safe condition and
completeness should be readily available to authorised personnel at all
times.
Do not remove any pages from this manual.
Any lost or mislaid pages should be replaced especially if
they relate to health and safety matters.

Continuation next page

0 General Information 0-2

0.1 General Information (Continuation)

Copyright This documentation contains copyrighted information.

Without prior consent of RENNER GmbH this information
must not be photocopied, duplicated, translated or put on
data carrier neither as a whole or part document.
RENNER GmbH reserves all further rights.

Modification of the For safety reasons any modification or alteration may be

compressor permitted only after having received the agreement of the man-
ufacturer.
If modifications are made without the prior agreement of the
manufacturer all warrantees and manufacturers responsibilities
will be invalidated.

In these cases, the process for conformity evaluation pursuant

to 2006/42/EC for all components may need to be carried out
again.

Suppliers’ The following suppliers documents are part of this manual and
documents *) must be kept save and related to:

Documents for manufacturer

RENNERlogic, RENNER GmbH

RENNERtronic or D-74363 Güglingen
RENNERtronic+
control

„Variable speed con- KEB Antriebstechnik GmbH

trol“ Försterweg 36 - 38
Manual D-32683 Barntrup
“Combivert F-5“

Operation manual RENNER GmbH

RKT air dryer D-74363 Güglingen

*) in case the compressor is equipped with any of these options

0 General Information 0-3

0.2 Structure and use of this manual

Contents The following information relates to the structure and use of this
manual.

Chapter This manual contains the following chapters:

Chapter Summary

0 General Information regarding:

– the manual,
– its usage
– personnel responsibilities

1 Definition of the symbols used

Basic safety instructions

2 Description and function of the compressor

3 Operating the compressor

4 Maintenance hints

A(xy) Appendix (es)

Numbering The pages have been consecutively numbered according to

of pages the chapter:
Example: 3-2
Signifies: Chapter 3, Page 2
Example: AT-1
Signifies: Appendix technical data, Page 1

Continuation next page

0 General Information 0-4

0.3 Intended usage / misuse

The intended usage of the compressor is described

Definition: Persons are regarded as authorized, when they have received

authorized persons adequate training/instruction and is then charged with defined
work on or with the compressor... Keys to the guard doors must
only be made accessible to authorized persons.

Intended usage The compressor should only be used according to the manu-
facturer recommendations in conjunction with the following
bullet points.
The compressor must be used only for the compression
of technically clean air without any detrimental or explosive
additives or impurities.
Ambient temperature must be below 40°C*.
Authorized persons only are allowed to work on the
compressor
The machine must only be operated with the safety devices
installed
The safety and operating advice contained in this manual
must be observed
Any instructions given by the operating company must be
observed
The legal accident prevention rules must be respected

Misuse Misuse is regarded as:

Operation by non-authorized persons
Operation by disregarding rules and regulations
Operation without corresponding treatment / cleansing
of the compressed air in the field of foodstuffs and breathing
air
Operation with defective safety-devices or those deactivated
or modified

* please consult your dealer or the manufacturer with details in case the ambient
temperature is higher in your compressor room

0 General Information 0-5

0.4 Requirement of the user

Contents Hereafter the duties and obligations of the user are outlined
when operating the machines

Safety of the plant The user has to particularly ensure that

the compressor must be used only according to Manu-
facturer recommendations in conjunction with all current
health and safety regulations
the compressor must be operated only when in faultless
condition and fully functional
the integrated safety devices are regularly serviced and are
fully functional
only adequately qualified and authorized personnel operate,
service, and repair the compressor

Protection of staff The operating company must ensure that the personal
protective equipment required is available for
the operating personnel,
the service and maintenance personnel
the maintenance and repair personnel and that it is
used accordingly

Briefing and The operating company must ensure:

training that prior to start up all personnel who will maintain,
service or operate the compressor are fully aware of the
current personal and environmental safety regulations
and procedures.
Annual personnel update of safety procedures would be
recomended
the complete manual must always be available at the site
of the compressor in a readable condition
that personnel are aware of the location of the manual,
the content and particularly the safety chapters.
the safety and warning advices mounted are not taken
away or made illegible

0 General Information 0-6

0.5 Personnel responsibilities

Contents The requirements in regard to personnel responsibilities are

as follows.

Duty of operating The personnel must carry out the following duties:
personal to control and inspect the compressor as to its faultless
and safe function (see chapter 2.1)
to operate the compressor according to the operating
points previewed
to recognize and delete or report respectively disturbances
and irregularities.

Responsibilities In order to carry through the requisitions the service personal

of operating must accomplish the following requirements
personnel The operator (of the compressor) must have received
instructions from the operating company as to the labor
protection law.
The operator must have a clear understanding of the
instructions given by the operating company and must carry
them out.

Duties of the The service and maintenance personnel must comply with the
maintenance per- following duties:
sonnel carry through regular inspection and maintenance work
up-keep of the compressor
carry through test runs of the machine
check the integrated safety devices

Requirement The following qualifications are required in regard to

of maintenance maintenance personnel:
personnel The maintenance personnel must have successfully
passed a test as skilled (machinery) labour - or equivalent.
The personnel must comply with the maintenance
instructions.

0 General Information 0-7

Chapter 1
Safety Advice

Contents This chapter informs you about

Definition of the symbols used.
Basic advice as to the safe handling of the compressor.
Advice regarding accidents.

Important advice!
It must be clearly understood that the safety advice given in
this manual should only be used as an additional aid to the
national safety accident prevention rules and laws currently
in force.

Existing accident prevention rules and regulations must be

retained and adhered to at all times.

Survey This chapter relates to the following subjects:

No Subject Page

1.1 Symbols 1-2

1.2 Basic safety advice 1-3

1.3 Accident conduct 1-6

1 Safety advice 1-1

1.1 Symbol

Contents Symbol definitions

Danger!

This symbol relates to the danger of life and health of people

Dangers to life will be particularly related to by using the

expression: danger for life.

Danger!

This symbol relates to danger for life and health of people due
to electric voltage.

Attention!

This symbol is a sign of danger for machine, material or the

environment

Advice!

This symbol is to indicate important advice and information

which contribute to your own safety, as well as to the better
understanding of the compressor operation.

Disposal!

This symbol indicates advice as to the disposal of machinery

parts and operating materials.

1 Safety advice 1-2

1.2 Basic safety advice

Contents Hereafter you will find basic safety advice for the safe handling
of the compressor.

Danger!

To minimise risk of personal injury, damage to equipment

or property, strictly follow the remedial actions stated below.

Possible danger Remedial action

Remaining dangers You should only operate this

The screw compressor has equipment
been designed and built ac-
Having the qualification
cording to latest technical
necessary
standards and according to
recognized safety regulations Having received
and is equipped with corre- complete instructions
sponding safeguarding quip- from the Operating
ment. Company
However, remaining risks Having completely
cannot be excluded. read and understood this
MANUAL
These dangers will be ex-
plained in this chapter. Before any maintenance
or service work is carried
Endangerment of people
out the RED STOP button
due to lack of qualification
must be pressed. The
and/or operational faults of the
incoming electrical supply
service personnel.
to the compressor must
also be switched off and
Explanation: isolated.
Operational faults may cause
personal injury, or damage to
equipment and property.

Protective gloves and protective goggles must be worn

during some of the maintenance work. Please observe the
corresponding advice

1 Safety advice 1-3

1.2 Basic safety advice (continuation)

Danger!

Please strictly follow the under mentioned safety advice to

avoid the danger of electrical shock or personal injury.

Possible danger Remedial actions

Danger of life Do not touch live cables or

Danger to people by an connections.
electric shock.
In case of damaged cables
report immediately to the
Explanation:
maintenance personnel.
The machine operates at
voltages up to 690 V with Ensure all doors to
an adequately high amper- electrical installations
age. are closed securely.
As voltages of more than
Always isolate electrical
44 mA can be fatal,
supply before starting any
corresponding precautions
maintenance work on the
are required.
compressor.
Only trained personnel
must carry out maintenance
and service work.
Wear rubber soled safety
shoes when working on the
compressor electrical circuit.
Make sure that during
maintenance or service work
no third party may switch on
the circuit breaker

There are no open flames and no sparks allowed at the site

of operation.

1 Safety advice 1-4

1.2 Basic safety advice (continuation)

Attention!

To minimise risk of personal injury, damage to equipment or

property, strictly follow the remedial actions stated below.

Possible damage Measures for prevention

Physical injury of the Do not remove or make

personnel and damage inoperative any safety device
to the compressor due
Rectify defects immediately
to removal or evasion
they are recognised
of protective devices
Electrical work/repairs must
be carried out by a qualified
electrician only

Damage to the Do not exceed the technical

compressor due to limit values stipulated
overloading

Burns through hot Do not touch compressor parts

compressor parts immediately after having opened
the doors of the canopy

Burns through hot Turn the oil filler cap slowly

lubrication oil when anticlockwise during the first
topping up or changing 5 rotations until a tangible
oil “snap-point”.
Thus the remaining pressure
will be slowly relieved
(see also chapter 5.7: Changing Oil)

Possible eye and Let the compressor sufficiently

skin burn due to hot cool down and handle with great
condensate spurt care before disconnecting it from
the c.a. system.
Wear protective goggles

Danger through Do not bring compressed air to

compressed air bear on any creature
Danger of life
Compressed air may
severely injure human
and domestic animals

1 Safety advice 1-5

1.3 Accident Conduct

Contents Hereafter you will get to know which measures must be taken at
accidents or disasters (e.g. fire or explosion)

Preparations for Please undertake the following measures at regular time

appropriate help at intervals so as to be prepared in case of an accident:
accidents Take part on regular basis in First - Aid courses in order
to brush up your knowledge.
Get yourself regularly informed about the possibilities
which are at your disposal in regards to rescue facilities for
First Aid in your company
Safe-guard a list at your work place containing the
telephone numbers required as well as the contact person.

Accident conduct At an accident, proceed in the following sequence:

Action If Then

1 there are injured administer first aid if you are a

people trained first aider?

2 there are inform the rescue team of the

injuries to people severity of injuries and type of
and damage to damage to property.
property

3 the disaster (fire) leave the machine

has happened immediately
use the marked emergency
exists and escape facilities.
do not use elevators/lifts!

4 there are injuries inform your supervisor

to people, damage immediately or another person
to equipment or from the list of company first
buildings aiders or safety officers. This list
should be clearly visible in the
working area.

1 Safety advice 1-6

Chapter 2
Machine description

Content This chapter covers the following:

definition of the safe access points for operating the com-
pressor,
overview of the compressor and its control instrumentation,
and
technical data.

Overview This chapter is subdivided as follows:

No. Subject Page

2.1 Authorised access points 2-2

2.2 Safety devices 2-4

2.3 Compressor unit 2-5

2.4 Instrumentation panel RENNERlogic 2-10

2.5 RENNERtronic Control (optional) 2-11

2.6 RENNERtronic plus Control (optional) 2-12

2.7 Frequency converter (optional) 2-13

2.8 Refrigeration drier (optional) 2-14

2 Machine description 2-1

2.1 Authorised access points

Content This section defines the safe access points for operating the
compressor and for carrying out minor inspection and mainte-
nance work.

Important Other access points are not intended for operating the com-
Note! pressor and are therefore not permitted as operator stations!
Safe operation can only be guaranteed from the operator termi-
nals specified. Work on the switch box and electrical installa-
tions may only be carried out by qualified electricians.

1 1

Figure
Access points
2

Continued overleaf

2 Machine description 2-2

2.1 Authorised access points (cont.)

Description of the The following access points only are provided for the operation
access points of the machine:

No. Operation ... Actions permitted

1 ... of the control panel Check working pres-

sure
Check oil and operating
temperature
Read operating hours

Switch compressor on

Emergency stop or
shut-down of compres-
sor

2 ... of the safety devices Carry out inspection

and minor maintenance
work

2 Machine description 2-3

2.2 Safety devices

Content This section provides an overview of the major compressor el-

ements and their functions.

3
Figure
safety devices
1

2
4

Description of the The following safety devices are fitted to the outside of the
safety devices compressor:

Item Description Function

1 Emergency stop Stops compressor immediately in

emergency

2 Electric panel Guard door on control box to be

door opened by qualified electricians only
CAUTION: Danger to life! Electrical
voltage!

3 Top lid Access to air filter, savety valve and

separator cartridge

4 Front panel Access to motor, drive belt, air end

5 Side panels Access to oil filter, oil filler neck,

pressure switch

2 Machine description 2-4

2.3 Compressor unit
7 6
Figure
compressor unit

10
8
12
13 9

11

7 6
Figure
compressor unit

10

13 8

12 9

11

2 Machine description 2-5

2.3 Compressor unit (cont.)

Description of the After removing the front walls of the compressor, you will see
compressor unit the most important components of the unit:

Item Description Function

6 Suction air filter Is used to filter suction air

cartridge

7 Separator cartridge Filters the finest residue oil

from the compressed air after
pre-separation

8 Air end Generate air pressure

9 V-belt Power transfer

10 Safety valve Pressure limitation

11 Electro-motor Drive

12 Oil filter Purifies the compressor oil

13 Oil filter neck Oil level control and refill

2 Machine description 2-6

2.3 Compressor unit (cont.)

Description Air end (item 8)

aggregate The direction of rotation of the air end is to the left (anti-
components clockwise) when looking from the front-side on to the shaft (see
picture). Pay attention to the directional arrow at the v-belt pul-
ley.

Suction air filter (item 6)

The suction air filter is directly mounted on to the suction stud of
the suction regulator.
The dry micro-filter with a rating of 10 µm filters the intake air.

Pressure switch (electric)

The pressure switch is directly connected to the outlet of the
machine. It controls the suction regulator. The values for pmax
and pmin are set at this switch.
pmax: is the upper service pressure at which the unit normally
stops pumping
Pmin: is the lower service pressure at which the unit normally
starts pumping again.

The pressure switch has been correctly set in the factory.

Authorised personnel must only carry out adjustments to the
pressure switch.

Suction regulator
The suction regulator is directly connected to the air end. It con-
trols the air volume sucked in by the compressor via the air suc-
tion filter.
Function of the suction regulator:
The suction regulator comprises of one main valve. This oper-
ates as a control valve and at the same time as a hermetically
sealed isolator valve. At full load the suction cross-section is
fully opened.
When the machine stops this valve closes quickly and thus the
suction cross section is locked altogether.
The multi-functions of the regulator are ensured by just one
flange mounted control unit.

Minimum pressure valve

The minimum pressure valve is situated at the outlet of the
compressor unit just before the air-after cooler.
It performs two tasks:

1) As a minimum pressure valve it prevents a loss of pressure

(in the air end) when no counter pressure in the air-mains is
available. A minimum pressure is necessary in order to safe-
guard lubrication of the air end.

2 Machine description 2-7

2.3 Compressor unit (continuation)

Description unit 2) As a “non return valve“ it prevents at the same time the re-
components verse flow of compressed air from the air mains or the air ves-
(contd.) sel, back into the compressor unit. Due to this function the
compressor unit is totally pressure relieved once it is stopped.

The valve operates automatically. The setting of the minimum

pressure valve must only be done by persons authorised by the
manufacturer.

Oil separator cartridge (Item 7)

The oil separator cartridge is not only designed for filtering the
oil from the compressed air, but serves at the same time to
reclaim the residual oil after pre-separation as drops, formerly
micro-distributed in the system. This cartridge is a spin on/off
type and – by means of the connection nipple – is screwed on
to the filter support of the oil re-claimer (see illustration below)

sealing

from return oil

separator
compressed air
Illustration: oil separator cartridge

Oil return scavenge window / oil return scavenge

non-return valve
The oil return window (fitted to some air ends) is situated
near to the oil separator cartridge and shows the scavenged
oil coming from the a.m. cartridge.

When starting the compressor the scavenge window is filled

with oil due to its accumulation during standstill. After a few
minutes a mixture of oil and air can be observed. Separation
of oil in the cartridge takes place.
If after a longer period of operating time no oil can be observed
in the scavenge window, a disturbance may have happened
e.g. a clogged borehole. As a consequence the oil separated
will be carried over in the compressed air into the air
mains/vessel.
Only personnel authorised by the manufacturer are allowed
to rectify such problems.

2 Machine description 2-8

2.3.2 Compression unit (continuation)

Description: Oil scavenge window / oil scavenge non-return valve

Compression unit The oil scavenge non-return valve prevents the oil separator
components (con- cartridge from flooding by scavenging oil from the air end.
tinuation)
Oil filter (item 12)
The oil filter (cartridge) cleans the compressor oil from impuri-
ties. The cartridge is screwed on to the scavenge stud by hand.
The efficiency of the filter is about 25 µm.

Combistat
The Combistat is a temperature indicator and control unit.
It is built into the instrument panel. It monitors the maximum
permissible service temperature of the unit, which is set at
110°C (red mark).
When this temperature is reached the electric circuit is discon-
nected and the unit stops automatically.
Do not bend the connecting line between the compressor and
the Combistat, otherwise the electric circuit is interrupted.

Safety valve (item 10)

The safety valve is mounted on the oil re-claimer before the oil
separator cartridge. It is set 1-2 bar above the max. gauged
pressure. The safety valve blows off in case the final pressure
is exceeded due to a fault somewhere in the system.

2 Machine description 2-9

2.4 Instrumentation Panel RENNERlogic

Figure
Instrumentation
panel 1
RENNERlogic
2

3 4 5 6

Description of the The following controls are found on the instrumentation panel:
Instrumentation
panel RENNERlogic Item Description Function

1 Start button Switches the compressor on

2 Stop button Switches the compressor off

3 Emergency stop Switches the compressor off

in case of emergency

4 Operating hour Counts the number of hours op-

meter erated by the compressor

5 Pressure gauge: Indicates pressure ratios or ex-

Working pressure cess pressure

6 Combistat tempera- Indicates operating temperature

ture indicator and overheating

2 Machine description 2-10

2.5 RENNERtronic Control (Optional)

Content The “RENNERtronic” controls and monitors the entire workings

of the compressor. It is possible to set or change a number of
parameters and functions.=> please also note the enclosed
instructions

Figure
Control 1 4 6
RENNERtronic

2 3

Instrumentation The "RENNERtronic" control features the following

components: instrumentation controls:
Control
RENNERtronic Item Description Function

1 Compressor ON Switches the compressor on

2 Compressor OFF Switches the compressor off

3 Multiple function Navigates in the menus, sets

keys parameters, etc.

4 Display Displays the parameters

5 LED (green) Service LED

6 LED (red) Fault / maintenance LED

Note!

Please see the explanations in Chapter 4 and the instruction

manual for the “RENNERtronic” control.

2 Machine description 2-11

2.6 RENNERtronic plus Control (Optional)

Content The “RENNERtronic plus” controls and monitors the entire

workings of the compressor. It is possible to set or change a
number of parameters and functions.=> please also note the
enclosed instructions

Figure 4 3
5
Control
RENNERtronic plus

Instrumentation The "RENNERtronic plus" control features the following

components: instrumentation controls:
Control
RENNERtronic plus Item Description Function

1 Compressor ON Switches the compressor on

2 Compressor OFF Switches the compressor off

3 Multiple function Navigates in the menus, sets

keys parameters, etc.

4 Display Displays the parameters

5 LED (green) Service LED

6 LED (red) Fault / maintenance LED

Note!

Please see the explanations in Chapter 4 and the instruction

manual for the “RENNERtronic plus” control.

2 Machine description 2-12

2.7 Frequency converter (optional)

Contents This section contains a brief summary of the control compo-

nents of the frequency converter (optional extra).

1
Pictures of
frequency
converter

3 2

Description of fre- The frequency converter control panel (3) features the following
quency converter control components:

No. Name Function

1 Display Displays the parameters

2 Key pad Keys to control and set the oper-

ating parameters

3 Control panel Frequency converter control

panel

Hazard!

The frequency converter operates at voltages which can deliver

a fatal electric shock upon contact. Installation and mainte-
nance work may be carried out by qualified electricians only.

NB!

Please see the explanations in the FU Appendix and the manu-

facturer’s instruction manual.

2 Machine description 2-13

2.8 Refrigerant drier (optional)

Contents This section provides a brief overview of the refrigeration drier,

installed as an optional feature.

