Installation and operating

manual
Refrigeration Dryer Series RDP 20 – 2600

Please read the instructions carefully before installation or use. The proper and safe operation of
the refrigeration air dryer is ensured only by following the recommendations and conditions
stated in the instructions.
20221128

For additional questions, contact the manufacturer and inform him of the information on the data
plate found on the front of the dryer.
3403165 - MANUAL for RDP 20-2600 - OMEGA AIR_EN_v1.5_23_01_30.docx
 Dear customer!

Thank you for purchasing our product. In order for the product to serve well and reliably, please read
these installation and operating instructions carefully.

In order to avoid misuse of equipment and potential hazards for the operator, please read thoroughly
and strictly follow the instructions contained in this installation and operating manual.

Before packing and shipping, each unit of the RDP refrigeration air dryers is subjected to rigorous tests
to ensure that the factory defects are removed and all the functions of the device for which it was
designed checked.

After correctly installing the unit in accordance with the instructions in this manual, it will be ready for
use without the need for additional settings. The operation is fully automated, and maintenance is
limited to a few checks and cleanings, as shown in the continuation of this manual.

These instructions must always be present at the unit and be available for the entire operating life
of the device. The instructions are considered as an integral part of each refrigeration air dryer.

This manual provides the user, installer and maintenance technician with all the technical information
needed to install, operate and perform routine maintenance work to ensure long service life. If spare
parts are required, they must be original. Requests for SPARE PARTS and any information relating to
the unit must be sent to the distributor or to the nearest service canter, indicating the MODEL and
SERIAL NUMBER located on the data plate of the device.

Due to uninterrupted technical development, we reserve the right to introduce the necessary changes
without prior notice. If you need further explanation or clarification, contact the manufacturer or
distributor of the device.

2
Table of Contents
1 GENERAL INFORMATION ............................................................................................................................... 4
1.1 DEVICE INFORMATION ........................................................................................................................................ 4
1.2 INFORMATION ON THE SUPPLIER ........................................................................................................................... 4
1.3 BASIC .............................................................................................................................................................. 5
1.4 REFRIGERATION AIR DRYERS ................................................................................................................................. 5
1.5 PROPER USE ..................................................................................................................................................... 5
2 SAFETY INSTRUCTIONS .................................................................................................................................. 6
3 TECHNICAL SPECIFICATIONS .......................................................................................................................... 8
3.1 COMPONENTS................................................................................................................................................... 8
3.2 SPECIFICATIONS ................................................................................................................................................. 8
4 REFRIGERATION AIR DRYER OPERATION ..................................................................................................... 11
5 REFRIGERATION AIR DRYER COMPONENTS ................................................................................................. 12
5.1 COMPRESSOR ................................................................................................................................................. 12
5.2 CONDENSER ................................................................................................................................................... 12
5.3. HEAT EXCHANGER 3IN1 ................................................................................................................................... 12
5.4 CONTROLLER RDC 2 ........................................................................................................................................ 13
5.4.1 ELECTRIC SCHEME RDC 2 ............................................................................................................................... 14
5.4.2 RDC 2 PARAMETERS ..................................................................................................................................... 15
5.4.3 RDC 2 MODBUS COMMUNICATION ............................................................................................................... 17
5.5 EXPANSION VALVES .......................................................................................................................................... 18
5.6 ELECTRONIC CONDENSATE DRAIN ........................................................................................................................ 18
5.7 SAFETY FUNCTIONS .......................................................................................................................................... 21
5.7.1 LOW/HIGH - PRESSURE SWITCH ....................................................................................................................... 21
5.7.2 SAFETY FUNCTIONS OF RDC 2 ......................................................................................................................... 22
5.8 FILTER / DEHYDRATOR ...................................................................................................................................... 22
5.9 CAPILLARY TUBE .............................................................................................................................................. 22
5.10 PRESSURE SWITCH ......................................................................................................................................... 23
6 EFFICIENCY .................................................................................................................................................. 23
7 TRANSPORT ................................................................................................................................................. 23
8 STORAGE ..................................................................................................................................................... 24
9 INSTALLATION ............................................................................................................................................. 24
9.1 GENERAL REQUIREMENTS FOR INSTALLATION ........................................................................................................ 24
9.2 INSTALLATION POSITIONING ............................................................................................................................... 26
9.3 INSTALLATION PROCEDURE ................................................................................................................................ 27
10 START-UP .................................................................................................................................................. 28
10.1 BEFORE START-UP .......................................................................................................................................... 28
10.2 START-UP..................................................................................................................................................... 28
11 REMOVE FROM USE .................................................................................................................................. 29
12 MAINTENANCE .......................................................................................................................................... 29
13 TROUBLESHOOTING TECHNICAL PROBLEMS .............................................................................................. 30
14 SPARE PARTS ............................................................................................................................................. 32
15 WARRANTY ............................................................................................................................................... 33
16 MAINTENANCE NOTEBOOKS ..................................................................................................................... 34
17 DRAWINGS OF RDP REFRIGERATION AIR DRYERS ...................................................................................... 36
18 ELECTRO SCHEMES OF RDP REFRIGERATION AIR DRYER ............................................................................ 42

3
 1 General information

1.1 Device information

Model of refrigeration air dryer:

Serial number:

Year of manufacture:

Date of installation:

Please fill in the fields carefully. Correct data enables proper and efficient maintenance of the device,
selection of suitable spare parts and technical support.

1.2 Information on the supplier

Name:

Address:

Phone / Fax:

e-mail:

4
1.3 Basic

Compressed air contains contaminants such as water, oil and particles. Impurities need to be removed
or their concentration reduced to an acceptable level according to the requirements of the application.
The ISO 8573-1 standard specifies the purity / quality of the air for contaminants. The humidity (water
vapor content) can be expressed in terms of Pressure Dew Point (PDP). Dew point is the temperature
at which the air is 100% saturated with moisture. When the air temperature falls below the dew point,
moisture condenses. Reduction of moisture content to the point of dew point +3°C can be achieved by
refrigeration air dryers.

1.4 Refrigeration air dryers

Refrigeration air dryers are the best choice in all standard applications, where pressure dew point 3 °C
suffices. Examples of such applications are process air in the processing industry (pneumatic
equipment, wood industry, paint shop, chemical industry, pharmacy, etc.).

