NEWGATE TECHNOLOGIES, INC.

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1 www W.newgatetechnologies.com NEWGATE TECHNOLOGIES, INC. Installation & Operations Manual SYNERGY Series High Inlet Temperature Refrigerated Air Dryers Models SYNERGY 025 ~ SYNERGY 125 Includes Safety Information Attention/Caution Pressurized Equipment: Never exceed the maximum working pressure indicated on the dryer data tag. Ensure dryer is fully depressurized and all electrical power is disconnected before working on the dryer. Electrical: Always install dryers in accordance with local electrical codes and standards. This dryer is not NEMA 4 or 7 rated and should not be installed in unprotected or potentially explosive areas. Air for Respiration: The air treated by this dryer should not be used for human respiration (breathing air) without approved monitoring controls and may require further additional and or specific air purification and treatment. Consult the OSHA norm regarding the necessary quality of compressed air for respiration or contact NewGate Technologies, Inc. for breathing air applications SW 7 th Road, Ocala, FL 34474, USA Tel: (352) Fax: (352)

2 Warranty This equipment is warranted for a period of 12 months from date of installation or 18 months from date of shipment (whichever occurs first) against defects in materials and workmanship. Call NewGate Technologies prior to performing all warranty work for authorization or return of product. This warranty covers all components of the dryer, with the following exceptions: - Electrical components (motor, fans, pressure switches, etc.) are covered for 6 months. - Electronic circuits including lamps and fuses are covered for 3 months. - Field adjustments to dryers to meet local conditions and which are different from standard factory settings is considered normal maintenance and not covered by warranty. The warranty is void if or for the following reasons: - Dryer identification data tag is removed or altered. - Repair or maintenance is performed without prior authorization by NewGate Technologies, and/or by unqualified personal. - If installation and maintenance procedures are not strictly adhered to and as specifically outlined in this operations manual. In the case of a manufacturing defect, call NewGate Technologies Inc. or your authorized dealer for repair or replacement. If authorization is given to return the product to NewGate Technologies Inc, the customer must pay the freight, whereas NewGate Technologies Inc will pay the return freight. If the dryer is not covered by warranty, or no warranty related defect is found, all freight costs are the responsibility of the customer. Total liability is limited to the total cost of the dryer only. This warranty covers the replacement or repair of the equipment only. Any other incurred costs or losses associated whether directly or indirectly with a defect in the dryer, are not covered by this warranty. NewGate Technologies, Inc. dryers are manufactured to meet or exceed ISO-7183-B international standards. Page 2 of 16

3 1.0 DESCRIPTION 1.1 How it works 1.2 Air circuit Refrigerant circuit Evaporator control Condenser control 1.4 Electrical circuit 2.0 INSTALLATION 2.1 Inspection, Damage and Handling 2.2 Location and Installation 2.3 Electrical connection 2.4 Condensate drain connection 3.0 OPERATION 3.1 Start up 3.2 During operation 4.0 MAINTENANCE 4.1 Condensers & Coolers 4.2 Internal Cold coalescing filter 4.3 Drain system 4.4 Electrical system 4.5 Trouble shooting guide 5.0 GENERAL ARRANGEMENT DRAWING 6.0 ELECTRICAL SCHEMATIC 7.0 FLOWCHART 8.0 TABLES Index 8.1 Capacity correction table 8.2 Control parameters table 8.3 Power Consumption, Amperage & Water Consumption table 9.0 MICROPROCESSOR CONTROLLER 9.1 Analog Controller Page 3 of 16