Diagrams of
refrigerant drier

1.) Compressed air inlet 6.) Electrical connections

2.) Cpmpressed air outlet 7.) Maintenance access
3.) Refrigerant air intake 8.) Mounting holes
4.) Refrigerant air outlet E100.) On-off switch
5.) Steam trap EICA.) Electronic
regulator

Hazard!
Observe the safety instructions in the separate operating man-
ual for the refrigerant drier. It is especially dangerous to breathe
in refrigerant vapour or come into contact with liquid refrigerant.
Smoking is not permitted when working around the refrigerant
drier since ash from cigarettes, or any other naked flame (e.g.
when welding) combines with the refrigerant to produce poison-
ous vapours.

2 Machine description 2-14

Description The refrigerant drier also has a cooling unit to cool the com-
Refrigerant drier pressed air. The unit also removes moisture from the com-
pressed air. The resulting condensate is drained off using a
condensate separator.

Attention!
Please see the explanations in chapter 4 and the KT Appendix
as well as the manufacturer’s instruction manual.

Please note

that the float of the steam trap is checked regularly and cleaned
when necessary. Exact instructions regarding the procedure
can be seen in the manufacturer's instruction manual in Point 5
Maintenance.

2 Machine description 2-15

Chapter 3
Installation and commissioning

Content This chapter contains the most important information on trans-

porting, installing and storing the compressor.

General Infor- The installation plan and the technical data of this specific
mation screw compressor model can be ordered from RENNER GmbH.
The compressor is delivered on a euro-pallet, packaged in a
carton and labelled.

Danger of tipping!
The machine can tip over at an inclination of more than 10°!
Use suitable transport means such as a forklift, lifting gear or
loading harness. Support it from the side.

Unpacking the machine has no special requirements and the

(interim) storage in the transport packaging is also not problem-
atic. Protect the compressor against tilting over by storing it on
level, firm ground.

Dispose of the packaging material (carton / marked sheets)

separately.

This chapter is subdivided into the following sections:

Overview No. Subject Page

3.1 Compressor installation 3-2

3.2 Connections 3-3

3.3 Compressor start-up 3-5

3 - Installation and start-up 3-1

3.1 Compressor installation

Content This section contains important instructions which you need to

observe in order to safely install the compressor and to prevent
damage or malfunction.

Warning!
Follow the safety instructions!
Always remain outside the danger zone of a raised load!

Compressor instal- Key word Ensure that

lation
Installation site • Surface: Flat, level, firm
• Building ceilings: Check load bearing
capacity
• Air: As cool as possible, clean, frost-free,
as little damp as possible
Temp.: +5°C (41°F) - +40°C (104°F)*
• Sufficient ventilation in the room
• Air intake must be sufficiently unobstruct-
ed
• Arrange the air intake opening in such a
way that no loose items can be sucked in
• The installation site is illuminated (to read
off the instruments, carry out maintenance
work9)
Lifting work • Secure any loose, swinging or pivoting
parts before lifting the compressor
• Use suitable lifting gear
(weight acc. to data sheet)
• Always remain outside the danger zone of
a raised load
Conduits, • Remove all blank flanges, stoppers, co-
pressure pipes vers and bags with drying agents before
mounting conduits
• Please ensure that the connection from
the aftercooler to the compressed air sys-
tem can expand as a result of heat and
must be connected by means of a flexible
hose.
Exhaust air • An exhaust duct must at minimum have
the diameter of the cooler outlet area and
can be 3m in max. length with one bow of
90°; for longer ducts, use additional fans
with 20% more power than the compres-
sor fan
• When installing several compressors
please ensure that no compressor sucks
in the heated exhaust air from another
compressor
* Please ask your retailer in the event of higher temperatures.
3 - Installation and start-up 3-2
3.2 Connections

Content This section covers important instructions which you need to

observe in order to safely connect the compressor to the com-
pressed air system as well as the electrical supply.

Warning!
Before connecting the machine to the compressed air system,
all conduits and hose connections inside the compressor must
be checked and, if necessary, retraced.

For plants with pressure tanks, an acceptance check of the air

collection tank must be made by a compressed air tank expert
before commissioning.
Start an inspection log!

A Compressed air connection

The system has all the required conduits and is ready for opera-
tion.
The following must be observed when connecting to the com-
pressed air system:

Compressed air Key word Ensure that

connection
Pressure • Suitable screws and conduits are used for
the operating pressure
• The end pressure of the system is not
higher than stated on the rating plate.
• A non-return valve between the machine
and the compressed air system is not
required as it has already been integrated
in the machine.
Connection • Connect the system without voltage and
isolated against vibrations to the com-
pressed air system e.g. by using a flexible
hose
Shut-off valve • The additional installation of a shut-off
valve is recommended to facilitate
maintenance tasks at the compressor
without de-pressurising the compressed
air system.
Condensate • An automatic steam trap can be integrat-
ed behind the after cooler for improved
condensate separation from the com-
pressed air

3 - Installation and start-up 3-3

3.2 Connections (continuation)

B Electrical connection
Attention! All wiring work on the controls, and the compressors
have to be carried out in consideration of the 5 safety rules.

Only the connection to the electricity supply is now required for

the machine which is now ready to use with all conduits in-
stalled.
The machine must only be connected by an electrician!
The following must be observed when connecting to the mains
supply:

Electrical connec- Key word Ensure that

tion
Voltage • Tthe machine is only connected to the
voltage stated on the engine rating plate
Rotation • The rotational direction is observed under
all circumstances! Based on the attached
arrows.
• Checking the rotational direction see
chap. 3.3/3.4. Not necessary for
frequency-controlled compressors
Fuses • Customer to install the main fuse and
circuit breaker with the EMERGENCY
STOP function; these must be able to
switch at least 1.1 times the motor output
and must be clearly allocated to the ma-
chine
• Ensure that the mains supply is sufficient-
ly secured (see data sheet)
Connection • The supply cable must be situated such
that there is no danger of tripping over it
• Insert the cable with leads L1, L2, L3, N
and PE through the PG connection
in the connection box
Connect the leads to terminals L1, L2, L3
N (wire 4) and PE respectively
Warning: if possible do not use plugs !!

3 - Installation and start-up 3-4

3.3 Compressor start-up

Content This section covers important information which you need to

observe in order to start up the compressor safely.

General points Each component of the machine is tested at the factory in con-
tinuous operation after the final assembly. The test ensures that
the components indicate the data given and operate fault-free.
During the initial hours of operation the machine must be
watched to determine any possible malfunctions.

Important!
The respective operating manuals must be read and observed
for machines with additional optionally installed components
(electronic control, frequency converter, refrigerant dryer).

Preparation The following points must be observed and carried out before
the first start-up:

Step Task to be carried out / Points to be

observed:

1 Have an electrician tighten all screw and terminal

connections in the control cabinet

2 The motor bearings of compressors, without perma-

nent greased motor bearings, that are unused longer
than 6 month have to be regreased before putting into
operation

3 A clearly visible sign must be affixed to machines with

remote control with the following wording:
Warning! This machine is remote controlled and
may start without warning!

When controlling the machine remotely you must take

the safety precautions which prevent the
machine from starting up while it is controlled
or maintained; place a relevant instruction on the
remote control switch
4 Do not use the emergency or main switch to switch
the machine off during normal operations
see chapter 4 “Normal Mode Operation" (Pages 4-5)

3 - Installation and start-up 3-5

3.3 Compressor start-up (continuation)

Checking the When first starting up the machine, as well as after each
rotational direction change to the electrical feed line, the rotation of the screw com-
INFO pressor must be checked.
The rotation of the V-belt pulley must follow the direction of the
attached arrows! If necessary, reconnect the connecting cable
(electrician).

WARNING!
The rotation control must be carried out as a two-hand opera-
tion!

An incorrect rotation for longer than 2 seconds will lead to faults

in the screw compressor!

There is a danger from moving parts when checking the rotation

with the safety doors open!

Proceed as follows when checking the rotation:

Step Operation: Figure / Expl.

1 Open the front door
2 Start the compressor by tap-
ping the green start button
once with the one hand; im-
mediately let go of the button

3 Within 2 seconds stop the

compressor by pressing
the red stop button with the
other hand.

3 - Installation and start-up 3-6

3.3 Compressor start-up (continuation)

Test run Carry out a test run so that the oil can be distributed throughout
INFO the machine.

Conduct a
Step Operation: Figure / Expl.
test run
1 Open the shut-off valve.
Press the start button and let
the machine run for approx. 5
seconds.

2 Press the stop button.

3 Repeat points 1 and 2 twice.

3 - Installation and start-up 3-7

Chapter 4
Operation / Normal use

Content This chapter covers the information required for normal opera-
tion of the compressor.

Overview This chapter is subdivided into the following sections:

No. Subject Page

4.1 Control instrumentation RENNERlogic 4-2

4.2 Control instrumentation RENNERtronic 4-3

4.3 Control instrumentation RENNERtronic plus 4-5

4.4 Starting normal operation 4-6

4.5 Switching off the compressor 4-8

4.6 Remedying malfunctions in normal operation 4-10

4 Operation / Normal use 4-1

4.1 Control instrumentation RENNERlogic

Content This section provides an overview of the instrumentation control

RENNERlogic.

Figure
Instrumentation
components 1
RENNERlogic
2

3 4 5 6

Function The control components have the following function(s):

Instrumentation
components Item Description Function/Use
RENNERlogic 1 Start button Starts the compressor

Note:
The main switch must be
switched on. The main
switch is installed by the
customer.
2 Stop button Stops the compressor
3 Emergency Stop Stops compressor im-
mediately in emergency
4 Operating hour meter Counts the number of
hours the compressor
has actually run
5 Pressure gauge Displays working pres-
Working pressure sure setting
6 Temperature display Displays the oil tempera-
Combistat ture and operating tem-
perature

4 Operation / Normal use 4-2

4.2 Control instrumentation RENNERtronic

Content This section provides an overview of the instrumentation control

RENNERtronic.

1 9

Figure
Instrumentation
control
RENNERtronic
2

3 4 5 6 7 8

Function The instrumentation control has the following function(s):

Instrumentation
control Item Description Function
RENNERtronic
1 Compressor ON / Switches the compressor on
Start

2 LED (green) Service LED

3 Compressor OFF/ Switches the compressor off

Stop

4 Arrow key UP The UP key takes you to the pre-

vious menu item and increases
parameter values.
Also serves to call up the INFO
level (in conjunction with the En-
ter key)

5 Arrow key DOWN The DOWN key takes you to the

next menu item and decreases
parameter values.
Also serves to call up the INFO
level (in conjunction with the En-
ter key)

4 Operation / Normal use 4-3

Item Description Function

Enter Select a menu item.

6 Confirm or save entries or
changes.

7 LED (red) Fault / maintenance LED

8 Quit Quit discards inputs and ends a

selected menu item.
It also acknowledges warning
and error messages.
9 Display Displays the parameters and the
error/warning messages.
1st line: Displays current opera-
tional data
2nd line: Displays menu values
as well as error and warning
messages.

4 Operation / Normal use 4-4

4.3 Control instrumentation RENNERtronic plus

Inhalt This section provides an overview of the instrumentation control

RENNERtronic plus.

Figure 1 9 8
Instrumentation
control
RENNERtronic
plus 2 7

3 5

Function The instrumentation control has the following function(s):

Instrumentation Pos. Bezeichnung Funktion
control
RENNERtronic 1 LED (green) Service LED
plus
2 Compressor ON / Switches the compressor on
Start

3 Compressor OFF/ Switches the compressor off

Stop

4 LED (red) Fault / maintenance LED

5 Enter Select a menu item.

Confirm or save entries or
changes.

6 Arrow key DOWN The DOWN key takes you to the

next menu item and decreases
parameter values.

7 Arrow key UP The UP key takes you to the pre-

vious menu item and increases
parameter values.

8 Function keys On the display (9) to the left of

F1, F2, F3 the function keys, there is always
the current assignment
9 Display Displays the parameters and the
error/warning messages.

4 Operation / Normal use 4-5

4.4 Starting normal operation

Content The following section explains how to start the compressor and
contains essential points for normal operation.

Danger!
There are moving parts inside the compressor housing which
can cause serious injuries.
Never operate the compressor with the housing open!

Before starting Check the following points before starting the compressor:
the compressor Is the oil level sufficiently high?
Is the main switch on?
Are any existing shut-off valves open?

Start compressor
and monitor in Step Operation Figure / Expl.
normal operation
1 Press the Start button to
start the compressor.

2 Monitor the following

points at regular intervals
during operation:
2a Working pressure
The working pressure
displayed must not ex-
ceed the maximum per-
missible value specified
on the type plate. If this
is the case, switch off the
compressor immediately.

4 Operation / Normal use 4-6

4.4 Starting normal operation (continuation)

Monitor normal Step Operation Figure / Expl.

operation
2b Oil temperature and
(contd.)
operating temperature
The oil temperature and
operating temperature
must not exceed 110°C.
If 110°C is exceeded the
compressor will cut out
automatically.
Important!
Should the compressor
fail to cut out automati-
cally it must be switched
off immediately by hand!
2c Operating hour meter
Various maintenance
work must be carried out
after a specified number
of operating hours.
The exact maintenance
intervals and relevant
servicing work are listed
in the maintenance
schedule.

4 Operation / Normal use 4-7

4.5 Switching off the compressor

Content This section explains how to switch off the compressor in nor-
mal operation and/or at the end of operations.

Stop normal To switch off the compressor carry out the steps below in the
operation order listed:

Step Operation Figure / Expl.

1 Press the red Stop but-
ton while the compres-
sor is running to shut
down the compressor.

3 The compressor now

switches to the follow-
on time and stops au-
tomatically after that.

NB!
The follow-on time must
not be shorter than the
pre-adjusted time! (A
longer period of time is
no problem).
4 Press the Emergency
Stop to secure the
compressor
Emergency Stop

4 Operation / Normal use 4-8

4.5 Switching off the compressor (continuation)

Completely shut off If you want to shut off the compressor completely:
(e.g. after completing the work), then in addition to the above
steps, you must also turn off the main switch.

Note:
Switching the machine off via the red emergency stop button
can lead to the oil frothing up in the separator tank. Possible
consequences:
Exit of oil exit with the discharge air.
Oil overflow in the separator cartridge
The compressed air could contain oil when re-starting the
machine.

Although this is not usually critical and is normalised during op-

erations, in certain cases, it could however become necessary
to replace the separator cartridge.

4 Operation / Normal use 4-9

4.6 Remedying malfunctions in normal operation

Content This section contains advice on remedying malfunctions.

Danger!

Human error in remedying faults or lack of professional training

can lead to serious damage to property or physical injury.
It is therefore essential that faults are rectified by duly qualified
persons.

Before removing Always take the following steps before starting any work:
faults Switch the compressor and main switch off!
Discharge all the compressed air from the compressor and
air vessel!

Malfunctions The following faults may occur during operation:

Fault Possible Cause Remedy

System starts • No power Establish
starting power supply
• Loose cables Retighten cables or
or fuses fuses
• Motor protection Unlock motor protec-
switch has cut out tion switch (switch
cabinet)
• Combistat cut out / Ensure correct cool-
defective ing;
install new Combistat
if defective

• Connecting lines to Ensure correct guid-

Combistat are kinked ing of connection ca-
bles

Continued overleaf

4 Operation / Normal use 4 - 10

4.6 Remedying malfunctions in normal operation (continuation)

Malfunctions
Fault Possible Cause Remedy
(contd.)
System starts • Time for Check and correct
with difficulty star-delta connec- time setting,
tion too long or too correct setting
short 3-6 seconds,
adjust on Relay K 1T
• Machine is under Determine reason
compression
load
• Voltage fluctua- Check solenoid valve
tions in the grid and relief valve and
change if necessary
• Ambient temper- Heat installation loca-
ature tion
too low causing
excess viscosity
of oil
• Oil is too viscous Select correct type of
oil: RENNER VDL N
ISO 68 or 46 for low
temperatures.
Compressor cuts • Motor overload Check and adjust
out before reaching tripping overload setting;
discharge pressure check and adjust dis-
charge pressure
switch setting; check
supply lead for phase
failure.
• Combistat cuts Ensure correct cool-
out due to ex- ing; install new Com-
cessively high bistat if defective
temperature
• Short circuit in Eliminate cause of
trip line short circuit, change
defective fuse

Continued overleaf

4 Operation / Normal use 4 - 11

4.6 Remedying malfunctions in normal operation (continuation)

Malfunctions
Fault Possible Cause Remedy
(contd.)
Motor overload • Blocked Eliminate reason for
tripping (therm. system seizure
overcurrent relay) • Phase failure Check supply line
has stopped the • Motor over- Check and adjust
system loaded overload setting;
check and adjust dis-
charge pressure
switch setting

• Ambient tempe- Ensure adequate

rature too high ventilation

Combistat cuts out • Insufficient oil Check and adjust oil

due to excessively level
high temperature
• Oil filter clogged Change oil filter
• Oil thermostat Replace oil thermos-
defective tat
• Oil cooler dirty Clean oil cooler (air
• Compressor in- or oil side)
correctly installed Refer to recommen-
dations for installation
• Combistat defec- Adjust or replace
tive or incorrectly Combistat
set
Safety valve blows • Safety valve de- Change safety valve
fective
• Oil separator Change separator
cartridge clogged cartridge

Continued overleaf

4 Operation / Normal use 4 - 12

4.6 Remedying malfunctions in normal operation (continuation)

Malfunctions
Fault Possible Cause Remedy
(contd.)
Oil in compressed air • Oil scavenge line and Have oil scavenge
nozzle in oil sight system cleaned
glass clogged
• Separator cartridge
defective Check cartridge and
• Oil tank level too high replace if necessary
Rectify oil level
• Compressor was
stopped
before end of run-on Never switch off
time compressor until run-
on time has elapsed
Compressor does not • Upper trigger point of Reset discharge
vent during continuous discharge pressure pressure switch
operation; compressor switch set too high
does not cut out during • Solenoid valve defec-
intermittent operation, tive
i.e. safety valve blows • Relief valve defective Change solenoid
• Minimum pressure valve
valve jamming Change relief valve

Check and adjust

minimum pressure
valve
Compressor vents • Solenoid valve defec- Change solenoid
continuously; low vol- tive valve
umetric capacity • Relief valve defective Change relief valve in
• Electric supply to so- intake regulator
lenoid valve discon- Restore supply line
nected connection
• Auxiliary contact on Y-
contactor defective Check switch and
replace if necessary
Non-existent or insuffi- • Intake filter clogged Change air filter
cient discharge capaci- • Intake regulator or
ty intake valve jamming Check regulator and
or positioned incor- butterfly valve and
rectly clean bearing and
(continuous operation) guides
• Leaks in the system
Rectify leaks

Continued overleaf

4 Operation / Normal use 4 - 13

4.6 Remedying malfunctions in normal operation (continuation)

Malfunctions
Fault Possible Cause Remedy
(contd.)
Intake regulator • Actuating cylin- Install new actuating
does not close at der defective, no cylinder, check sole-
discharge pressure control pressure noid valve

• Nozzle blocked Clean nozzle

or frozen
Pressure vessel not • Non-return valve Change non-return
depressurising defective valve

Oil in compressor, • Loose connec- Tighten connection

oil mist on tion in oil line
venting • Check seal on oil Tighten screw,
drain plug seal if necessary
• Machine is shut Do not switch com-
off if under load pressor off until it has
(e.g. emergency coasted for
stop switch) three minutes, or
check the minimum
run-on time and set
to three minutes
• Check condition Fit new O-ring if nec-
and fit of O-ring essary
on intake regula-
tor
System runs noisily • V-belts not cor- Check V-belt tension
rectly tensioned and tighten if neces-
sary
• V-belt sets not Replace with match-
compatible ing set of belts
• V-belt pulleys not Check alignment of
aligned with each pulleys and adjust if
other necessary

4 Operation / Normal use 4 - 14

Chapter 5
Maintenance instructions

Content This chapter contains information on the maintenance work

required.

Overview This chapter is subdivided as follows:

No. Subject Page

5.1 What to take into account 5-2

5.2 Remove faults 5-5

5.3 Venting the compressor system 5-6

5.4 Cleaning work 5-7

5.5 Checking oil level 5-8

5.6 Changing oil filter 5-9

5.7 Changing oil 5-10

5.8 Cleaning oil level sight glass 5-11

5.9 Cleaning oil cooler 5-11

5.10 Check safety valve 5-12

5.11 Tensioning and changing the drive belts 5-13

5 Maintenance 5-1
5.1 What to take into account

Content This section contains general information to be heeded during

servicing and maintenance work.