1.5 Proper use

⚠ RDP refrigeration air dryers are designed for efficient and quality preparation of dry compressed
air. This device must only be used for the purposes for which it was designed. All other uses of the
device are considered incorrect.

⚠ The manufacturer is not liable under any circumstances for damage resulting from improper,
incorrect or unreasonable use of the device.

⚠ Only use genuine spare parts. Warranty or Reclamation cannot be claimed for damage or
malfunction of the device caused by the use of non-original parts.

5
 2 Safety instructions

⚠ Improper use of the compressed air system and electrical installations can lead to injury or death.

⚠ Improper handling (transport, installation, use, maintenance) of a refrigeration air dryer can lead
to serious injury or death. The result of improper use may be damage to the device and/or reduced
efficiency of the dryer.

⚠ When operating the dryer, you must follow all relevant safety and accident prevention instructions,
all regulations and instructions for use. The RDP refrigeration air dryer was developed in accordance
with the generally recognized rules of engineering practice.

⚠ Ensure that the installation complies with local legislation.

⚠ The user or operator of the refrigeration air dryer must be familiar with the installation,
commissioning and operation of the appliance.

⚠ All safety information is intended to ensure your personal safety. If you do not have experience
with such systems, contact the manufacturer or local supplier for technical assistance.

⚠ Before working on the dryer, ensure that the dryer is vented and not under pressure (this also
includes the closest components of the installation in front and behind the dryer) and that the dryer
is not connected to an electrical source.

⚠ Do not exceed the maximum operating pressure or operating temperature (information on the
data label).

⚠ The permissible operating temperatures and working pressures for the accessories of the
adsorption dryer are given in the technical documentation of this accessory. The maximum
temperature and pressure of the assembled system is the lowest maximum temperature or pressure
of any individual part of the system.

⚠ Ensure that the refrigeration air dryer is not subject to vibrations that can cause fatigue and
cracking of material.

⚠ Ensure that the fluctuation of the power supply voltage is below ±10% of the rated voltage.
Voltage fluctuations can cause damage to the device and/or reduced efficiency of the dryer.

⚠ The refrigeration air dryer must not be subjected to mechanical stress.

⚠ All installation and maintenance work on the refrigeration air dryer can only be carried out by a
qualified and experienced specialist.

⚠ It is forbidden to make any changes to the refrigeration air dryer.

⚠ Vent the refrigeration air dryer system before performing any kind of installation or maintenance
work.

6
⚠ Ensure that the refrigeration air dryer is installed in accordance with specifications and without
mechanical loads.

⚠ Only use genuine spare parts.

⚠ Only use refrigeration air dryers for intended purpose.

⚠ When transporting the dryer, check and follow the local regulations for lifting and transporting
heavy objects.

⚠ In the event of fire, do not use extinguishing water on the dryer and nearby objects.

⚠ Wear suitable protective equipment: ear plugs, safety goggles, safety helmet, safety gloves and
safety shoes.

Figure 1: Location of the data plate

7
 3 Technical Specifications

3.1 Components

Figure 2: Components (shown: RDP 100)

1. Heat exchanger 3in1 7. Main power switch

2. Condenser 8. Capillary tube
3. Compressor 9. Sensor for fan operation
4. Electronic condensate drain 10. Filter / dehydrator
5. Controller
6. Hot gas bypass valve

3.2 Specifications

8
 TECHNICAL SPECIFICATIONS
Max. operating pressure 16 barg (RDP 20-1900), 14 barg (RDP 2600)
Max. inlet air temperature 55 °C (for temperature ≠ 35 °C apply correction factor)
Operating ambient temperature 1 °C to 45 °C (for temperature > 25 °C apply correction factor)
Storage conditions 1 °C to 65 °C, <90 % relative humidity
Pressure dew point + 3 °C
Filter requirement (inlet) Prefilter 3 μm
Communication MODBUS
Digital input Remote ON/OFF
Digital output Alarm
Condenser type Air cooled
Max. noise level at 1m < 65 dbA
Compressor operation Non-cycling
Condensate drain Automatic (Zero loss type)
Refrigerant R134a
Protection class IP 20
Handling option Manual (RDP 20-100), Forklift (RDP 140-2600)

MATERIALS
Casing Carbon steel
Casing corrosion protection Epoxy powder paint
Evaporator Brazed plate stainless steel (RDP 20-1900), aluminium (RDP 2600)
Evaporator insulation Polyurethane foam
Condenser Copper tube, aluminium fins
Compressor Carbon steel
Refrigerant piping Copper
Controller enclosure Plastic

