TTR 250 HP - Humidifier TROTEC - Free user manual and instructions

USER MANUAL TTR 250 HP TROTEC

Observe the notes in the Operating Instructions.

• The basic condition for the safe handling and trouble- free operation of this air dehumidifier is to know the basic indications and regulations applicable to safety.

• The present Operating Instructions include the most important indications required for the safe operation of the air dehumidifier.

• These Operating Instructions and especially the in- dications on safety must be observed by all persons working on the air dehumidifier.

• The rules and regulations for the prevention of acci- dents applicable on site must be observed in addition to this. Obligations of the Operator The operator has the obligation to allow work on the air dehumidifier only for persons who:

• Are well acquainted with the basic regulations on occupational safety and on the prevention of acci- dents, who have been familiarised with how to operate the air dehumidifier ; and who:

• Have read the Section on Safety and the warning notices included in these Operating Instructions, confirming by their signatures that they have under- stood these notes. The operator must check the observance of the safety regulations by the personnel on a regular basis. Obligations of the Personnel All persons who are charged with performing work on the air dehumidifier must assume the following obli- gations before taking up work:

• Observe the basic regulations on occupational safety and accident prevention.

• Read the Section on Safety and the warning notices included in these Operating Instructions, confirming by their signatures that they have understood these notes. Hazards during the Operation of the Air Dehumidifier The air dehumidifier has been manufactured according to the state of the art and the generally accepted rules of safety engineering. Use the air dehumidifier only:

• For the intended purpose; and when it is

• In a perfectly safe condition. Faults which may affect safety must be eliminated immediately. Intended Use The air dehumidifier is designed only for dehumidifying atmospheric air. Any other use or any use in addition to this shall be deemed not intended. TROTEC GmbH & Co. KG will not assume any liability for damages resulting from such unintended use. The intended use does also include:

• The observance of all indications given in the Operating Instructions ; and

• The due performance of inspection and maintenance activities.EN Operating manual – Air Dehumidifiers TTR 250 HP B - 2 Warranty and Liability Our „General Conditions of Sale and Delivery“ will be applied in principle. These Conditions will be made available to the operator by the latest when conclu- ding the contract. Claims under a warranty or under a liability for injury to persons or damage to property will be ruled out if such claims are due to one or more of the following causes:

• Misuse of the air dehumidifier;

• Inappropriate mounting, start-up, operation and main- tenance of the air dehumidifier.

• Operation with defective safety appliances, or with safety and protective devices which are not mounted adequately and orderly, or not operative;

• Non-compliance with the indications given in the Operating Instructions on the transportation, storage, mounting, start-up, operation and maintenance of the air dehumidifier;

• Unauthorised structural alterations;

• Unauthorised alteration to the technical design;

• Defective monitoring of components subject to wear and tear;

• Inexpert performance of repairs; or

• Catastrophes caused by foreign objects or force majeure. Organisational Measures

• The operator must provide the required personal pro- tection equipment.

• All existing safety appliances must be checked on a regular basis. Safety Guards

• All protective devices must be installed as appropriate and be in an operative condition before starting the air dehumidifier.

• Protective devices may only be removed when: a) The air dehumidifier is not operated; and when b) It is protected against restarting.

• The operator must install the protective devices himself in accordance with regulations if the device is supplied in individual parts. Informal Safety Measures

• The Operating Instructions must always be kept at the place where the air dehumidifier is operated.

• General and local regulations for accident prevention and environmental protection must be provided and observed in addition to the Operating Instructions.

• All notes on safety and hazards on the air dehumidifier must be kept in a legible condition. Training of Personnel

• Only trained and instructed personnel may work on the air dehumidifier.

• The responsibilities of the personnel must be defined clearly with regard to mounting, start-up, operation, maintenance and repair. Air Dehumidifier Control

• Only instructed personnel may operate the controls. Hazards Caused by Electrical Energy

• Work on the power supply may only be carried out by professional electricians.

• Check the air dehumidifier‘s electrical equipment on a regular basis. Eliminate any loose connections and damaged cables immediately.

• The switch room must always be locked. Access to this room is only allowed to authorised personnel using a tool.

• If work on voltage-carrying parts is required, a second person must be present to cut power supply if necessary in an emergency.B - 3 Operating manual – Air Dehumidifiers TTR 250 HP

Maintenance, Upkeep and Troubleshooting

• Perform prescribed setting, maintenance and inspection activities when due.

• Inform the operating personnel before starting any maintenance and upkeep work.

• Protect all installation parts and operating fluids such as vapour connected upstream and downstream of the air dehumidifier against unintentional restarting or re- closure.

• Disconnect power on the air dehumidifier and protect the main switch against unintentional reclosure before starting any maintenance, inspection or repair activity.

