TS10 - TS3000

Installation, Operating

&
Maintenance Manual

Thermo Star

TS50 - TS3000
refrigeration dryer
DATE: September 2001
S/N: DR 10010001
APDD 762B
Warnings
Important:
Keep this manual with the machine throughout its entire service life.
Carefully read this manual before carrying out any operation on the machine.
This machine is designed for PROFESSIONAL USE only. Only use the machine for
the purpose for which it is intended. Improper use of the machine absolves the
manufacturer from all liability. This manual has been compiled to help the final user
perfrom just those operations which do not require removal of the panels.
All other operations which involve the removal of covers from instruments or electrical
circuit-breakers using special tools must only be carried out by trained personnel due
to the danger of rotating parts or live components.
Each machine is equipped with an electric disconnect device which allows the
operator to work on the machine in absolute safety. This device must always be used
to disconnect the mains supply to avoid any risk of danger during maintenance work
(electric shocks, scalding, automatic start-up, moving parts and remote control).
Before servicing the dryer always make sure the compressed air circuit is depressurized.
The key provided to remove the panels must be kept by the head of maintenance.
When requesting technical assistance or ordering spare parts, always quote the model and
serial number on the identification plate mounted externally on the unit.
IMPORTANT: This manual is subject to modification. For the most comprehensive and upto-date information, the user is therefore required to consult the manual supplied with the
machine.
INDEX
1
1.1
1.2
1.3
1.4
1.5
2
2.1
2.2
3
3.1
3.2
3.3
3.4
3.5
3.6
3.7
4
4.1
4.2
4.3
4.4
5
6
7
Figure 1
Figure 2
Figure 3
Figure 3A
Figure 3B
Figure 4
Figure 4A
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Introduction
Foreword
Packaging
Transport
Storage
Inspection
Installation
Installation drawing
Condensate drain connection
Start-up and operation
Electronic control
Preliminary checks
Starting the dryer
Stopping the dryer
Sound pressure level
Air and refrigeration circuit diagram
Operation
Maintenance
Preventive maintenance
Disassembling the unit
Refrigerant leaks in the refrigeration circuit
Refrigerant charging
Calibration
Spare parts list
Troubleshooting
Installation
Decal location
Parts lists and locations
Sheet Metal Parts List
Spare Parts list
Overall dimensions
Weights
Condensate drain connections
Refrigerant diagram
Calibration chart
Electrical diagram
Electrical Parts List
2
See enclosures for figure references
Introduction
1.1
Foreword
The TS dryers are designed to guarantee high quality compressed air and
minimum maintenance.
You must carefully read this manual to obtain maximum performance
from your dryer and ensure its correct installation and start-up in compliance with manufacturer instructions.
1.2
Packaging
The dryer is packaged with a strong cardboard box strapped to a wooden
pallet. On two sides of the boxing there are printed all of the instruction
symbols (UNI ISO 780) for the movement, transporting and stocking of
the product.
1.3
Transport
Keep the unit in an upright position and do not install outside.
Use a forklift truck to move the machine.
Care should be taken to avoid damaging internal components
through poor handling during movement, installation or use.
Unpack the machine as close as possible to the installation site.
1.4
Storage
If stored the packaged units must be kept inside, protected from humidity,
direct light and rain.
1.5
Inspection
On receipt of the machine, make sure it has incurred no damage during
transit. If any damage is detected, contact the freight carrier
immediately.
Installation
(see Fig. 1)
a) Do not install the dryer outdoors even if protected by a roof. Never
expose the dryer to temperatures below 41 F (5 C) or above 104F (40C).
b) The compressed air inlet timperature must never exceed 122F (50C).
For different temperature values to those indicated above, consult the
manufacturer.
c) For models TS50-TS200 only: to avoid drawing in dust, position the
dryer at least 12 inches (30cm) above the floor using a suitable block-mount.
d) Allow for a 60 inches (1.5 meters) gap around the unit to facilitate
mainenance and ensure unimpeded air discharge from the condenser.
For models TS700-TS2800 only: leave a space of at least 80 inches (2
meters) above aircooled machines.
e) For most compressed air applications we recommend following the
installation plan shown. This layout ensures optimum compressor, filter and
dryer performance and also guarantees excellent air quality while minimizing
operating costs. Do not obstruct the dryer air grills.
f) Avoid recirculation of hot condenser air back onto the condenser air inlet.
g)
If the system is prone to instantaneous pressure surges which exceed

the dryers rated capacity, mount a suitable sized receiver near the
overpressure source. For more precise information, contact the manufacturer or distributor.
h) It is obligatory to install a 1 micron filter on the dryer intake
a side to prevent rust, scale or other pollutants from entering the
system and clogging the condensate drain and heat exchangers,
thereby causing severe pressure drops. This filter must be close
to the dryer inlet.
i) On water cooled units we recommend installing a filter on inlet side
to prevent the ingress of debris that will gradually choke the
passages, with negative effects on machine performance levels.
j)
Cooling water hardness should not exceed 25 d fr = 14
! dH = 18 Clark. If water is harder in your area, consult the
manufacturer.
Condenser cooling water pressure:
minimum = 43.5 psig (3 barg)
maximum = 145 psig ( 10 barg)
For different pressure settings contact the manufacturer.
k) Always install a bypass line and shut-off valves to permit maintenance
or calibration without interrupting the compressed air flow to the user.
l) Correctly connect the dryer to the air inlet and outlet connections. If the
compressed air network is prone to vibrations, use braided hoses to
make the connections. If the main air lines are subject to high levels of
pulsation, ensure that the connections are equipped with pulsation
dampeners.
m) Do not connect condensate drains common to other pressurized drain
lines in a closed circuit. Make sure the outflow from the condensate
drains is unimpeded. The condensate pipe must be connected in such a
way that the specified sound pressure level is not exceeded during
draining. (see para. 3.5).
n) The ambient air around the dryer and compressor must not contain solid
or gaseous contaminants. All compressed and condensed gases can
generate acids or chemical products which may damage the compressor or components inside the dryer. Take particular care with sulphur,
ammonia, chlorine and installations in marine environments. For further
advice or assistance consult the manufacturer.
o) Power supply connection (see Fig. 8):