SIZES
Compressed air Electrical connection Ambient air Refrigerant Dimensions & Mass
Model (3)Flo Connection Pressure Power supply (4)Power/ Cooling Heat Type Mass WxLxH Net
w drop Consumption flow rejec.
m3/h bar Ph~V-Hz kW m3/h kW kg mm kg
RDP 20 20 G 3/8” BSP-F <0,2 1~230-50* 0,160 / 0,135 350 0,2 R134a 0,190 352 x 485 x 499 25
RDP 35 35 G 3/8” BSP-F <0,2 1~230-50* 0,170 / 0,135 350 0,3 R134a 0,230 352 x 485 x 499 25
RDP 50 50 G 3/4” BSP-F <0,2 1~230-50* 0,20 / 0,18 350 0,4 R134a 0,330 352 x 485 x 499 26
RDP 75 75 G 3/4” BSP-F <0,2 1~230-50/230-60 0,40 / 0,25 350 0,6 R134a 0,380 352 x 485 x 499 27
RDP 100 100 G 3/4” BSP-F <0,2 1~230-50/230-60 0,45 / 0,32 350 0,8 R134a 0,585 352 x 485 x 499 32
RDP 140 140 G 1” BSP-F <0,2 1~230-50/230-60 0,50 / 0,38 700 1,1 R134a 0,61 356 x 551 x 684 50
RDP 180 180 G 1” BSP-F <0,2 1~230-50* 0,60 / 0,45 700 1,5 R134a 0,71 356 x 551 x 684 52
RDP 235 235 G 1” BSP-F <0,2 1~230-50* 0,73 / 0,60 700 1,9 R134a 0,89 356 x 551 x 684 56
RDP 300 300 G 1 1/4” BSP-F <0,2 1~230-50/230-60 1,0 / 0,7 1100 2,4 R134a 1,07 495 x 588 x 826 84
RDP 380 380 G 1 1/4” BSP-F <0,2 1~230-50/230-60 1,1 / 0,8 1100 3,1 R134a 1,20 495 x 588 x 826 90
RDP 480 480 G 1 1/2” BSP-F <0,2 1~230-50/230-60 1,2 / 1,0 1100 3,9 R134a 1,31 495 x 588 x 826 99
RDP 600 600 G 2” BSP-F <0,2 1~230-50/230-60 1,3 / 1,1 2200 4,9 R134a 1,59 489 x 708 x 972 110
RDP 750 750 G 2” BSP-F <0,2 3~400-50/440-60 2,0 / 1,5 2200 6,1 R134a 2,19 489 x 708 x 972 120
RDP 950 950 G 2” BSP-F <0,2 3~400-50/440-60 2,4 / 1,9 2200 7,7 R134a 2,55 489 x 708 x 972 150
RDP 1150 1150 G 2 1/2” BSP-F <0,2 3~400-50/440-60 2,4 / 2,0 1900 9,4 R134a 3,49 670 x 858 x 1534 250
RDP 1300 1300 G 2 1/2” BSP-F <0,2 3~400-50/440-60 2,6 / 2,3 1900 10,6 R134a 3,25 670 x 858 x 1534 280
RDP 1500 1500 G 2 1/2” BSP-F <0,2 3~400-50/440-60 2,7 / 2,4 4600 12,2 R134a 5,00 670 x 858 x 1534 290
RDP 1900 1900 G 2 1/2” BSP-F <0,2 3~400-50/440-60 3,8 / 3,4 3800 15,5 R134a 5,30 662 x 856 x 1534 310
RDP 2600 2600 DN100 <0,2 3~400-50* 8,0 / 3,6 4000 16,1 R134a 11,0 870 x 1500,5 x 1893 500
↓ Larger sizes available upon request ↓

(3)
Nominal conditions: inlet flow 20 °C at 1 bara, ambient 25 °C, dryer inlet 35°C at 7 barg, 3 °C pressure dew point (-20,5 °C atmospheric).
(4)
For 60 Hz 20 % more than stated, consumption at nominal conditions.
* Special 60 Hz version available.

9
 CORRECTION FACTORS
To calculate the correct capacity of a given dryer based on actual operating conditions, multiply the nominal
inlet flow by the appropriate correction factor(s). CORRECTED CAPACITY = NOMINAL FLOW CAPACITY x COP x
CAT x CIN x CDP

OPERATING PRESSURE DEW POINT

[bar] 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 °C 3 5 7 10
[psi] 29 44 58 72 87 100 115 130 145 160 174 189 203 218 232 °F 37,4 41 44,6 50
COP 0,39 0,60 0,77 0,86 0,93 1,00 1,05 1,10 1,14 1,18 1,21 1,2 1,27 1,30 1,32 CDP 1 1,10 1,21 1,39

INLET TEMPERATURE AMBIENT TEMPERATURE

°C ≤25 30 35 40 45 50 55 °C ≤25 30 35 40 45
°F 77 86 95 104 113 122 131 °F 77 86 95 104 113
CIN 1,2 1,12 1 0,83 0,69 0,59 0,5 CAT 1 0,96 0,9 0,82 0,72

10
4 Refrigeration air dryer operation

The refrigeration air dryer is designed to remove moisture from the input air to achieve the desired
dew point at the exit.

All refrigeration air dryers described above operate according to the same principle. The operation of
the refrigeration air dryer can be divided into two main circuits: Air and refrigeration circuit.

1 Heat exchanger 3in1

a Air / air heat exchanger

b Air / coolant heat exchanger

c Separator

2 Inlet of compressed air

3 Outlet of compressed air
4 Compressor
5 Condenser
6 Hot gas bypass valve
7 Filter / Dehydrator
8 Capillary tube/Thermal expansion
valve
9 Condensate drain

Air Circuit: Hot, moisture saturated air enters the 3in1 heat exchanger. The air then passes through
the evaporator, also called the air / refrigerant heat exchanger. The air temperature is reduced to
about 2 ° C, which causes condensation of the water vapor. The liquid is merged into larger droplets
and collected in a separator, from where the condensate drain removes it from the system. The cool
air without liquid water is returned through the air / air heat exchanger, where it is heated to
approximately 5 ° C lower temperature than the input air.

Refrigeration circuit: The refrigerant enters the compressor and then enters the condenser at high
pressure, where it transfers heat to the ambient air and condenses. The liquid then passes through the
capillary tube, where its pressure and consequently the temperature decreases. At low pressure, the
liquid refrigerant enters the heat exchanger where it receives heat from the inlet compressed air and
causes the evaporation of the refrigerant. The low-pressure gaseous refrigerant returns to the
compressor, which compresses it and starts the cycle again. During periods of reduced compressed air
load, the excess of the refrigerant automatically passes through the hot gas bypass valve back to the
compressor.

* For more detailed information contact your supplier.

11
 5 Refrigeration air dryer components

5.1 Compressor

The compressor sucks the gaseous phase of the refrigerant from the evaporator (low pressure side)
and compresses it to the condensation pressure (high pressure side). Built-in compressors are
manufactured by leading manufacturers and are designed for applications where high compression
ratios and high temperature differences are present. Hermetically sealed structure is tight and
provides high energy efficiency and long service life. The anti-vibration springs that carry the
compressor reduce sound emissions and transmission of vibrations. The refrigerant flowing through
the compressor to the cylinders of the compressor also cools the electric motor. Thermal protection
protects the compressor against overheating and overcurrent. The protection is automatically reset
when normal temperature operating conditions are reached.

5.2 Condenser

The condenser is a component in which the gas coming from the compressor cools, condenses and
changes the aggregate state from the gaseous to the liquid. The condenser is a pipe in which the
refrigerant is flowing, and on which fins are placed. The heat transfer is accelerated by an efficient fan.
It is important to ensure that the room temperature does not exceed the nominal values. It is also
important that the condenser unit is always clean and that dust or other impurities are not
accumulated on it.