Personnel Servicing and maintenance work may only be carried out by

requirement duly qualified personnel.

The specific personnel requirements are set out in Chapter 0.

Danger!

It is essential to adhere to the following safety instructions in

order to avoid all risks of personal injury or death:

Potential Source of Dan- Preventive Measures

ger

Crushing from moving Always maintain a safe dis-

parts tance from all moving parts
when carrying out test runs

Electric shock Switch off all voltage sources

before starting work.
Take measures to prevent
power
sources from being switched
on again by accident

Inappropriate spare parts Always replace self-locking

nuts and screws
Only use spare parts includ-
ed in the approved lists

Unauthorised/premature Do not release the unit for

approval of unit for opera- operation until the safety de-
tion vices are fully functional.
Only then is the work com-
pleted!

5 Maintenance 5-2
5.1 What to take into account (continued)

After completion of The following steps must be carried out after completing the
work work:

Step Operation

1 Follow the maintenance schedule and complete the

inspection sheets, activity logs, etc. (see Appendix W
“Maintenance Check”).

2 Check that the safety devices are working correctly.

Do not release the machine for operation if the safety
devices are not in perfect working order.

3 Reinstall and secure any safety devices that have

been removed.

4 Remove any tools, foreign objects and materials left

lying around.

5 Carry out a test run and check the function of the ser-
viced components.

6 If you leave the machine before completing the work

keep the keys safe and inaccessible to unauthorised
persons.

Spare parts, Only genuine spare parts should be used when replacing com-
accessories ponents such as the oil filter, oil, air filter, separator cartridge, V-
belt, etc.

Repairs Only allow authorised dealers to carry out repair work.

A list of other persons authorised by the manufacturer to carry
out repairs can be obtained from the manufacturer on request.

Do not allow repairs to be carried out by any persons other

than those authorised by the manufacturer!

Servicing is carried out as agreed with the authorised dealer.

5 Maintenance 5-3
5.1 What to take into account (continued)

General Take the standard safety precautions and proceed with great
Notes care when carrying out any servicing work.
Please follow especially the points below:

Servicing work to be carried out by qualified personnel only.

Correct tools only to be used for servicing work.
Unit and power supply to be switched off before any servic-
ing work is carried out. Take measures to ensure that the
unit cannot be switched on accidentally!
Unit must be allowed to cool before carrying out servicing
work to avoid risk of burns!
Exception: oil change (unit at operating temperature); safety
instructions to be strictly adhered to in this case!
Unit to be disconnected from all sources of pressure and all
pressure removed before executing a maintenance work or
dismounting pressurised parts.
Scrupulous standards of cleanliness to be maintained dur-
ing servicing work; parts and exposed openings to be cov-
ered with a clean cloth, paper or masking tape.
Motor, air filter, electrical components, control equipment,
etc. to be protected from ingress of moisture, e.g. when be-
ing wiped.
Welding or other heat-based work never to be carried out in
close proximity to the oil system; oil tank to be fully dis-
charged and cleaned before such work.
No tools, loose parts or rags to be left in or on the unit.
Operating pressures, temperatures, time settings, control
equipment and cut-out devices to be checked for perfect
working order before unit is released for operation after
maintenance work.
Doors on unit to be closed before switching on the unit (in-
cluding for test run)!
Sound-absorbing materials to be left in place and retained.

5 Maintenance 5-4
5.2 Remove faults

Content This section covers general points on troubleshooting and con-

tains references to relevant sources of information.

Danger!
Always take measures to ensure that the machine can be
shut off in an emergency by a second person.
You may only rectify faults or carry out checks if you are
duly qualified (specialist training in mechanical or electrical
engineering).
Adhere to the general safety instructions contained in this
manual for handling the machine.
Follow the instructions given in this chapter and all other
maintenance instructions issued by the operator and pay
due regard to the documentation relating to the components
included in the unit (e.g. frequency converter, refrigerant
dryer).

List of faults The necessary action to be taken in the event of faults is out-
lined...

... in Chapter 4.6. “Remedying malfunctions in normal opera-

tion” and
... in the operator’s internal servicing documents.

5 Maintenance 5-5
5.3 Venting the compressor system

Contents This section outlines the main points to be taken into account
when the unit has to be vented.

Why vent? The pressure has to be removed from the unit before all servic-
ing and maintenance work. The unit vents automatically when
switched off but if there is a fault the unit might remain pressur-
ised even after being switched off. Since this is not evident from
the outside it is always essential to vent the unit before servic-
ing work.

Beware of burns when unit is at operating temperature!

The oil filler plug can reach temperatures
up to approx. 110 °C ! Always use gloves when handling
the oil filler plug!
When the oil filler plug is unscrewed the residual pressure
may cause hot oil to squirt out! It is therefore essential to
wear safety goggles!

Venting the com- It is essential to adhere to the following instructions in order to

pressor system avoid the above risks of personal injury or death:

Step Operation
Switch off the unit and take measures to prevent it
1
from being restarted.
2 Unscrew cap on filler neck (oil filler plug) by hand.
The first five rotations of this plug must be made
slowly in an anti-clockwise direction until the detect-
3 able “snap point” is reached; the oil filler plug has a
side safety borehole through which the residual
pressure can gradually discharge.
Wait until all the pressure in the unit has been re-
4
lieved; the unit is now depressurised.

5 Maintenance 5-6
5.4 Cleaning work

Content The following section contains information on cleaning the

compressor and the air filter.

General points In terms of general cleaning, vacuum the unit or wipe it with a
damp cloth. Check the intake passage regularly, where neces-
sary removing any leaves, dust, dirt or similar matter in the in-
terests of an efficient air supply.

Never direct compressed air at living beings!

Misuse of the compressed air unit can cause serious tissue
damage or even fatal injuries.

Cleaning the air

Step Operation
filter
1 Switch off the unit and take measures to prevent it
from being restarted.
2 Unscrew filter cover and remove filter cover.
3 Remove filter cartridge.
4 Wipe dust out of filter housing with a slightly damp
cloth.
5 Replace filter.
6 Insert filter in housing.
7 Fit filter cover and screw on, ensuring that the cover
is correctly seated.
8 Carry out test run and functional check.

5 Maintenance 5-7
5.5 Checking oil level

Content This section outlines the procedure for checking the oil level in
the compressor.

General points The level in the oil tank is a key factor in the operational safety
of the unit. Due diligence should be exercised in conducting the
following checks at the specified times. Otherwise we cannot
accept liability in the event of damage.

Follow the safety instructions for venting the unit (see

Chap. 5.3)

Checking the oil

Step Instructions
level
1 Switch off the unit and take measures to prevent it
from being restarted.
RS-PRO 2-30 - 55
2 Wait until the unit has been switched off for at least
three minutes.
3 To check the oil level, look on the oil sight glass:
Minimum oil level: bottom edge of the oil sight glass
Maximum oil level: upper edge of the oil sight glass
4 Unscrew cap on filler neck of block by hand.
5 Compressors without oil sight glass:
RS-PRO 3-11 Minimum oil level: oil reaches to the transition from
the filler neck to the housing
Maximum oil level: oil reaches to the bottom of the
thread of the filler cap
6 If necessary, refill to the maximum oil level with oil of
the same kind.
7 Replace the oil filler plug firmly by hand.
8 Switch on the unit and check for leaks at the oil filler
neck.
9 If necessary, change the O-ring at the filler neck.

5 Maintenance 5-8
5.6 Changing oil filter

Content This section outlines the procedure for changing the oil filter.

Important note! An oil filter may only be changed when the unit is switched off
and fully depressurised and without power.

Changing the oil

Step Operation
filter
1 Switch off the unit and take measures to prevent it
from being restarted. Allow the unit to cool to approx.
70°C and then remove the pressure as described in
Chapter 5.3.
2 Loosen the old oil filter with the hexagon screw and
remove it.
3 Place the new oil filter in the air end and tighten it.
4 Start the unit and check the oil filter for leaks.
5 Check the oil level and, if necessary, refill to maxi-
mum mark.
6 Record the oil filter change on the maintenance
check sheet.

Comply with environmental guidelines

when disposing of used filter cartridges!

5 Maintenance 5-9
5.7 Changing oil

Content This section outlines the procedure for changing the oil.

Important note! The oil may only be changed when the unit is switched off and
fully depressurised! The unit should be at operating tempera-
ture (approx. 60°C - 80°C) when the oil change is carried out.
The unit should be run with the type of oil best suited to its op-
eration. The oil used by the factory is RENNER VDL N ISO 68.
It is recommended that this grade of oil is used.
Other oil grades must be comparable to the RENNER VDL ISO
68. Only refill the unit with oil of the same make and the same
grade.
Do not mix oils of different kinds!
Follow the safety instructions for venting the unit
(see Chap. 5.3)!

Changing the oil

Step Operation
1 Switch off the unit and take measures to prevent it
from being restarted. Allow the unit to cool to approx.
70°C and then remove the pressure as described in
Chapter 5.3.
2 Take a receptacle suitable for collecting the oil and
position it under the ball valve on the base of the
compressor block and then unscrew the plug and
open the ball valve.
3 Drain all the oil from the compressor block then close
the ball valve and replace the plug.
4 Pour the new oil into the filler neck up to the maxi-
mum level and replace the oil filler plug firmly by
hand.
5 Switch the unit on, let it run 2 to 3 times for only
about 5 seconds and switch it off again.This allows
the oil to be distributed in the unit before it is put on
load.
6 Switch the unit on and allow it to run for approx.
three minutes.
7 Check the oil level and, if necessary, refill to maxi-
mum mark.
8 Check drain plug and oil filler plug for leaks.
9 Record the oil change on the maintenance check
sheet.

Comply with environmental guidelines when disposing of

used oil!
* The machine must be completely emptied before using a synthetic oil,
e.g. (RENNER Super Lub).
(Including cooler and filter)

5 Maintenance 5-10
5.8 Cleaning oil return window

Content This section outlines the procedure for cleaning the oil scav-
enge sight gauge (optional extra).

General points The oil scavenge sight gauge is screwed onto the line on the
separator cartridge.

Cleaning the oil

Step Operation
level indicator
1 Switch off the unit and take measures to prevent it
from being restarted. Allow the unit to cool to approx.
70°C and then remove the pressure as described in
Chapter 5.3.
2 Undo the screws on the oil scavenge sight gauge.
3 Remove sight gauge and wipe over with a cloth.
4 Check seal and replace if necessary.
5 Refit sight gauge.

5.9 Cleaning oil cooler

Content This section outlines the procedure for cleaning the oil cooler.

General points If the oil cooler is not very dirty it can be left in the unit and
blown with compressed air while the unit is switched off.
If the oil cooler is very dirty proceed as outlined below.

Cleaning the oil

Step Operation
cooler
1 Switch off the unit and take measures to prevent it
from being restarted. Allow the unit to cool to approx.
70°C, disconnect from the power supply, and remove
the pressure as described in Chapter 5.3.
2 Remove the oil cooler.
3 Steam clean the oil cooler.
4 Refit oil cooler.
5 Start the unit and check for leaks.

5 Maintenance 5-11
5.10 Check the safety valve

Check After 2000 operating hours - however at least 1x a year

General points The check process may only take a few seconds and be
completed only by hand

Caution risk of injury!

Scalding danger by escaping hot air-oil mixture
Since this is a dangerous process, please proceed with extreme
caution.
Additionally, safety precautions should be taken, such as safety
goggles and ear protection.

Check the safety

valve 1

Step Operation
1 Unscrew the cap (1) by turning counterclockwise (do
not use any tools!)
2 The cap must lift and let out air.
3 Close the cap by turning clockwise.
4 After closing the cap, no more air should escape.

The average service life of the valve seal is 3 years!

5 Maintenance 5-12
5.11 Tensioning and changing of drive belts(s)

Content This section outlines the procedure for tensioning and/or chang-
ing the V-belt.

General points The belt can be set to the optimum tension using the adjust-
mentscrews on the air end block.

Fig. Tighten
drive belt
2

The optimum capacity of the system and service life of the

V-belt is guaranteed only if the belt is correctly tensioned.
Please check the setting before start up and after 100 oper-
ating hours, as well as according to the information in the
maintenance plan.

For replacing or re-tensioning the V-belt, please proceed as

follows:
Tighten
Step Operation
drive belt
1 Switch off the unit, disconnect it from the power sup-
ply, and take measures to prevent it from being re-
started.
2 Loosen the lock nut at the bottom side of the tension-
ing device (1)
3 Discharge the motor using the top adjusting screw,
until the correct voltage has been reached (2)*
4 Now fix the adjustment screw and the lock nut

*The belt tension is set with an frequency meter. The ideal set-
ting values for the belt are available on request from RENNER
GmbH

5 Maintenance 5-13
Change the
Step Operation
V-belt
1 How to "tighten a V-belt", step 1 and 2
2 After loosening the lock nut, lift the motor until the V-
belt is released enough to loosen it from the pulleys.
3 Insert the new V-belt (please only use RENNER orig-
inal spare parts) via the top V-belt pulley and then via
the drive side.
4 For tensioning, please proceed in the reverse order
and then set the correct tension as is described in
the item "Tension V-belt".

Check for each V-belt replacement the alignment of the V-

belt pulleys to each other.
Please use a adequate belt alignment tool.

Please note that the correct V-belt tensioning values and

the alignment of the pulleys are a deciding feature for the
service life of the V-belt.

5 Maintenance 5-14
Chapter 6
Decommissioning and disposal

Content This chapter contains important advice for (temporarily)

decommissioning or disposing of your compressor.

Survey This chapter is divided into the following sub-sections:

No. Subject Page

6.1 Decommissioning of plant 6-2

6.2 Re-commissioning after storage 6-3

6.3 Shut-down and disposal 6-4

6 Decommissioning and disposal 6-1

6.1 Decommissioning of plant

Content This section contains instructions you need to follow when

decommissioning the compressor for an extended period of
time, and when subsequently returning it to operation.

When decommissioning for an extended period of time, prepare

the unit as follows:

Decomissioning of Step Activity

plant
1 A qualified electrician should disconnect the
compressor from power supply and lock off isolator
to ensure it can not be restarted by accident.

2 Check oil level and fill if necessary (see

Chapter 5.5 "Checking oil level") The unit
should be stored with its oil tank filled to the
max. recommended level

3 Slacken the V-belt (see Chapter 5.11

“Tensioning and changing of belt”).
Do not cover the unit with any material that
is impermeable to air. Doing so intensifies the
corrosion of individual parts.

6 Decommissioning and disposal 6-2

6.2 Re-commissioning after storage

Re-commissioning Compressor units that have been switched off,

information decommissioned or stored away for longer than 3 months,
should not be put back into operation until the following
measures have been carried out.

Re-commissioning Follow the procedure outlined below to return the compressor to

after storage operation after being out of commission for 3 months or more.

Step Activity

1 Turn the screw compressor in the direction of

rotation several times by hand.

2 Remove the air inlet filter and manifold and pour

approx. 0.1 litres of oil (“manufacturer recommended
compressor oil only”) into the suction port. Then, turn
the screw compressor by hand in the direction of the
rotation arrow (anti-clockwise) once more.

3 Check the oil level (in the reclaimer tank) and fill
where necessary, see 5.5. “Checking of oil level”.

4 Connect unit: see Chapter 3.2 “Connections”.

5 Re-adjust the V-belt (see Chapter 5.11

“Tensioning and changing of belt”).

6 Decommissioning and disposal 6-3

6.3 Shut-down and disposal

Content This section describes what you need to consider when shutting
down and disposing of the unit.

DANGER
Observe the safety instructions outlined in this handbook,
the instructions specified in the supplier's documentation as
well as accident prevention guidelines.

Danger of life!
Moving or lifting the compressor should only be undertaken
in a safety conscious manner.
Always ensure no one is within the danger zone when the
compressor is being lifted.

DANGER
When carrying out the following disassembly work be aware
of sharp corners and edges which may cause cuts. For this
reason always wear protective gloves.

Environment
The following instructions must be observed properly
to prevent any possible damage to the environment. The
Operating Company must ensure that the regulations are
adhered to correctly even where disposal is carried out
by an authorized firm of specialists.

Disassembly of the To dismantle the compressor, proceed as follows and observe

compressor the following points:

Step Activity

1 Find out how each component (or the whole

machine) needs to be disposed of.
If unsure, consult your local environmental agency.

2 Depressurise all components and vent the unit

(see Chapter 5.3. “Venting the plant”).

6 Decommissioning and disposal 6-4

6.3 Shut-down and disposal (Cont.)

Materials The following materials were predominately used in the

Information construction of the unit:

Material Where used

Batteries, NiCad-/Li • Control

Copper • Cables

Steel • Machine frame

• Side panels and doors
• Motor and components

Plastic, rubber, PVC • Gaskets

• Tubes
• Cables

Tin • Boards

Polyester • Boards

Hazardous waste The following parts, materials and fluids must be disposed of
Information separately:

Denomination Application

LCD displays • Display devices

Note:
LCD displays contain
highly poisonous fluids

Electronic scrap • Electrical supply

• Controls (SPS etc.)
• Boards with electronic parts

Compressor oil • Complete compressor

The environment:
Dispose of all parts of the unit in a manner that prevents
damage from being caused to other peoples’ health or the
environment.

6 Decommissioning and disposal 6-5

Appendix T: Data sheet Manual
RENNER GmbH

Nominal Quantity Cooling Outlet Electr.

Type Free air delivery Start Noise level HRC Fuse Dimensions mm Weight Air receiver
power of oil air connection Conn.

m³/min kW db(A) ltr m³/h Amp mm² LxBxH kg

7,5 bar 10 bar

RS-PRO 3,0 0,54 0,41 0,29 0,24 3,0 direkt 65 / 61* 1,95 300 ½" 16 2,5 540 (740*) x 554 x 1014 153 / 167* x-500
RS-PRO 4,0 0,69 0,55 0,44 0,37 4,0 direkt 65 / 61* 1,95 340 ½" 16 2,5 540 (740*) x 554 x 1014 153 / 167* x-500
RS-PRO 5,5 0,91 0,78 0,61 0,51 5,5 Υ∆ 65 / 61* 1,95 560 ½" 16 2,5 540 (740*) x 554 x 1014 172 / 186* x-500
RS-PRO 7,5 1,25 1,09 0,86 0,79 7,5 Υ∆ 65 / 61* 3,15 980 ½" 25 4,0 540 (740*) x 554 x 1014 198 / 212* x-500
RS-PRO 11 1,61 1,56 1,29 1,11 11,0 Υ∆ 71 / 67* 3,15 1950 ½" 35 6 540 (740*) x 554 x 1014 216 / 230* x-500
RS-PRO 2-30 5,22 4,61 3,59 3,29 30,0 Υ∆ 74* 30 5700 1 ¼" 63 16 1305 x 830 x 1640* 746 -
RS-PRO 2-37 6,36 5,58 4,66 4,10 37,0 Υ∆ 77* 30 6700 1 ¼" 80 25 1305 x 830 x 1640* 762 -
RS-PRO 45 7,70 6,92 5,71 4,99 45,0 Υ∆ 77* 35 8100 1 ½" 100 35 1485 x 880 x 1760* 939 -
RS-PRO 55 9,02 7,94 6,93 6,09 55,0 Υ∆ 79* 35 9900 1 ½" 125 50 1485 x 880 x 1760* 1017 -
RSK-PRO 3,0 0,54 0,41 0,29 0,24 3,0 direkt 61* 1,95 600 ½" 16 2,5 995 x 554 x 1014* 193* x-500
RSK-PRO 4,0 0,69 0,55 0,44 0,37 4,0 direkt 61* 1,95 640 ½" 16 2,5 995 x 554 x 1014* 193* x-500
RSK-PRO 5,5 0,91 0,78 0,61 0,51 5,5 Υ∆ 61* 1,95 860 ½" 16 2,5 995 x 554 x 1014* 216* x-500
RSK-PRO 7,5 1,25 1,09 0,86 0,79 7,5 Υ∆ 61* 3,15 1280 ½" 25 4,0 995 x 554 x 1014* 237* x-500
RSK-PRO 11 1,61 1,56 1,29 1,11 11,0 Υ∆ 67* 3,15 2250 ½" 35 6 995 x 554 x 1014* 255* x-500
RSK-PRO 2-30 5,22 4,61 3,59 3,29 30,0 Υ∆ 74* 30 6400 1 ¼" 63 16 1654 x 830 x 1640* 829 -
RSK-PRO 2-37 6,36 5,58 4,66 4,10 37,0 Υ∆ 77* 30 7400 1 ¼" 80 25 1654 x 830 x 1640* 845 -
RSK-PRO 45 - 6,92 5,71 4,99 45,0 Υ∆ 77* 35 8800 1 ½" 100 35 1834 x 880 x 1760* 1022 -
* with rear duct silencer
RSD-PRO - Compressor on air receiver
RSDK-PRO - Compressor and refrigeration dryer on air receiver
Please refer to the corresponding data sheet or the price list for dimensons and weight of compressors with air receiver
We reserve our right to change this spec without notice

AT Appendix Data sheet AT

EC Declaration of Conformity according to machine guideline 2006/42/EC Appendix
II 1.A

The manufacturer / distributor

RENNER GmbH Kompressoren
Emil-Weber-Straße 32
74363 Güglingen
hereby declares that the following product

Product description: RENNER Screw Compressor

Manufacturer: RENNER
Serial no.:
Series / type description: RS-PRO, RSF-PRO, RSK-PRO, RSD-PRO, RSDK-PRO, RSDF-PRO,
RSKF-PRO, RSDKF-PRO 3 – 11, 2-30 – 55 kW
Description:
Screw Compressor for generating compressed air of 7,5 to 15 bar

meets all relevant provisions of the above stated guideline and the other applied guidelines (to follow) -
including the changes applicable at the time of the declaration.

