INSTRUCTION MANUAL

Refrigerating Compressed-Air Dryer

ORION Air Dryer

RAX240F

CAUTION
This air dryer is designed for industrial use. Handle with care.
Please read this manual carefully and operate this equipment
accordingly.
Retain this manual for future reference.

This manual is comprised of two sections.

Operation Guide...................................................................Pages 1 to 29
Installation Guide..................................................................Pages 30 to 49
 Thank you for your purchasing ORION products
To ensure safe and efficient use, please install and operate this equipment in accordance with the
instructions provided in this manual.
Product specifications are subject to change without notice. Please be aware that recent changes to
product specifications may not be reflected in the content of this manual.

Safety Precautions
Before operating this equipment, be sure to read through the "Essential Safety Precautions" section of
this manual.
Failure to observe precautions may result in injury or property damage.
Essential safety precautions are categorized as WARNINGS or CAUTIONS. The meaning
of each category is as follows.

Failure to observe the instructions contained in a WARNING

WARNING may result in death or severe injury.

Failure to observe the instructions contained in a CAUTION

CAUTION may result in injury or physical damage.

Failure to observe WARNINGS and CAUTIONS can have severe consequences! Please read through
this user manual carefully and handle the machine accordingly.
After read through this manual, store this near the dryer so that you can refer it as necessary.
If you transfer this equipment to another user, be sure to include this manual together with the
equipment. Place the manual in a prominent location on the equipment so that the new user is sure
to notice it.

Safety symbols
The symbol indicates warnings and cautions. The drawing in the triangle indicates the
content of the action that required paying attention. (The left illustration means that you should
be careful of fan revolution.)

The symbol indicates a prohibited action or operation. The drawing in (or near) the circle
indicates the content of the action. (The indication at left means that you must not disassemble
the unit.)

The symbol indicates an action that you are strongly required to ensure. (The indication at
left means that you must connect the unit to ground.)

The symbol indicates important information. Although important, this information does not
constitute a "warning" or "caution."
 Operation Guide

Contents

Essential safety precautions ................................................ 2

To maintain efficient and trouble-free operation ................... 5

Appearance ......................................................................... 8

Operating method .............................................................. 10

Safety devices ................................................................... 15

Periodic inspection and cleaning ....................................... 16

Troubleshooting ................................................................. 22

Storing the dryer (for long-term storage) ............................ 26

Consumables and replacement parts ................................ 27

Maintenance intervals of main parts .................................. 28

Option installation .............................................................. 29

1
 Essential safety precautions
Instructions for use (WARNINGS)

WARNINGS
Failure to observe the instructions contained in a WARNING may result in death or severe injury.

Do not modify the machine.

A modified product is excluded from the warranty.
Do not allow other person to disassemble or to repair the machine than
those of nearest our dealer or professionals.
Improper disassembling or repairing may result in bodily injuries due to
malfunctioning, electric shocks or fire accident.
Do not touch switches with wet hands.
Keep wet hands away from switches, electric plugs, and all other electrical
components. Touching electrical areas with wet hands may result in electric shock.

Do not run the machine while the cabinet is open.

Touching the inside of the dryer while operation is in progress may result in injury or
electric shock.
Do not souse water over the machine and in machine chamber.
Do not use water to wash it. It may cause fire or electric shock.
Do not damage or modify the power cord.
Do not place heavy objects on it, heat it, stretch it, or allow the cord to become
caught. Damage of the cord may result in electric shock or fire.
Be sure to release pressurized air from the compressor before you begin
cleaning, maintenance or inspection.
Pressurized air in the compressor may blow out and cause injury.
Caution when to reassemble the auto drain trap.
If the auto drain trap is not correctly reassembled it may come away and air gush out
to cause injury.

2
 Essential safety precautions
Instructions for use (WARNINGS)

WARNINGS
Failure to observe the instructions contained in a WARNING may result in death or severe injury.

If the leakage breaker trips, contact your dealer of service specialist for
advice.
Resetting the breaker without correcting the underlying problem may result in electric
shock or fire.
If this equipment operates abnormally, shut off operation and contact
your dealer or service specialist for advice.
Continued operation may result in electric shock or fire.
If you need to move this equipment, consult your dealer or service
specialist.
Improper installation may result in water leakage, electric shock, or fire.
Surely check the oil in air compressor.
Check the lubricating oil in air compressor following the instructions stipulated by the
manufacturer. If not, the lubricating oil may deteriorate, and carbon may accumulate in
Air Dryer to cause explosion or fire.
Cut off the main power before beginning cleaning, maintenance, or
inspection.
Leaving the power connected may result in electric shock, injury, or fire.

3
 Essential safety precautions
Instructions for use (CAUTIONS)

CAUTIONS
Failure to observe the instructions contained in a CAUTION may result in injury or physical damage.
Do not flow undesignated fluid into the dryer.
This dryer is designed to operate on compressed air only. Inlet of a different fluid may
damage it and may lead to injury or water leakage.
Be not exceeding the maximum working pressure value.
The maximum working pressure for this dryer is 0.98 MPa. Operation at pressures
above this limit may damage it and may lead to injury or water leakage.
Do not sit on, lean on, or place objects on this machine.
Overturning of this may result in injury or water spillage. Water spillage may in turn
result in electricity leakage.
Do not use flammable sprays in the vicinity of this machine.
Also, do not place flammable objects in the vicinity. Sparks from switch operation may
ignite flammable material.
Keep hands clear of the fin when cleaning the condenser.
Touching the fin may result in injury.

Do not place fingers or objects (pencils, etc.) into the air intake and air
discharge areas.
Rapidly rotating fans are located in these areas. Inserting fingers or objects into the
path of fan rotation may result in injury.

Periodically check that the leakage breaker is working correctly.

If the breaker is defective it may fail to trip in event of electric leakage, resulting in
electric shock.
Be sure to include this operating manual if transferring this machine to
another.
If you sell or otherwise transfer this machine to another user, tape this manual onto
the equipment so that the new user is sure to notice it. New users must read this
manual to ensure that they can operate this machine safely.
Consult about the optional installation with supplier.
Otherwise, injury way be caused.

4
 Essential safety precautions
Instructions for use (Waning label on product)

Warning label on product

A warning label is affixed to this product in the location indicated below. This label lists essential warning.
Please read the entire label carefully before starting to use this machine.
This label must remain readable at all times. If the label becomes scratched or dirty, please contact your
dealer for a replacement label.

Back Front

To maintain efficient and trouble-free operation

WARNINGS
If you need to remove the cabinet, please proceed follow this instruction. Do not run the dryer
while the cabinet is open or detached. Touching the inside of the dryer may result in injury or
electric shock.

CAUTIONS
This unit dries compressed air only. Operating on any other fluid type may result in machine
damage that may in turn lead to injury, water leakage, or other such problems.

5
 To maintain efficient and trouble-free operation

1. Be sure that working conditions remain within the specified operating ranges. Operation outside of
specified ranges may result in equipment failure.
Item RAX240F
Air processing capacity 1 (m3/min
(50/60Hz) ) 38 45
Processed-Ai
r Conditions

Inlet air pressure 2 (MPa) 0.69

Inlet air temperature ( ) 40
Pressure dew point of outlet air ( ) Pressurized: 10+1
Ambient temperature ( ) 32
Applicable fluid Compressed air
Conditions
Usage

Inlet air temperature ( ) 5 to 60

Ambient temperature ( ) 2 to 40
working air pressure 2 (MPa) 0.29 to 0.98
Three-phase 200 10% 50/60
Power voltage (V Hz)
Three-phase 220 10% 60
1 The air processing capacity indicated above is converted to a value at atmospheric pressure, 32 ,
and 75%RH based on ANR.
2 As indicated on pressure gauge.