Model
TS50-TS100
TS150-TS325
TS400-TS3000
Standard
115V(+ 10%) 1~60Hz
230V(+ 10%) 1~60Hz
460V(+ 10%) 3~60Hz
For models TS50-TS150 a power cable type 3xAWG16 SJT is supplied,

complete with NEMA 5-15P plug.
Substitution of power cable (see Fig. 3)
Check that the dryer is completely isolated electrically and that the dryers
main switch is in the OFF position.
Disconnect the power cable from the terminal block in the following order: live
and neutral (L,N) and then the ground connection .
Remove the cable grommet (39) and extract the power cable (24).
Insert the new cable from the rear of the dryer and into the electrical panel as
indicated in the drawing. Connect the ground cable and the live and neutral
cables (L,N) and insert the cable grommet (39).
For modesl TS150-TS3000 use a cable that complies with regulations in force
in the country of installation (connected to terminals L and N for
single-phase machines and to terminals L1-L2-L3-GND for three-phase
machines), connected to the junction box, with minimum wire sizes: (see
machine electrical schematic in Fig. 8).
Install, upstream from the plant, a residual current circuit

breaker IDn = 0.3A with a 3 mm gap between contacts when open.
TT-type power supply system with grounded electric control panel
terminal .
4
2.1
Installation drawing (see Fig. 4)
2.2
1)
Condensate drain connection (see Fig. 5)

Connect elbow (W) to connection (X) (both supplied with dryer) and
connect these to drain point (Z) on the dryer.
Connect the drain (Y) to elbow (W) and connect the power plug (V) to
the drain (U).
For models TS1200-TS3000 an elecronic level sensing condensate
drain is already installed and cabled.
Any maintenance operation must be done by an expert technician.
2)
3 Start-up and operation

3.1
Electronic control (models TS250-TS3000)
3.1.1 Introduction
These dryers are equipped with an electronic control mounted on the front
of the machine. The front panel (synoptic panel) is covered with a transparent polycarbonate film which illustrates the refrigeration circuit and relative
functions (screen printed). The electronic control is located at the top of this
panel.
3.1.2 Front Panel
Press for 2 seconds to reset the alarm or warning

signal once the cause of the alarm has been
eliminated. This is also used for the functions:
TEMPERATURE SCALE SELECTION, CLEAR
REPORT, SETTING LAST SERVICE DATE, and
for reading the compressor HOURS COUNTER.
All operations are controlled and displayed on the electronic control front panel:
This is used to access the STATUS REPORT.
LEDs
ALARM
red LED illuminated
one or more alarms tripped
WARNING
flashing red LED
one or more warning signals

tripped
off remote (yellow)
REMOTE OFF
yellow LED illuminated
dryer switched off by remote

control
on (green)
ON
green LED illuminated
dryer running
line (yellow)
LINE
yellow LED illuminated
dryer powered up
alarm (red)
Display
When powered up the display indicates the unit of measure (C or F) for
the temperature shown.
During operation the display indicates the dew point temperature (T0).
When the dryer enters alarm status, the display indicates the relative alarm
code.
In STATUS REPORT mode, the display indicates the most recent dryer
status events.
In the case of high dew point conditions, the temperature reading and Hd
warning code are displayed alternately.
In the case of low dew point conditions, the temperature reading and Ld
alarm code are displayed alternately.
3.1.3 Operation
Starting and stopping
When the dryer is powered up (yellow line LED illuminated) the unit may be
started and stopped using the on/off button. Start-up is deferred by a 6second time delay during which the green on LED flashes.
Keypad
Dryer on/off button.
This button is used when the dryer is not in operation for the
following functions:
SETTING THE LAST SERVICE DATE, inserting the time for
MAINTAIN COLD MASS and for reading the STATUS
REPORT.
Remote On/Off
The unit may be switched on and off using a remote switch installed by the
customer (the electronic control must be switched on for the remote control
to operate). The unit switches on/off in accordance with the make/break
status of the remote contract (see terminals 6-R4, 230V, 60 Hz)
Open = unit OFF
Closed = unit ON
The remote control is enabled by pressing the remote ON button.
6
If the dryer is switched off using the on/off button on the electronic control the unit
STOPS (irrespective of the remote signal).
Remote control warning/alarm contact (energized)
3.1.4
Alarms and warnings
HP - High pressure alarm

If the high pressure switch trips the compressor stops and the alarm message HP is
displayed. Once the cause of the alarm has been eliminated press the reset button to
clear the alarm.
The digital warning/alarm output of the remote control operates as follows:

Contact Status
closed (energized)
open (de-energized)
alternately open/closed
no alarm
alarm (dryer stationary)
warning (dryer running)
Options exclusively for remote control