5.3. Heat exchanger 3in1

The heat exchanger 3in1 combines air / air heat exchanger, air / coolant heat exchanger and
condensate separator. The compressed air counterflow in the air / air heat exchanger ensures
maximum heat transfer. A large cross-section of the flow channel in the heat exchanger 3in1 provides
low speed and low-pressure losses. The large dimensions of the heat exchanger air / refrigerant and
the counter-flow design enable the complete evaporation of the refrigerant (preventing the return of
the liquid to the compressor). A highly efficient condensate separator is located inside the heat
exchanger 3in1. No maintenance required, the effect of collecting drops ensures a high degree of
moisture separation.

12
5.4 Controller RDC 2

The controller can be started by holding SET + UP button for 3 seconds. For RDP 750-2600 it is
recommended that the controller remains in OFF state for at least 2 hours before start-up. At start-up,
the controller shows the message ‘’Comp time 1 min’’ and the compressor starts after a minute passes.

After the countdown is finished, the controller RDC 2 shows the temperature of the dew point reached
by the refrigeration air dryer in the normal operation. By pressing the UP (▲) button, the outlet
temperature of the compressor is displayed. By pressing the DOWN (▼) button, the condensation
temperature is displayed (the temperature sensor is connected) or the condensation pressure is
displayed (the pressure sensor is connected). In case of fault, an alarm will appear on the display. The
alarm automatically turns off when the dryer is restarted and is operating properly.

a) Sensors:
1) Tdew = Dew point temperature
2) Tcomp = Compressor temperature
3) Tcond ali pcond = Condensation temperature or pressure (4-20 mA)

b) Regulated components:

1) Fan (ON/OFF)
• Fan symbol is displayed when in ON state
2) Compressor (ON/OFF)
• Compressor symbol is displayed when in ON state

c) Operation of fan and compressor

1) Normal operation:
• The compressor is always running
• The fan is regulated based on measured condensation temperature or pressure
• Dew point temperature is displayed.
2) Alarm operation
• In alarm state the normal operation is overridden.
• If more alarms are activated the last one activated has priority with display and
fan/compressor operation. All other active alarms have to be resolved before
continuing in normal operation.
• Alarm is displayed.

13
 5.4.1 Electric scheme RDC 2

The controller has 3 outputs (230 V), for compressor, fan and drain. The other outputs are for alarm.
The alarm is triggered via opto triac, which can handle 600VAC/50mA. Suggested connection for alarm
terminals:

14
Controller can also be turned OFF/ON via In. Remote by changing the parameter 13 (Remote control)
from 0 to 1. When the circuit is connected, the controller goes to OFF state, when the circuit is
disconnected, the controller is in ON state. (See the attached scheme above).

For the MODBUS communication, the twisted pair cable needs to be screwed to the A and B terminals.
To communicate with the PC, an adapter is needed. The address for the MODBUS communication is 1.

5.4.2 RDC 2 parameters

Parameter Allowed to
Parameter Press UP Press DOWN Default
number name change

Drain Cycle Increase Decrease

1 yes 1
Value value value
Drain Period Increase Decrease
2 yes 200 sec
Value value value

Increase Decrease
3 no 0
value value

Increase Decrease
4 no 5
value value
Min
Increase Decrease
Compressor yes
5 value value 1 min
OFF time
Increase Decrease
no
6 value value 2
Increase Decrease
7 no 5
value value
Increase Decrease
8 no 0
value value
Increase Decrease
no 0
9 value value
Increase Decrease
no 0
10 value value
Increase Decrease
11 no 40.0
value value
Increase Decrease
12 no 39.5
value value
Remote Increase Decrease
13 yes 0
Control value value

MOD BUS Increase Decrease

14 yes
Address value value 1

Increase Decrease
15 no 365
value value

15
 In the following paragraph, a procedure to change the minimal compressor OFF time is shown.

To change the minimal compressor OFF time, you must choose programming parameter no. 5 and
change the value from default to the desired value. To do that you must:

• Hold SET button for 3 seconds

• Enter password (000) (press SET 3 times)

• Continue pressing SET button until you reach parameter number 5

• You will see the default parameter value (1 min). Change it to a desired value, if necessary, if
not skip the next step

• Wait a couple of seconds, the controller exits automatically

Turn off the dryer and then turn it back on.

Every other parameter can be changed by similar procedure. Differences are in parameter number and
in parameter value.

To reset the parameters in the WORKING status, you must first hold SET+UP for 3 seconds and you
move to STANDBY status. When in STANDBY status, you can reset the parameters to default values
by holding UP+DOWN for 3 seconds.

16
5.4.3 RDC 2 MODBUS communication

ADDRESS NAME TYPE VARIABLE X UNIT

40013 ADDRESS RDWR Address = X

40014 Service Time R_ONLY Service Time = X day

40015 No. of alarms in last 24h R_ONLY Alarm 24 H Number= X

40016 No. of alarms since service R_ONLY Total Alarms = X
40017 Days Between Maintenance R_ONLY Days after Service = X
40018 Output Compressor Status R_ONLY 0= Comp. OFF 1= Comp. ON
40019 Output Fan Status R_ONLY 0= Fan OFF 1= Fan ON
40020 Output Drain Status R_ONLY 0= Drain OFF 1= Drain ON
40021 Output Alarm Status R_ONLY 0= Alarm OFF 1= Alarm ON
40022 T_Dew R_ONLY T_Dew = (X-200)/10 °C
40023 T_Comp R_ONLY T_Comp = (X-200)/10 °C
40024 T_Cond R_ONLY T_Cond = (X-200)/10 °C
40025 P_Cond R_ONLY P_Cond = X/10 Bar
40026 Digital Input status R_ONLY 0= contact open 1 = contact close
40027 Buttons R_ONLY 0= no switches 1= SET
2=UP 3= SET & UP
4= DOWN 5= SET & DOWN
6= UP & DOWN
7= SET & UP & DOWN
40028 Alarm CLn Status R_ONLY 0=no alarm 1 = alarm active
40029 Alarm Lt Status R_ONLY 0=no alarm 1 = alarm active
40030 Alarm Ht status R_ONLY 0=no alarm 1 = alarm active
40031 Alarm PF1 Status R_ONLY 0=no alarm 1 = alarm active
40032 Alarm PF2 R_ONLY 0=no alarm 1 = alarm active
40033 Alarm PF3 R_ONLY 0=no alarm 1 = alarm active
40034 Controller Status R_ONLY 0= STANDBY 1=NORMAL
OPERATION 2=PROGRAMMING
MODE 3=ALARM MODE
4= TESTING MODE

17
 5.5 Expansion valves

This valve injects a portion of the hot gases (taken

from the compressor outlet) into the tube between
the evaporator and the suction side of the
compressor, thereby maintaining a constant
temperature / pressure of the evaporator at about +2
° C. This injection prevents the formation of ice in the
evaporator of the dryer under any load conditions.