• Place a danger sign to prevent re-closure.

• Check loosened screw connections for solid fit.

• Check the function of safety appliances at the end of the maintenance activities. Structural Alterations to the Air Dehumidifier

• No alteration, addition or remodelling of the air de- humidifier is allowed without authorisation by the manufacturer. This also applies to welding on sup- porting members.

• All remodelling measures require the written confir- mation of TROTEC GmbH & Co. KG.

• All machine parts which are not in a perfect condition must be replaced immediately.

• Use only original spare and wearing parts.

• Third-party components do not provide any guarantee for being designed and manufactured according to the required stresses and strains while observing safety specifications. Air Dehumidifier Cleaning and Waste Disposal

• All substances and materials used must be handled and disposed off adequately. This applies especially to a) Work on the lubrication system and to b) Cleaning with solvents. Copyright The copyrights for the present Operating Instructions are held by TROTEC GmbH & Co. KG. These Operating Instructions shall only be used by the operator and his or her personnel. It includes notes and regulations which must not be - duplicated - distributed or - disclosed in another way without the authorisation of TROTEC GmbH & Co. KG. Contraventions will be prosecuted under criminal law.

02. generAL DeScrIptIOn

Utilisation Air dehumidifiers working according to the principle of adsorption are used to solve drying problems in pro- cess engineering, air conditioning and for air dehumi- dification in production and storage rooms containing products and facilities which require a particularly low air humidity. Air dehumidifiers equipped with electric heating may only be operated in rooms exposed to explosion ha- zards after having consulted the manufacturer. Adsorption technology allows lower dew points and operationally reliable dehumidification at lower air temperatures. At these points, cold dehumidifiers cannot reach this performance for physical reasons any longer. In addition, air dehumidifiers work by far more efficiently under these operating conditions. Design The air dehumidifier is equipped completely with rotor, fan, driving motor, heater for regeneration and electrical system. Air humidity is adsorbed using the silica gel rotor. Operating Principle The air dehumidifier works continuously using two air flows (between 2:1 and 3:1, approximately). The larger process airflow is dehumidified in the rotor which turnsEN Operating manual – Air Dehumidifiers TTR 250 HP B - 4 slowly (= adsorption), while the smaller regeneration airflow is heated and thus expels the water adsorbed from the silica gel again (= desorption).

Casing The air dehumidifier has a casing made of stainless steel which contains all necessary equipment. Rotor The air dehumidifier is equipped with a patented silica gel rotor. This rotor is made of flat and corrugated non-woven layers consisting of chemically bonded silica gel and metal silicate. This creates a large number of air channels running in axial direction and having both a large surface and a direct connection to the inter- nal pore structure of the silica gel. This allows a good transition of water vapour and it also makes for the extraordinarily high adsorption capacity of the silica gel rotor. The particular manufacturing process of the rotor ma- terial makes certain that the silica gel is not destroyed by saturated air. This makes it possible to operate the air dehumidifier with pre-cooling. No damage will be caused even when the heating or the regeneration airflow fails. The permanent link between the silica gel and the base material prevents the sorption material from being carried away by the airflow. No super-saturation will occur even when the rotor is not operating, thus not requiring any particular safety measures. The rotor has a high mechanical resistance and it is non-flammable. The rotor is driven by an electric mo- tor with a toothed belt transmission. Filter The filter mat is made of standard non-woven fabric. Fan The fan is driven directly by an electric motor. The dehumidifier is a continuously working device with integrated heat recovery, and it can reach very low dew points. By turning, the rotor carries the thermal energy from the hot regeneration zone to the rinsing zone, the rotor cools down while heating the entering regeneration air. As a result, process air is less hot and the dew point is lower.B - 5 Operating manual – Air Dehumidifiers TTR 250 HP

Regeneration Heating The PTC regeneration heating used has the follo- wing advantages: - Power consumption is varied easily by the air volume flow. - There is no overheating; the heating flow goes down to zero when there is no airflow. This is made possible by the PTC thermistor, i.e., by a temperature-dependent semiconductor resistor. Its resistance value increases very strongly when the temperature rises, starting at a defined tem- perature (Curie point). This positive temperature coefficient is the very origin of the PTC thermistor‘s name. In practice, this characteristic resistance curve makes for a temperature which remains al- most constant over a wide range. Variations in room temperature, voltage or in the airflow will only have a small influence on thermistor temperature. The regeneration airflow may be reduced corres- pondingly if the maximum dehumidifier capacity is not required. Heating will react immediately by a higher resistance, while maintaining the surface temperature. Thus, a smaller regeneration airflow means a lower heating capacity while maintaining the regenerati- on air at an almost constant temperature.