4 1.0 DESCRIPTION 1.1 How it works Compressed air leaving the compressor is very hot and is completely saturated (RH 100%). It therefore contains a large quantity of water in the form of vapor. As the air flows in the pipeline, its temperature continues to drop, and condensation in the form of liquid water occurs. A mechanical or coalescing condensate separator or filter must now remove this water, else it will cause problems to components downstream. However, none of these devices can remove the water vapor that is still present in the air. For most applications this is an unacceptable condition and the air needs to be dried. The most common form of drying is through the process of refrigeration. This procedure involves further cooling of the compressed air to a lowest possible temperature of about 38º F and then separating the resultant liquid condensate. Subsequently, the dry but cold air is re-heated by the incoming hot air, and is delivered to the plant. The mechanical separation of the liquid condensate from the air is a critical function and is accomplished in NewGate s dryers with a our G Series cold coalescing filter rather than by relying on inexpensive and inefficient mechanical separation methods. The removal of liquid oil, which also drops out of vapor state along with the water, is also accomplished most efficiently at this stage by the coalescing filter. This is a significant benefit to our customers, and guarantees no further condensation of oil vapors will occur further down in the plant air stream. The air is now considered oil free for all practical purposes. All NewGate Technologies dryers are designed to International ISO standard 7183-B. 1.2 Air circuit (see also 7.0) In the Synergy High Inlet Temperature dryers, cooling of the air is done in three stages. In the 1 st stage, the compressed air is cooled in the air-cooled aftercooler, where the air temperature is brought down to about 110 ºF. The air is then processed in the integrated coalescing filter/separator, where all of the liquid water condensed in the afttercooler is separated and removed via an electronic drain valve. The air is now ready to proceed to the refrigerated dryer section of the package. In the refrigerated dryer section, the cooling of the air is done in two stages. In the 1 st stage air-to-air heat exchanger (pre-cooler/re-heater), the temperature of the hot incoming air is reduced by the cold outgoing air, which is at the same time re-heated during the heat exchange process. The incoming air then enters the 2 nd stage air-to-refrigerant exchanger (evaporator), where the air temperature is further reduced to about 38ºF dew point. At this point, the maximum amount of water and oil is condensed and removed through the cold coalescing filter electronic drain valve. The dry air now re enters the air-to-air heat exchanger and is reheated to about 80ºF before exiting the dryer to the plant. 1.3 Refrigerant circuit (see also 7.0) After compression the refrigerant is a high pressure and high temperature gas. The refrigerant gas then enters the water or air cooled condenser where it changes to a liquid at high pressure. This liquid refrigerant then passes through a drying filter and through an expansion valve where the high pressure liquid is allowed to expand back to a gaseous state. It is then directed into the air-to-refrigerant heat exchanger (evaporator) at a temperature of approximately 28ºF. In the evaporator, the entire liquid refrigerant converts back into a low pressure gas and returned to the refrigerant compressor inlet. This cycle repeats itself. NewGate Technologies, Inc. uses only EPA approved R22, R134a and R404 refrigerants. Page 4 of 16

5 1.3.1 Evaporator control When a reduction of the thermal load occurs (because of reduction of incoming airflow or air temperature), the refrigerant temperature and pressure in the evaporator will also reduce, and this could lead to a potential freezing of the liquid water on the air side of the evaporator in the dryer system. To avoid this potential to freeze, a hot gas by-pass valve is utilized. This valve deviates hot gas from the compressor hot discharge directly into the evaporator (by-passing the condenser), resulting in an increase in the thermal load and effectively preventing freezing. This valve can be adjusted to attain the parameters of table 8.2, or to compensate for actual field conditions that may differ from factory set standards Condenser control In certain circumstances, if low ambient temperatures or low thermal loads occur, there is a tendency for the refrigerant discharge pressure (downstream of the condenser) to be reduced too much. In certain dryer models this reduction in the discharge pressure could compromise the functions of the expansion and hot gas by-pass valves. These models are therefore equipped with an additional control device. In dryers equipped with water-cooled condensers, this device consists of a valve installed at the water intake along with a refrigerant discharge pressure sensor. The valve turns on and off based on a pre-determined discharge pressure value. With the water off, the condenser cooling is reduced. This in turn increases the discharge pressure. A constant refrigerant discharge pressure is thus maintained. Air-cooled models are equipped with a pressure switch that controls the condenser cooling fan. Again, by turning the cooling fan on and off, a constant refrigerant discharge pressure is maintained. 1.4 Electrical circuit SYNERGY Dryer Models 025 to 080 are 115/1/60 models and are equipped with a standard power cord with a molded and grounded plug. SYNERGY Dryer Models 100 and 125 are 230/1/60 models, requiring electrical hook-up by a qualified electrician. An internal junction box is provided for this connection. The user is responsible for providing a fused electrical circuit with a capacity as outlined in Table 8.3. Once the electrical power connected to the dryer, the dryer system can be turned on by pressing the Power-On button located on the front panel. The entire system comes on live, including the refrigerant compressor, fans, automatic drain etc. In certain models, the start up of the compressor is assisted by a capacitor and start relay. All models have a thermal overload protection switch in the event of high temperatures and electrical overload conditions. If actuated, it can take up to 2 hours for this protection device to reset. The condenser fan is automatically switched on when the dryer is started. The automatic drain consists of an electronic circuit that actuates a solenoid valve at intervals that can be adjusted. 2.0 INSTALLATION 2.1 Inspection, Damage and Handling It is the sole responsibility of the customer to fully inspect all merchandise prior to accepting the products from the freight company and to immediately make a claim with the freight company for any damages found. NewGate Technologies, Inc. cannot accept any responsibility for any freight damage once the unit has left our facility. Page 5 of 16