2. After pressing the OFF switch, be sure to wait at least 3 minutes before pressing the ON switch to
resume operation. Restarting within 3 minutes may activate safety devices or cause damage to the
compressor.
3. Ambient temperature should remain between 2 and 40 during use.
Usage at temperatures below 2 may cause freezing of water in the drain area. Usage at
temperatures above 40 may impede heat release from the condenser, resulting in safety-device
activation and equipment shutdown. If you have a problem related to ambient temperature, please
consult your dealer or service specialist.
4. Confirm that airflow is in the correct direction. Air should be taken in at the front, left side and rear of
the unit and discharged from the top of the unit.
5. If the dryer is shut down by activation of safety devices, please contact your dealer or this office for
advice.
6. If the air dryer is connected directly to the air compressor, the dehumidifying capacity may deteriorate
due to entering of supersaturated drain water. Also, be sure to install the drain separator and air tank
before the air dryer since the attached drain trap becomes shortage of drain capacity, and the water
may drop from the end.
7. In case of using the air dryer in the compressed air line with rapid compressor fluctuation, be sure to
install the air tank after the air dryer so that the pressure fluctuation becomes 0.34MPa/min or less. If
the pressure fluctuation is rapid, it may result in malfunction.
8. Be sure to flow the compressed air gradually. If the air is flown fast, the drain water may roll up or the
parts inside the heat exchanger may be damaged.
9. Be sure to install the check valve in outlet part of the air dryer if the compressed air has a possibility to
flow back depends on the end air condition. If the back-flow is occurred without installing the check
valve, the parts inside the air dryer may be damaged.

6
 To maintain efficient and trouble-free operation

10. In case of air blowing at the air piping construction, be sure to carry out the valve operation or to use
the bypass circuit. If there is a rapid pressure fluctuation, the parts inside the air dryer may be
damaged.
11. Power supply should be started at least 12 hours before you begin to operate the dryer.
To ensure smooth operation, the compressor heater should be powered up in advance to ensure that
coolant does not liquefy in the compressor.
12. In case of plumbing air compressor and air dryer directly, prepare buffer functions, such as a flexible
tube, so that vibration of air compressor does not transmit to air dryer directly. Vibration may break
the inside of the heat exchanger.
Especially, the reciprocating air compressor has larger vibration.

7
 Appearance
External view / Internal structure

External view

Air inlet Air outlet

Inlet for damp compressed air Outlet for dried compressed air.
from the compressor.

Control panel
Control this
machine.

Rear
Front Name plate

Power-cord opening
(For metal conduit)
The power cord extends from here.
Base
Auto drain trap Use the aperture to fix this
Used to drain water and oil. device in place.

Internal structure (As viewed with cabinet removed.)

Fan motor for condenser Heat exchanger

In order to change the high Condenses water out of
temperature and pressure gas incoming compressed air.
from the compressor to the
liquid, cool down the condenser
heat.

Air-cooled condenser
Liquefies the hot pressurized gas
coming from the compressor.
Switchboard
Electrical-component
board.

Refrigerating compressor
Compresses coolant gas to high
pressure to enable good
condensation.

8
 Appearance
Control panel / Switchboard

Control panel
Air-pressure gauge

Condensing Evaporating
pressure gauge pressure gauge

ALARM lamp (red)

ON switch (green)
RUN lamp (green) OFF switch (red)

POWER lamp (white)

Protection cover

Switchboard Inside of the protection cover

High-pressure switch
reset button
LOCAL/REMOTE switch
High-pressure switch
activates, and cancels
the compressor stopped
condition.

9
 Operating method
When starting up for the first time, or after a long-term storage

WARNING
Do not operate switches with wet hands, and never touch electrical components. Improper
handling may result in electric shock.

WARNING
Do not operate the dryer while the cabinet is open or detached. Touching the inside of the dryer
may result in injury or electric shock.
Do not use water to clean this machine, and do not allow water to spray or spill onto or in the
vicinity of this. Water contact may result in fire or electric shock.

WARNING
When the dryer go abnormal operation, press the OFF switch and then cut the main power.
Then contact our dealer or the specialist. Continuing to run the dryer while operation is
abnormal condition may result in fire or electric shock.

When starting up for the first time, or after a long-term storage

Before starting the operation, be sure to check or carry out followings.

1. When it is run for the first time, or run it after more than 24 hours the main power has not been applied
to the machine. Start up the power supply at least 12 hours before beginning operation. If you forget to
do this, it may cause a compressor failure.

Switch the source power ON so that the POWER lamp comes on. For smooth operation, the
compressor's heater should be powered up in advance to ensure that coolant does not liquefy in the
compressor.

2. Ask a specialist to make sure the phase is correct (not reversed) For information, refer to page 41,
"Wiring work" in the Installation Guide section of this manual.

10
 Operating method
Preparation

Preparation
Open the ball valve located in the pipe running to the auto drain trap.
The unit will not drain if the valve is left closed.

Ball valve Auto drain trap

Open

Close the bypass valve.

You should open this valve only during trial runs and inspections. There is no need to open this valve
during normal operation.

Close Bypass valve

Airflow direction

Open
Open

11
 Operating method
Select the operating mode

Select the operating mode

You can set the operating mode to either LOCAL or REMOTE.
The factory default mode is LOCAL.

Differences between modes

Start by Stop by
Operation
Local ON switch Remote ON switch Local OFF switch Remote OFF switch
LOCAL
REMOTE

Set the mode (Stop the air compressor, and then cut off the power to the air dryer.)
1. Remove the protection cover.
(1) Loosen the two setscrews.
(2) Remove the protection cover.
2. Set the LOCAL/REMOTE switch to the appropriate setting.
3. Remount the protection cover.
4. You can now proceed to operate the machine in accordance with the instructions given the following
pages.

Protection
cover

LOCAL / REMOTE switch

Two screws

Before you run the dryer in REMOTE mode, you must have a qualified electrician to set up the
wiring.

12
 Operating method
Run in LOCAL Mode

Run in LOCAL Mode

Start the operation
1. Set the LOCAL/REMOTE switch to LOCAL.
(See "Select the operating mode”)
2. Press the ON switch. (See Fig. 1.)
3. The (green) RUN lamp comes on to indicate that the dryer
is running.
4. When the dryer has started running, begin to flow of
compressed air.

[Caution]
(Fig.1)
(1) Check the bypass valve is all closed.
Close
(2) Valves should be turned slowly.
[Procedure] Airflow direction
(1) Slowly open the dryer's inlet valve,
glance at the AIR PRESSURE gauge.
(2) Stop turning the valve when the gauge
pressure reading begins to rise. Confirm
Open
that the pressure rise is proceeding Open
slowly.
(3) When the pressure rises to either the air
tank pressure or to the pressure set by
the compressor, resume turning the
valve again (slowly) until it is fully open.
(4) Slowly open the outlet valve while
watching the AIR PRESSURE gauge. Open the inlet Close the Open the
(5) Stop turning the valve when the gauge's valve bypass valve outlet valve
pressure reading begins to fall, then wait
for the pressure to begin a slow rise, and
then proceed to turn the valve again
(slowly) until it is fully open.
5. Check the gauge readings.
The various gauge readings should stabilize a short time after the flow of compressed air has started
up. The stabilized readings should be in the ranges indicated below.
Gauge Good Problem correction
Within "green" range If above "green" range: See page 22.
EVAP. PRESSURE 1
(0.37 to 0.69MPa) If below "green" range: See page 22.
If above limit: See page 22.
COND. PRESSURE 2 1.27 to 2.55MPa
If below limit: See page 22.
AIR PRESSURE Not above 0.98MPa Not above 0.98MPa
1. Although evaporating pressure may go outside of the green range according to the inlet air
temperature and processing air conditions, it is not unusual.
2. In the winter, if the inlet air temperature becomes low, it might indicate below the minimum, but it
is not failure.

13
 Operating method
Run in LOCAL Mode / Run in REMOTE Mode

Stop the operation

1. Stop the air compressor.
2. Press the OFF switch. (See Fig. 2.)
3. The (green) RUN lamp goes off to indicate that the dryer
has stopped operation.