The control unit also provides a MAINTAIN COLD MASS function. This function
consists in causing the compressor to run for a time defined by preset ON and OFF
events. The various intervals are defined as follows:
tC
compressor disconnect delay time following opening of the REMOTE
OFF contact.
tA
compressor OFF time.
tb
compressor ON time.
To select the time intervals, proceed as follows:
Hold down the ON-OFF button and switch on the main disconnect switch.
Press the ON-OFF button to enter the times setup function; the display will show the
letters CC.
a)
Press RESET to set interval tA (alarm LED flashes); compressor OFF time
minutes will be displayed; press RESET to set the required number of minutes.
to advance to interval tb (remote off LED flashes): press RESET
to set the required number of minutes.
LP - Low pressure alarm

If when dryer is running the pressure falls below the setpoint the compressor stops
and the alarm message LP is displayed. This alarm is provided with a 3 minute delay
prior to tripping and reset automatically.
ST - High temperature alarm
If the high temperature thermostat trips, the compressor stops and the alarm message
ST is displayed. Once the cause of the alarm has been eliminated, press the reset
button to clear the alarm.
Ld - Low dew point temperature alarm
If, when the dryer is running, the temperature falls below 28F (-2C), the low dew
point temperature alarm is tripped after a 3 minute delay causing the compressor to
stop. The alarm message Ld and temperature reading are displayed alternately. This
alarm is reset when the temperature rises above the 32F (0C) threshold.
PI - Compressor internal protection alarm
When the compressor motor overheats, this internal thermal protection device
intervenes to stop the (scroll) compressor to avoid burn out. (The device automatically
resets once it has cooled down.)
Hd - High dew point temperature warning
If, when the dryer is running, the temperature exceeds 59F (15C), the high dew point
temperature warning alarm is tripped after a 3 minute delay. The compressor continues running and the warning message Hd and temperature reading are displayed
alternately. THIS ALARM RESETS AUTOMATICALLY WHEN THE TEMPERATURE
RETURNS BELOW 55F (13C).
b)
Press
c)
Press
to advance to interval tC (on LED flashes); press RESET to set the
AS - Temperature sensor fault warning
required number of minutes.
Press
to store your settings. You can now start the dryer by pressing ON-OFF. If
the tC register is set to zero, the MAINTAIN COLD MASS function is not available.
FS - Full -scale warning

This warning indicates that the temperature reading exceeds the screen display limits.
Below 10F (-9C) or above 99F (37C)
This warning indicates that temperature sensor T0 is faulty (open or short circuited).
The compressor continues running but alarm Ld and warning Hd are disabled so that
the dryer can operate in safety - i.e. with pressure switch HP and thermostat ST
operational.
EP - Eprom error
This alarm message indicates that the Eprom memory is faulty. All operations are
disabled and the control unit enters alarm status.
THE ELECTRONIC CONTROL MUST BE REPLACED
Er - Activation error
If the on/off button is pressed when the control unit is in remote off status
(yellow LED illuminated) the error message Er is displayed for 2 seconds.
ALARM trip/reset sequence
3.1.5 General functions

REPORT and HOUR COUNTER MANAGEMENT (USER AREA)
N.B.: The REPORT/HOUR COUNTER option is only enabled when the unit is
in STAND-BY (line LED illuminated).
Press the REPORT key and hold it down for 6 seconds to access the USER
area.
a)
Press the ON-OFF button to access the REPORT option and display the
last 8 alarms and/or warnings generated.
Access to this option is confirmed by the code rE (REPORT) on the
display.
-Press the key to scroll through the last 8 events in chronological order:
1 ---last event --2 ---penultimate event --3 ----------------------------8 --- eighth event ---
b)Press the RESET button to skip the Report page and enter the HOUR
COUNTER function. The unit can record up to 99,999 operating hours. The
counter is advanced at 20 minute intervals. Current operating hours are displayed
in three pages at intervals of 2 seconds.
- First page:
displays THOUSANDS; the red alarm LED
flashes at the same time
- Second page:
displays HUNDREDS; the yellow remote off
LED flashes at the same time
- Third page:
displays TENS; the green on LED flashes at the
same time.
The combination of the three pages gives the total machine operating hours.
To exit the HOUR COUNTER function press the RESET button again.
8
TEMPERATURE SCALE SELECTION (MANUFACTURER AREA)
This unit can display temperatures in Celsius or Fahrenheit.
d)
a) Switch on the main disconnect switch while holding down the ON-OFF
button.
b) The display will present the code CF.
c) Press RESET to select the required unit of measure.
d) Switch Off and switch On the control unit to store the selected unit of
measure.
e)
f)
g)
h)
SETTING THE LAST SERVICE DATE (MAINTENANCE AREA)
i)
so that the yellow power on LED on the control panel illuminates

(models TS250-TS3000) or the line lamp (models TS100-TS200).
Wait about 5 minutes until the dryer is running at the correct
operating temperatures and pressures.
Slowly open the air inlet valve to pressurize the dryer.
Open the outlet valve. The dryer is now operating (drying).
Always leave the dryer running while the air compressor is operating.
For Models TS50-TS200 only: after stopping the dryer, wait at
least
3 minutes before starting it again.
!
!
Switch On the main disconnect switch while holding down the RESET button:
this action opens the CLEAR REPORT function. Entry to the function is confirmed by code CL on the display.
Press RESET to enter the SET LAST SERVICE DATE function. The display will
show the letters AA to indicate the year, while the red Alarm LED flashes.
Press the
key to display the letters MM for the month, while the yellow
remote OFF LED flashes.
Press
again to display the letters GG for the date; the green ON LED will
flash.
Press the ON-OFF button to quit this function.
3.2
a)
b)
c)
3.3
a)
b)
c)
3.4
a)
b)
Stopping the dryer