The following further EU directives were applied:

EMC directive 2014/30/EU
Directive 2014/29/EU
RoHS directive 2011/65/EU

The following harmonised standards were applied, in its current version:

EN 1012-1 Compressors and vacuum pumps - Safety requirements - Part 1:
Compressors
EN 286-1 Simple unfired pressure vessels designed to contain air or nitrogen - Part 1:
Pressure vessels for general purposes
EN 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General
requirements
EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and
risk reduction
EN ISO 13849-1 Safety of machinery -Safety relevant parts of controls - Part 1: General
principles for design
EN ISO 13849-2 Safety of machinery -Safety relevant parts of controls - Part 2: Validation

Name and address of person who is authorised to compile the technical documentation:
Michael Zottl
RENNER GmbH Kompressoren
Emil-Weber-Straße 32
74363 Güglingen

_______________________________ ______________________________
(B. Renner) (Michael Zottl)
Managing Director Contractor for documentation

AEC - Appendix EC Conformity AEC-1

 Appendix W - Maintenance Control
for RS-PRO 3 - 11
with less than 2000 hours / year
after ... years

commissi
Maintenance work

periodi
oning
1 2 3 4 5 6 7 8 9 10

cally
Fill out commissioning report
Check screw connections and tighten if necessary
Check that all connections are firm and tight
Checking the oil Level
Check the V-belt tension and wear
Tighten electric clamps
Functional check of pressure and temperatur gauges
Measuring / testing current consumption
Check ON and OFF settings and adjust if necessary
Check the alignment of the V-belt pulleys
Check the dirt level of the air filter and the possibly mounted ventilator filter pads
Compressors with air receiver, empty the condensate water*
Examine all the hoses to ensure that they are in good working condition
Check funktion of the condensate drain*
Check contactors for wear
Control the oil / air cooler and clean if necessary
Check the compressor to ensure that it has no leaks
Check the overall condition of the compressor
Check air filter element, replace if necessary
Clean / replace the filter mats*
Check / replace the safety valve
Changing the oil filter
Change the oil
Change the fine separator cartridge
Check the follow-on time (>= 3 min)
Replace thermal valve element
Change oil suction / recirculation hoses
Change control air hose
Replace solenoid valve
Maintenance set minimum pressure valve
Change the V-belt
Replace the O-ring on the oil filler plug
Maintenance condensate drain*
Servicing kit for the intake regulator
Replace minimum pressure valve completely
Replace oil hoses*
Replace pressure switch / pressure sensor
Replace motor bearings A and B side
Replace electrical contactors
Maintenance package 1 (see maintenance package List for each compressor)
Maintenance package 2
Maintenance package 3
Maintenance package 4
Maintenance package 5
Maintenance package 6
Maintenance package 7
Maintenance package 8
Maintenance package 9
Maintenance package 10
* if existing
 Appendix W - Maintenance Control
for RS-PRO 3 - 11
with more than 2000 hours / year
after ... hours

commissi
Maintenance work

periodi
oning

cally
2000 4000 6000 8000 10000 12000 14000 16000 18000 20000

Fill out Commissioning report

Check screw connections and tighten if necessary
Check that all connections are firm and tight
Checking the oil Level
Check the V-belt tension and wear
Tighten electric clamps
Functional check of pressure and temperatur gauges
Measuring / testing current consumption
Check ON and OFF settings and adjust if necessary
Check the alignment of the V-belt pulleys
Check the dirt level of the air filter and the possibly mounted ventilator filter pads
Compressors with air receiver, empty the condensate water*
Examine all the hoses to ensure that they are in good working condition
Check funktion of the condensate drain*
Check contactors for wear
Control the oil / air cooler and clean if necessary
Check the compressor to ensure that it has no leaks
Check the overall condition of the compressor
Check air filter element, replace if necessary
Clean / replace the filter mats*
Check / replace the safety valve
Changing the oil filter
Change the oil
Change the fine separator cartridge
Check the follow-on time (>= 3 min)
Replace the O-ring on the oil filler plug
Change oil suction / recirculation hoses
Change control air hose
Maintenance set minimum pressure valve
Change the V-belt
Replace thermal valve element
Maintenance condensate drain*
Replace solenoid valve
Servicing kit for the intake regulator
Replace minimum pressure valve completely
Replace oil hoses*
Replace pressure switch / pressure sensor
Replace motor bearings A and B side
Replace electrical contactors
Maintenance package 1 (see maintenance package List for each compressor)
Maintenance package 2
Maintenance package 3
Maintenance package 4
Maintenance package 5
Maintenance package 6
Maintenance package 7
Maintenance package 8
Maintenance package 9
Maintenance package 10
* if existing
 Appendix W - Maintenance Control
for RS-PRO 2-30 - 55
after ... hours

commissi
Maintenance work

periodi
oning

cally
4000 8000 12000 16000 20000 24000 28000 32000 36000 40000

Fill out Commissioning report

Check that all connections are firm and tight
Check screw connections and tighten if necessary
Check ON and OFF settings and adjust if necessary
Check the V-belt tension and wear
Checking the oil Level
Tighten electric clamps
Functional check of pressure and temperatur gauges
Measuring / testing current consumption
Check the alignment of the V-belt pulleys
Check the dirt level of the air filter and the possibly mounted ventilator filter pads
Examine all the hoses to ensure that they are in good working condition
Check funktion of the condensate drain for RSK(F)-PRO*
Check contactors for wear
Control the oil / air cooler and clean if necessary
Check the compressor to ensure that it has no leaks
Check the overall condition of the compressor
Check air filter element, replace if necessary
Clean / replace the filter mats*
Check / replace the safety valve
Changing the oil filter
Change the oil
Change the fine separator cartridge
Check the follow-on time (>= 3 min)
Lubricate the motor bearings from 45 kW
Maintenance oil regulating valve
Replace solenoid valve
Change the V-belt
Replace the O-ring on the oil filler plug
Maintenance set minimum pressure valve
Change control air hose
Maintenance condensate drain for RSK(F)-PRO*
Replace motor bearings A and B side
Servicing kit for the control unit
Servicing kit for the intake regulator
Replace oil hoses
Replace pressure switch / pressure sensor
Maintenance package 1 (see maintenance package List for each compressor)
Maintenance package 2
Maintenance package 3
Maintenance package 4
Maintenance package 5
Maintenance package 6
Maintenance package 7
Maintenance package 8
Maintenance package 9
Maintenance package 10
* if existing
Appendix W2
Maintenance of Motor Bearings

Contents This Appendix provides an overview of how motor bearings are

to be maintained. This description only applies to current sys-
tems and may differ to the maintenance required for older mo-
tors.

Continuously lubri- Our compressors up to 37kW are fitted with motors having
cated motor bear- closed, continuously lubricated deep-groove ball bearings –
ings theoretical service life is between 15,000 and 30,000 operating
hours (oh). If operating conditions are different to that defined
in the instruction manual, it is imperative that the maintenance
intervals are adjusted to the prevailing circumstances and con-
ditions to ensure reliable operations. Should there be high lev-
els of dirt and dust, frequent switch-ons and high ambient tem-
peratures as well as operations at 60Hz, the maintenance inter-
vals must be adjusted accordingly.

Description 1. Switch off unit and prevent it from being restarted by

Procedure for re- accident.
placing bearings 2. If applicable, uninstall the motor and remove the ancillary
components (fan impeller, frame, fan cover, pulley)
3. Disassemble the bearing cover (center) and bearing shield
(outside)
4. Remove the old bearing with a puller (if difficult, carefully
warm up the bearing) and remove the old grease
5. Carefully warm up the inner ring of the new bearing
6. Push the new bearing to the stop on the shaft and keep it
there briefly
7. Generously grease the new bearing with suitable grease
8. Re-assemble the bearing cover and bearing shield
9. Re-install bearing seal

The type designations of the motor bearings can be found in

Table 1.

AW2 – Appendix Motor Bearings AW-1

Appendix W2 Maintenance of Motor Bearings (cont.)

Motor bearings re- Our motors from 45 kW are fitted with “open” ball bearings.
quiring re- Motors this size and up have re-lubrication devices on the A-
lubrication and B-sides.
These bearings must be re-lubricated regularly in accordance
with the information given in the maintenance check sheet.
Our motors are pre-lubricated from the factory with a polyurea-
based high-temperature grease for min. 150°C.
For instance, SKF LGHP 2 or a polyurea-based equivalent
is to be used. Order no.: 10254
It is imperative that these specifications are adhered to when
re-lubricating the motor bearings as mixing different greases
can significantly shorten the life of the bearings.

NB! If operating conditions are different, it is imperative that the

maintenance intervals are adjusted to the local circumstances
and conditions to ensure reliable operations. This means that
should there be high levels of dirt and dust, frequent switch-ons
and high ambient temperatures as well as operations at 60Hz,
the maintenance intervals must be shortened.

Procedure for re- Please carry out the following steps to re-lubricate the mo-
lubrication tor bearings:

1. Switch off unit and prevent it from being restarted by

accident.
2. Thoroughly clean the grease nipples and surrounds.
3. Remove the cap of the re-lubrication device.
4. Remove the cover of the drainage opening (usually oppo-
site). Excess grease is discharged here.
5. Introduce approx. half of the grease to be used for re-
lubrication – it is best to use a grease gun. Then let the mo-
tor run for approximately 1 minute.
6. Switch the unit off and introduce the remaining re-lubrication
grease.
7. Re-install the cap of the re-lubrication device and the cover of
the drainage opening.

Idleness of If the motors are idle for a longer period of time, the motor shaft
motors should be rotated once a month. Rotate the motor shaft manu-
ally for at least 5 rotations and bring to a stop in a different posi-
tion to the starting position.
If the motors have to be idle for more than 6 months, the motor
bearings must be re-lubricated before start-up.
If the motors have to be idle for more than 2 years, the motor
bearings must be replaced.

AW2 – Appendix Motor Bearings AW-2

Appendix W2 Maintenance of Motor Bearings (cont.)

The details of the bearings installed by us and the lubrication

quantities to be filled (only for WEG motors) are listed below:

Re-
Grease
lubrica-
Size Output (kW) A-side B-side quantity
tion in-
(grams)
terval
90 1,5 / 2,2 6205 ZZ 6204 ZZ - -
112 3,7 6307 ZZ 6206 ZZ - -
112 3 / 4 / 5,5 6207 ZZ 6206 ZZ - -
132 4 / 4,5 / 5,5 / 7,5 / 9 / 1-11 6308 ZZ 6207 ZZ - -
160 11 / 15 6309 C3 6209 Z-C3 - -
180 18,5 / 22 6311 C3 6211 Z-C3 - -
200 30 / 37 6312 C3 6212 Z-C3 - -
225 45 6314 C3 6314 C3 27 5000
250 55 6314 C3 6314 C3 27 5000
280 75 / 85 / 90 / 1-110 6314 C3 6314 C3 27 5000
315 110 / 132 / 160 6314 C3 6314 C3 27 5000
Table 1

AW2 – Appendix Motor Bearings AW-3

 Appendix W 3 Manual
Maintenance Work RENNER GmbH

Operat. Airfilter Oilfilter Motor bearings other service work

Oilseparator cartridge Oilfilling Drive belt Signature and date
Hours cartridge cartridge A + B Side (take another sheet if required)

differential pressure

delta p in bar

retensioned
replenished

regreased
replaced

replaced

replaced

replaced

replaced

replaced
checked

checked
cleaned

Please tick the work which has been done and/or record measured data which confirm by signature .

AW – Appendix Maintenance Work AW 3

Appendix ADS
End Pessure Switch

Contents This chapter provides a brief overview of all the pressure switch
functions.

Warning!

From the factory side, the pressure switch is ideally adjusted to

the respective machine configuration. Any change to the default
settings can have serious consequences on the service life of
your system. The legal warranty will expire if making changes
that have not been discussed in advance with RENNER Kom-
pressoren GmbH.

Function The pressure switch controls the switch-on and switch-off pres-
sure applicable for the respective system. The difference be-
tween switch-on and switch-off pressure is generally 1.5 bar.
For changes to the switch-off pressure settings made on the
factory side, the safety valve is activated if the the permitted
maximum pressure is exceeded.

Continued overleaf

AADS - Appendix Pressure Switch AADS-1

Appendix ADS
End Pressure Switch

AADS - Appendix Pressure Switch AADS-2

Appendix FU
Frequency converter

Content This short section gives you the key information about the
operation of the frequency converter. (For more information
see the detailed and enclosed manual of the converter
manufacturer)

Function The frequency converter allows continuous operation of

the motor, thus enabling production of compressed air to be
adjusted according to need.
The rotational speed varies between just over 30 and 100% of
the compressor motor speed.
The frequency converter is configured and parameterized at
the factory.

Should an error occur, the compressor is switched off and the

message “Error Converter” appears on the display of the
RENNERtronic control system. Error messages which appear
on the display of the frequency converter are also important.
Error messages begin with an E for error. Examine the reasons
for the error and the measures to be taken against it in the
appropriate chapter of the instruction manual for the frequency
converter (see section "Error diagnosis").

CAUTION

Make sure that the air circulation is not restricted or blocked in

any way. A sufficient clearance area must be provided between
the ventilation grid and the walls of the room.

AFU - Frequency converter AFU-1

Appendix FU – Frequency converter

Figure
Control panel

Control panel, No. Description Function

shortcuts
1 Display Displays parameter numbers
and set parameter values

2 UP / START UP = increase parameter

number / parameter value
START = start drive
3 ENTER / F/R ENTER =
confirm entries (save)
F/R = direction of rotation
4 FUNC. / SPEED FUNC. = function key. Toggle
between parameter number (s)
and parameter value(s)
SPEED = driver mode
5 DOWN / STOP DOWN = decrease parameter
number / parameter value
STOP = Stop drive

AFU - Frequency converter AFU-2

Appendix KT
Operating instructions
for the refrigerant drier

Content In this chapter you receive a brief overview for the optionally
installed refrigerant drier.

Please follow the refrigerant drier safety instructions found in

the separate operating manual. It is particularly dangerous to
breath-in the cooling steam or get in contact with the cooling
agents. Smoking when working on the refrigerant drier is pro-
hibited, since the cooling agent will developpoisonous vapours
when getting in touch with the glowing end of a cigarette or oth-
er open flame (e.g. welding work).

Function The refrigerant air drier contains a cooling system for cooling
the compressed air. The compressed air is also de-humidified.
The condensate created here is discharged through a conden-
sate separator.

Make sure that the air inlet and outlet is never impaired or
blocked. Adequate distance must be maintained between the
ventilation grids and room walls.
Please follow the figure in Chapter 2.3 and the information in
Chapter 2.3.1 of the Operating Manual of the refrigerant drier
supplier.

After turning on the refrigerant drier, wait 5 minutes until the

pressure has equalised. Only then, start the compressor.

AKT – Operating instruction for refrigerant drier AKT-1

Appendix KT refrigerant drier (cont.)

Figure
Refrigerant drier

1.) Compressed air inlet 6.) Electrical connections

2.) Compressed air outlet 7.) Maintenance access
3.) Cooling air inlet 8.) Fixing holes
4.) Cooling air outlet E100.) Switch-on
5.) Steam trap EICA.) Electronic regulator

Figure
control panel

AKT – Operating instruction for refrigerant drier AKT-2

Appendix KT refrigerant drier (cont.)

Electronic Item Description Function

Regulator
1 10x green LED Pressure dew point indicator

2 Green area Pressure dew point normal

3 Red area Pressure dew point is too high

Compressed air drier is turned on

4 Green LED
In the setting mode the blinking
LED shows which data will be
displayed
Condensate magnetic valve is
5 Yellow LED
active
Ventilator is turned on
6 Yellow LED
Multi-function key for editing the
7 Setting switch
parameter.
Press the button for 2 sec-
onds:
Switch from display to setting
mode
Briefly press the button:
Switch between menues
Press button together with up
key:
Current setting is changed
Up / deflector test
8 Up key
Pressing the up key will exit the
setting mode

AKT – Operating instruction for refrigerant drier AKT-3

Appendix KT refrigerant drier (cont.)

Maintenance Before completing any maintenance work, please follow all

safety provisions for electrical systems and electrical de-
vices (see Chapter 1 of the original operating manual).

The compressed air refrigerant drier must be mainained at dif-

ferent intervals. The maintenance intervals heavily depend on
the utilisation type and the conditions oft he installation site. The
following maintenance work must be completed daily:

1. Check the function of the steam trap; check if water is

drained; valve test (manual drain condensation):

2. Check the pressure dew point display; for deviations

from the normal range, see chapter 5.2.2 and 5.2.3 in
the original operating manual

3. Check the compressor for contamination

Specific notes about other maintenance intervals and work

can be found in the manufacturer original operating manual
under Point 5 Maintenance.

AKT – Operating instruction for refrigerant drier AKT-4

Appendix AD
Compressed air receiver
2
Illustration:
air receiver

Description No. Description Function

of air receiver
1 Connection from Inlet of compressed air into
compressor the air receiver

2 Safety valve Protects the air receiver

against too high a pressure

3 Compressed air outlet Outlet of compressed air to

the c.a. system

4 Condensate drain Drains the condensate for

collection

• Please observe the regional laws and regulations for the

control of air receivers and notice the periodic inspections
• Please take care for a condensate drain system
• Please take the necessary mesures as to discharge the
condensate if no automatic system

Caution!
To grant the functionality of the air receivers, all flexible hoses of the
receivers have to be changed after 2 years at the latest. This affects
especially the 2 x 90l air receivers. Both receivers have to be able to
be discharged separately.
The number of load changes in the air receiver should not be too high.
Therefore, the compressor is not disconnected from the mains and do
not let the pressure in the receiver fall too low. (purchase quantity <
delivery quantity)

AD App Air receiver AD-1

 EN - english

Instructions for installation and operation

Compressed air refrigeration dryer

DRYPOINT® RA 20-960

1
Dear customer,
Thank you for deciding in favour of the DRYPOINT® RA 20-960 compressed-air refrigeration dryer. Please read these
installation and operating instructions carefully before mounting and starting up the DRYPOINT® RA 20-960 and follow
our directions. Perfect functioning of the DRYPOINT® RA 20-960 and thus reliable compressed-air drying can only be
guaranteed when the provisions and notes stipulated here are strictly adhered to.