SETTING
The hot gas bypass valve is factory set during the test
phase. As a rule, no additional settings are needed, but
if an intervention is required, an experienced cooler
technology engineer should do this. Figure 3: Bypass valve

The screw needs to be adjusted without the load on

the dryer. Rotate the screw until the following value is
reached:

Hot gas setting: R134.a pressure 2.0 barg (±0.1 bar)

Figure 4: Thermal expansion valve

5.6 Electronic condensate drain

EMD series drains are electronically controlled condensed water drains that discharges water trapped
in the lowest parts of compressed air installation out of the system. The EMD series drains consists of
a water tank, valve assembly and electronics. The water tank should be the lowest part of the
compressed air system where condensed water collects. In the tank, there is a water level sensor. This
way, electronics could detect the tank is full. Then, it operates the electromagnetic valve to discharge
condensed water from compressed air system. The valve is operated by electronics. It opens the valve
when a button on the electronics cover is pressed or when water level in the tank reaches threshold.

By pressing the test button, we could see if EMD is operational. Besides, the test button makes possible
to discharge water that has collected in a system during maintenance manually.

The main mode of operation is a water level triggered discharging. The valve opens when water level
in EMD’s tank reaches threshold and it closes back before the tank is empty. This way, only
condensed water is discharged and no compressed air is lost.

18
Electronic board

By pressing the test button, valve is opened.

Green LED indicator shows water level in tank.

Short green flashes show that water in tank is
under the threshold.

Test button
Long green flashes indicate that the tank is
almost full.
LED indicator

When the tank is full, the green is on

permanently.
Test button

Red LED indicator is on permanently during

alarm mode.
LED indicator

Maintenance
Test buttonand troubleshooting

Troubleshooting and maintenance procedures can only be performed by qualified personnel with
the necessary knowledge.
LEDany
Before indicator
maintenance or service parts make sure that:
- no part or device is powered and must not be connected to a power source
- that no part or device is under pressure and must not be connected to a compressed air
system under pressure,
Test- that
button
the maintenance staff fully and accurately read the operating instructions, and in
particular the chapters relating to safety at work.

LED indicator
For EMD to work reliably, a strainer should be cleaned regularly. The Strainer of EMD is located in the
entrance to a valve. Its purpose is to intercept larger solid particles that would clog valve. Cleanings
period depends on condition of compressed air system.

19
 Strainer cleaning procedure
Keep to the safety rules when working with
pressure equipment.
First, close the valve then press the test button to
depressurize EMD.
In case there is no valve at condensate drain, use
valves at dryer’s input and output.

Remove strainer insert and clean it. At the same

time, check integrity of mesh.

Be careful while cleaning, because solid particles in

debris may be sharp.

Clean also O-ring sealing and its gland thoroughly.

Otherwise, strainer sealing may start to leak.
Be careful while cleaning, because solid particles in
debris may be sharp.
Return strainer insert back to its position. It needs
not to be tightened with tools! Then, open valve
slowly.

After powering EMD, it enters overload mode and afterwards, it enters alarm mode.

During power down, large amount of condensed water has collected in compressed air system. Hold the
test button until all the water is drained.

EMD enters alarm mode occasionally. But it gets back to normal mode immediately after all the water is
drained by holding the test button.
The reason might be extremely hot and moist day.
EMD is undersized and it should be replaced by bigger drain.

Pressing test button does not open the valve.

Check electric power and cable connections.
Check the fuse.

There is no LED signal although the valve could be opened by pressing test button.
The LED is not bright enough to be seen in daylight.

20
Fuse is blown.
Check integrity of electronics. Replace the fuse if there is no visible damage on electronics.

Air leaks through the drain pipe even when EMD is disconnected from power.
There might be debris in valve or valve may be damaged. Check integrity of strainer. The valve assembly
should be cleaned or replaced by authorized person.

Long flashes of green LED indicate full tank although the tank is empty.
Clean the water level sensor surface.

EMD is in alarm and there is no water drained, only air.

Clean the water level sensor surface.

EMD is in alarm and valve opens, but there is no water or air drained.
Path between EMD’s tank and valve is clogged. Clean the tank, strainer and valve assembly. Replace
strainer or valve assembly when they are damaged.

Condensed water is not drained automatically. Instead, it is drained only when test button is pressed.
If the amount of drained water is small, then the water in tank hasn’t reached the threshold, yet.
If water is drained during pressing the test button, then we should check the piping in front of EMD.
Pipe’s inclination is too small or there may be debris in the pipe so that air in the EMD’s tank is trapped.
When the test button is pressed, this air escapes through drainage and makes place for condensed
water. Solution: clean pipe, build venting. Switch timer function on.

Red LED is flashing.

EMD is in one of production modes or there is some other error. First, check supply voltage. Then,
contact supplier.
For detailed installation and operating manual of the condensate drain, please contact your
supplier.

5.7 Safety functions

For protection against low/high-pressure, the low/high-pressure switch is added (RDP 750-2600).
Other safety functions are implemented in the controller.

5.7.1 Low/High - pressure switch

LPS: Low-pressure protection device on the suction side of the compressor trips, if the pressure drops
below the pre-set value. The values are automatically reset when the nominal conditions are restored.