Use the switch or off button to stop the dryer.
Stop the dryer 2 minutes after shutting down the air compressor or
interrupting the air flow to the dryer.
Compressed air must never enter the dryer when the compressor
! is not running.
3.5
Sound pressure level

The sound pressure level recorded for these dryers 1 meter from the
machine in free field condistions is less than 70 db (A).
3.6
Air and refrigeration circuit diagram (see Fig. 6)
3.7
Operation
The dryer operates automatically. It is factory set for a dew point
of 38F (3C) (ISO 7183, Part 2) and therefore requires no further
calibration.
Do not exceed the machines design limits, bypass excess air flow and
check the unit model and/or installation.
For maximum performance from your dryer, follow the maintenance
schedule described in Chapter 4.
Preliminary checks
Before starting up the dryer, make sure:

The air inlet valves are closed and that there is no air flow through the
dryer.
The main power supply is commensurate with the dryer voltage.
The dryer is installed in compliance with the installation instructions given
in Chapter 2.
Starting the dryer
Use the switch or on button to start the dryer.
Always start up the dryer before activating the air compressor.
For models TS100-TS3000 only: set the main disconnect switch QS to ON
For Models TS250-TS3000 only: on units with three - phase

scroll compressors fitted, it is highly important to check the
direction of rotation of the compressors. If supplied with the
wrong phase frequency they will turn in the opposite
direction. In this case they are very noisy and risk getting
damaged. SWAP OVER THE PHASES IMMEDIATELYY. Check
that the (LP) gauge pressure on the front of the panel
decreases.
Maintenance
Before accessing live electrical parts, disconnect the power supply to

the dryer using disconnect switch QS or disconnect the cable connections.
SAFETY DEVICES
SK
installed on modelsTS50-TS2000
ST
installed on models TS50-TS3000
HP
LP
PI
installed on models TS2000TS3000
COMPRESSOR TYPE
PISTON
compressor on models TS50-TS100 (single phase)
ROTARY compressor on models TS150-TS200 (single phase)
SCROLL compressor on models TS250-TS3000 (three phase / single
phase)
4.1 Preventative maintenance
For optimum performance from your dryer follow the periodic maintenance
schedule described below.
WEEKLY
CONDENATE DRAIN
Make sure the condensate drains correctly and, if necessary, disassemble and clean the filters, solenoid valves and condesate drain and
check the electrical circuit.
MONTHLY
COMPRESSOR
Make sure the compressor head temperature is between 59F (15C)
and 131F (55C) when running. If this is not the case, consult section 7,
troubleshooting.
EVERY 4
MONTHS
YEARLY
CONDENSER
Remove any dust from the condenser fins.
COMPRESSOR
Make sure compressor power consumption complies with data plate
specifications.
4.2 Disassembling the unit

The machine has been designed and constructed to guarantee continuous
operation. The long service life of some components such as the fan and
compressor depends on good maintenance. The unit must only be disassembled by a refrigerant specialist. Refrigerant liquid and lubricating oil
inside the refrigeration circuit must be recovered in compliance with current
standards in the machine destination country.
RECYCLING
DISASSEMBLY
frame and panels
steel/epoxy resin polyester
heat exchanger (cooler)
aluminum
pipes
copper/aluminum
drainage system
brass/PC
heat exchanger insulation
EPS (polystyrene sintered)
pipe insulation
gum synthetic
compressor
steel/copper/aluminum/oil
condenser
steel/copper/aluminum
refrigerant
R407C (HFC)
valve
brass
electrical cable
copper/PVC
CONDENSATE DRAIN
Completely disassemble the drain and clean all its components.
The electric control panel is equipped with terminals for the connection of a remote alarm.
Do not use solvents to clan the control panel on the front of the unit.
10
4.3
Refrigerant leaks in the refrigeration circuit
FOREWORD
This unit is delivered in perfect working order already charged as specified in
the table shown in Fig. 4.
Refrigerant leaks may be identified by tripping of compressor overload
protector (SK/PI) or safety thermostat (ST).
IF A LEAK IS DETECTED IN THE REFRIGERANT CIRCUIT SEEK TECHNICAL ASSISTANCE.
4.4
Refrigerant charging (see Fig. 4)
THIS OPERATION MUST ONLY BE PERFORMED BY A REFRIGERANT
SPECIALIST.
WHEN REPAIRING THE REFRIGERANT CIRCUIT, COLLECT ALL THE
REFRIGERANT IN A CONTAINER AND DISPOSE OF IN THE APPROPRIATE MANNER.
Characteristics of refrigerant R407
In normal temperature and pressure conditions, the refrigerant is a colorless,
class A1/A1 gas with TVL value of 1000ppm (ASHRAE classification).
If a refrigerant leak occurs, thoroughly air out the room before commencing
work.
Calibration
The dryer is supplied factory set with the values shown in the table illustrated
in Fig. 7 and therefore requires no further calibration.
Spare parts list
(see Fig. 3B)
This spare parts list contains most of the parts available. When ordering spare
parts always quote the quantity, part code and machine serial number.
Troubleshooting
The following diagram lists the various problems which may occur during the dryers service life. In
the case of serious difficulties, contact a refrigerant specialist.
NOTE: Always bypass the dryer when it is out of service.
11
12
Fig. 1 Installation
compressor
bypass
(recommended)
receiver
bypass
(recommended)
filter (1 micron)
bypass
(recommended)
filter (0.01 micron)

to compressed air ring
main
TS
drainage network
Description of labels attached to the dryer (see Fig. 2)
13
14
Description of labels attached to the dryer (see Fig. 2)
DECAL SHEET NUMBER 54625918
15
16
Fig. 2 Decal location (TS50-TS200)
Fig. 2 Decal location (TS250-TS500)