1. Check whether the reducing dampers (if any) are

widely open and whether the air ducts are free.

2. Are the filters mounted correctly?

3. Is the preliminary safety device selected correctly

according to the technical data?

4. Start the air dehumidifier by setting the ON/OFF

switch to „ON“. The control light in the switch shows that the device is operating.

5. Use the reducing dampers installed on the building

side to adjust the air volumes. Process and humid air volumes must always be tuned in proportion to one another. The rotor will become too hot and the capacity for dehumidification will not be used efficiently if the humid air volume is too big. The humid air volume should also be adjusted by re- duction at the outlet when the dry air volume has been adjusted. A temperature of less than 50°C should be used as a reference value at the humid air outlet. The smaller the humid air value, the lower is the hu- mid air temperature. The humid air volume may be reduced if the capacity for dehumidification is not needed. CAUTION: Clogged filters reduce the air volume.

TROTEC air dehumidifiers are designed for long ope- rating times without needing a great effort in terms of maintenance. Please observe the following notes: Disconnect the air dehumidifier from the mains before dismounting the air dehumidifier. If it has been in ope- ration before this, let the air dehumidifier cool down for about 15 minutes before dismounting. A. Filter Replacement Filters should be checked and replaced if necessary on a regular basis. The intervals between each filter replacement depend on the application of the device in the corresponding individual case. A filter life of ap- proximately 6 months may be assumed under normal conditions. Clogged filters affect filter capacity. Never operate the dehumidifier without having in- stalled the filters correctly! B. General Maintenance We recommend to check all installed components every 6 months or more frequently if required by utili- sation, and to clean the following parts using a vacu- um cleaner or compressed air under low pressure: mEN Operating manual – Air Dehumidifiers TTR 250 HP B - 6

1. Gear motor and toothed belt

5. Maintenance openings, sealings

C. Rotor Cleaning Although it is described below, the washing process should not be performed during normal maintenance. We recommend to have this work done by the TRO- TEC Service, or, at least, to call an TROTEC Service Centre before washing.

2. Disconnect the power supply (unplug the mains

connector) to prevent the device from being switched on unintentionally. Injuries which are dangerous to life may occur otherwise.

3. Dismount the rotor carefully and make certain that

the surfaces are not damaged in this process.

4. Place the rotor in a bath for approximately 30 minutes,

adding a weakly acid detergent or toluol.

5. Flush the rotor using fresh water under low pressure.

6. Drain the liquid from the rotor and blow the structure

of the rotor free using compressed air under low pressure.

7. Mount rotor and toothed belt carefully.

8. Make certain that all sealings are correctly in place.

9. Start the dehumidifier without including it in the

process and measure its capacity after approxi- mately 30 minutes. Never use strongly alkaline detergents as they may lead to the complete deterioration of the rotor.

It is easy to check the dehumidifier function by taking the temperature at the uninsulated air tubes. Under normal conditions: - the dry air outlet is warm (25 - 40 °C) and - the humid air outlet is warm or hot (30 - 50 °C). You can proceed as follows if the capacity for dehumi- dification is not satisfactory: A. Dry and humid air outlets are warm A1. Check entering humidity and compare with data sheet. The capacity of the device may be too low to cope with existing conditions. A2. Check air flows, filters and reducing damper adjustment. A3. Check rotor sealings. B. Both air outlets are cold. B1. Is the device switched on? B2. Has it broken down because of a fault? B3. Check the regeneration heater. B4. Check the fan. B5. Check whether the reducing damper in the rege- neration channel is not closed. B6. Check the air filter. C. The dry air outlet is cold and the humid air outlet is very hot C1. Check whether the rotor is turning. C2. Check whether the reducing damper in the process channel is not closed.C - 1 Mode d’emploi – Déshumidificateurs d’Air TTR 250 HP

05. SERVICE OG VEDLIKEHOLD

GmbH & Co. KG Grebbener Straße 7 D-52525 Heinsberg hereby declares that due to their construction and design the following dehumidifiers, including those products introduced into the market by us, comply with the EU guidelines and directives as stated below. Important information: This declaration is no longer legally valid if the unit is not used, installed or maintained as inten- ded or when any unauthorised changes are made to the unit. Type of unit: Dehumidifier Series/Model: TTR 160, 250, 250 HP, 300, 700 Applicable regulations: Applied norms: 89/392/EWG 73/23/EWG Machine guideline Low voltage guideline DIN EN 292: Sicherheit von Maschinen, Geräten und Anlagen DIN EN 60 204.1: elektrische Ausrüstung für IndustriemaschinenDéclaration de conformité de la CE Heinsberg, le 21 février 2009 Chef de produit TROTEC