Calibrated pressure: R 134.a Stop 0.7 barg - Restart 1.7 barg

HPS: High-pressure protection device trips, if the pressure exceeds the pre-set value. The
values need to be manually reset when the nominal conditions are restored by pressing
the red rubber button.

Calibrated pressure: R 134.a Stop 26 barg – Manual restart 21 barg

Figure 5: High pressure switch

21
 5.7.2 Safety functions of RDC 2

CONTROLLER CAUSE - PROPOSED ACTIVITY

DISPLAY
»OFF« Controller is in off state. The controller can be started by holding SET + UP
button for 3 seconds.
»Comp time X Wait X minutes until compressor starts. X is the parameter that can be changed.
min«
»PF« Temperature sensor failure - Ensure that the temperature sensor is properly
connected to the controller / replace the temperature switch.
1 – Dew point sensor
2 – Compressor sensor
3 – Condensation sensor
»Cln« High condensation temperature/pressure – Check that the temperature sensor
is correctly inserted into its position, check the cooling system sealing / charging
/ check the hot gas bypass valve.
»Lt« Low dew point temperature - Check that the temperature sensor is correctly
inserted into its position, check the cooling system sealing / charging / check the
hot gas bypass valve.
»Ht« High compressor outlet temperature – Check that the temperature sensor is
correctly inserted into its position, check the cooling system sealing / charging /
check the hot gas bypass valve.

5.8 Filter / dehydrator

Moisture and impurities can be present in the refrigeration circuit. This can reduce the lubrication of
the compressor and block the expansion valve or capillary tube. The dryer filter / dehydrator is located
in front of the capillary tube to remove moisture and impurities from the circulation system.

5.9 Capillary tube

The capillary tube is located between the condenser and the evaporator and functions as a metering
device for reducing the pressure of the refrigerant. The pressure reduction is a design-based function.
The length and inner diameter of the capillary tube are precisely dimensioned, ensuring good
performance in all designed conditions.

22
5.10 Pressure switch

Pressure switches are for use in refrigeration and air

conditioning systems to give protection against
excessively low suction pressure or excessively high
discharge pressure.

It is used for starting and stopping fan on air cooled

condenser.

Set the HP pressure on the “CUT-OUT” scale. Set the HP

deferential on the “DIFF” scale. The HP start pressure is
the HP stop pressure plus the deferential.

Set the “CUT OUT” to 8,5 bar and “DIFF” to 3 bar.

Start and stop pressures for both the LP and HP sides of

the system should always be checked with an accurate
pressure gauge.

Set the switch for the fan motor to stop at 8,5 bar and start at 11,5 bar.

6 Efficiency

The efficiency of the refrigeration air dryer and the desired pressure dew point temperature depends
mainly on the right size of the RDP drier. To ensure efficient operation, the RDP refrigeration air dryers
are available in a large number of sizes and operating conditions.

It is advisable to provide the following information when ordering or technical assistance:

• Working pressure
• Working volume flow
• Ambient temperature
• Inlet air temperature
• Dew point requirement

7 Transport

• Transport must be carried out by trained personnel.

• Follow local regulations for lifting and transporting heavy loads.
• Provide adequate lifting and transport equipment.
• A forklift truck can be used to lift the refrigeration air dryer.

23
 (7.7)
The refrigeration air dryer may be damaged during transport. In the event of damage to the interior
components of the dryer, the installation and use may result in injury or death! Check the dryer for
any visible damage after removing the packaging. If the refrigeration air dryer is damaged, contact the
transport operator and the dryer manufacturer.

8 Storage

In order to prevent damage to the refrigeration air dryer during storage, the following conditions must
be provided:

• The dryer should only be stored in a dry and enclosed space <90 % relative humidity.
• During storage, the ambient temperature must be within the temperature range of 1 ° C to
65 ° C. Contact the manufacturer for other storage temperatures.
• Make sure the refrigeration air dryer input and output are sealed.

In case you intend to store a dryer that has already been used, follow the instructions below:

• Turn off the dryer.

• Disconnect the power supply.
• Disconnect the refrigeration air dryer from the air connection.
• Disconnect the pipe connections.
• Seal the input and output of the dryer.
• Clean the front of the condenser
• Cover the dryer to protect it from dust.

9 Installation

9.1 General requirements for installation

The RDP refrigeration air dryer is designed to operate in an environment that ensures the following
conditions:

• Internal installation, clean and dry space

• Non-aggressive atmosphere
• The minimum ambient temperature is +1 ° C
• The maximum ambient temperature is +45 ° C
• Ensure adequate ventilation to cool the device
• Installation without vibration (refers to the floor and pipes)
• Ensure the fluctuation of the power supply voltage is below ±10% of the rated voltage.
• For maintenance and servicing, provide sufficient space for uninhibited work around the unit
(1 m).
• The ventilation grilles of the device must not be covered for the operation of the system

The air supplied to the refrigeration air dryer must satisfy the following conditions:

24
• The quality of compressed air 2 for particulate matter (if the dryer is equipped with a super
fine coalescent filter 0,01um)
• The quality of compressed air 2 for oil particles (if the dryer is equipped with a super fine
coalescent filter 0,01um)
• Absence of aggressive substances

25
 9.2 Installation positioning

Below are the two most common configurations of installations in which the RDP refrigeration
air dryer is installed. The schemes below are not mandatory and they are just a sample. A
different arrangement of components is always possible.

1. Compressor 6. Refrigeration air dryer

2. Air conveyor 7. Pressure vessel
3. Condensate Separator 8. Filter
4. Pre-filter (min. 5 micron) 9. Condensate drain
5. Bypass air valve

Type A installation is recommended when the compressor operates at a reduced interruption rate and
total consumption that equals the flow of the compressor.

Type B installation is recommended when air consumption is usually repeated with conical values that
are much higher than the compressor flow. The capacity of the pressure vessel must be dimensioned
according to possible instantaneous needs (peak consumption).