3
17
18
Fig. 2 Decal Location (TS700-TS3000) aircooled
Fig. 2 Decal Location (TS700-TS3000) watercooled
19
20
PARTS INDEX
A. timed solenoid drain
1.
MC
compressor
2.
refrigerant condenser
3.
EVI-2 fan motor
4.
evaporator
5.
separator
6.
insulation
7.
expansion capillary
8.
refrigerant filter
9.
hot gas valve
10.
air-air heat exchanger
11.
dew point thermometer
12.
PV
fan pressure switch
13.
HL
on lamp (green)
14.
QS
main disconnector switch
15.
HP
high pressure switch
16.
ST
high temperature thermostat
17.
low pressure manometer
18.
compressor valve
19.
HLA alarm lamp (red)
21.
C1-Cs compressor starting capacitor
21a. C-Cr compressor run capacitor
22.
C2
fan motor run capacitor
24.
power cable
25.
thermometer sensor pocket
26.
LP
low pressure switch (not applicable)
27.
28.
29.
30.
30a.
31.
32.
33.
35.
36.
37.
38.
39.
40.
T0.
SK
KM
TH1
FU1
FU4-5
FU6-7
KA
KA1
KA2
QF
(B)
QF1
QF2
KM2
KM1
TC1
gas charge point (location only)

water pressostatic valve
high pressure tap (location only)
general automatic switch
fan motor automatic switch
fan motor contactor
compressor motor contactor
auxiliary transformer
power cable inlet (location only)
remote control cable entry point (location only)
electronic control
temperature sensor NTC
cable grommet
liquid separator
dew point temperature sensor
overload protector
compressor relay
fan motor thermal protection
electronic control fuse
auxiliary transformer fuses
auxiliary fuse
starting relay
high pressure alarm relay
general alarm - warning relay
residual current circuit - breaker (by installer)
remove bridge if remote on-off is installed
NOTES:
21
22
Fig. 3 Part List & Location (TS50-TS200)
31
DESCRIPTION
PART NUMBERS
A. timed soleniod drain

1. compressor
2. refrigerant condenser
3. fan motor
4. evaporator
5. separator
6. insulation
7. expansion capillary
8. refrigerant filter
9. hot gas valve
10. air-air heat exchanger
11. dew point thermometer
12. fan pressure switch
13. main switch (TS50-TS75) or
on lamp (green) (TS100-TS200)
14. main switch (TS100-TS200)
15. high pressure switch (TS50-TS200)
16. high temperature thermostat
19. alarm lamp (red) TS50-TS200
21. compressor starting capacitor
(TS50-TS100)
21a. compressor run capacitor
(TS100-TS200)
22. fan motor run capacitor
(TS100-TS200)
24. power cable
25. thermometer sensor pocket
30. cable grommet
31. foot mount (Qty. 4)
evaporator o-ring, small
evaporator o-ring, large
rotalock, small
rotalock, large
- - - - - - = Not Applicable
50
42512095
*
*
*
*
*
38027421
54640628
92451236
38003901
*
89236145
38003968
89236079
----------89240857
38004024
38027801
22075303
75
42512095
*
*
*
*
*
38027421
54640636
92451236
38003901
*
89236145
38003968
89236079
----------89240857
38004024
38027801
22075303
100
42512095
*
*
*
*
*
38027438
54640644
89234272
38003901
*
89236145
38003968
------
150
42512103
*
*
*
*
*
38027439
54640651
89234272
38003919
*
89236145
38003968
------
200
42512103
*
*
*
*
*
38027447
54640669
89234272
38003919
*
89236145
38003968
------
38003976
89240857
38004024
38027801
22075311
38003976
89240857
38004024
38027801
------
38003976
89240857
38004024
38027801
------
------
------
22075311
38027579
38027561
------
------
38027785
38027777
38027777
38027819
38027454
54668116
38013876
38007738
-----54669148
38027587
38027819
38027454
54668116
38013876
38007738
-----54669148
38027587
38027819
38027454
54668116
38013876
38007738
38027504
54669148
38027587
38027819
38027454
54668116
38013876
38007738
38027504
54669148
38027587
38027819
38027454
54668116
-----38007738
38007746
54669148
38027587
* - See Fig 3B on Page 33 for part numbers
23
24
Fig. 3 Parts List and Location (TS250-TS500)
Location Only
Location Only
DESCRIPTION
PART NUMBERS

1. compressor
3. fan motor
4. evaporator
5. separator
6. insulation
9. hot gas valve
14. main switch
15. high pressure switch
17. low pressure manometer
30. general automatic switch
30A. fan motor automatic switch
31. fan motor contractor
32. compressor motor contactor
33. auxiliary transformer
37. electronic control/temperature sensor
evaporator o-ring, small
evaporator o-ring, large
rotalock, small
rotalock, large
# - See Electrical Parts List Fig 9
250
42512103
*
*
*
*
*
38027397
54640685
89234280
38003927
*
38003968
38003984
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38007738
38027504
54669148
38027587
325
42512103
*
*
*
*
*
38027397
54640685
89234280
38003927
*
38003968
38003984
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38007738
38027504
54669148
38027587
400
42512103
*
*
*
*
*
38007763
54640719(2)
89234280
38003927
*
38003968
38003984
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38007738
38027504
-----38027587
500
42512103
*
*
*
*
*
38027413
54640719(2)
89234280
38003927
*
38003968
38003984
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38007738
38027504
-----3802758
* - See Fig 3B on Page 33 for part numbers
25
26
Fig. 3 Parts List and Location (TS700-TS1400)
Location Only
Location Only
PART NUMBERS
DESCRIPTION