(Fig.2)

Run in REMOTE Mode

Before you can operate the dryer in REMOTE mode, you must have a qualified electrician set up
the necessary wiring.
Start the operation
1. Set the LOCAL/REMOTE switch to REMOTE.
(See "Select the operating mode")
2. Start up the remote start switch.
3. The (green) RUN lamp comes on to indicate that the dryer is running.
4. Operate the dryer just as you would in LOCAL mode.
(Refer to "Operating the dryer," Steps 4 and 5, on page 13.)

Stop the operation

1. Stop the air compressor.
2. Switch the dryer off using either the remote switch or the
dryer's OFF switch (see Fig. 3).
3. The (green) RUN lamp goes off to indicate that the dryer
has stopped operation.

(Fig.3)
Frequent switching ON and OFF shall not be done.
Make sure to restart the operation at an interval longer than 3 minutes once it was stopped.
This is a necessary measure to protect refrigerating compressors.
Flow of compressed air should be raised gradually. Starting the flow all at once may result in
surging of drain water or in internal damage of the heat exchanger.
If you are going to supply high-temperature or high-humidity air soon after start-up, you should
turn on the air dryer at least 3 minutes in advance. During the initial output period the out
flowing air may still be damp and it is possible that water droplets may formed.
The fan may turns off and on repeatedly when ambient temperature is low. This is a normal
action that is taken to prevent a freezing inside the heat exchanger.

14
 Safety devices

Safety device Function How to reset

Resolute the problem.
Shuts down electric circuitry (stops all (See page 22.)
operation) if coolant pressure becomes Press the RESET button.
High-pressure switch
too high. (See page 24.)
(Function Pressure 2.94 0.1 MPa) Press the ON switch.
(or remote ON switch).
Resolute the problem.
(See page 22.)
Shuts down electric circuitry (stops all
Press the RESET button.
Thermal relay operation) if compressor overheats or if
(See page 25.)
overcurrent occurs.
Press the ON switch.
(or remote ON switch).
Shuts down electric circuitry (stops all
Discharge thermostat Call dealer for service.
operation) if refrigeration gas leakage.
For information about how to identify and clear the problem that caused the safety activation, refer to the
"Troubleshooting" section on page 22.

WARNING
Cut off the main power before fixing. It may result in electric shock, injury, or fire.

15
 Periodic inspection and cleaning

WARNING
Be sure to release pressurized air from the compressor before you begin cleaning ,
maintenance or inspection, it may blow out and cause injury.

WARNING
If you remove the cabinet to enable inspection or cleaning, be sure to get it back when this
work has done Do not operate this machine while the cabinet is open or detached. Touching
the inside of this machine may result in injury or electric shock.
Do not use water to clean this machine, and do not allow water to spill onto or in the vicinity of
this machine. Water contact may result in fire or electric shock.

WARNING
Cut off the main power the dryer before beginning maintenance, cleaning, or inspection.
Leaving the power supply connected while work is in progress may result in electric shock,
injury, or fire.

CAUTION
Keep hands clear of the fin when cleaning the condenser. Touching the fin may result in injury.

16
 Periodic Inspection and cleaning
Table of inspection and maintenance

Table of inspection and maintenance

Inspection Period
Parts to be
Items to be checked Weekly Monthly Every4years Remarks
checked Daily
(Every 60 Hr) (Every 250 Hr) (Every 12000 Hr)
Abnormal Sound or Call dealer
Overall
Vibration for service.
Check the pointer
Pressure gauge condition
(See page 13)
Operation check
Replace if
(daily), disassemble
Auto drain trap there is a
cleaning (weekly)
failure.
(See page 19)
Clean the filter
Condenser filter surface
(See page 21)
Clean when
Clean the fin surface
Condenser it is
(See page 21)
necessary.
Check worn-out and
Electric parts, loosen of screw.
switches, meters Check damage of Replace or
electric wire. Repair if
Air or refrigerant there is a
Heat-exchanger
leakage Failure.
Refrigerant Refrigerant
circuit leak
Note
1. means do it by user.
2. means contact with your dealer.
3. Depend on the condition; such as where a lot of dusts are there or corrosive gas exist, or ambient
temperature is high, etc. There might be a case that the life of air dryer becomes shorter. In this case,
cleaning or replacement is necessary before reached to the above inspection standard.
4. Inspection time is not warranty period.

17
 Periodic inspection and cleaning
Daily check

Daily check
Check auto drain trap (AD-5).
Check visually the condition of the drain trap once a day.
Make sure that the trap is operating drain off periodically.

Once or twice a week, you should turn the

drain plug to the right to drain off the water
that has collected in the drain bowl, after
switching off the dryer. (During winter
operation, if there is a possibility that the
collected water will freeze, you should do
Confirm that
this every day.) After draining off the water, water is draining
turn the plug to the left to close. out here.
Drain plug

Adjusting the Draining Interval, to reduce

the interval, turn the valve in the "+"
direction. To extend the interval, turn in the
"-" direction. Drain capacity varies
according to operating pressure and other
usage conditions. You must adjust the
draining interval in accordance with the
actual capacity. You make the adjustment by
turning the needle valve on the auto drain
trap so that the water line in the bowl is
visible from the outside. (The bowl must not
Needle valve
become filled.)
Note that if the interval is too long, the drain
will fill up. Setting the interval too short, on
the other hand, will result in unnecessary air
loss.
If silent operation is required, you can
install a muffler designed specifically for the
AD-5 drain trap, or you can replace the AD-5
with an FD-10-A float-type auto drain trap.
For more information, refer to page 29
("Option Installation Procedures") and
contact your dealer.

18
 Periodic inspection and cleaning
Weekly check and maintenance

Weekly check and maintenance

Disassemble and clean the auto drain trap
Auto drain trap
The trap should be disassembled and cleaned once a week. If the Close
trap is not cleaned regularly, it causes the trap to fail.
1. Be sure you have the following items ready.
Drain plug
Cleaning brush
Container (box) to hold the disassembled parts
Air gun
Ball valve
2. Release the pressurized air from the drain trap.
(1) Close the ball valve.
(2) Loosen the drain plug.
When you loosen the plug, the water in the bowl drain outs Filter packing
and the internal pressure is released. Filter
Cap
3. Clean the filter, disk, and other parts. Washer Disk cap
Packing Disk
(1) Turn the cap to the left, and remove it. Valve opening
(2) Use air or other means to remove dirt from the filter. O-ring
Inlet Body
(3) Clean the disk and the disk cap.
4. Clean the inside of the bowl. Silencer

(1) Turn the ring to the left, and remove it.

(2) Use air or other means to remove dirt from the screen. Nipple
Ring
(3) Wash out the bowl with water, and wipe dry with a clean cloth.
Outlet(water)
Use water only. Detergents should not be used. Screen
(4) Check for broken parts. Bowl
O-ring
Give special attention to the O-rings. Broken O-rings may Drain plug
result in air leakage.
5. Reassemble the trap.
(1) Reassemble by reversing the disassembly procedure.
Do not make a mistake in packing and washer assembly and the disc direction (a slot should be
facing down).
(2) If you find it difficult to screw on the cap, try rubbing some grease onto the upper surface of the filter
packing and onto the upper O-ring (O-ring in the Figure).
Not enough screwed part may result in malfunction. Screwing by tools may damage the screw, so
be sure to screw in by hands.

The drain should not be exposed to direct sunlight, as such exposure may damage the drain
bowl.
The following substances can damage the drain bowl. These substances should never be
present within the drain or in the atmosphere around the drain.
Organic solvents (aromatic, chloride, and hydrocarbon compounds)
- Benzene, toluene, xylene, ethylbenzen, styrene, thinner, etc. -
Sulfurous acid gas, chorine gas, CFC gas
Acids: hydrochloric acid, sulfuric acid, acetic acid, carboxylic acid, oxy acid.
Alcohols Ketones Amines Phenols

19
 Periodic inspection and cleaning
Weekly check and maintenance

In case of losing the cap by tools, when the tools are touched on angle of dodecagon, the cap
cannot be fixed since the cap may be deformed and the thread may be damaged. Do not loosen the
cap in the position of not permitting the tools use.