26
9.3 Installation procedure

• The RDP refrigeration air dryer is typically delivered on the standard pallet on which it is
screwed with four screws.
• The RDP refrigeration air dryer can be lifted with forklift trucks.
• Remove the screws and the pallet before positioning the dryer at the desired location.
• The refrigeration air dryer should be installed in such a way that it is protected from weather
(for example, a compressor station).
• It is recommended to have 1 m of space around the dryer. This measure facilitates
maintenance.
• Make sure that the dryer is protected against vibration and mechanical wear.
• The dryer must stand firmly on a horizontal basis. The tilt of the unit must not exceed ± 3 °.
The best way to achieve these conditions is to fasten the dryer with screws onto a horizontal
base through the appropriate openings on the base. If the dryer is not installed properly, there
may be improper operation. Fastening the dryer with screws is not obligatory.
• RDP 20 - 235 drier models can be attached to
the wall with wall screws - the position of the
holes in the illustration is shown. (maximum
size M8)
• The pipe connections for the compressed air
in the front and back of the dryer must be
fitted with suitable valves that allow the
independent installation or removal of the
dryer from the system.
• Install a super fine coalescent filter on the
input side and pre-filter on the output side. It
only applies if the dryer has no built-in filters.
• Check that the air is properly treated before
the dryer (air conveyor, cyclone separator,
filters, condensate separators ...).
• Remove the plastic covers from the dryer's
input and output.
• Connect the air source to the dryer.
• The temperature and flow of the intake air
into the refrigeration air dryer must remain
within the limit values indicated on the
nominal label of the device.
• The pipelines of the system must be free of dust, rust, filings and other impurities and must
correspond to the flow of the dryer.
• It is also recommended that you arrange an air bypass line.
• Connect the dryer to the power source. Ensure that the supply voltage and the frequency
correspond to the data on the type label (± 5% acceptable tolerance for the supply voltage).
• Remove the packaging and other material that could hinder the dryer during normal
operation.

27
 10 Start-up

10.1 Before start-up

Before start-up, check that the operating parameters correspond to the nominal values indicated on
the data label of the dryer (frequency, air pressure, air temperature, ambient temperature, ...). This
dryer has been fully tested, packaged and checked before shipping. Nevertheless, it may happen that
it is damaged during transport. Before starting it up for the first time, check its compliance, and for the
first few hours of operation, you should also carefully monitor its behaviour.

• Ensure that the connection to the compressed air system is correct!

• Ensure that the condensate piping is properly secured and connected to the collection
system or collector
• Ensure that the bypass air circuit is closed and that the dryer is insulated from the system
• Check and ensure that the condenser is clean, free of impurities

10.2 Start-up

• Connect the dryer to the power supply. For dryers RDP 750-1900, the power supply should
be connected to terminals 8, 10 and 12.

• Connect the dryer to the compressed air system

• Move the switch to ON position - pos. I on the switch.
• Wait for a few minutes; make sure that the dew point temperature on the controller is
appropriate and that the condensate drainage is normal.

28
11 Remove from use

To switch off the refrigeration air dryer, move the switch to the OFF position - pos. O on the switch.
Disconnect the refrigeration air dryer from the power supply. Ensure that the dryer is not pressurized
(check bypass conduit valves). Disconnect the dryer from the compressed air system.

To protect the RDP refrigeration air dryer during storage, seal the input and the output of the dryer,
clean the front of the condenser and cover it with a cover.

12 Maintenance

During the maintenance work on the refrigeration air dryer, turn it off and wait 30 minutes for it to
cool down. Some components can reach high temperatures during operation.

Weekly check that the dew point shown on the controller is appropriate. Also check the correct
operation of the condensate drainage system. In case of impurities on the condenser, clean them.

Monthly clean the condenser with an air jet from the inside to the outside. Repeat the procedure from
the opposite direction, making sure that you do not damage the aluminium ribs of the condenser.

Annually check for potential refrigerant leakages. Measure and record the compressor and condensing
temperature.

The condensate drain is designed to to work for more than 4 000 000 condensate releases. In case of
malfunction use the condensate drain service kit for refurbishment.

29
 13 Troubleshooting technical problems

During the maintenance work on the refrigeration air dryer, turn it off and wait for at least 30 minutes
for it to cool down. Some components can reach high temperature during operation. Avoid contact
with these components until they completely cool down.

SYMPTOM POSSIBLE CAUSE - PROPOSED ACTIVITY

OFF is displayed on ● If OFF is displayed on controller press SET UP - button for 3 seconds to start the
the controller dryer.
The dryer does not ● Make sure that the system is connected to a power source.
start ● Check the electrical installation (internal and external).
● Activated internal thermal protection of the compressor - wait 30 min, then try
again.
● Check the electrical installation.
● If installed, replace internal thermal protection and / or start-up relay and / or
The compressor start-up capacitor and / or working capacitor
does not work ● If installed - The HPS pressure sensor has been activated.
● If installed - The LPS pressure sensor has been activated.
● The TS thermal safety switch has been activated - see the relevant section of
these instructions.
● If the compressor still does not work, replace it.
● Check the electrical installation.
The condenser fan ● The PV pressure switch is defective - replace it.
does not work ● Leakage has occurred in the cooling circuit - get in touch with an engineer in
(air-cooled units) the field of refrigeration.
● Replace the fan if it still does not work.
● The dryer does not start.
● Dew point sensor incorrectly detects temperature - check if the sensor is fully
inserted into the sleeve.
● The compressor does not work.
● Ambient temperature is too high, or ventilation is too low - ensure adequate
ventilation.
● The inlet air is too hot. Establish normal operating conditions.
● The inlet pressure is too low. Establish normal operating conditions.
The dewpoint is too
● The flow of inlet air is higher than the flow of the dryer - reduce flow - establish
high
normal operating conditions.
● The condenser is dirty - clean it.
● The condenser fan does not work.
● Condensate has not been drained from the dryer.
● The hot gas bypass valve is not properly set up - contact an engineer in the field
of refrigeration.
● Leakage has occurred in the cooling circuit - contact a specialist in the field of
refrigeration.
● Fan always on - PV pressure switch is defective - replace it.
The dewpoint is too ● Ambient temperature is too low - establish nominal operating conditions.
low ● The hot gas bypass valve is not properly set up - contact an engineer in the field
of refrigeration.
Excessive pressure ● Condensate has not been drained from the dryer.
drop in the dryer ● Dew point is too low - the condensate is frozen and blocks the air flow.

30
 ● Check the dampening of the pipe connections.
.....................................................................................................

● Check the electrical installation.