1. compressor
3. fan motor
4. evaporator
5. separator
6. insulation
7. expansion capillaries
7E. expansion capillaries
9. hot gas valve
14. main switch
40. liquid separator
evaporation o-ring, small
evaporation o-ring, large
rotalock, small
rotalock, large
700
42512103
*
*
*
*
*
38027397
54640743
54641071
89241699
38003935
*
38003968
38003992
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38027512
38007738
38007746
54669148
38027587
800
42512103
*
*
*
*
*
38007753
1000
42512103
*
*
*
*
*
38027413
1200
42512103
*
*
*
*
*
38027413
1400
----*
*
*
*
*
38007753
54640750
54641097
89241699
38003935
*
38003968
38003992
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38027512
38007738
38007746
54669148
38027587
54640768
54641105
54640776
54641113
89241699
38003935
*
38003968
38003992
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38027620
38007738
38007746
54669148
38027587
54640776
54641113
89241699
38003935
*
38003968
38003992
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38027520
38007738
38007746
54669148
38027587
54640784
54641121
54641139
89241699
38003935
*
38003968
38003992
89240857
38004024
38004032
38027454
#
#
#
#
#
38010286
38027520
38007738
38007746
54669148
38027587
* - see Fig 3B on Page 33 for part numbers
27
28
Fig. 3 Parts List and Location (TS1650-TS3000) aircooled
Location Only
Location Only
PART NUMBERS
DESCRIPTION

1.
compressor
2.
3.
fan motor
4.
evaporator
5.
separator
6.
insulation
7.
expansion capillary
7.
expansion capillaries
7.
7.
7.
7.
8.
refrigerant filter
9.
hot gas valve
14. main switch
28 pressostatic water valve
30a. fan motor automatic switch
rotalock, small
rotalock, large
suction rotalock valve
discharge rotalock valve
1650
-----*
*
*
*
*
38007753
2000
-----*
*
*
*
*
38007753
2400
-----*
*
*
*
*
38007753
3000
-----*
*
*
*
*
38007753
54640826
54641120
54641238
54641246
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
38027454
91197343
#
#
#
#
#
38010286
38027538
38007738
38007746
54669148
38027587
38028205
54640792
54641147
54641154
54641170
54641188
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
38027454
91197368
#
#
#
#
#
38010286
38027538
38007738
38007746
54669148
38027587
91157701
38028205
54640792
54641147
54641154
54641170
54641188
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
38007454
91197368
#
#
#
#
#
38010286
38027538
38007738
38007746
54669148
38027587
91157701
38028205
54640800
54640834
54641253
54641261
54641279
54641287
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
38027454
91197368
#
#
#
#
#
38010286
38027546
38007738
38007746
54669148
38027587
---------
29
30
Fig. 3 Parts List and Location (TS1650-TS3000) Watercooled
Location Only
Location Only
DESCRIPTION
PART NUMBERS

1.
compressor
2.
3.
fan motor
4.
evaporator
5.
separator
6.
insulation
7.
expansion capillary
7.
7
7
7
7
8.
refrigerant filter
9.
hot gas valve
14. main switch
28. pressostatic water valve
rotalock, small
rotalock, large
suction rotalock valve
discharge rotalock valve
1650
-----*
*
*
*
*
38007753
2000
-----*
*
*
*
*
38007753
2400
-----*
*
*
*
*
38007753
3000
-----*
*
*
*
*
38027413
54640826
54641120
54641238
54641246
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
54640792
54641147
54641154
54641170
54641188
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
54640792
54641147
54641154
54641170
54641188
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
54640800
54640834
54641253
54641261
54641279
54641287
89241699
38003943
*
38003968
38004008
89240857
38004024
38004032
91197343
#
#
#
#
#
38010286
38027538
38007738
38007746
54669148
38027587
38028205
91197368
#
#
#
#
#
38010286
38027538
38007738
38007746
54669148
38027587
91157701
38028205
91197368
#
#
#
#
#
38010286
380227538
38007738
38007746
54669148
38027587
91157701
38028205
91197368
#
#
#
#
#
38010286
38027546
38007738
38007746
54669148
38027587
---------
31
32
Ref Nbr
Description
TS50
TS75
TS100
TS150
TS200
Enclosure, 3 sided
38010849
38010849
38013868
38013868
38013868
Ref Nbr
Description
TS250
TS325
TS400
TS500
Front panel
38027009
38027009
38027009
38027009
Rear panel
38005302
38005302
38005302
38005302
Top panel
38328019
38328019
38328019
38328019
Left side panel
38328001
38328001
38328001
38328001
Right side panel
38027017
38027017
38027017
38027017
Compressor shield
38027025
38027025
38027025
38027025
Ref Nbr
Description
TS700
TS800
TS100
TS1200
TS1400
TS1650
TS2000
TS2400
TS3000
Front panel
38027058
38027058
38027058
38027058
38027058
38027058
38027058
38027058
38027058
Rear panel
38027108
38027108
38027108
38027108
38027116
38027140
38027140
38027140
38027140
Top panel
38027033
38027033
38027033
38027033
38027033
38027132
38027132
38027132
38027132
Left side panel
38027041
38027041
38027041
38027041
38027041
38027124
38027124
38027124
38027124
Dividor panel
38019949
38019949
38019949
38019949
38019949
38019949
38019949
38019949
38019949
Condensor top panel
38027165
38027165
Air filter support angle
38027157
38027157
38027157
38027157
38027157
38027173
38027173
38027173
38027173
Right front corner
38027074
38027074
38027074
38027074
38027074
38027074
38027074
38027074
38027074
Right rear corner
38027066
38027066
38027066
38027066
38027066
38027066
38027066
38027066
38027066
10
Left front corner
38027082
38027082
38027082
38027082
38027082
38027082
38027082
38027082
38027082
11
Left rear corner
38027090
38027090
38027090
38027090
38027090
38027090
38027090
38027090
38027090
* = Item not illustrated