Position of tools

No Good Good

If the cap is not tightened enough, the disk cap moves up and down, and the disk, washer, packing
and cap may be damaged. Be sure to tighten the cap well by hands and hold down the disk cap.

Clearance Hold down

In case of removing the screen, the pipe may be damaged when you move left and right. Be sure to
pull downward to remove the screen.

Body

Pipe
Screen

20
 Periodic inspection and cleaning
Monthly check and cleaning

Monthly check and cleaning

Cleaning the condenser filter

1. How to remove the condenser filter
(1) Slide the filter upward to make it free from the lower pawl.
(2) Pull it out downward.
2. How to clean condenser filter
(1) After removing it, use a vacuum cleaner to remove dust from it.
(2) When it is soiled severely, clean it in water laced with detergent, dry
it well in the shade and set it to the original position.

Vacuum cleaner Soft sponge brush

Clean the filter with water brushing

it along the mesh.

Cleaning of condenser
Clean when it is necessary.
1. Remove the condenser filter.
2. Use a vacuum cleaner, brush, or air gun to clean the condenser.

Air gun
Condenser

Dust accumulation on the condenser may lead to reduced heat-exchange performance. Severe
accumulation may activate safety devices and cause the dryer to shut down.
Don’t clean the filter with hot water or dry it with fire.
Make sure to get the condenser filter back when you re-operate the Air Dryer. Suction of dust
and other matters may result in machine troubles.
When cleaning, be careful to avoid damage and deformation to the condenser fin.

21
 Troubleshooting
Troubleshooting table

WARNING
Be sure to release pressurized air from the heat exchanger before beginning maintenance.
Pressurized air remaining in the exchanger may blow out and cause injury.

WARNING
If the dryer behaves abnormally, press the OFF switch and then cut the main power. Then
contact your dealer or the specialist. Continuing to run the dryer while operation is abnormal
may result in fire or electric shock.
Before taking corrective action, switch off the air compressor and then cut the main power to
the air dryer. Leaving power on may result in electric shock.

Troubleshooting table
If a problem occurs during operation, refer to the following chart to locate the possible causes and solutions.

Refrigeration gas leakage

too high. Or too much air
Drain (in automatic drain

Drain (in automatic drain

Electric part is defective

Ambient temperature is

Fan motor is defective.

Air pressure is too low.

Power supply phase is

Inlet air temperature is

Condenser is clogged.
The LOCAL/REMOTE

Power is not supplied.

Cause

Fan-control pressure
Voltage is abnormal.

The power source is

is being processed.
switch to REMOTE

switch is defective.
Safety device trip.

trap) is block up.

reversed phase.
trap) is frozen.

single-phase.
Problem too high.
Power lamp (white) comes on.
Alarm lamp (red) comes on.
Operation lamp (green) does not come on.
Dryer doesn't run when you press the
Power lamp (white) comes on.
ON switch.
Operation lump (green) does not come on.
Power lamp (white) does not come on.
Operation lump (green) does not come on.
The EVAP, PRESS. is normal but water or oil
droplets are present. (The EVAP, PRESS.
gauge reading is within the green area).
The EVAP, PRESS. Is too high, and water or
oil droplets are present. (The EVAP, PRESS.
gauge reading is over the green area.)
Dryer runs, but... The EVAP, PRESS. is too low. (The EVAP,
PRESS. gauge reading is below the green
area.)
The COND. PRESS. Reading is above 2.55
MPa.
The COND. PRESS. Reading is below
1.27MPa.

The high-pressure switch was tripped.

Dryer stops suddenly during normal
operation (due to action of safety The thermal relay was tripped.
device).
The discharge thermostat was tripped.
Set LOCAL/REMOTE switch to

10%,
Regulate the condition on air
Regulate the condition on air

processed or Call dealer for

Conditioning the ambient air

or consult dealer or service

dealer or service specialist.

Disassemble and clean the

Take measures to prevent

10%, or consult

Call dealer for service.

Call dealer for service

Call dealer for service

Call dealer for service

temperature under 40
Clean the condenser.

Three-phases 200V
Change the phase.

What To Do...
Supply power.
processed.

specialist.
freezing.

service.
LOCAL.
200V

trap.

See page... 12 19 35 21 41

Refer to page 24, "Restarting the dryer after safety shutdown," for instructions on how to
resume operation following activation of one of the safety devices.

22
 Troubleshooting
Troubleshooting flow chart

The auto drain trap does not drain.

Screen is clogged. Wash inside of the bowl and the cap.

YES
Is the disk operated?

Inside of the disk is clogged. Wash inside of the bowl and the cap.

Valve opening is clogged. Wash the valve opening and the air blow.
NO

Filter is clogged. Wash the filter and the air blow.

The air and water are continuously draining from the auto drain trap.

Friction or damage of body. Replace the body.

YES Ware or damage of washer and

Replace the washer and packing.
Disk is operated.

packing.

Friction or damage of body. Replacement of disk

Friction or damage of needle

Replacement of needle valve and body.
NO valve.

Operation failure of disk. Washing of inside of the bowl and cap.

The air is leaking from the auto drain trap.

Friction and deterioration of the washer, the Replace of the washer, the packing, the
packing, the cap and the O-ring. cap and the O-ring.

23
 Troubleshooting
Restarting the dryer after safety shutdown

Restarting the dryer after safety shutdown

WARNING
If the dryer behaves abnormally, press the OFF switch and then cut the power. Then contact
your dealer or the specialist. Continuing to run the dryer while operation is abnormal may
result in fire or electric shock.
Be sure to cut the main power to the dryer before resetting any of the safety devices. Leaving
power on may result in electric shock or in injury.
Be sure to close the cabinet after resetting safety devices or taking other corrective action.
Never operate the dryer while the cabinet is open or detached. Touching the inside of the dryer
may result in injury or electric shock.

When the high-pressure switch has tripped

1. Switch off the air compressor and cut the main power off.
2. Correct the problem.
(Refer to the "Troubleshooting" section on page 22.)
3. Remove the protection cover.
4. Press the high-pressure switch RESET button. (See Fig. 1.)
5. Put the cabinet back in place.
6. Resume power supply to the air dryer.
7. Press the ON switch on the control panel. (See Fig. 2)

(Fig.1) (Fig.2)

24
 Troubleshooting
Restarting the dryer after safety shutdown

When the thermal relay was tripped

1. Switch off the air compressor and cut the power to the air dryer.
2. Correct the problem.
(Refer to the "Troubleshooting" section on page 22.)
3. Remove the lower right cabinet on the front.
Procedure for removing the lower right cabinet
(1) Remove the two screws holding the cabinet to the base.
(2) Hold up the bottom of the cabinet, and pull forward to 1 2
move the panel.
(Adapting a hooking method)

4. Press the thermal relay's RESET button. (See Fig. 3.)

5. Put the cabinet back in place.
6. Resume power supply to the air dryer.
7. Press the ON switch on the dryer's control panel. (See Fig. 2.)

Thermal relay for the fan motor

(RESET button)

Thermal relay for the compressor

(RESET button)

(Fig. 3.)

The unit have two thermal relays: one for the fan motor, and the other for the compressor. Each
of these relays has its RESET button. Make sure that you press the button for the thermal relay
that has been tripped.

When the discharge thermostat was tripped

1. Switch off the air compressor and cut the power to the air dryer.
2. Call dealer for service.

25
 Storing the dryer (for long-term storage)

1. Cut off the power.

Switch off the main power breaker.

Switch off

2. Evacuate the water from the auto drain trap.

Loosen the drain plug to evacuate the water collected in the drain.

Drain out the water.

3. Store the dryer.

Do not store the dryer where is exposed to dirt, rain, snow, water, etc.

4. When ready to resume use...

Before resuming use, please inspect the entire dryer carefully. Then set up for operation in
accordance with the instructions given in page 10 of this manual.