2 DRYPOINT® RA 20-960
Contents
1 Name plate 5
2 Safety instructions 5
2.1 Safety pictograms in accordance with DIN 4844 6
2.2 Signal words in accordance with ANSI 8
2.3 Overview of the safety instructions 8
3 Proper use 11
4 Exclusion from a field of application 11
5 Operating instructions in accordance with the 97/23/EC Pressure Equipment Directive 12
6 Transport 13
7 Storage 13
8 Installation 14
8.1 Place of installation 14
8.2 Installation plan 15
8.3 Correction factors 16
8.4 Connection to the compressed-air system 17
8.5 Connection to the cooling-water network 17
8.6 Minimum cooling water requirements: 18
8.7 Electrical connections 19
8.8 Condensate drain 19
9 Start-up 20
9.1 Preliminary stages 20
9.2 Initial start-up 20
9.3 Shut down and restart 21
10 Technical data 22
10.1 Technical data DRYPOINT RA 20-110 1/230/50-60 22
10.2 Technical data DRYPOINT RA 135-960 1/230/50 23
10.3 Technical data DRYPOINT RA 330-960 3phase 3/400/50 24
10.4 Technical data DRYPOINT RA 20-330 1/115/60 25
10.5 Technical data DRYPOINT RA 135-960 1/230/60 26
10.6 Technical data DRYPOINT RA 330-960 3phase 3/460/60 27
11 Technical description 28
11.1 Control panel 28
11.2 Functional description 28
11.3 Flow chart (air-cooled) 29
11.4 Flow chart (water-cooled) 29
11.5 Refrigerating compressor 30
11.6 Condenser (air-cooled) 30
11.7 Condenser (water-cooled) 30
11.8 Cooling-water regulating valve 30
11.9 Filter dryer 30
11.10 Capillary tube 30
11.11 Aluminium heat exchanger 30
11.12 Hot-gas bypass valve 30
11.13 Refrigerant pressure switches LPS – HPS – PV 31
11.14 Safety temperature switch TS 31
11.15 Compressor crankcase heater (RA 330-960 3phase) 31
11.16 DMC 18 electronics (control unit compressed-air dryer) 32
11.16.1 Switching the dryer on 32
11.16.2 Switching the dryer off 32
11.16.3 Indication of the operating parameters 32
11.16.4 Indication of a service warning/service alarm 32
11.16.5 Operation of the potential-free failure/alarm contact 33
11.16.6 How to change operating parameters – SETUP menu 33
11.16.7 Selection of the BEKOMAT drain model 33
11.17 Electronically level-controlled BEKOMAT condensate drain 34
12 Maintenance, troubleshooting, spare parts and dismantling 35
12.1 Checks and maintenance 35

DRYPOINT® RA 20-960 3
12.2 Troubleshooting 36
12.3 Recommended spare parts 39
12.4 Maintenance works at the refrigeration cycle 43
12.5 Dismantling the dryer 43
13 Appendices 44
13.1 Dryer dimensions 44
13.1.1 Dryer dimensions DRYPOINT RA 20-70 44
13.1.2 Dryer dimensions DRYPOINT RA 110-135 45
13.1.3 Dryer dimensions DRYPOINT RA 190-240 46
13.1.4 Dryer dimensions DRYPOINT RA 330-370 47
13.1.5 Dryer dimensions DRYPOINT RA 490-630 48
13.1.6 Dryer dimensions DRYPOINT RA 750-960 49
13.1.7 Dryer dimensions DRYPOINT RA 330-370 3phase 50
13.1.8 Dryer dimensions DRYPOINT RA 490-630 3phase 51
13.1.9 Dryer dimensions DRYPOINT RA 750-960 3phase 52
13.2 Exploded diagrams 53
13.2.1 Components of the exploded diagrams 53
13.2.2 Exploded diagram DRYPOINT RA 20-70 /AC 54
13.2.3 Exploded diagram DRYPOINT RA 110-135 /AC 55
13.2.4 Exploded diagram DRYPOINT RA 190-240 /AC 56
13.2.5 Exploded diagram DRYPOINT RA 330-370 /AC 57
13.2.6 Exploded diagram DRYPOINT RA 490-630 /AC 58
13.2.7 Exploded diagram DRYPOINT RA 750-960 /AC 59
13.2.8 Exploded diagram DRYPOINT RA 330-370 /WC 60
13.2.9 Exploded diagram DRYPOINT RA 490-630 /WC 61
13.2.10 Exploded diagram DRYPOINT RA 750-960 /WC 62
13.2.11 Exploded diagram DRYPOINT RA 330-370 3phase /AC 63
13.2.12 Exploded diagram DRYPOINT RA 490-630 3phase /AC 64
13.2.13 Exploded diagram DRYPOINT RA 750-960 3phase /AC 65
13.2.14 Exploded diagram DRYPOINT RA 330-370 3phase /WC 66
13.2.15 Exploded diagram DRYPOINT RA 490-630 3phase /WC 67
13.2.16 Exploded diagram DRYPOINT RA 750-960 3phase /WC 68
13.3 Electric diagrams 69
13.3.1 Electric diagrams – list of components 69
13.3.2 Electric diagram DRYPOINT RA 20-135 70
13.3.3 Electric diagram DRYPOINT RA 190-240 71
13.3.4 Electric diagram DRYPOINT RA 330-370 72
13.3.5 Electric diagram DRYPOINT RA 490-960 73
13.3.6 Electric diagram DRYPOINT RA 330-960 3phase Sheet 1/3 74
13.3.7 Electric diagram DRYPOINT RA 330-960 3phase Sheet 2/3 75
13.3.8 Electric diagram DRYPOINT RA 330-960 3phase Sheet 3/3 76
14 EC Declaration of Conformity 79

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4 DRYPOINT® RA 20-960
 Name plate
1 Name plate
The name plate is on the back of the dryer and comprises all primary data of the device. Always refer to these when
contacting the manufacturer or the sales department.
All guarantee claims will expire in the event that the name plate is modified or removed.
The dryer model printed on the nameplate includes one or more suffixes that specify one or more features of dryer.

Explanation of 1st suffix for power supply requirements :

1st SUFFIX DESCRIPTION OF FEATURE
none 1/230/50
-C 3/400/50
-P 1/115/60
-E 1/230/60
-R 3/460/60
-S 3/230/60 (with internal autotransformer)
-F 3/380/60 (with internal autotransformer)
-T 3/690/60 (with internal autotransformer)

Explanation of 2nd suffix for cooling requirements :

2nd SUFFIX DESCRIPTION OF FEATURE
/ AC Air cooled
/ WC Fresh water cooled
/ SWC Sea water cooled, tube bundle condenser
/ TBH Fresh water cooled, tube bundle condenser

Explanation of (eventual) 3rd suffix for special features :

3rd SUFFIX DESCRIPTION OF FEATURE
-TAC Anti corrosion treatment
-SP Special feature
-OF Dryer oil free

Examples : DP RA960-R /AC  DRYPOINT RA960, 3/460/60, Air cooled

DP RA630-C /WC  DRYPOINT RA630 3/400/50, Water cooled
DP RA630 /WC -TAC  DRYPOINT RA630 1/230/50, Water cooled, Anti corrosion treatment

2 Safety instructions
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Please check whether or not these instructions correspond to the device type.
Please adhere to all advice given in these operating instructions. They include essential information
which must be observed during installation, operation and maintenance. Therefore, it must be ensured
that these operating instructions are read by the fitter and the responsible operator / certified skilled
personnel prior to installation, start-up and maintenance.
The operating instructions must be accessible at all times at the place of application of the DRYPOINT®
RA 20-960 compressed-air refrigeration dryer.
In addition to these operating instructions, local and national regulations need to be observed, where
required .
Ensure that operation of the DRYPOINT® RA 20-960 compressed-air refrigeration dryer only takes place
within the permissible limit values indicated on the name plate. Any deviation from these limit values
involves a risk for persons and for the material, and may result in malfunction or a breakdown.
After installing the device correctly and in accordance with the instructions in this manual, the dryer is
ready to operate, further settings are not required. Operation is fully automatic and maintenance is
limited to several examinations and cleaning measures which are described in the following chapters.
This manual must be available at all times for future reference and is a constituent part of the dryer.
If you have any queries regarding these installation and operating instructions, please contact BEKO
TECHNOLOGIES GMBH.

DRYPOINT® RA 20-960 5
Safety instructions
2.1 Safety pictograms in accordance with DIN 4844

Observe operating instructions

General danger symbol

Supply voltage

Danger: component or system under pressure

Hot surfaces

Non-breathable air

Do not use water to extinguish the fire

Do not operate with open cover (housing)

Maintenance works or controlling measures must only be carried out by qualified personnel1

Do not smoke

Note

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6

ARIA
AIR
LUFT Connection point compressed-air inlet
AIR

ARIA
AIR
LUFT Connection point compressed-air outlet
AIR

Connection point condensate drain

Connection point cooling-water inlet (water-cooled)

Connection point cooling-water outlet (water-cooled)

1
Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technical training, who are
well-grounded in the respective provisions and laws and capable of carrying out the required works and of identifying and avoiding
any risks during the machine transport, installation, operation and maintenance.
Qualified and authorised operators are persons who are instructed by the manufacturer regarding the handling of the refrigeration
system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

6 DRYPOINT® RA 20-960
 Safety instructions

Works can be carried out by the operator of the plant, provided that they are skilled accordingly2.

NOTE: Text that contains important specifications to be considered – does not refer to safety precautions.
The device was carefully designed with particular attention paid to environmental protection:
 CFC-free refrigerants
 CFC-free insulation material
 Energy-saving design
 Limited acoustic emissions
 Dryer and packaging comprise reusable materials
This symbol advises the user to observe the environmental aspects and comply with the recommendations
connected with this symbol.

2
Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technical training, who are
well-grounded in the respective provisions and laws and capable of carrying out the required works and of identifying and avoiding
any risks during the machine transport, installation, operation and maintenance.
Qualified and authorised operators are persons who are instructed by the manufacturer regarding the handling of the refrigeration
system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

DRYPOINT® RA 20-960 7
Safety instructions
2.2 Signal words in accordance with ANSI

Imminent hazard
Danger!
Consequences of non-observance: serious injury or death
Potential hazard
Warning!
Consequences of non-observance: possible serious injury or death
Imminent hazard
Caution!
Consequences of non-observance: possible injury or property damage
Potential hazard
Notice!
Consequences of non-observance: possible injury or property damage
Additional advice, info, hints
Important!
Consequences of non-observance: disadvantages during operation and maintenance, no danger

2.3 Overview of the safety instructions

Certified skilled personnel

Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to
undertaking any measures on the DRYPOINT® RA 20-960 compressed-air refrigeration dryer, the
certified skilled personnel shall read up on the device by carefully studying the operating instructions.
The operator is responsible for the adherence to these provisions. The respective directives in force
apply to the qualification and expertise of the certified skilled personnel.
For safe operation, the device must only be installed and operated in accordance with the indications in
the operating instructions. In addition, the national and operational statutory provisions and safety
regulations, as well as the accident prevention regulations required for the respective case of
application, need to be observed during employment. This applies accordingly when accessories are
used.

Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping compressed
air or through bursting and/or unsecured plant components.
Compressed air is a highly dangerous energy source.
Never work on the dryer when the system is under pressure.
Never direct the compressed-air outlet or condensate drain hoses at persons.
The user is responsible for the proper installation of the dryer. Non-observance of the instructions in the
"Installation" chapter leads to the expiration of the guarantee. Improper installation may result in
dangerous situations for the personnel and/or the device.
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Danger!
Supply voltage!
Contact with non-insulated parts carrying supply voltage involves the risk of an electric shock
resulting in injuries and death.
Only qualified and skilled personnel are authorised to run electrically-operated devices. Prior to
undertaking maintenance measures at the device, the following requirements must be met:
Make sure that the power supply is switched off and that the device is off and marked for maintenance
measures. Please also ensure that the power supply cannot be re-established during the works.
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Caution!
Refrigerant!
The compressed-air refrigeration dryer uses HFC-containing refrigerants as a coolant.

Please observe the corresponding paragraph entitled "Maintenance works at the refrigeration cycle".

8 DRYPOINT® RA 20-960
 Safety instructions

Warning!
Refrigerant leak!
A refrigerant leak involves the danger of serious injury and damage to the environment.
The DRYPOINT® RA 20-960 compressed-air refrigeration dryer contains fluorinated greenhouse
gas/refrigerant.
Installation, repair and maintenance works at the refrigeration system must only be carried out by
certified skilled personnel (specialists). A certification in accordance with EC regulation 303/2008 must
be available.
The requirements of the EC 842/2006 directive must be met under all circumstances.
Please refer to the indications on the name plate as regards the type and amount of refrigerant.
Comply with the following protective measures and rules of conduct:
 Storage: Keep the container tightly closed. Keep it in a cool and dry place. Protect it against heat
and direct sunlight. Keep it away from ignition sources.
 Handling: Take measures against electrostatic charging. Ensure good ventilation/suction at the
workplace. Check fittings, connections and ducts for tightness. Do not inhale the gas. Avoid contact
with the eyes or the skin.
 Prior to carrying out works on refrigerant-carrying parts, remove the refrigerant to such an extent
that safe working is possible.
 Do not eat, drink or smoke during work. Keep out of the reach of children.
 Breathing protection: ambient-air-independent respirator (at high concentrations).
 Eye protection: sealing goggles.
 Hand protection: protective gloves (e.g. made of leather).
 Personal protection: protective clothing.
 Skin protection: use protective cream.
In addition, the safety data sheet for the refrigerant needs to be observed!
Caution!
Hot surfaces!
During operation, several components can reach surface temperatures of more than +60°C.
There is the risk of burns.
All components concerned are installed inside of the closed housing. The housing must only be
opened by certified skilled personnel3.

Caution!
Improper use!

The device is intended for the separation of water in compressed air. The dried air cannot be used for
breathing-air purposes and is not suitable for the direct contact with food.
This dryer is not suitable for the treatment of contaminated air or of air containing solids.

3
Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technical training, who are
well-grounded in the respective provisions and laws and capable of carrying out the required works and of identifying and avoiding
any risks during the machine transport, installation, operation and maintenance.
Qualified and authorised operators are persons who are instructed by the manufacturer regarding the handling of the refrigeration
system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

DRYPOINT® RA 20-960 9
Safety instructions

Note!
Contaminated intake air!
In the event that the intake air is strongly contaminated (ISO 8573.1 class 3.-3 or poorer quality), we
recommend the additional installation of a prefilter (e.g. CLEARPOINT F040), to avoid clogging of the
heat exchanger.

Caution!
Heating-up through fire!
In the event of a heating-up through fire, the containers and pipes of the refrigerant system can
burst.
In this case, please proceed as follows:
Switch off the refrigeration plant.
Switch off the mechanical ventilation of the machinery compartment.
Use ambient-air-independent respirators.
Containers and plants which are filled with refrigerant can burst violently in the event of fire.
The refrigerants themselves are incombustible, but they are degraded to very toxic products at high
temperatures.
Remove the container/plant from the fire zone, as there is the risk of bursting!
Cool down containers and bottles via a directed water jet from a safe position.
In the event of fire, please use an approved fire extinguisher. Water is not a suitable agent to
extinguish an electrical fire.

This must only be carried out by persons who are trained and informed about the hazards emanating
from the product.

Caution!
Unauthorised intervention!
Unauthorised interventions may endanger persons and plants and lead to malfunction.
Unauthorised interventions, modification and abuse of the pressure devices are prohibited.
The removal of sealings and leadings at safety devices is prohibited.
Operators of the devices must observe the local and national pressure equipment regulations in the
country of installation.

Pos: 8 /Beko Technische Dokumentation/Sicherheit/Sicherheitshinweise, weitere BM (nicht Ex) @ 0\mod_1183616103770_6.doc @ 4009os: 9 /Beko Technische Dokumentation/Sicherheit/Zusatz Sicherheitshinweise BM33 @ 0\mod_1231926887620_6.doc @ 12829s: 10 /Beko Technische Dokumentation/Sicherheit/Vorsicht Fehlfunktion @ 0\mod_1214378096290_6.doc @ 9359

Note!
Ambient conditions!
In the event that the dryer is not installed under suitable ambient conditions, the ability of the device to
condense refrigerant gas is impaired. This can result in a higher load of the refrigerating compressor,
and in a loss of efficiency and performance of the dryer.
This in turn leads to overheated condenser fan motors, to malfunction of electric components and to a
breakdown of the dryer. Failures of this type will affect warranty considerations.
Do not install the dryer in an environment in which chemicals with a corrosive effect, explosive gases,
toxic gases, evaporation heat, high ambient temperatures or extreme dust and dirt can be found.

Pos: 12 /Beko Technische Dokumentation/Überschriften/1/Bestimmungsgemäße Verwendung @ 0\mod_1183637706293_6.doc @ 5383

10 DRYPOINT® RA 20-960
 Proper use
3 Proper use
This dryer was designed, manufactured and tested to separate the moisture which normally exists in compressed air.
Any other use is considered improper.
The manufacturer shall not be liable for problems occurring as a consequence of improper use. The user alone is
responsible for any damage resulting from that.
Furthermore, the correct use includes the compliance with the installation instructions, in particular in respect of:
• The voltage and frequency of the main voltage supply.
• The pressure, temperature and flow rate of the inlet air.
• The pressure, temperature and cooling-water throughput (water-cooled).
• The ambient temperature.
When delivered, the dryer is tested and fully assembled. The customer only needs to connect the device to the system
in accordance with the instructions in the following chapters.

Pos: 15 /Beko Technische Dokumentation/Übeschriften/1/Ausschluss vom Anwendungsbereich @ 0\mod_1236003439359_6.doc @ 13709

4 Exclusion from a field of application

Pos: 16 /Beko Technische Dokumentation/Bestimmungsgemäße Verwendung/BEKOMAT/Ausschluß Anwendung BM 31/32/33 @ 0\mod_1236003837511_6.doc @ 13736

Note!
Improper use!

The device is intended for the separation of water in compressed air. The dried air cannot be used for
breathing-air purposes and is not suitable for the direct contact with food.
This dryer is not suitable for the treatment of contaminated air or of air containing solids.

DRYPOINT® RA 20-960 11
Operating instructions in accordance with the 97/23/EC Pressure Equipment Directive
5 Operating instructions in accordance with the 97/23/EC Pressure Equipment Directive
The DRYPOINT® RA 20-960 compressed-air refrigeration dryer contains pressure equipment in the sense of the
97/23/EC Pressure Equipment Directive. Therefore, the entire plant needs to be registered with the supervisory
authority if required in accordance with the local regulations.

For the examination prior to the start-up and for periodic inspections, the national regulations need to be observed,
such as the industrial safety regulation in the Federal Republic of Germany. In countries outside the EU, the respective
regulations in force there need to be adhered to.

The proper use of pressure devices is the basic requirement for safe operation. As regards pressure devices, the
following points need to be observed:
 The DRYPOINT® RA 20-960 compressed-air refrigeration dryer must only be employed within the pressure and
temperature range limits indicated by the manufacturer on the name plate.
 No welding must be carried out on the pressure parts.
 The DRYPOINT® RA 20-960 compressed-air refrigeration dryer must neither be installed in insufficiently
ventilated rooms nor near heat sources or inflammable substances.
 To avoid fractures resulting from material fatigue, the refrigeration dryer should not be exposed to vibrations during
operation.
 The maximum operating pressure indicated by the manufacturer on the name plate must not be exceeded. It is the
installer's responsibility to install the appropriate safety and control devices. Prior to the start-up of the DRYPOINT®
RA 20-960 compressed-air refrigeration dryer, the connected pressure generator (compressor etc.) must be set to
the max. permissible operating pressure. The integrated safeguard needs to be checked by an approved
inspection agency.
 The documents related to the DRYPOINT® RA 20-960 compressed-air refrigeration dryer (manual, operating
instructions, manufacturer's declaration etc.) must be kept safe for future reference.
 No objects whatsoever must be installed at or placed on the DRYPOINT® RA 20-960 compressed-air refrigeration
dryer and the connecting lines.
 Installation of the plant in frost-free places only.
 Operation of the plant is only permissible with fully closed and intact housing and cover panels. Operation of the
plant with damaged housing/cover panels is prohibited.

12 DRYPOINT® RA 20-960
 Transport
6 Transport
Check the packaging for visible loss or damage. If no visible damage can be ascertained, place the unit in close
proximity to the place of installation and unpack the device.
During this procedure, the dryer must always remain in an upright position. The components may be damaged when
the unit is tilted or turned upside down.
Store the device in a dry environment and do not expose it to extreme weather conditions.
Handle with care. Strong shocks can cause irreparable damage.