- = Not applicable
Locate Ref Nbr on Decal Location drawing Fig. 2.
Fig 3B Spare Parts List (see Fig. 3)

Model
1. *
50
75
38003554
1. *
100
150
38003562
38003570
38003588
38003596
200
38003604
1. *
2. (A)
250
325
400
500
89328298
38003752
38003661
89328322
1000
38003679
1200
38003687
89328830
2. (W)
3. *
800
3. *
1650
38003695
89328355
91101170
38003802
1400
2000
2400
3000
38003703
38003711
38003729
89328371
89328389
38003760
38003612
38003653
89328280
700
38003778
91111013
38003810
38003802
38003828
38003844
3. *
38003851
38003877
4. 5. 6.
10. (*)
89328488
89328496
89328504
89328512
89328520
89328538
89328512
89328520
8938538
89328520
89328538
4. 5. 6.
10. (**)
89327985
89327993
89328009
89328017
89328025
89328033
89328017
89328025
89328033
89328025
89328033
8.
92451236
9.
89234272
38003901
11.
38003919
89234280
38003927
14.
38003935
2X
38003935
38003943
89236145
12.
13.
89241699
38003968
89236079
38003976
38003984
38003992
15.
89240857
16.
38004024
17.
38004008
38004032
28.
91198341
37.
38004040
38.
89328108
Power supply 115V 1Ph ~ 60Hz

Power supply 208/230V 1 Ph ~ 60Hz
* Power supply 460V 3Ph ~ 60Hz
91197343
91197368
(*) 12 bar 175 psi (A) Air

(**) 16 bar 232 psi (W) Water
33
34
Fig. 4 Overall dimensions TS50 - TS75
NOTE: ( ) distance expressed in inches.
35
36
Fig. 4 Overall dimensions TS700 - TS1400 aircooled
37
38
Fig. 4A Weights
refrigerant / charge
R407C
weight
Model
F.L.A. (A)
air connections
(Kg)
(lb)
(Kg)
(OZ)
115V 1 ~ 60 Hz
TS50
63
139
0.66
23
8.1
TS75
63
139
0.66
23
8.1
TS100
65
143
0.66
23
10.1
TS150
66
146
0.84
30
max air pressure
208/230V 1 ~ 60Hz
1" NPT
12 bar
(175 psi)
8.5
TS175
68
150
1.00
35
TS200
70
154
1.10
39
1.5" NPT
10
39
40
Fig. 4A Weights
weight
Model
refrigerant / charge
R407C
F.L.A. (A)
F.L.A. (A)
208/230V 1 ~ 60Hz
460V 3 ~ 60Hz
(Kg)
(lb)
(Kg)
(OZ)
TS250
TS325
140
309
2.20
78
TS400
144
317
2.10
74
TS500
150
331
2.00
71
TS700
400
882
3.10 (A)
2.30 (W)
109 (A)
81 (W)
TS800
420
926
3.60 (A)
2.30 (W)
127 (A)
81 (W)
TS1000
TS1200
450
992
4.80 (A)
3.30 (W)
169 (A)
116 (W)
11.3 (A)
10.0 (W)
TS1400
470
1,036
5.50 (A)
3.30 (W)
194 (A)
116 (W)
14.6 (A)
13.3 (W)
max air
pressure
17.8
4.2
2" NPT
5.3
7.9 (A)
6.6 (W)
TS1650
550
1,213
7.00 (A)
5.00 (W)
247 (A)
176 (W)
TS2000
580
1,279
7.50 (A)
6.00 (W)
265 (A)
212 (W)
TS2400
590
1,301
10.00 (A)
6.70 (W)
353 (A)
236 (W)
23.5 (A)
20.9 (W)
TS3000
660
1,456
10.00 (A)
5.70 (W)
353 (A)
201 (W)
28.2 (A)
25.6 (W)
(A) Air (W) Water
water
air
connections connections
.75" NPT
3" NPT
12 bar
(175 psi)
1" NPT
4" ANSI
150 LBS
1.5" NPT
6" ANSI
500 LBS
20.5 (A)
17.9 (W)
Fig. 5 Condensate drain connections
only for TS50 - TS325 models
See Section 2.2 on Page 4 for reference code.
41
42
Fig. 6 Refrigerant diagram TS50 - TS200 (see Fig. 3)
1. compressor
3. fan motor
4. evaporator
5. separator
9. hot gas valve
10. air - air heat exchanger
Refrigerant R407C

1. compressor
3. fan motor
4. evaporator
5. separator
9. hot gas valve
26. low pressure switch (N.A.)
T0. dew point temperature sensor
Refrigerant R407C
43
44
1. compressor
3. fan motor
4. evaporator
5. separator
9. hot gas valve
18. compressor valve
26. low pressure switch (N.A.)
Refrigerant R407C
Fig. 6 Refrigerant diagram TS700 - TS3000 watercooled (see Fig. 3)
1. compressor
4. evaporator
5. separator
9. hot gas valve
18. compressor valve
26. low pressure switch(N.A.)
28. pressostatic water valve
Refrigerant R407C
45
46
Fig. 7 Calibration
MODEL
COMPONENT LIST
SETTING
9
Hot gas Valve
69.6 Psig (4.8 bar)