26
 Consumables and replacement parts
AD-5 (Standard accessory)

Consumable parts and replacement parts

In regard to parts mentioned below, replace them if worn, torn, or damaged when cleaning.
Disk, Packing, Washer, O-ring, Filter
Standard of the periodic replacement
Replacement
Part number Part name Unit Remark Period judgment
standard
Pressure switch
1 0A001099010 1 RAX240F every 2 yr. Abnormal
(for fan control)
2 Filter 1 every 1.5 yr.
3 Packing 1 every 6 mo. to 1 yr.
4 Washer 1 every 6 mo. to 1 yr.
AD-5 Friction or
5 See below Disk 1 every 1 to 1.5 yr.
(Parts) damage
6 Cap 1
every 4 to 5 yr.
7 Body 1
8 O-ring 1 every 1.5 yr.
Take the replacement time as a guideline, because it depends on use conditions (ambient
temperature, installation environment, etc.).

No. Part Part No.

1 Body ass'y 04032157010
2 Cap 04009368010
3 Disk 04080758010
4 Disk cap 04009370010
5 Filter 04009371010
6 Filter packing 04009372010
7 Ring 04009373010
8 Bowl 04009374010
9 Bowl guard 04009375010
10 Lock nut 04009376010
11 Needle valve 04009377010
12 Drain plug 04009378010
13 Nipple 04009381010
14 Screen ass'y 04009383010
15 Street elbow 50000904110
16 O-ring 35155641000
17 O-ring 35155004000
18 O-ring 35154500000
19 Silencer 04009380010
20 Packing 04090331010
21 Washer 04090332010
22 Muffler ass'y 03006716010
Muffler assembly is an extra-cost option.
Please order parts with part names, part No. and number to be ordered.
Part structures and specifications are subject to change for reformation without prior notice.
Replacement period will change depending on the installation environment.
Replacement period is accelerated when much oil is not contained in drain.

27
 Maintenance period of main parts
Guideline of hours of use for which parts need to be replaced depending on use conditions

Guideline of hours of use for which parts need to be replaced depending on use conditions
Part number Part name Quantity / unit Maintenance period
1 0A000162010 Refrigerating compressor 1
20,000 Hours
2 0A004083000 Fan assy. 1
Since maintenance period depends on installation environment etc., the replacement of the main
parts is no always required according to the hours of use. Replace and repair them if a failure occurs.

28
 Option installation
Muffler ass'y for the AD-5 auto drain trap / FD-10-A auto drain trap

Option
No. Part Pieces Part No. Remarks
1 Muffler ass'y 1 03006716010 For AD-5
2 Auto drain trap 1 FD-10-A Float type

Muffler ass'y for the AD-5 auto drain trap

1. Release the pressurized air from the drain trap.
(1) Close the ball valve.
(2) Loosen the drain plug.
When you loosen the plug, the water in the bowl drain outs and the internal pressure is released.
2. Remove the street elbow.
(1) Remove the elbow, and then remove the silencer and nipple from the elbow.
3. Install the muffler.
(1) Connect the "IN" side of the muffler to the drain outlet.
(2) Connect the silencer and nipple to the "OUT" side of the muffler.
The illustration at right shows the appearance after the muffler has been installed.

AD-5
Close Street elbow Muffler

Silencer

Nipple
Silencer
Drain plug
Nipple
Ball Valve

FD-10-A auto drain trap

1. Release the pressurized air from the existing (AD-5) drain trap.
Ball Valve FD-10-A
(1) Close the ball valve.
(2) Loosen the drain plug.
When you loosen the plug, the water in the bowl drain outs and the
internal pressure is released.
2. Remove the AD-5 drain trap. Wind sealing
3. Install the FD-10-A drain trap. tape here.
(1) Wrap pipe sealing tape around the end of ball-valve (2 or 3 winds).
(2) Install the FD-10-A.
(3) Confirm that there is no air leakage.
(Fastening of the ring to FD-10-A must be done by your hands.
Fastening by the tool such as wrench may give an excessive force and the ring will not come off.)

Follow the instruction manual which come with a replaced drain trap.

29
 Installation Guide

Contents

Essential safety precautions .............................................. 31

Carrying in ......................................................................... 33

Installation ......................................................................... 34

Specifications ..................................................................... 45

External dimansions .......................................................... 46

Wiring ................................................................................ 47

To prevent trouble by the corrosion.................................... 48

30
 Essential safety precautions
Installation precautions (WARNINGS)

WARNINGS
Failure to observe the instructions contained in a WARNING may result in death or severe injury.

Do not modify this machine.

Improper modification of internal wiring or piping may lead to electric shock or fire.

Do not install in areas where flammable gas leaks may occur.

Presence of flammable gas around this equipment may result in fire.
Do not install in areas where water may splash or pour onto the unit.
Presence of water on the unit may result in electric shock or fire.
Do not install in an atmosphere where corrosive gas, organic solvent, or chemical
solution may exist, or do not install in a place where these materials may adhere.
Install in these places may corrode the Air Dryer, and it may result in electric shock or
fire.
Do not change the settings of safety devices.
Changing the safety settings may lead to equipment damage or fire.
Be sure to install this machine in accordance with the instructions given in this
manual.
Improper installation may lead to water leakage, electric shock, or fire.
Do not ground from the dryer when you carry out electric welding for piping work.
Also do not weld while the piping connected.
Grounding from the dryer at the time of electric welding may result in malfunction of
electric parts, etc.
Installation should be carried out by your dealer or by a specialized installation
engineer.
Improper installation may lead to water leakage, electric shock, or fire.
Electrical work should be carried out in accordance with the information given in
this manual.
Use dedicated circuitry only. Improper workmanship or insufficient electrical capacity
may result in electric shock, fire, or other hazard.
Be sure to use specified cables.
Fasten cables to terminals such that the connection area is isolated from external
forces. Improper connection or poorly fastened cables may lead to electric shock or
fire.
Be sure to provide proper ground connection.
Do not connect earth cable to gas or water pipes, lightning rods, etc. Improper
grounding may lead to electrical shock.

31
 Essential Safety Precautions
Installation Precautions (CAUTIONS)

CAUTIONS
Failure to observe the instructions contained in a CAUTION may result in injury or physical damage.
Do not sit on, lean on, or place objects on this equipment.
Overturning of equipment may result in damage or injury.

Be sure that the installation site is sufficiently strong to bear the full weight of
this machine.
The dryer must be set up level, and must secured into place so that it cannot be
accidentally overturned. Improper installation may lead to injury from water leakage
or overturning of the machine.
An appropriate leakage breaker must be installed.
Failure to install a breaker may result in electric shock.
Be sure that drain piping is correctly installed and in good working order.
Water leaks caused by improper draining may cause property damage.

32
 Carrying in
Preparation / Carrying in to the Installation site

Preparation
After unpacking the dryer, check the name plate to make sure that you have received the system that
you ordered. And check the accessories too. (See page 36)
Also confirm that the unit has not suffered any shipping-relating damage. If there is any difficulty,
please contact your dealer.

Name plate

Carrying in to the installation site

The unit is heavy load. Caution when you carry.
Mass
RAX240F
Mass (kg) 555

1. The base of the unit includes forklift slots. If lifting with a forklift, insert the forks so that they reach all
the way to the opposite side of the unit.
2. The slots can be used for lifting using wire.

Supporting frame

Top of the forks

Keep the unit upright when carry it. Transporting the unit on its side (or upside down) may
result in damage.
Do not lift the unit by applying wires to the inlet and outlet pipes.
Otherwise, it may result in damage.

33
 Installation
Installation site

WARNING
Installation should be carried out by your dealer or by a specialized installation engineer.
Installing this unit on your own may result in air leakage, electric shock, or fire.