7 Storage
Keep the device away from extreme weather conditions
even when packaged.
Keep the dryer in an upright position, also while it is
stored. Tilting the device or turning it upside down can
cause irreparable damage to some components.
When the dryer is not in use, it can be stored in its
packaging in a dust-free and protected place at a
temperature of up to max. 50°C and at a specific humidity
of max. 90%. If the storage period exceeds 12 months,
you should contact the manufacturer.
SCC0001

The packaging material is recyclable. Dispose of the material in accordance with the
directives and provisions in force in the country of destination

DRYPOINT® RA 20-960 13
Installation
8 Installation
8.1 Place of installation

Note!
Ambient conditions!
In the event that the dryer is not installed under suitable ambient conditions, the ability of the device to
condense refrigerant gas is impaired. This can result in a higher load of the refrigerating compressor, and in
a loss of efficiency and performance of the dryer.
This in turn leads to overheated condenser fan motors, to malfunction of electric components and to a
breakdown of the dryer. Failures of this type will affect warranty considerations.
Do not install the dryer in an environment in which chemicals with a corrosive effect, explosive gases, toxic
gases, evaporation heat, high ambient temperatures or extreme dust and dirt can be found.

Minimum installation requirements:

• Choose an area which is clean and dry, free from dust and protected against atmospheric disturbances.
• The load-bearing zone must be even, horizontal and able to bear the weight of the dryer.
• Minimum ambient temperature +1°C.
• Maximum ambient temperature 50°C.
• Ensure a proper cooling air replacement.
• Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitate maintenance operations.
The dryer does not require attachment to the floor surface.

Do not obstruct the ventilation grille (not even partially).

Prevent any recirculation of the outgoing cooling air.
Protect the dryer against draughts.

Note!
Dryers models RA 20 – 135 can be wall-mounted. See fixing dimensions on dimensional drawings in the
appendices section.
The hanging mounting inevitably causes the obstruction of the ventilation grid positioned on the panel
facing the wall fixing. This obstruction, in any case, does not prejudge the efficiency of the ventilation
inside the dryer which is guaranteed by other grids on the other panels.

14 DRYPOINT® RA 20-960
 Installation
8.2 Installation plan

-A-
IN

7
1 Air compressor
OUT
5
3 4 9
2 Aftercooler
1
3 Condensate separator
4 Prefilter
2

9 9 9
6 5 Bypass group

8
6 Dryer
7 Compressed-air tank
-B-
IN 8 Final filter
7

OUT
9 Bekomat condensate drain
3 4 5 9
1

2
6 9
9 9

Installation type A is recommended when the total consumption corresponds to the throughput rate of the compressor.
Installation type B is recommended when the air consumption constantly varies, with peak values which considerably
exceed the throughput rate of the compressor. The storage capacity of the tank must be dimensioned in such a way
that a possible short-term high air demand (peak air consumption) can be compensated.

Do not obstruct the ventilation grille (not even partially).

Prevent any recirculation of the outgoing cooling air.
Protect the dryer against draughts.
Note!
Contaminated intake air!
In the event that the intake air is strongly contaminated (ISO 8573.1 class 3.-3 or poorer quality), we
recommend the additional installation of a prefilter (e.g. CLEARPOINT F040), to avoid clogging of the
heat exchanger.

DRYPOINT® RA 20-960 15
Installation

8.3 Correction factors

Correction factor for operating pressure modifications:
Air inlet pressure bar(g) 4 5 6 7 8 10 12 14
Factor (F1) 0.77 0.86 0.93 1.00 1.05 1.14 1.21 1.27

Correction factor for ambient temperature modifications (air cooling):

Ambient temperature ºC 25 30 35 40 45 50
Factor (F2) 1.00 0.96 0.91 0.85 0.76 0.64

Correction factor for air inlet temperature modifications:

Air temperature ºC 25 30 35 40 45 50 55 60
Factor (F3) 1.27 1.21 1.00 0.84 0.70 0.57 0.48 0.42

Correction factor for dew point modifications:

Pressure dew point ºC 3 5 7 10
Factor (F4) 1.00 1.09 1.19 1.37

Calculation of the actual air throughput:

Actual air throughput = air throughput acc. to planning x factor (F1) x factor (F2) x factor (F3) x factor (F4)

Example:
The DRYPOINT RA 240 has a planned nominal capacity of 240 m³/h. The highest achievable air mass
under the following operating conditions is:

 Air inlet pressure = 8 bar(g)  Factor (F1) = 1.05

 Ambient temperature = 30°C  Factor (F2) = 0.96
 Air inlet temperature = 40°C  Factor (F3) = 0.84
 Pressure dew point = 5°C  Factor (F4) = 1.09
Every function parameter corresponds to a numerical factor which, multiplied by the planned nominal capacity,
determines the following:

Actual air throughput = 240 x 1.05 x 0.96 x 0.84 x 1.09 = 222 m³/h

222 m³/h is the maximum flow rate of the dryer under the aforementioned operating conditions.

Selection of the best suitable model in accordance with the operating conditions:
Requ. air throughput
Air throughput acc. to planning =
Factor (F1) x Factor (F2) x Factor (F3) x Factor (F4)

Example:
The following operating parameters are known:
 Required air mass = 180 m3/h
 Factor (F1) = 1.05
 Air inlet pressure = 8 bar(g)
 Factor (F2) = 0.96
 Ambient temperature = 30°C  Factor (F3) = 0.84
 Air inlet temperature = 40°C  Factor (F4) = 1.09
 Pressure dew point = 5°C
To find out the correct dryer version, the required air mass must be divided by the correction factors of the
parameters indicated above:
180
Air throughput acc. to planning = = 195 m³/h
1.05 x 0.96 x 0.84 x 1.09

The suitable model for these requirements is DRYPOINT RA 240 (with a spec. nominal capacity of 240 m³/h).

16 DRYPOINT® RA 20-960
 Installation
8.4 Connection to the compressed-air system

Danger!
Compressed air!
All works must only be carried out by qualified skilled personnel.
Never work on compressed-air systems which are under pressure.
The operator or the user must ensure that the dryer is never operated with a pressure exceeding the
maximum pressure value indicated on the name plate.
Exceeding the maximum operating pressure can be dangerous for the operator but also for the device.

The air temperature and the air flow at the inlet of the dryer must lie within the limit values indicated on the name plate.
The connecting lines must be free from dust, iron rust, shards and other contaminations and correspond to the flow
rate of the dryer. Should air with a very high temperature be treated, the installation of an aftercooler may be
necessary. For the implementation of maintenance works, the installation of a bypass system is recommended.

The dryer was designed in such a manner that vibrations that may occur during operation are limited. Therefore, it is
advisable to employ connecting lines (flexible hoses, vibration-inhibiting fittings etc.) which protect the dryer against
possible vibrations in the pipework.
===== Ende der Stückliste =====

Note!
Contaminated intake air!
In the event that the intake air is strongly contaminated (ISO 8573.1 class 3.-3) or poorer quality, we
recommend the additional installation of a prefilter (e.g. CLEARPOINT F040), to avoid clogging of the
heat exchanger.

8.5 Connection to the cooling-water network

Danger!
Compressed air and unqualified personnel!
All works must only be carried out by qualified skilled personnel.
Never work on compressed-air systems which are under pressure.
The user must ensure that the dryer is never operated with a pressure exceeding the nominal values.
Possible overpressure can be dangerous for the operator but also for the device.

The temperature and the amount of cooling water need to correspond to the limit values indicated on the name plate.
The cross-section of the connecting lines, which should preferably be flexible, must be free from dust, iron rust, shards
and other contaminations. We recommend employing connecting lines (flexible hoses, vibration-inhibiting fittings etc.)
which protect the dryer against possible vibrations in the pipework.

Note!
Contaminated intake water!
In the event that the intake water is strongly contaminated we recommend the additional installation of a
prefilter (500 micron), to avoid clogging of the heat exchanger.

DRYPOINT® RA 20-960 17
Installation

8.6 Minimum cooling water requirements:

Temperature 15 … 30°C (1) HCO3 / SO4 >1.0 mg/l or ppm

Pressure 3…10 bar(g) (2) NH3 <2 mg/l or ppm
-
Delivery pressure > 3 bar (2) (3) Cl 50 mg/l or ppm
Total hardness 6.0…15 dH° Cl2 0.5 mg/l or ppm
PH 7.5…9.0 H2S <0.05 mg/l or ppm
Conductivity 10…500 μS/cm CO2 <5 mg/l or ppm
Residual solids <30 mg/l or ppm NO3 <100 mg/l or ppm
Saturation mark SI -0.2 < 0 < 0.2 Fe <0.2 mg/l or ppm
HCO3 70…300 mg/l or ppm Al <0.2 mg/l or ppm
SO42- <70 mg/l or ppm Mn <0.1 mg/l or ppm

Note: (1) – Other temperatures upon request – check the data on the name plate.
(2) – Other pressures upon request – check the data on the name plate.
(3) – Pressure difference at the water connection of the dryer at maximum water flow.
Other delivery pressures upon request.

CAUTION!
During the piping of the dryer, the inlet and outlet connections need to be supported as is shown in the
illustration.
Non-observance will cause damage.

18 DRYPOINT® RA 20-960
 Installation
8.7 Electrical connections

Danger!
Supply voltage!
The connection to the electric mains should only be carried out by qualified skilled personnel and must
correspond to the legal provisions in force in your region.

Prior to connecting the device, please check the name plate to avoid exceeding the indicated values. The voltage
tolerance is +/- 10%.
DRYPOINT RA 20-370 dryers are supplied with a VDE 16A standard power cord and safety plug (two-pole and earth
connection). DRYPOINT RA 490-960 devices have a junction box on the back plate.
Make sure that suitable fuses or circuit breakers in accordance with the indications on the name plate are available.
The wall socket must be equipped with a fault current circuit breaker (In=0.03A) which must be adjusted according to
the power consumption of the dryer (see nominal values on the name plate of the dryer). The cross-section of the
power supply cable must correspond to the power consumption of the dryer. In this respect, the ambient temperature,
the cable laying conditions, the length of the cables and the requirements of the local electricity supplier need to be
considered.

Danger!
Supply voltage and missing earth connection!
Important: ensure that the plant is connected to earth.
Do not use plug adapters at the power plug.
Possible replacement of the power plug must only be carried out by a qualified electrician.
8.8 Condensate drain

Danger!
Compressed air and condensate under pressure!
The condensate is discharged at system pressure.
The drain pipe needs to be secured.
Never direct the condensate drain pipe at persons.

The dryer is delivered with an already integrated electronically level-controlled BEKOMAT condensate drain. Connect
the condensate drain with a collection system or container by properly screwing it on.
Do not connect the drain with pressurised plants.

Do not discharge the condensate into the environment.

The condensate accumulating in the dryer contains oil particles which were released into the air by the
compressor.
Dispose of the condensate in accordance with the local provisions.

It is advisable to install a water-oil separator, to which the total amount of condensate from the
compressors, dryers, tanks, filters etc. is supplied.
We recommend ÖWAMAT oil-water separators for dispersed compressor condensate and BEKOSPLIT
emulsion-splitting plants for emulsified condensate.

DRYPOINT® RA 20-960 19
Start-up
9 Start-up
9.1 Preliminary stages

Note!
Exceeding of the operating parameters!
Ensure that the operating parameters comply with the nominal values indicated on the name plate of the
dryer (voltage, frequency, air pressure, air temperature, ambient temperature etc.).

Prior to delivery, this dryer was thoroughly tested, packed and checked. Please verify the soundness of the dryer
during the initial start-up and check the perfect functioning during the first operating hours.

The initial start-up must be carried out by qualified personnel.

During the installation and operation of this device, all national regulations regarding electronics and
any other federal and state ordinances, as well as local provisions, need to be adhered to.

The operator and the user must ensure that the dryer is not operated without panels.

9.2 Initial start-up

Note!
The dryer must not be started up more than six times an hour. Wait at least five minutes prior to
every restart.
The user is responsible for the compliance with these provisions. Irreparable damage can be caused by
starting up the device too often.

The method below should be applied during the first start-up, after longer downtimes or subsequent to
maintenance works.
The start-up must be carried out by certified skilled personnel.

Processing sequence (see Section 11.1 "Control panel")

 Ensure that all steps of the "Installation" chapter have been carried out.
 Ensure that the connection to the compressed-air system is in accordance with the provisions and that the lines are
fixed and supported properly.
 Ensure that the condensate drain pipe is fixed in accordance with the provisions and that it is connected with a
collection system or a container.
 Ensure that the bypass system (if installed) is open and that the dryer is disconnected from the compressed-air
system.
 Ensure that the manual valve of the condensate drainage cycle is open.
 Ensure that the cooling-water flow and the cooling-water temperature are in accordance with the provisions (water-
cooled).
 Remove any packaging material and other items which may block the space around the dryer.
 Establish the mains connection (plug into socket).
• RA 330-960 3phase - switch on the main switch - pos. A control panel.
• RA 330-960 3phase - wait at least two hours before starting the dryer (the crankcase heater of the compressor
needs to heat up the compressor oil).
• Start the dryer by switching on the main switch on the control panel (pos. 1).
• Make sure that the DMC 18 electronic control unit is switched on.
• Ensure that the power consumption complies with the values on the name plate.
• Ensure that the fan runs properly – wait for the first interventions (air-cooled).
• Wait until the dew point remains stable.
• Slowly open the air inlet valve.
• Slowly open the air outlet valve.
• Slowly close the central bypass valve of the system (if installed).
• Check the pipes for air leakage.
• Ensure the proper functioning of the condensate drain cycle (wait for the first condensate discharges).

20 DRYPOINT® RA 20-960
 Start-up
Note!
A dew point between 0°C and +10°C displayed on the DMC 18 control unit is considered to be correct
according to the possible operating conditions (flow rate, air inlet temperature, ambient temperature etc.).

During the operation, the refrigerating compressor runs continuously. The dryer needs to be switched on during the
entire compressed-air usage time, even if the compressed-air compressor works periodically.

9.3 Shut down and restart

RA 330-960 3phase - during short-term inactivity (max. two to three days), it is advisable to leave the
dryer and the control panel connected to the supply current circuit. Otherwise, it would be necessary at a
restart of the dryer to wait two hours, until the crankcase heater of the compressor has heated up the oil
in the compressor.

Shut down (see Section 11.1 "Control panel")

• Ensure that the dew point temperature indicated on the DMC 18 electronic control unit is stable.
• Interrupt the compressed-air supply.
• After a few minutes, stop the dryer by switching off the main switch on the control panel (pos. 1).

Restart (see Section 11.1 "Control panel")

• Make sure that the condenser is clean (air-cooled).

• Ensure that the cooling-water flow and the temperature are in accordance with the provisions (water-cooled).
• Check whether or not voltage is applied at the dryer.
• Start the dryer by switching on the main switch on the control panel (pos. 1).
• Ensure that the DMC 18 electronic control unit is switched on.
• Wait a few minutes and then check, whether or not the dew point temperature indicated on the
DMC 18 electronic control unit is stable and whether or not the condensate is drained off at regular intervals.
• Establish the compressed-air supply.

RA 330-960 3phase - dryer remote control ON/OFF

• Remove the jumper between terminals 1 and 2 of the terminal strip and wire a potential-free contact (see electric
diagram).
• Switch ON the main switch - pos. 1 on the control panel.
• Close the contact at terminals 1 and 2 to switch on the dryer.
• Open the contact at terminals 1 and 2 to switch off the dryer.
Only use potential-free contacts that are suitable for low voltage. Ensure the sufficient insulation of
potentially dangerous voltage-carrying components.

Caution!
Automatic restart / remote control ON/OFF. The unit may start up without any active influence!
The user will be responsible for the installation of proper protections for possible sudden power
restoration to the dryer.

During the operation, the refrigerating compressor runs continuously. The dryer needs to be switched on during the
entire compressed-air usage time, even if the compressed-air compressor works periodically.

Note!
A dew point between 0°C and +10°C displayed on the DMC 18 control unit is considered to be correct
according to the possible operating conditions (flow rate, air inlet temperature, ambient temperature etc.).

Note!
The dryer must not be started up more than six times an hour. Wait at least five minutes prior to
every restart.
The user is responsible for the compliance with these provisions. Irreparable damage can be caused
when starting up the device too often.

DRYPOINT® RA 20-960 21
Technical data
10 Technical data
10.1 Technical data DRYPOINT RA 20-110 1/230/50-60

22 DRYPOINT® RA 20-960
 Technical data
10.2 Technical data DRYPOINT RA 135-960 1/230/50

DRYPOINT® RA 20-960 23
Technical data
10.3 Technical data DRYPOINT RA 330-960 3phase 3/400/50

24 DRYPOINT® RA 20-960
 Technical data
10.4 Technical data DRYPOINT RA 20-330 1/115/60

DRYPOINT® RA 20-960 25
Technical data
10.5 Technical data DRYPOINT RA 135-960 1/230/60

26 DRYPOINT® RA 20-960
 Technical data
10.6 Technical data DRYPOINT RA 330-960 3phase 3/460/60

DRYPOINT® RA 20-960 27
Technical description
11 Technical description
11.1 Control panel
The control panel explained below is the only dryer user interface.
RA 20 – 240 RA 330 – 960

K I K
ON

1
0

Set Set
1

PQS0055
PQS0054

2 3 1 2 3

1 Main switch
2 Electronic control unit DMC 18
3 Air and refrigerant gas flow chart

RA 330 – 960 3phase

1
0
Set

T2

K 3
T4 T3

T1
PQS0056

A Main switch
1 Main switch
2 Electronic control unit DMC 18
3 Air and refrigerant-gas flow chart

11.2 Functional description

Operating principle – All dryer models described in this manual function according to the same principle. The hot and
moisture-loaded air is led into an air/air heat exchanger. Afterwards, the air flows through an evaporator, which is also
known as an air/refrigerant heat exchanger. The air temperature is reduced to approximately 2°C, so that water vapour
condenses to liquid. The continuously accumulating condensate is collected in the separator to be discharged via the
condensate drain. Subsequently, the cold and dry air is led through the air/air heat exchanger, so that it is reheated to
up to 8°C below the inlet temperature when leaving the dryer.

Refrigeration cycle – The refrigerant is conducted through the compressor and reaches a condenser under high
pressure. There, cooling-down takes place, making the refrigerant condense to a liquid state which is under high
pressure. The liquid is pressed through a capillary tube where the resulting pressure drop ensures that the refrigerant
evaporates at a defined temperature. The liquid refrigerant which is under low pressure is led into the heat exchanger,
where it expands. The cold resulting from the expansion serves to cool down the compressed air in the heat exchanger.
During this process, the refrigerant evaporates. The low-pressure gas is resupplied to the compressor, where it is
compressed again. It then re-enters the cycle. In phases of a reduced compressed-air load, the excess refrigerant is
resupplied automatically to the compressor via the hot gas bypass valve.

28 DRYPOINT® RA 20-960
 Technical description
11.3 Flow chart (air-cooled)

2 3 4 5

P< TS P> PV

1a
25
7

1 8
1b 9 M

12
T1
11 10
1c
DGF0073

13 21

11.4 Flow chart (water-cooled)

2 3 4

P< TS P>

1a
25
7 18

1
1b 19

12
T1
11 10 20
1c
DGF0074

13 21

1 Aluminium heat exchanger module 9 Condenser fan (air cooled)

a – Air/air heat exchanger 10 Filter dryer
b – Air/refrigerant heat exchanger 11 Capillary tube
c – Condensate separator 12 T1 temperature sensor (dew point)
Refrigerant pressure switch LPS (P<)
2 13 Condensate drain shut-off valve
(RA 490-960 and RA 330-960 3phase)
Safety temperature switch TS
3 18 Condenser (water-cooled)
(RA 330-960 and RA 330-960 3phase)
Refrigerant pressure switch HPS (P>)
4 19 Cooling-water regulating valve (water-cooled)
(RA 490-960 and RA 330-960 3phase)
5 Refrigerant fan pressure switch PV 20 Liquid collector (water-cooled)
6 Refrigerating compressor 21 BEKOMAT condensate drain
Compressor crankcase heater (RA 330-960
7 Hot-gas bypass valve 25
3phase)
8 Condenser (air-cooled)
Compressed-air flow direction Refrigerant gas flow direction

DRYPOINT® RA 20-960 29
Technical description
11.5 Refrigerating compressor
The employed refrigerating compressors are constructed by leading manufacturers. The hermetically sealed
construction is absolutely gastight. The integrated safeguard protects the compressor against overheating and excess
current. The protection is automatically reset as soon as the nominal conditions are reached again.