The condensate was ● Dew point is too low - the condensate is frozen and blocks the air flow.
not drained from ● The compressed air pressure is too low and the condensate is not removed -
the dryer establish normal operating conditions.
● The electronic condensate drain is not working properly.
The dryer
continuously drains ● The electronic condensate separator is dirty.
the condensate
● The dryer does not start.
● If it is installed - Unprepared air flows through the bypass conduit - close the
There's water in the
bypass conduit.
pipeline.
● The dryer does not discharge condensate.
● Dew point is too high.
● Check which of the following caused the activation:
1. Overload heat - set normal operating conditions.
2. The temperature of the input air is too high - establish normal operating
conditions.
3. The ambient temperature is too high, or the ventilation of the room is too low
- ensure adequate ventilation.
High compressor 4. The condenser is dirty.
outlet temperature 5. The fan does not work.
6. The hot gas bypass valve is not properly set up - contact the engineer in the
field of refrigeration.
7. Coolant is leaking - consult with an engineer in the field of refrigeration.
- Reset the thermal switch by pressing the button on the thermal switch itself -
check the proper operation of the dryer.
- TS thermal switch is defective - replace it.

31
 14 Spare Parts

PART RDP
DESCRIPTION
NUMBER 20 35 50 75 100 140 180 235 300 380 480 600 750 950 1150 1300 1500 1900 2600
1401365 1 1 1
1401437 1
1401431 1 1
1401369 1
1401439 1
1401440 1 1
Compressor
1401441 1 1
1401507 1
1401508 1 1 1
1401376 1
1401410 1
1401421 1
2101729 1 1 1
2101700 1 2
Fan & Condenser pack 2101701 1 1 2 2
2101732 1 1
2101802 2
2101732 2
2101822 1 1
Condenser 2101839 1 1 1
2101855 1
Fan 1101981 1
Fan motor 2101864 1 1 1 1 1
Fan blade 2101865 1 1 1 1 1
Fan diffuser 2101863 1 1 1 1 1
2204801 1 1 1 1 1 1 1 1
2204746 1 1
Hot gas by-pass valve 2204736 1 1 1
2204748 1 1 1
2204749 1 1 1 1
Expansion valve 2204771 1
Expansion valve connector 2204773 1
2101578 1 1 1 1
2100441 1 1
2100597 1 1
Filter 2101609 1 1
2300921 1 1 1 1
2300922 1 1 1 1
2300925 1
Fan regulation pressure switch 3000412 1 1 1 1 1 1 1 1 1 1 1
High pressure switch 3001154 1 1 1 1 1 1 1
Low pressure switch 3001111 1 1 1 1 1 1 1
RDC 2 Controller 2101826 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Pressure transducer PP011 2101898 1
PT1000 probe PMT6-67 3000857 1
XEV 22 D Dixell Driver 2101897 1
NTC temperature probe 1m 4001120 3 3 3 3 3 3 3 3 3 3 3 3
NTC temperature probe 2m 4001141 3 3 3 3 3 3 3
Main 1 - phase Switch 1219579 1 1 1 1 1 1 1 1 1 1 1 1
3001135 1 1 1 1 1 1
Main 3 - phase Switch
3001156 1
Main 3 - phase Switch - handle 3001136 1 1 1 1 1 1 1
Electronic drain 321900860 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 - phase circuit breaker 3003681 1 1 1 1 1 1 1
3003715 1 1 1 1 1 1
3- phase circuit breaker
3003713 1
Phase protection relay 3003527 1
3001134 1 1 1 1 1 1
Contactor
3001162 1
3003680 1
3003682 1 1 1
Motor protection 3003683 1 1
3003695 1
3003699 1

32
15 Warranty

The warranty is valid for 12 months from the date of purchase and no more than 14 months from the
date of dispatch.
During this time, the parts that were originally incomplete will be repaired or replaced free of charge.
This does not include travel costs, accommodation and food for our technicians.
The guarantee excludes any possible direct or indirect damage to people, animals or property resulting
from improper use or inadequate maintenance of the device, and is limited solely to production errors.
When claiming a warranty, you must provide information from the identification label.

Guarantee is invalid if:

1. The instructions were not followed for installation and maintenance
2. The unit was not used according to the instructions.
3. The unit operated even though the improper operation was apparent.
4. Non-original parts were used.
5. The unit did not work within the allowed technical parameters.
6. Unauthorized structural changes were made on the unit or parts thereof.

33
 16 Maintenance notebooks

MAINTENANCE TYPE DATE SIGNATURE NOTES

First installation

34
MAINTENANCE TYPE DATE SIGNATURE NOTES

35
 17 Drawings of RDP refrigeration air dryers

RDP 20 - 100

36
 RDP 140 - 235

37
38
RDP 300 - 480
 RDP 600 - 950

39
40
RDP 1150 - 1900
 RDP 2600

41
 18 Electro schemes of RDP refrigeration air dryer

RDP 20 - 235

42
RDP 300 - 600

43
 RDP 750- 1900

44
RDP 2600

45
46
 EC Declaration of Conformity
Omega Air d.o.o. Ljubljana
Cesta Dolomitskega odreda 10
1000 Ljubljana
Slovenia

Declares that

Product: RDP
Model: RDP 20, RDP 35, RDP 50, RDP 75, RDP 100, RDP 140, RDP 180, RDP 235, RDP 300,
RDP 380, RDP 480, RDP 600, RDP 750, RDP 950, RDP 1150, RDP 1300, RDP 1500, RDP 1900,
RDP 2600
Description: Compressed air refrigeration dryer

Is in conformity with the following directives

Machinery directive 2006/42/EU

ISO 12100:2010,
ISO 13857:2019

Pressure Equipment Directive (PED) 2014/68/EU

Electromagnetic Compatibility Directive (EMC) 2014/30/EU

EN 61000-6-3:2021,
EN 61000-6-2:2019,
EN 61000-3-2:2019,
EN 61000-3-3:2014/A1:2019

Low Voltage Directive (LVD) 2014/35/EU

Our quality management system is

certified by BUREAU VERITAS in
conformity with ISO 9001:2015

A.Dobnikar
Technical manager

Date of issue 30.1.2023

47