Installation site

WARNING
Do not install in areas in areas where flammable gas leaks may occur. Presence of flammable
gas around this machine may result in fire.
Do not install where directly exposed to elements. Penetration of water into the dryer may
result in electric shock or fire.
Do not install in an atmosphere where corrosive gas, organic solvent, or chemical solution may
exist, or do not install in a place where these materials may adhere. Install in these places may
corrode the Air Dryer, and it may result in electric shock or fire.

WARNING
Flooring under the dryer must be level, stable, and strong enough to support the full weight of
the dryer. The unit must be installed level, and should be fastened in place (with anchor bolts,
etc.) to prevent accidental overturning. Improper installation may lead to injury from water
leakage or overturning.

34
 Installation
Installation site

1. Provide some space around the air dryer to keep

good ventilation and for maintenance space. If it is 200
not possible, you may install it so that the right side
comes close to the wall.
When the sufficient space is not available above the
dryer, provide a ventilating fan in the vicinity to
circulate fresh air in.
60
60
60

2. Do not install where unit will be exposed to direct

sunlight or heat.
Such exposure may reduce the ability of the
condenser to exhaust heat, and performance
decrement of the dryer.

3. Ambient temperature should be between 2 and

40 .
If using the device under ambient temperatures
below 2 , install an antifreeze belt around the drain
trap and piping to prevent freezing of drain water. 40
(See illustration at right. Antifreeze belts are
commercially available.) 2
Ambient temperatures above 40 can impede heat
release from the condenser, resulting in
If ambient temperature
safety-device activation and equipment shutdown. If may fall below 2 ,
install antifreeze belt
you need to install the unit in an area where ambient (commercially
available) around
temperature may exceed 40 , set up ductwork as drain trap and pipes.

necessary to supply outside air directly to the air

intake area on the cabinet, or construct an outdoor
exhaust port to carry exhaust air (warm air) outside
the building. Be sure that the design does not result
in a drop in the fan airflow.

4. Do not install in a dusty location.

Dust accumulation on the condenser may degrade the
unit's performance.

35
 Installation
Attaching accessories / Piping work

Attaching accessories

Accessories
Auto drain trap AD-5 1 unit
Ball valve 1/2B 1 unit
Drain Analysis Set 0A004641000 1 unit (Refer to P47)

Mounting the drain trap

Install the ball valve and the drain trap in the drain
pipe with label on the dryer side.
After the installation, be sure to open the ball valve.

Rear Accessories

Open Be sure to install that the

auto drain trap discharge
Drain pipe port comes to below.

Ball valve

Auto drain trap

When you tighten the accessories too much, contact port screw part or parts may deform, and
it may cause damage it.

Piping work
Pipe diameters for air-inlet and air-outlet connections h
The dimensions of the flange of this unit are shown in the
table below. (Material: SUS304)
t

c
D

Dimensions Nominal
External diameter
Flange external Dimensions of
Bolt holes Nominal
size
of applicable
diameter flange parts
Bolt thread
pipe ( ) Diameter of size
Model A B D( ) t Quantity Diameter h( )
Center c( )
RAX240F 100 4 114.3 210 18 175 8 19 M16

36
 Installation
Piping work

Pipe connection method

1. Note the position of the inlet and outlet.
Look see the sticker that air inlet and air outlet.

2. Adjust the air pipe at assembly.

When using an existing pipe, adjust the height of the air-drying by inserting spacer below the dryer
base.
3. If possible, do not arrange the pipe above the air outlet.
If you have to arrange it there, leave the space (500mm high) there for installing a duct or for
maintenance of the fan motor.
Close
4. If possible, do not allow rise in the piping Bypass valve
from the air compressor to the air dryer. Secure a sufficient space
If you cannot avoid a rise, install a valve or (more than500 mm)
drain trap so that water can escape. Airflow direction
(See Fig. 2.) Open
Open

5. Install a bypass valve (bypass circuit)

(Fig.1)
between the dryer's air inlet and air
outlet.
(See Fig. 1.) If pipe route includes a rise

(Fig. 2) Install a valve or drain trap.

6. Arrange the piping so that pipe weight and vibration do not impact directly on the air dryer.
7. If installing piping outdoors in a cold-climate, wrap heat-insulating material around outdoor section of
the piping.
If condensation forms around the dryer's outlet pipe, you should also wrap heat-insulating material
around this pipe (even if the pipe is indoors).

37
 Installation
Piping work

Drain piping method

1. Connect to the piping
Once it carries out air opening, discharge drain piping of the auto drain trap. If it pipes directly, drain
may not be discharged due to backpressure.

<Incorrect piping example>

Pipe after carrying out
air opening. Not air opening
Use the piping Piping bore diameter is small. / Piping is long.
bore diameter that Drain is gathered.
is bigger enough.

Piping outlet is inside the drain.

Support or Support or
fixing bracket fixing bracket

2. Connect to a vinyl hose.

<Incorrect piping example>
Long connection hose

Drain is gathered.
Connection Hose band
hose

Connection hose outlet is inside the drain.

Be sure to correctly identify the inlet and outlet sides when making the connection. Setting up
the connection backwards will not only impede performance but may also result in equipment
failure.
If you use multiple dryer units in parallel, set up the piping so that the compressor supplies air
evenly to all units. Installation should be carried out by your dealer or by a specialized
installation engineer.
If piping is likely to produce considerable scaling by using an oil-free compressor, existing
piping already has considerable scaling, you should set a line filter ahead of the dryer.
Valves used within piping should be either globe valves or gate valves. If the rapid valve
open-close operation is carried out by ball valve etc., the drain water may back-flow or parts
inside the heat exchanger may be damaged.
When carrying out piping work, take adequate care to prevent entry of dirt or other foreign
matter into the air path.
In case of replacing the auto drain trap, after closing the ball valve and taking out the air
pressure inside the trap, fix the ball valve not to rotate, and tighten and screw into the trap.
In case of using the Air Dryer in high humidity environment, install the heat insulation material
or drain, because condensation occurs on the auto drain trap etc., and it may wet the floor.

38
 Installation
Piping work / Wiring work

Be sure to install the check valve in outlet part of the Air Dryer if the compressed air has a
possibility to flow back depends on the end air condition. If the back-flow is occurred without
installing the check valve, the parts inside the Air Dryer may be damaged.
In case of air blowing at the air piping construction, be sure to carry out the valve operation or
to use the bypass circuit. If there is a rapid pressure fluctuation, the parts inside the Air Dryer
may be damaged.
In case of plumbing air compressor and air dryer directly, prepare butter functions, such as a
flexible tube, so that vibration of air compressor does not transmit to air dryer directly.
Especially, the reciprocating air compressor has larger vibration.

Wiring work

WARNING
Do not change the settings of safety devices. Changing the safety settings may lead to damage
or fire.

WARNING
Do not modify. Improper modification of internal wiring or piping may lead to electric shock or
fire. Also, a modified product is excluded from the warranty.

WARNING
Electrical work should be carried out in accordance with the information given in this manual.
Use dedicated circuitry only. Improper workmanship or insufficient electrical capacity may
result in electric shock, fire, or other hazard.
Be sure to use specified cables. Fasten cables to terminals such that the connection area is
isolated from external forces. Improper connection or poorly fastened cables may lead to
electric shock or fire.

WARNING
Be sure to provide proper earth cable. Do not connect them to gas or water pipes, conductor
rods, etc. Improper setting may lead to electrical shock.

CAUTION
An appropriate leakage breaker must be installed. Failure to install a breaker may result in
electric shock.

This dryer must be connected to an industrial power supply. (If you connect to secondary side
of inverter may result in machine failure.)