11.6 Condenser (air-cooled)

The condenser is the component in which the gas coming from the compressor is cooled down, condensed and
liquefied. Under no circumstances must the temperature of the ambient air exceed the nominal values. It is also
important that the condenser unit is kept free from dust and other impurities.

11.7 Condenser (water-cooled)

The condenser is the component in which the gas coming from the compressor is cooled-down, condensed and
liquefied. The water inlet temperature must not exceed the nominal values. Likewise, a correct flow must be ensured.
The water entering the condenser must be free from impurities.

11.8 Cooling-water regulating valve

The cooling-water regulating valve serves to keep the condensation pressure or the condensation temperature
constant during water cooling. When the dryer is switched off, the valve automatically blocks the cooling-water flow.

11.9 Filter dryer

Despite controlled vacuuming, traces of moisture can accumulate in the refrigeration cycle. The filter dryer serves to
absorb this moisture and to bond it.

11.10 Capillary tube

The capillary tube is a copper tube with a reduced diameter which is located between the condenser and the
evaporator, serving as a restrictor to reduce the pressure of the refrigerant. The pressure reduction serves to reach an
optimum temperature inside of the evaporator. The lower the outlet pressure at the capillary tube, the lower the
evaporation temperature.
The length and the inner diameter of the capillary tube are exactly dimensioned to ensure the performance of the
dryer. Settings or maintenance works are not required.

11.11 Aluminium heat exchanger

The heat exchanger module consists of an air/air heat exchanger, an air/refrigerant heat exchanger, and of a high-
performance separator. The compressed air flows top-down through the heat exchanger. The large cross-sections of
the flow passages cause low flow rates and low compressed-air losses. In the air/air heat exchanger, the heat
exchange is effected in a reverse current. This guarantees maximum heat transfer. The heat transfer in the
air/refrigerant heat exchanger also takes place in a reverse current. This allows full evaporation of the refrigerant. The
high-performance separator ensures almost complete separation of the condensate. Maintenance of the high-
performance separator is not required.

11.12 Hot-gas bypass valve

At partial load, the valve directly returns a part of the hot gas to the suction line of the refrigerating compressor. The
evaporation temperature and the evaporation pressure remain constant.

30 DRYPOINT® RA 20-960
 Technical description

11.13 Refrigerant pressure switches LPS – HPS – PV

To ensure the operational reliability and the protection of the dryer, a series of pressure switches are installed in the
gas cycle.

LPS : Low-pressure guard on the suction side of the compressor, which is triggered when the pressure drops below
the predetermined value. The values are reset automatically as soon as the nominal conditions are re-
established.
HPS : The high-pressure control unit on the discharge side of the compressor is activated when the pressure
exceeds the predetermined value. It has a manual reset button on the control itself.
PV : Fan control pressure switch which is installed on the discharge side of the compressor. It keeps the
condensation temperature and pressure constantly in the range of the preadjusted limit values (air-cooled)

11.14 Safety temperature switch TS

To ensure the operational safety and the soundness of the dryer, a safety
temperature switch (TS) is installed at the refrigeration cycle. In the event that the
pressure gas temperature is too high, the sensor of the temperature switch will
2 stop the refrigerating compressor to prevent the pressure gas temperature getting
too high.

The temperature switch is reset manually, but only when the normal operating
1

conditions are reached again. Unscrew the cover (see pos. 1 in the illustration)
and press the reset button (see position 2 in the illustration).
PQS0005

11.15 Compressor crankcase heater (RA 330-960 3phase)

At low temperatures, the oil can more easily intermix with the refrigerant gas. When the compressor starts, oil can be
drawn into the refrigeration cycle, leading to "hydraulic shocks".
To prevent this, a resistance heater is installed in the suction side of the compressor. When the system is connected
with the electric mains and the compressor is idle, the heater will keep the oil at the correct temperature.
This heater is controlled via a temperature switch which prevents the overheating of the oil.
Note: The heater must be connected to the mains at least a few hours prior to the start-up of the refrigerating
compressor.

DRYPOINT® RA 20-960 31
Technical description
11.16 DMC 18 electronics (control unit compressed-air dryer)

Led - temperature in °C
Led - temperature in °F
Led – drain ON
Led – alarm/service

Set Button – access configuration menu

PQS0045

Set
Button – decrease / service

DISPLAY Button – increase / drain test

The DMC18 controls the alarms and the settings of the dryer operation and of the BEKOMAT drain.
11.16.1 Switching the dryer on
Connect the dryer to the electric mains and switch it on via the ON/OFF switch (pos. 1 Section 11.1).
During normal operation, the display shows the dew point temperature.
The condensate drain test is always possible via the button.

11.16.2 Switching the dryer off

Switch the device off via the ON/OFF switch (pos. 1 Section 11.1).

11.16.3 Indication of the operating parameters

During normal operation, the display shows the dew point temperature (in °C or °F).
Press the Set button and keep it pressed to display the parameter (alarm release temperature at a high
dew point).
Press the button and keep it pressed to display the hours remaining until the next maintenance.
Press the Set + buttons and keep them pressed to display the total number of operating hours of the
dryer.
Note: The temperatures are indicated in °C or °F (LED or is on).
The total operating hours and the hours until the next maintenance are indicated in the field 0...999 hours,
and in thousand hours from 1.0 hours onwards (example: when the display shows 35, this means 35 hours
and when the display shows 3.5, this means 3,500 hours).

11.16.4 Indication of a service warning/service alarm

A service warning/alarm is an exceptional event and requires the attention of the operator/service technician. The dryer
will not be stopped.
When a service warning/alarm is active, the LED flashes.
The display successively shows the dew point temperature and the active service warnings/alarms.
Service warnings/alarms are automatically reset as soon as the problem has been eliminated, except for
(maintenance time expired), where manual resetting is required (press the button and keep it pressed for at
least 20 seconds).
NOTE: the operator/service technician must check the dryer and eliminate the problem that led to the
activation of the service warning.
Service warning alarm Description

PF – Probe failure: failure temperature probe

HdP – High dew point: dew point too high, higher than the adjusted HdS value.

LdP – Low dew point: dew point too low, lower than the adjusted LdS value.

drA - Drain: failure Bekomat IF condensate drain

SrV - Service: maintenance service time expired SrV

NOTE: when the dryer is switched on but no system pressure is applied, the drain trouble indication
may appear.

32 DRYPOINT® RA 20-960
 Technical description

11.16.5 Operation of the potential-free failure/alarm contact

The DMC 18 is equipped with a potential-free contact to indicate failures or alarm conditions.

Dryer is switched on and no service warning/alarm is active.

4 5

Dryer is off or a service warning/alarm is active.

4 5

11.16.6 How to change operating parameters – SETUP menu

The setup menu can be used to change the dryer’s operating parameters.

Only qualified personnel must be allowed to access to the setup menu. The manufacturer is
not responsible for malfunctioning or failure due to modification to the operating parameters.

With dryer ON simultaneously press buttons Set + for at least 5 seconds to enter the setup menu.
Access to the menu is confirmed by message on the display (first parameter of menu).
Keep Set
pressed to display the value of the selected parameter and use arrows and to change
the value. Release the button Set to confirm the value and skip to following parameter.

Press + to exit setup menu (if no button is pressed after 30 seconds the menu is exited
automatically).

Standard
ID Description Limits Resolution
setup

HdS - High DewPoint Setting : Alarm threshold for a high 0.0…25.0 °C 0.5 °C 20
DewPoint (the alarm disappears when the temperature drop or or or
0.5°C / 1°F below alarm point) 32 … 77 °F 1 °F 68
Hdd - High DewPoint Delay : high DewPoint alarm enable 01 … 20
1 min 15
delay minutes

LdS - Low DewPoint Setting : Alarm threshold for a low -10 … 0.0 °C 0.5 °C -5
DewPoint (the alarm disappears when the temperature or or or
becomes 0.5°C / 1°F higher than the alarm point) 14 … 32 °F 1 °F 23
Ldd – Low DewPoint Delay : low DewPoint alarm enable 01 … 20
1 min 5
delay minutes
0.0 … 9.0
SrV - Service Setting: setting of service warning timer. 0.5
(x 1000) 8.0
00 = service warning timer disabled. (x1000) hours
hours

SCL - Scale: display scale of temperatures. °C … °F - °C

11.16.7 Selection of the BEKOMAT drain model

The DMC18 controls two types of BEKOMAT drains.

The correct settings are carried out in the factory and proper functioning is checked during the
final inspection of the dryer.

DRYPOINT® RA 20-960 33
Technical description
11.17 Electronically level-controlled BEKOMAT condensate drain
The electronically level-controlled BEKOMAT condensate drain boasts a special condensate management which
ensures that condensate is discharged safely and without an unnecessary loss of compressed air. This drain has a
condensate collection container in which a capacitive sensor continuously monitors the liquid level. As soon as the
switching level is reached, the capacitive sensor transmits a signal to the electronic control and a membrane solenoid
valve opens to discharge the condensate. The BEKOMAT closes before compressed air emerges.

Note!

These BEKOMAT condensate drains were designed in particular for the operation in a DRYPOINT RA
refrigeration dryer. The installation in other compressed-air processing systems or the replacement with
another drain brand can lead to malfunction. The maximum operating pressure (see name plate) must
not be exceeded!

Ensure that the upstream valve is open when the dryer starts operation.

To obtain detailed information regarding drain functions, troubleshooting, maintenance and

spare parts, please read the installation and operating instructions of the BEKOMAT condensate
drain.

34 DRYPOINT® RA 20-960
 Maintenance, troubleshooting, spare parts and dismantling
12 Maintenance, troubleshooting, spare parts and dismantling
12.1 Checks and maintenance

Certified skilled personnel

Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to
undertaking any measures on the DRYPOINT® RA 20-960 compressed-air refrigeration dryer, the
certified skilled personnel4 shall read up on the device by carefully studying the operating instructions.
The operator is responsible for the adherence to these provisions. The respective directives in force
apply to the qualification and expertise of the certified skilled personnel.
For safe operation, the device must only be installed and operated in accordance with the indications in
the operating instructions. In addition, the national and operational statutory provisions and safety
regulations, as well as the accident prevention regulations required for the respective case of
application, need to be observed during employment. This applies accordingly when accessories are
used.

Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping compressed
air or through bursting and/or unsecured plant components.
Compressed air is a highly dangerous energy source.
Never work on the dryer when the system is under pressure.
Never direct the compressed-air outlet or condensate drain hoses at persons.
The user is responsible for the proper maintenance of the dryer. Non-observance of the instructions in
the "Installation" and "Maintenance, troubleshooting, spare parts and dismantling" chapters leads to the
expiration of the guarantee. Improper maintenance may result in dangerous situations for the personnel
and/or the device.

Danger!
Supply voltage!
Contact with non-insulated parts carrying supply voltage involves the risk of an electric shock
resulting in injuries and death.
Only qualified and skilled personnel are authorised to run electrically-operated devices. Prior to
undertaking maintenance measures at the device, the following requirements must be met:
Make sure that the power supply is switched off and that the device is off and marked for maintenance
measures. Please also ensure that the power supply cannot be re-established during the works.

Prior to carrying out maintenance works at the dryer, switch it off and wait for at least 30 minutes.

Caution!
Hot surfaces!
During operation, several components can reach surface temperatures of more than +60°C.
There is the risk of burns.
All components concerned are installed inside of the closed housing. The housing must only be opened
by certified skilled personnel.
Some components can reach high temperatures during operation. Avoid any contact until the system or
the component has cooled down.

4
Certified skilled personnel are persons who are authorised by the manufacturer, with experience and technical training, who are
well-grounded in the respective provisions and laws and capable of carrying out the required works and of identifying and avoiding
any risks during the machine transport, installation, operation and maintenance.
Qualified and authorised operators are persons who are instructed by the manufacturer regarding the handling of the refrigeration
system, with experience and technical training, and who are well-grounded in the respective provisions and laws.

DRYPOINT® RA 20-960 35
Maintenance, troubleshooting, spare parts and dismantling

DAILY:
• Check whether the dew point indicated on the electronics is correct.
• Ensure that the condensate drain system functions properly.
• Make sure that the condenser is clean.
EVERY 200 HOURS OR MONTHLY

• Clean the condenser using an air jet (max. 2 bar / 30 psig) inside out. Make
sure not to damage the aluminium lamellae of the cooling package.
• Finally, verify the operation of the device.

EVERY 1,000 HOURS OR ANNUALLY

• Verify all screws, clamps and connections of the electric system to make sure that they are fastened
securely. Check the device for broken and ruptured cables or cables without insulation.
• Check the refrigeration cycle for signs of oil and refrigerant leaks.
• Measure the current strength and note it down. Ensure that the read values are within the permissible
limit values, as indicated in the specification table.
• Check the hose lines of the condensate drain and replace them, if required.
• Finally, verify the operation of the device.

EVERY 8,000 HOURS

• Replace BEKOMAT Service Unit.

12.2 Troubleshooting

Certified skilled personnel

Installation works must exclusively be carried out by authorised and qualified skilled personnel. Prior to
undertaking any measures on the DRYPOINT® RA 20-960 compressed-air refrigeration dryer, the
certified skilled personnel shall read up on the device by carefully studying the operating instructions.
The operator is responsible for the adherence to these provisions. The respective directives in force
apply to the qualification and expertise of the certified skilled personnel.
For safe operation, the device must only be installed and operated in accordance with the indications in
the operating instructions. In addition, the national and operational statutory provisions and safety
regulations, as well as the accident prevention regulations required for the respective case of
application, need to be observed during employment. This applies accordingly when accessories are
used.
Danger!
Compressed air!
Risk of serious injury or death through contact with quickly or suddenly escaping compressed
air or through bursting and/or unsecured plant components.
Compressed air is a highly dangerous energy source.
Never work on the dryer when the system is under pressure.
Never direct the compressed-air outlet or condensate drain hoses at persons.
The user is responsible for the proper maintenance of the dryer. Non-observance of the instructions in
the "Installation" and "Maintenance, troubleshooting, spare parts and dismantling" chapters leads to the
expiration of the guarantee. Improper maintenance may result in dangerous situations for the personnel
and/or the device.

Danger!
Supply voltage!
Contact with non-insulated parts carrying supply voltage involves the risk of an electric shock resulting
in injuries and death.
Only qualified and skilled personnel are authorised to run electrically-operated devices. Prior to
undertaking maintenance measures at the device, the following requirements must be met:
Make sure that the power supply is switched off and that the device is off and marked for maintenance
measures. Please also ensure that the power supply cannot be re-established during the works.

36 DRYPOINT® RA 20-960
 Maintenance, troubleshooting, spare parts and dismantling

Prior to carrying out maintenance works at the dryer, switch it off and wait for at least 30 minutes.

Caution!
Hot surfaces!
During operation, several components can reach surface temperatures of more than +60°C. There is
the risk of burns.
All components concerned are installed inside of the closed housing. The housing must only be opened
by certified skilled personnel.
Some components can reach high temperatures during operation. Avoid any contact until the system or
the component has cooled down.

FAULT POSSIBLE REASON – SUGGESTED MEASURE

 The dryer does not  Check whether or not the dryer is connected with the electric mains.
start.  Check the electric cabling.
 RA 330-960 3phase- Blow of fuse (FU3 on the electric diagram) of the auxiliary circuit -
replace it and check the proper operation of the dryer.
 The refrigerating  The internal heat protection of the compressor was activated – wait 30 minutes and then
compressor does not retry.
work.  Check the electric cabling.
 If installed – replace the internal heat protection and/or the start-up relay and/or the starting
capacitor and/or the operating capacitor.
 If installed – the HPS pressure switch was activated – see the corresponding point.
 If installed – the LPS pressure switch was activated – see the corresponding point.
 If installed – the TS safety temperature switch was activated – see the corresponding point.
 In the event that the compressor still does not work, replace it.
 The fan of the  Check the electric cabling.
condenser does not  The PV pressure switch is defective. Contact a BEKO service technician.
work (air-cooled).  RA 330-960 3phase- Blow of fuse (FU1-FU2 on the electric diagram) - replace it and check
the proper operation of the dryer.
 There is a leak in the refrigeration cycle – contact a BEKO service technician.
 In the event that the fan still does not work, replace it.
 Dew point too high.  The dryer does not start up – see the corresponding point.
 The T1 dew point sensor does not record the temperature properly – ensure that the sensor
is pushed down to the bottom of the aluminium tube immersion sleeve.
 The refrigerating compressor does not work – see the corresponding point.
 The ambient temperature is too high or the room ventilation insufficient – ensure sufficient
ventilation (air-cooled).
 The inlet air is too hot – re-establish the nominal conditions.
 The inlet air pressure is too low – re-establish the nominal conditions.
 The inlet air throughput is higher than the throughput of the dryer – reduce the flow rate - re-
establish the nominal conditions.
 The condenser is dirty – please clean it (air-cooled).
 The condenser fan does not work – see the corresponding point (air-cooled).
 The cooling-water flow is insufficient – re-establish the nominal conditions (water-cooled).
 The dryer does not discharge the condensate – see the corresponding point.
 The hot-gas bypass valve needs to be re-adjusted – contact a BEKO service technician to
have the nominal setting re-established.
 There is a leak in the refrigeration cycle – contact a BEKO service technician.
 Dew point too low.  The fan runs continuously – the PV pressure switch is defective – replace it (air-cooled).
 The ambient temperature is too low –re-establish the nominal conditions.
 The hot-gas bypass valve needs to be re-adjusted – contact a BEKO service technician to
have the nominal setting re-established.

DRYPOINT® RA 20-960 37
Maintenance, troubleshooting, spare parts and dismantling

 Extreme pressure drop  The dryer does not discharge the condensate – see the corresponding point.
in the dryer.  The dew point is too low – the condensate is frozen and blocks the air – see the
corresponding point.
 Check the flexible connection hoses for obstructions.
 The dryer does not  The shut-off valve at the condensate outlet is closed – open it.
drain the condensate.  Check the electric cabling.
 The dew point is too low – the condensate is frozen – see the corresponding point.
 The BEKOMAT condensate drain does not work properly (see BEKOMAT MANUAL).
 Failure during the  Please read the separate BEKOMAT installation and operating instructions.
condensate discharge.
 Water in the line.  The dryer does not start – see the corresponding point.
 If installed - untreated air flows through the bypass unit – close the bypass.
 The dryer does not drain condensate – see the corresponding point.
 Dew point too high – see the corresponding point.
 If installed: the HPS  Check which of the following reasons is responsible for the triggering:
high-pressure switch 1. The ambient temperature is too high or the room ventilation insufficient – ensure sufficient
has triggered. ventilation (air-cooled).
2. The condenser is dirty – please clean it (air-cooled).
3. The condenser fan does not work – see the corresponding point (air-cooled).
4. The cooling water is too hot – re-establish the nominal conditions (water-cooled).
5. The cooling-water flow is insufficient – re-establish the nominal conditions (water-cooled).
 Reset the pressure switch by pressing the button on the controller itself – check the proper
functioning of the dryer.
 The HPS pressure switch is defective – contact a BEKO service technician for the
replacement.
 If installed:  There is a leak in the refrigeration cycle – please contact a BEKO service technician.
the LPS low-pressure  The pressure switch is automatically reset as soon as the normal conditions are re-
switch was triggered. established – check the dryer for proper functioning.
 If installed:  Check which of the following reasons is responsible for the triggering:
the TS safety 1. Excess thermal load – re-establish the standard operating conditions.
temperature switch 2. The inlet air is too hot – re-establish the nominal conditions.
was triggered. 3. The ambient temperature is too high or the room ventilation insufficient – ensure sufficient
ventilation.
4. The condenser unit is dirty – please clean it.
5. The fan does not work – see the corresponding point.
6. The hot-gas bypass valve needs to be re-adjusted – contact a specialist for refrigerating
plants to have the nominal calibration re-established.
7. The cooling-water temperature is too low – re-establish the nominal conditions (water-
cooled).
8. The adjusting valve for the cooling-water flow needs to be re-adjusted – contact a specialist
to have the nominal calibration re-established (water-cooled).
9. There is a leak in the refrigeration cycle – please contact a BEKO service technician.
 Reset the temperature switch by manually pushing the button on the temperature switch –
check the perfect functioning of the dryer.
 The TS temperature switch is defective – replace it.
 The DMC18 LED  When the LED flashes: one or more service warnings/alarms are active. The
is on. display shows the dew point temperature and the active service warnings/alarms.
 The service warnings are indicated by the following messages:
1. : PF – Failure temperature probe T1 (dew point) – check the electric cabling
and/or replace the probe.
2. : Hdp – Dew point too high (higher than the adjusted alarm value) – see the
corresponding section.
3. : Ldp – Dew point too low (lower than the adjusted alarm value) – see the
corresponding section.
4. : drA – The Bekomat BM-IF condensate drain does not work properly - see the
corresponding section.
5. : SrV - Service – maintenance notification time expired (parameter SrV) – carry
out the scheduled maintenance and reset the hour meter.
NOTE: SrV Service (service time expired) needs to be reset manually (press the
button and keep it pressed for at least 20 seconds).