(+0.1, -0)
TS50 - TS3000
12
Fan pressure switch
START: 240.8 Psig (16.6 bar)

DIFF: 60.9 Psig (4.2 bar)
STOP: 180 Psig (12.4 bar)
TS50 - TS3000
16
High temperature
thermostat (ST)
248 F (120 C)
TS50 - TS100
TS150 - TS500
TS700 - TS3000
NOTES
Fig. 7 Calibration
COMPONENT LIST
TS50 - TS3000
TS250 - TS3000
15
High pressure switch (HP)
26
Low pressure switch (LP)
(Not Applicable)
SETTING
NOTES
STOP: 377 Psig (26 bar)


DIFF: 14.5 Psig (1 bar)
STOP: 49.3 Psig (3.4 bar)
N.B. STOP delay ~ 3 min.
TS700 - TS3000
28
Water pressostatic valve
232 Psig (16 bar) (+1, -0)
TS50 - TS3000
20
High temperature dew point
thermostat (HTD) - optional
50 F (10 C)
47
48
Fig. 8 Electrical diagram TS50 - TS75
Customer
Supplied
I-R
Supplied
Fig. 8 Electrical diagram TS100
Customer
Supplied
I-R
Supplied
49
50
Customer
Supplied
I-R
Supplied
Customer
Supplied
I-R
Supplied
to page 53
- refers to locator scale at top of page
51
52
to page 53
Customer
Supplied
I-R
Supplied

to page 54
53
54
55
56
to page 57
Customer
Supplied
I-R
Supplied

to page 58
57
58
59
60
to page 61
Customer
Supplied
I-R
Supplied

to page 62
61
62
63
64
Fig. 9 Electrical Parts List TS250 - TS5000 (See Fig. 8)
TS250-325
TS250-500
TS250 - TS500
TS250-800
TS700 - TS1400 TS1650 - TS2400
(230 1~60Hz) (230 3~60Hz) (460 3~60Hz) (230 3~60Hz)
(460 3~60Hz)
(460 3~60Hz)
TS3000
(460 3~60Hz)
REF.
Description
QS
main disconnector
switch
89242705
89242697
89242697
89242705
89242705
89242713
89242713
QF1
general automatic
switch
38017950
38017943
38017935
38017976
38017976
91110536
91110536
QF2
fan motor auto

switch
38018024
38018032
38018032
FU4 -5
auxillary
transformer fuses
38017927
38017927
38017927
38017927
FU6 - 7
auxillary fuse
38017919
38017919
38017919
38017919
38017919
38017919
38017919
TCI
auxillary
transformer
38017984
38017984
38017984
38017984
KM1
compressor motor
contactor
38018008
38018008
38018016
380017851
38017851
38017992
38017992
KM2
fan motor contactor
38018016
38018016
38018016
38018016
38018016
38018016
38018016
FU1
electronic control
fuse
38017901
38017901
38017901
38017901
38017901
38017901
38017901
KA1
high pressure alarm

relay
38017869
38017869
38017869
38017869
38017869
38017869
38017869
KA2
general alarmwarning relay
38017869
38017869
38017869
38017869
38017869
38017869
38017869

TS10 - TS3000

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TS10 - TS3000

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Installation, Operating

DATE: September 2001

If the system is prone to instantaneous pressure surges which exceed

o) Power supply connection (see Fig. 8):

For models TS50-TS150 a power cable type 3xAWG16 SJT is supplied,

Install, upstream from the plant, a residual current circuit

Installation drawing (see Fig. 4)

Condensate drain connection (see Fig. 5)

3 Start-up and operation

Electronic control (models TS250-TS3000)

3.1.2 Front Panel

Press for 2 seconds to reset the alarm or warning

This is used to access the STATUS REPORT.

one or more alarms tripped

one or more warning signals

off remote (yellow)

dryer switched off by remote

Dryer on/off button.

Alarms and warnings

HP - High pressure alarm

The digital warning/alarm output of the remote control operates as follows:

Options exclusively for remote control

LP - Low pressure alarm

FS - Full -scale warning

3.1.5 General functions

SETTING THE LAST SERVICE DATE (MAINTENANCE AREA)

so that the yellow power on LED on the control panel illuminates

Stopping the dryer

Sound pressure level

Air and refrigeration circuit diagram (see Fig. 6)

Before starting up the dryer, make sure:

For Models TS250-TS3000 only: on units with three - phase

Before accessing live electrical parts, disconnect the power supply to

4.2 Disassembling the unit

steel/epoxy resin polyester

heat exchanger (cooler)

heat exchanger insulation

EPS (polystyrene sintered)

Refrigerant leaks in the refrigeration circuit

Spare parts list

(see Fig. 3B)

filter (0.01 micron)

Description of labels attached to the dryer (see Fig. 2)

DECAL SHEET NUMBER 54625918

Fig. 2 Decal location (TS250-TS500)

Fig. 2 Decal Location (TS700-TS3000) watercooled

gas charge point (location only)

A. timed soleniod drain

* - See Fig 3B on Page 33 for part numbers

A. timed soleniod drain

# - See Electrical Parts List Fig 9

* - See Fig 3B on Page 33 for part numbers

A. timed soleniod drain

# - See Electrical Parts List Fig 9

* - see Fig 3B on Page 33 for part numbers

A. timed soleniod drain

# - See Electrical Parts List Fig 9

* - see Fig 3B on Page 33 for part numbers

A. timed soleniod drain