39
 Installation
Wiring work

Remove the cabinet

Before doing wiring work you must remove the lower right
cabinet on the front.
1. Remove the two screws holding the cabinet to the base.
2. Hold up the bottom of the cabinet, and pull forward to move
the panel.
1 2
(Adapting a hooking method)

Electrical wiring
1. Refer to the below table and select the power supply code.
Model RAX240F
Three phase, 200 10% (50/60),
Power source (V/Hz)
220 10% (60)
Max. electric current (A) 28.0
Breaker capacity (A) 40
Earth cable (mm2) 2.0 or more

2. Install an overload leakage breaker (overload-protect

function plus current leakage function). The breaker must
be dedicated to the dryer. (Use high-speed type with 30mA
current sensitivity.)
3. Connect up the power cord.
Connect the cord wires to terminals R, S, and T on the
distributing board's terminal block.
4. Power-Cord Arrangement
(1) Pass the power cord through the power-cord opening
on the rear plate.
The opening on the rear plate is for a power-conduit
connection.
Model Conduit Ground
RAX240F E51
The rear plate offers two cord openings. You can use
one of these for the power cord. (The other is
available for remote-control cable, etc.)
(2) Arrange the cord internally and attach to heat-insulated
pipes such that the cord cannot come into contact with
internal components. Do not attach the cord to exposed
copper pipes, as these get hot during operation.

Power-cord
opening

Fastening band

40
 Installation
Wiring work

(3) Be sure that cord is not too tight. If using a power-cord conduit, be sure to take into account the
possibility of condensation dripping down onto the cord.
(4) If using a power-cord conduit, add support midway along the conduit so that the conduit will not
weigh on the cabinet.
5. Connect to ground.
A qualified electrician must set up ground connection. The ground line must be connected to the
ground terminal. The line diameter must be at least 2mm2.
6. Power voltage should remain within 10% of the rated value while the dryer is operating.
7. The dryer uses 3-phase power. You should confirm that the phase is not inverted. (See directly below.)

Check the Phase.

If the dryer does not operate when you press the ON switch, it is possible that this relay has
been tripped.
To correct the problem, first cut off the power. Then proceed to reverse the position of any two
of the three power wires on the primary side. This will correct the phase.
Note that you should never try to defeat this protection by pressing on the electromagnetic
contactor so as to force the unit to run. Also note that the wire change must be made at the
primary side only, and not at the secondary side.
Note: Driving the compressor in reverse will cause it to break.

Secondary
side
R S T R S T

Primary
Reverse side
R and T

Power line

Refer to page 10 for information about how to start up the dryer.

41
 Installation
Set up to use remote operation, alarm signal and running signal

Set up to use remote operation, alarm signal and running signal

WARNING
Since there is voltage over the terminal block, be sure to turn off the main power supply before
carrying out the wiring work.

The dryer includes remote-control terminals and signal terminals (non-voltage).

Connect up the terminals as required.
Wiring for remote control
1. Remove the jumper line connecting terminals 2 and 3.
<terminal block>
Remove the jumper line
2. Connect the remote OFF switch to terminals 2 and 3.

3. Connect the remote ON switch to terminals 4 and 5.

Remote ON switch
Remote OFF switch
Wiring for alarm signal
Connect to terminals 12 and 13.

Wiring for running signal Alarm signal

Connect to terminals 15 and 16.

Running signal

Prepare the momentary type (no-voltage) for remote switch. If the alternate type is used, the
protective device may not activate and the Air Dryer may result in malfunction.
Operation method
Momentary Alternate
ON, when pressing the switch one time and keeping the
Self-return operation makes ON while pressing the switch, operation condition until it is cancelled by pressing the
and it makes instantly OFF when detaching the switch. switch again.
(Press ON, Press OFF)
If you select remote operation, you will not be able to switch the dryer ON locally (by pressing
the dryer's ON switch). But it is always possible to turn the dryer off by pressing the dryer's
OFF switch.
Refer to the wiring diagram when setting up the wiring (The diagram is affixed to the back of
the lower right cabinet on the front.)

42
 Installation
Important information regarding indoor installation ventilation

Important information regarding indoor installation ventilation

If the ambient temperature rises above 40°C, heat dissipation will be reduced and the built in safety
system may shut down the dryer.
Figure 1 shows the amount of heat emitted from the dryer cooling ventilation exhaust ports.
If it can be assumed that the ambient temperature where the dryer is installed could rise to over 40°C,
a system of forced ventilation will be necessary.
Figure 1
Item Model RAX240F
Power frequency 50Hz 60Hz
Exhaust heat output (kW) 18.3 21.5
Exhaust air output (m3/min) 115 138

Exhaust heat output (kW

1. Overall ventilation Density of air (1.2kg/m3
Calculate the overall room ventilation requirements using the : Specific heat capacity of air
formula below: (0.0002794kW/kg )
Room temperature ( )
H Outside temperature or temperature
Amount of air to be ventilated of ducted in cooling air ( )
( /min Cp (t2 t1) 60

This calculation shows the minimum suggested ventilation required. Be sure to also consider other
sources of heat (from sunlight etc.) and increase the amount of ventilation accordingly.

2. Area around the dryer

If ducting for cooling is employed, be sure the ducting does not block the air flow from the dryer fan.
If a fan for forced air ventilation is to be installed at the outlet of the duct near the dryer, make sure
there is at least a 200 mm space between the duct opening and the dryer to avoid freezing of the
dryer's internal heat exchanger.
In order to facilitate fan motor maintenance, ducting should be constructed such that it is removable
when necessary. (Minimum required maintenance access space above dryer: 500 mm.)

Ventilation outlet

Removable portion
of duct
500 over

200

Gap between duct

inlet and top of dryer

43
 Installation
Important information regarding indoor installation ventilation

Ducting design – please take the following into consideration.

Duct cross section
(1) Extending the duct up
Minimum cross section area (m2) B×W 0.4
Maximum length (m) 10

(2) Installation of rectangular duct elbow sections

In addition to the cross section notes above, ensure that the length of Lx and Ly are below 2m
(refer to Figure 1.)

Straight rectangular elbow Curved rectangular elbow

Figure 1. Examples of rectangular duct elbow sections

If Lx or Ly must be over 2m, the gap between the duct inlet and the dryer should be 20cm and the
outlet of the vent must be fitted with an electric exhaust fan.
Recommended fan EF-50FTB3 (Mitsubishi Electric)
Minimum airflow requirement (m3/min) 138
Important: Neither Lx nor Ly should be longer than 5 m. (See Figure 2.)

The duct illustration in this figure is just one example.

The direction of the ducting from the dryer, to the left,
right, front or back, makes no difference as long as Duct
the above guidelines are followed.

Figure 2.
Installation when Lx or Ly duct sections
are longer than 2m.

Dryer

Keep obstacles, such as walls and other things that would collect duct exhaust grime, at least
2 m away from the duct exhaust port. Not doing so will impede air flow, preventing sufficient
cooling, and possibly cause the built in safety device to automatically shut down the dryer.
If the duct is attached directly to the dryer, ensure that the duct is also supported in other
places in order to prevent it from falling down.

44
 Specifications

Model RAX240F
Air processing capacity (50/60Hz) m3/min 38/45
Specified conditions

processing capacity

Inlet air pressure

for Above air

MPa 0.69
(Gauge pressure)
Inlet air temperature 40
Pressure dew point of outlet air 10
Ambient temperature 32
Applicable gas Compressed air
Conditions on

Inlet air temperature 5 to 60

application

Ambient temperature 2 to 40
Applicable air pressure
MPa 0.29 to 0.98
(Gauge pressure)
Overall dimensions (Height Depth Width) mm 1583×905×1969
Mass kg 555
Air inlet/outlet pipe connection B A 4 100 Flange joint
Electric power source (50/60Hz) V Three-phase.200/200,220
characteristics

Power consumption (50/60Hz) kW 4.6/5.7,5.6

Electric

Electric current (50/60Hz) 17.9/19.2,19.1

A
Power capacity kVA 9.7
Compressor kW 3.75
Condenser Fin and tube forced air cooled
Heat exchanger Stainless steel shell & Cross-wave fin type
Equipment

Refrigerant controller Capillary tube system

details

Capacity controller Capacity control valve

Refrigerant R-407C
Auto drain trap Disk type
Fan motor for condenser W 500 750
Over current relay
Protective devices