38 DRYPOINT® RA 20-960
 Maintenance, troubleshooting, spare parts and dismantling

12.3 Recommended spare parts

NOTE: To order the recommended spare parts or other elements, the data on the name plate must be
indicated.

DRYPOINT® RA 20-960 39
Maintenance, troubleshooting, spare parts and dismantling

40 DRYPOINT® RA 20-960
 Maintenance, troubleshooting, spare parts and dismantling

DRYPOINT® RA 20-960 41
Maintenance, troubleshooting, spare parts and dismantling

42 DRYPOINT® RA 20-960
 Maintenance, troubleshooting, spare parts and dismantling
12.4 Maintenance works at the refrigeration cycle

Caution!
Refrigerant!
Maintenance and repair works at refrigeration systems must only be carried out by BEKO service
technicians in accordance with the local provisions.
The total amount of refrigerant in the system must be collected for recycling purposes, resource recovery
or disposal.
The refrigerant must not be discharged into the environment.

When delivered, the dryer is ready to operate and filled with a refrigerant of the R134a or R407C type.

Should you detect a refrigerant leak, please contact a BEKO service technician. Prior to any intervention,
the room needs to be ventilated.
When the refrigeration cycle needs to be refilled, please also contact a BEKO service technician.
You will find the refrigerant type and amount on the name plate of the dryer.

Properties of the refrigerants used:

Refrigerant Chemical formula MIK GWP

R134a - HFC CH2FCF3 1000 ppm 1300
R32/125/134a (23/25/52)
R407C - HFC 1000 ppm 1653
CHF2CF3/CH2F2/CH2FCF3

12.5 Dismantling the dryer

When the dryer is dismantled, all parts and operating materials related to the plant need to be disposed of separately.

Component Material
Refrigerant R407C, R134a, oil
Roof and supports Structural steel, epoxy paint coat
Refrigerating compressor Steel, copper, aluminium, oil
Aluminium heat exchanger Aluminium
Condenser unit Aluminium, copper, structural steel
Pipe Copper
Fan Aluminium, copper, steel
Valve Brass, steel
BEKOMAT condensate drain PVC, aluminium, steel
Insulant Synthetic rubber without CFCs, polysterene, polyurethane
Electric cable Copper, PVC
Electric parts PVC, copper, brass

We recommend observing the safety provisions in force for the disposal of each material type.
The refrigerant contains lubricating-oil droplets which are released by the compressor.
The refrigerant must not be discharged into the environment. It must to be sucked off from the dryer
using a suitable device, and then needs to be supplied to a collection point.

DRYPOINT® RA 20-960 43
Appendices
13 Appendices
13.1 Dryer dimensions

13.1.1 Dryer dimensions DRYPOINT RA 20-70

44 DRYPOINT® RA 20-960
 Appendices

13.1.2 Dryer dimensions DRYPOINT RA 110-135

DRYPOINT® RA 20-960 45
Appendices

13.1.3 Dryer dimensions DRYPOINT RA 190-240

46 DRYPOINT® RA 20-960
 Appendices

13.1.4 Dryer dimensions DRYPOINT RA 330-370

DRYPOINT® RA 20-960 47
Appendices

13.1.5 Dryer dimensions DRYPOINT RA 490-630

48 DRYPOINT® RA 20-960
 Appendices

13.1.6 Dryer dimensions DRYPOINT RA 750-960

DRYPOINT® RA 20-960 49
Appendices

13.1.7 Dryer dimensions DRYPOINT RA 330-370 3phase

50 DRYPOINT® RA 20-960
 Appendices

13.1.8 Dryer dimensions DRYPOINT RA 490-630 3phase

DRYPOINT® RA 20-960 51
Appendices

13.1.9 Dryer dimensions DRYPOINT RA 750-960 3phase

52 DRYPOINT® RA 20-960
 Appendices
13.2 Exploded diagrams

13.2.1 Components of the exploded diagrams

1 Alu drying module 20 Refrigerant reservoir (water-cooled)

1.1 Insulation material 21 Bekomat drain
2 Refrigerant pressure switch LPS 22 Main switch
3 Safety temperature switch TS …
4 Refrigerant pressure switch HPS 51 Front panel
5 Refrigerant fan pressure switch PV 52 Back plate
6 Compressor 53 Right sidewall
7 Hot-gas bypass valve 54 Left sidewall
8 Condenser (air-cooled) 55 Cover
9 Condenser fan 56 Base plate
9.1 Motor 57 Upper plate
9.2 Blade 58 Carrier support
9.3 Grid 59 Support bracket
10 Filter dryer 60 Control panel
11 Capillary tube 61 Electric connecting plug
12 T1 temperature probe (dew point) 62 Electric cabinet
13 Condensate drain service valve 65 Condenser filter
17 Air dryer control 66 QE door
18 Condenser (water-cooled) 81 Adhesive label flow chart
19 Condenser water-regulating valve (water-cooled)

DRYPOINT® RA 20-960 53
Appendices

13.2.2 Exploded diagram DRYPOINT RA 20-70 /AC

54 DRYPOINT® RA 20-960
 Appendices

13.2.3 Exploded diagram DRYPOINT RA 110-135 /AC

DRYPOINT® RA 20-960 55
Appendices

13.2.4 Exploded diagram DRYPOINT RA 190-240 /AC

56 DRYPOINT® RA 20-960
 Appendices

13.2.5 Exploded diagram DRYPOINT RA 330-370 /AC

DRYPOINT® RA 20-960 57
Appendices

13.2.6 Exploded diagram DRYPOINT RA 490-630 /AC

58 DRYPOINT® RA 20-960
 Appendices

13.2.7 Exploded diagram DRYPOINT RA 750-960 /AC

DRYPOINT® RA 20-960 59
Appendices

13.2.8 Exploded diagram DRYPOINT RA 330-370 /WC

60 DRYPOINT® RA 20-960
 Appendices

13.2.9 Exploded diagram DRYPOINT RA 490-630 /WC

DRYPOINT® RA 20-960 61
 Appendices

13.2.10 Exploded diagram DRYPOINT RA 750-960 /WC

62 DRYPOINT® RA 20-960
 Appendices

13.2.11 Exploded diagram DRYPOINT RA 330-370 3phase /AC

DRYPOINT® RA 20-960 63
 Appendices

13.2.12 Exploded diagram DRYPOINT RA 490-630 3phase /AC

64 DRYPOINT® RA 20-960
 Appendices

13.2.13 Exploded diagram DRYPOINT RA 750-960 3phase /AC

DRYPOINT® RA 20-960 65
 Appendices

13.2.14 Exploded diagram DRYPOINT RA 330-370 3phase /WC

66 DRYPOINT® RA 20-960
 Appendices

13.2.15 Exploded diagram DRYPOINT RA 490-630 3phase /WC

DRYPOINT® RA 20-960 67
 Appendices

13.2.16 Exploded diagram DRYPOINT RA 750-960 3phase /WC

68 DRYPOINT® RA 20-960
 Appendices
13.3 Electric diagrams

13.3.1 Electric diagrams – list of components

MC : Compressor
KT : Compressor thermal protection
KR : Compressor starting relay (if installed)
CS : Compressor starting capacitor (if installed)
CR : Compressor operating capacitor (if installed)
MV : Condenser fan
CV : Fan starting capacitor (if installed)
DMC18 : DMC18 electronic instrument – air dryer control
BT1 : T1 Temperature probe – dew point
HPS : Pressure switch – compressor discharge side (HIGH PRESSURE)
LPS : Pressure switch – compressor suction side (LOW PRESSURE)
PV : Pressure switch – fan control
TS : Safety temperature switch
ELD : BEKOMAT drain
S1 : ON/OFF switch
QS : Main switch with locking device
RC : Compressor crankcase heater
BOX : Electrical connection

NT1 : Only air-cooled

NT2 : Check the transformer connections with regard to the supply voltage
NT3 : Jump, if not installed
NT4 : Provided and cabled by the customer
NT5 : Internal control
NT6 : Time-controlled drain outlet (not used)
NT7 : Only water-cooled

BN = BROWN OR = ORANGE
BU = BLUE RD = RED
BK = BLACK WH = WHITE
YG = YELLOW/GREEN WH/BK = WHITE/BLACK

DRYPOINT® RA 20-960 69
70
0 1 2 3 4 5 6 7 8 9
Appendices

L1 BN-1 1 2 2

N BU-2 4 5 4

PE

PE
DMC18 - Air Dryer Controller
1/230V/50Hz+PE (*) ELD DRAIN
MODEL SELECT.
OR °C
1/230V/60Hz+PE (*) 3 3
OR
°F
1/115V/60Hz+PE (*) BM
31-IF
FUSE MAX 10 A 2 2
RCD Id 0.03A suggested
+24V D S G T1
4 5 7 8 9 10 11
SUPPLY BY PLUG
13.3.2 Electric diagram DRYPOINT RA 20-135

MAX 1A
YE
GR
BN
WH

PV
2 4

NO Alarm Alarm
and or
Power ON Power OFF

BT1
MC1

KT
MV1
C NTC 2k
M M ELD
S 1~ R 1~ +24V Drn Sen Gnd
CV
KR

CS

(*) See dryer nameplate

Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
BEKO TECHNOLOGIES GMBH
BKRASEL0088 00
http:// www.beko.de
Note :
Sheet 01 of 01

DRYPOINT® RA 20-960
 0 1 2 3 4 5 6 7 8 9

L1 BN-1 1 2 2

N BU-2 4 5 4

PE

DRYPOINT® RA 20-960
PE
DMC18 - Air Dryer Controller
1/230V/50Hz+PE (*) ELD DRAIN
MODEL SELECT.
OR °C
1/230V/60Hz+PE (*) 3 3
FUSE MAX 10 A
°F
OR BM
31-IF
1/115V/60Hz+PE (*) 2 2
FUSE MAX 13 A
+24V D S G T1
4 5 7 8 9 10 11
RCD Id 0.03A suggested

TS MAX 1A
13.3.3 Electric diagram DRYPOINT RA 190-240

SUPPLY BY PLUG C
YE
GR
BN
WH

PV
1 2 4

NO Alarm Alarm
and or
Power ON Power OFF

BT1
MC1
C
KT
MV1
NTC 2k
M M ELD
1~ 1~ +24V D S G
S R
CV

CR

(*) See dryer nameplate

Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
BEKO TECHNOLOGIES GMBH
BKRASEL0089 00
http:// www.beko.de
Note :
Sheet 01 of 01

71
Appendices
72
0 1 2 3 4 5 6 7 8 9
Appendices

L1 BN-1 1 2 2

N BU-2 3 4 4

PE

PE
DMC18 - Air Dryer Controller
1/230V/50Hz+PE (*) ELD DRAIN
MODEL SELECT.
OR °C
1/230V/60Hz+PE (*) 3 3
FUSE MAX 10 A
°F
OR BM
31-IF
1/115V/60Hz+PE (*) 2 2
FUSE MAX 13 A
+24V D S G T1
4 5 7 8 9 10 11
RCD Id 0.03A suggested
HPS
4 2
MAX 1A
13.3.4 Electric diagram DRYPOINT RA 330-370

SUPPLY BY PLUG
YE
GR
BN
WH

1 PV
2 4

NO Alarm Alarm
and or
TS Power ON Power OFF
C

BT1
MC1
C
KT
MV1
NTC 2k
M M ELD
1~ 1~ +24V D S G
S R
CV

CR

(*) See dryer nameplate

Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
BEKO TECHNOLOGIES GMBH
BKRASEL0090 00
http:// www.beko.de
Note :
Sheet 01 of 01

DRYPOINT® RA 20-960
 0 1 2 3 4 5 6 7 8 9

L1 BN-1 1 2 2

N BU-2 3 4 4

PE

DRYPOINT® RA 20-960
PE
DMC18 - Air Dryer Controller
1/230V/50Hz+PE (*) ELD DRAIN
MODEL SELECT.
OR °C
1/230V/60Hz+PE (*) 3 3
FUSE MAX 16 A
°F
RCD Id 0.03A suggested BM BM
31-IF 32-IF
Smin 2.5sqmm/14AWG 2 2 RA750...960

+24V D S G T1
HPS 4 5 7 8 9 10 11
4 2

1
MAX 1A
13.3.5 Electric diagram DRYPOINT RA 490-960

YE
GR
BN
WH

LPS PV
2 4 2 4

1 1

NO Alarm Alarm
and or
TS Power ON Power OFF
C

BT1
MC1 MV1
C
KT KV
NTC 2k
M M ELD
1~ 1~ +24V D S G
S R

CR CV

(*) See dryer nameplate

Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
BEKO TECHNOLOGIES GMBH
BKRASEL0091 00
http:// www.beko.de
Note :
Sheet 01 of 01

73
Appendices
74
0 1 2 3 4 5 6 7 8 9
Appendices

QS
FU1-2

3/400V/50Hz+PE
3/400V/50Hz+PE (*)
OR
3/460V/60Hz+PE (*)
FUSE MAX 16 A
RCD Id 0.03A suggested
Smin 2.5sqmm/14AWG
PV TF 3/460V/60Hz+PE

FU3
CV
1 3 5
KC1
[2-1]
2 4 6

21
KC1
13.3.6 Electric diagram DRYPOINT RA 330-960 3phase Sheet 1/3

[2-2] 22

S T
TP
M
3
U V
W
M MV1
3

MC1 TP RC
U2
M A B
1
(*) See dryer nameplate
MV1
Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
BEKO TECHNOLOGIES GMBH
BKRA5478QCD005 01
http:// www.beko.de
Note :
Sheet 01 of 03

DRYPOINT® RA 20-960
 0 1 2 3 4 5 6 7 8 9

2 1
A

5 4 REMOTE
B ON - OFF

S1
HPS

DRYPOINT® RA 20-960
DMC18 - Air Dryer Controller
P
3 ELD DRAIN
MODEL SELECT.
°C
°F
BM BM
31-IF 32-IF
RA750...960
LPS
+24V D S G T1
2 4 5 7 8 9 10 11
P

MAX 1A

YE
GR
BN
WH
NO Alarm Alarm
and or
Power ON Power OFF

BT1
13.3.7 Electric diagram DRYPOINT RA 330-960 3phase Sheet 2/3

TS
P
NTC 2k
ELD
+24V D S G

A1
KC1
A2
1 2
[1-3]
3 4
[1-3]
5 6
[1-3]
11 12
[1-8]

Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
BEKO TECHNOLOGIES GMBH
BKRA5478QCD005 01
http:// www.beko.de
Note :
Sheet 02 of 03

75
Appendices
76
0 1 2 3 4 5 6 7 8 9
TERMINAL
TYPE

CBC.4
CBC.4
CBC.4
Appendices

-
-
-
-
WIRE

11
00

13
14
13
10
S0
S0

R0
R0

to CV
to CV

1
4

2
3
5
6
7
V
V

P
P

U
U

W
W
TERMINAL

RC1
RC2
RC
HPS LPS ELD PV MV1 PV MV1
M M
3 1

BEKOMAT
FAN MOTOR
FAN MOTOR
13.3.8 Electric diagram DRYPOINT RA 330-960 3phase Sheet 3/3

REMOTE ON/OFF
FAN PRESSURE SWITCH
FAN PRESSURE SWITCH

LOW PRESSURE SWITCH

HIGH PRESSURE SWITCH

COMPRESSOR CRANKCASE HEATER
Technical modifications are subject to change without notice; errors not excluded.
Drawing no. : Rev.
BEKO TECHNOLOGIES GMBH
BKRA5478QCD005 01
http:// www.beko.de
Note :
Sheet 03 of 03

DRYPOINT® RA 20-960
 Appendices

DRYPOINT® RA 20-960 77
Appendices

78 DRYPOINT® RA 20-960
 EC Declaration of Conformity
14 EC Declaration of Conformity

DRYPOINT® RA 20-960 79
EC Declaration of Conformity

80 DRYPOINT® RA 20-960
 EC Declaration of Conformity

DRYPOINT® RA 20-960 81
EC Declaration of Conformity

82 DRYPOINT® RA 20-960
 A Hot-gas bypass valve .........................................30

Advice, safety instructions .................................... 5 I

Appendices ......................................................... 44 Initial start-up ......................................................20
B Installation ...........................................................14
Installation plan ...................................................15
BEKOMAT .......................................................... 34
M
C
Maintenance .......................................................35
Capillary tube ...................................................... 30
Maintenance works at the refrigeration cycle .....43
Certified skilled personnel .............................. 8; 36
Minimum installation requirements .....................14
Circuit diagram ....................................... 70; 71; 72
Circuit diagrams .................................................. 69 O
Condensate drain ............................................... 19 Overview of the safety instructions .......................8
Condenser .......................................................... 30 P
Connection to the compressed-air system ......... 17
Place of installation .............................................14
Connection to the cooling-water network (water-
Pressure Equipment Directive ............................12
cooled) ............................................................ 17
Proper use ..........................................................11
Contaminated intake air...................................... 15
Control panel ...................................................... 28 R
Cooling-water regulating valve ........................... 30 Recommended spare parts ................................39
Correction factors ............................................... 16 Refrigerating compressor ...................................30
D Removal from service .........................................21
Restart ................................................................21
Danger compressed air ..................8; 9; 35; 36; 37
Danger supply voltage .............................. 8; 35; 36 S
Dismantling ......................................................... 35 Safety instructions ............................................5; 8
Dismantling the dryer.......................................... 43 Safety pictograms in accordance with DIN 4844 ..6
Dryer dimensions..................44; 45; 46; 47; 49; 50 Safety temperature switch ..................................31
E Spare parts ...................................................35; 39
Start-up ...............................................................20
EC Declaration of Conformity ............................. 79
Storage ...............................................................13
Electrical connections ......................................... 19
Exclusion from a field of application ................... 11 T
Exclusion of a field of application ....................... 11 Technical data ..................... 22; 23; 24; 25; 26; 27
Exploded diagram...........53; 54; 55; 56; 57; 58; 59 Technical description ..........................................28
F Transport.............................................................13
Troubleshooting ..................................................35
Field of application.............................................. 11
Type plate .............................................................5
Filter dryer........................................................... 30
Flow chart ........................................................... 29 U
Functional description......................................... 28 Unauthorised intervention ...................................10
H
Heat exchanger .................................................. 30

DRYPOINT® RA 20-960 83
Headquarters : 中华人民共和国 / China France
BEKO TECHNOLOGIES (Shanghai) Co. BEKO TECHNOLOGIES S.à.r.l.
Deutschland / Germany Ltd. Zone Industrielle
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Phone: +91 40 23080275 [email protected] JP-210-0855
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Phone: +81 44 328 76 01
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Benelux Polska / Poland Scandinavia

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España / Spain South East Asia 臺灣 / Taiwan

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Polígono Industrial "Armenteres" (Thailand) Ltd.
16F.-5, No.79, Sec. 1,
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Xintai 5th Rd., Xizhi Dist.,
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New Taipei City 221,
Phone: +34 93 632 76 68 Bangkok 10510
Taiwan (R.O.C.)
[email protected] Thailand
Phone: +886 2 8698 3998
Phone: +66 (0) 2-918-2477
[email protected]
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Česká Republika / Czech Republic United Kingdom USA

BEKO TECHNOLOGIES s.r.o. BEKO TECHNOLOGIES LTD. BEKO TECHNOLOGIES CORP.
Mlýnská 1392 2 West Court 900 Great SW Parkway
CZ - 562 01 Usti nad Orlici Buntsford Park Road US - Atlanta, GA 30336
Phone: +420 465 52 12 51 Bromsgrove Phone: +1 (404) 924-6900
[email protected] GB-Worcestershire B60 3DX [email protected]
Phone: +44 1527 575 778
[email protected]

Original operating instructions in English.

Subject to technical changes / errors excepted.
DRYPOINT_RA_20-960_manual_en_2012_09