Compressor Opposite phase relay

Crank case heater
High pressure switch
Refrigeration circuit Fan control pressure switch
Discharge thermostat
Fan motor Overcurrent relay
Front panel (right), base : N3.0
Paint color Munsell No.
Others : 7.5Y7.5/0.5
Remarks
1. This air dryer is designed for indoor use.
2. The air processing capacity is converted to a value at atmospheric pressure, 32 , and 75%RH based
on ANR.
3. The performance test is conducted with a substitute load. (Low-pressure air)

45
External dimensions

(Units: mm)

46
Wiring

47
 To prevent trouble by the corrosion

Trouble by the product corrosion

The trouble by the corrosion is out of a guarantee.
This dryer has the copper plumbing for refrigerant gas fitting, the heat exchanger inside plumbing. When
this copper pipe corrodes, and a hole opens, refrigerant gas leaks it and reaches driving inability and
reaches in particular the trouble that water appears in the compressed air exit side of the air dryer. In
addition, there is a threat that it is connected for a problem in the security such as the electric leakage
accident and the trouble that it is it when copper use is held as conductive materials such as electric
wirings and corrodes it.
Therefore, it is important to avoid environment with the causticity for copper to prevent trouble by the
corrosion. When dew condensation and drying are repeated, and there is a corrosive ingredient, the
copper plumbing in the heat exchanger in particular is concentrated at the copper plumbing surface, and
there is corrosion in the situation that is easy to be promoted. The attention that is enough for not only
the setting environment of the air dryer but also the inhalation air of the air compressor is necessary.

Setting environmental matters that require attention

The consideration of the setting place is necessary so that there is the case that a material with the
possibility to promote corrosion such as NOx (nitrogen oxide), SOx (sulfur oxide), the CO2 (carbon
dioxide) is included in during factory exhaust, and an air dryer and an air compressor are not affected by
the factory exhaust. When corrosive is used in a factory, the attention that is enough so that there is not
influence of the corrosive ingredient is particularly necessary for an air dryer and the setting environment
of the air compressor. In addition, attention is necessary in there being a case to cause the corrosion
(formicary-shaped corrosion) of the copper pipe when a chlorine-based organic solvent
(trichloroethylene), aldehyde and alcohol (form aldehyde or the ethanol of the use medicine occurring
from building materials) are inhaled in an air dryer as a rare example, and it is made hydrolysis.

Corrosive material example

Among medicine for the copper pipe-resistant-related data, causticity shows high material example (1)
as follows.
It is aniline, aniline dye, ammonia (wet), sulfur (fusion), ammonium chloride, zinc chloride, hydrochloric
salt (hydrochloric acid), ferric chloride, copper chloride, chlorine (wet), a sodium peroxide, chromic acid,
iron acetate solution, Potassium cyanide, sodium cyanide, hydrocyanic acid, sodium hypochlorite, a
hydrobromic acid, nitric acid, ammonium nitrate, cupric nitrate, silversalt, mercury, mercurial salt, lime
sulfur, sodium thiosulfate, Nichrome acid potassium (the acidity), Nichrome acid sodium, hydrofluoric
acid, hydrogen sulfide (wet), sulfuration sodium, barium sulfate, ammonium sulfate, ferric sulfate.

(1) It is an example, and the ingredient mentioned above is not the thing which showed copper
corrosion environmental all.

48
 To prevent trouble by the corrosion

Drain Water Quality Management

Corrosive substances in the dryer drain water can lead to corrosion of the piping in the heat exchanger
as well as lead to possible leakage of refrigerant. In order to estimate the drain water quality, after
having performed a test run, or at some set interval, use the included Drain Analysis Set to perform a
water quality check on drain water taken from the auto drain trap. The drain measurement set can test
for 5 water components: pH, chloride ion, nitrate ion ,sulfite ion, and ammonium ion. For instructions
on how to perform the test, please refer to the directions included in the test package. After opening
the test package, keep the contents in a cool dark place, away from high temperatures and high
humidity.

Potential corrosive outbreaks indicated by drain chemical components

Because of variations in individual installation environments, it is impossible to name every possible
case. In the event that corrosive components are detected, one should consider either an outbreak or
advancement of the indicated corrosion and impliment measures to reduce the presence of such
components. In addition, periodic water analysis testing should be performed. If additional information
is required, please consult with your dealer.

Drain examination of water record

Measurement day pH chloride Nitric acid Sulfurous acid Ammonia

49
memo
memo
memo
 Product Warranty
This product shall be warranted as follows. For warranty repairs, please contact the dealer where the product was sold after confirming the product model and
serial number.
1. Warranty Period
(1) Refrigerant circuits Two years from the date of purchase, or 10,000 operating hours, whichever comes first.
(2) Others One year from the date of purchase.
What Is Covered by this Warranty
(1) If breakdown occurs within the above warranty period and the cause of the breakdown lies with ORION, then the damaged part(s) will be
replaced or repaired by ORION free of charge. Note that depending on the country/region where the product is being used, repairs may take
more time or be impossible. Please consult with your dealer in advance regarding service and repair options for products to be operated
outside of Japan.
(2) In principal, the owner of the product will confirm diagnosis of the breakdown according to the operating manual. However, there might be cases
where this work may be carried out instead by a member of ORION's service network. In such cases, there will be no charge where the cause
of the breakdown lies with ORION.
(3) Note that even during the warranty period, there will be costs incurred by the user (outside the warranty) in the following cases:
Breakdown resulting from operating under unsuitable operating conditions, environment, handling, use, or method of operation outside those
written in the specifications or operating manual of the product, or as a result of carelessness or negligence on the part of the user.
Breakdown resulting from non-ORION products (user's own equipment or software design, etc.).
Breakdown resulting from repairs or modifications conducted by non-ORION designated contractors.
Breakdown which could be recognized as being avoidable in cases where an ORION product is used in conjunction with the user's equipment
where the user's equipment is legally regulated to have a safety device whereby inclusion of the safety device could have averted breakdown,
or in cases where the addition of function, structure, etc., could have, according to common knowledge of the industry, averted breakdown.
Any breakdown which is recognized as being avoidable had normal fixed term inspections, and/or normal maintenance and replacement of
consumables, been performed as indicated in the operating manual, etc.
Replacement of consumables (parts to be replaced at fixed terms or based on inspection).
Breakdown due to external factors beyond human control such as fire etc., or breakdown resulting from natural disaster such as earthquake,
lightning, storm and flood damage, etc.
Breakdown due to reasons unforeseeable due to the technological standard at the time the product was shipped from ORION.
Any breakdown resulting from corrosion caused by operating the product in an atmosphere that contains corrosive gases, organic solvents,
chemical solutions, etc., or in an environment where such substances could come into contact with the product.
(4) In cases where a separate contract, etc. has been established, that contract will take priority.
3. Warranty Obligation Exclusions
Regardless of the warranty period, compensation for any of the following will not fall under the obligations of this warranty: any hindrance or
accident compensation resulting from reasons not under ORION's obligations; any lost opportunities, lost profit, secondary losses, damages to
non-ORION products incurred by users resulting from the breakdown of ORION products; and any replacement work, readjustment of on-site
machinery and equipment, and operating work by users.
4.Product Use Limitations
(1) When using ORION products in connection with important facilities, be sure to establish backup and/or failsafe measures so that even in the
event of breakdown of such products, such breakdown will not lead to serious accidents or losses.
(2) ORION products are designed and produced as general purpose equipment to be used in general industrial applications. Therefore, this
warranty will not apply when used in the following applications: However, in cases where the customer/user takes full responsibility and
confirms the performance of the product in advance, and takes necessary safety precautions, please consult with ORION and we will consider if
use of the product in the desired application is appropriate.
Atomic energy, aviation, aerospace, railway works, shipping, vehicles (cars and trucks), medical applications, transportation applications,
and/or any applications where it might have a great effect on human life or property.
Electricity, gas, or water supply systems, etc. where high levels of reliability and safety are demanded.
K No.3589 2019.2.26 C TG KH