6 Unless otherwise specified, dryer models SYNERGY 025 to SYNERGY 125 are packed in corrugated cardboard boxes. Units should be unloaded with a forklift or an appropriate device. 2.2 Location and Installation Location The installation area must be well ventilated in order to avoid elevated ambient temperatures, which will negatively effect the performance of the dryer, especially the air-cooled models. All dryers must be permanently covered from the elements and from freezing temperatures at all time. Only equipment specially designed for outside installation can be placed outdoors without protection. Enclosed compressor rooms are natural dryer installation sites, but be cautious and ensure that these areas are properly ventilated and have ambient temperatures not exceeding 80ºF. The unit should be installed on a firm, level base or floor. Tall units should be bolted permanently to the floor or base utilizing the bolt holes provided. Connecting piping should be free of vibration. Where vibration exists, special flexible connections should be used and installed. Always leave adequate space around the unit for proper operation, maintenance and cooling. Insure adequate cross flow ventilation at all times. It is a good practice to install a bypass around the dryer to allow for routine maintenance without interrupting the process airflow. Any by-pass valves utilized ideally should have a special device to avoid the accidental opening of it Install the dryer in following sequence: Air compressor Air receiver NewGate G Series Filter NewGate SYNERGY Dryer 2.3 Electrical connection Dryer models come in different amperage ratings and should be supplied with a dedicated and properly fused power supply. Follow all local electrical codes and utilize a qualified electrician for all electrical connections. Verify the electrical requirements for each dryer against the electrical diagram in this manual and as indicated on the data tags on every dryer. Proper electrical grounding is a must in order to prevent electrical shock that could result in death or serious injury. 2.4 Condensate & Drain system On all units, the automatic drain valve comes with a plastic tube for piping away liquid condensate. This condensate will contain coalesced oils and should be treated based on local and state codes for condensate discharge. It is critically important that liquid condensate is properly and freely removed from the dryer, else re-entrainment will occur. Therefore, continuously inspect and monitor dryer for proper electronic drain valve operation and for clogged or damaged/bent discharge piping. Page 6 of 16

7 3.1 Start up 3.0 OPERATION On initial start-up on all Synergy dryers, allow the unit to warm up for at least 10 minutes prior to allowing airflow through the unit. When opening or closing the compressed air valves, always do so slowly, in order to avoid shock or damage to the heat exchangers and coalescing filters, and piping system. Failure to follow these instructions immediately voids dryer warranty. 3.2 During Operation Regularly check the automatic drain valve(s) operation and ensure that condensate is being discharged normally. Since there is generally a fairly large amount of water being discharged on a continuous basis, watch this operation. On models with a condenser control device, the fans start and stop suddenly during normal operation. During very hot days they may operate constantly. Use caution when in and around these dryers during normal operation. 4.0 MAINTENANCE Your dryer will require very little maintenance, however, it is recommended you inspect them at least once a day. An authorized NewGate Technologies serviceman must carry out more comprehensive maintenance. Ensure that on air-cooled models the condensers are kept clean and free from debris or become blocked. This is the most common and most serious form of dryer failure and is easily preventable. 4.1 Coolers & Condensers CAUTION! Fans start automatically Disconnect power before any maintenance/service. Always disconnect the dryer from the power supply before working on the dryer, and to avoid injury from rotating fan blades. Inspect and clean the coolers and condensers and free any debris from the coils. Be sure not to bend the aluminum fins on the cooler and condenser coils. Caution: If it is necessary to remove the fan blade, be sure to mark its direction and position so that you can reinstall it to the original factory settings. Reversed fan blades will cause serious performance problems and reduce the life of the unit. Page 7 of 16

8 4.2 Internal Cold Coalescing Filter All SYNERGY dryers come equipped with an internally installed Coalescing Separator/pre-filter and a Cold Coalescing Filter as standard. The first element replacement should be made within the first 900 hours of operation. Subsequently, replace the elements every hours or when the filter change out indicator on the control panel located on the front of the dryer lights up. Considering the possible chemical degradation of the filter element components, it is always advisable to change out the element at least once a year. Other considerations: Filter elements become progressively blocked over time, and therefore require more compressor energy to drive the air through them. A simple calculation based on your cost of energy per kilowatt-hour can help determine the right time to change filter elements in your compressed air system. NewGate Technologies s engineering staff can assist with this analysis, and help you save valuable energy costs. 4.3 Drain system The electronic drain should be inspected once a week. If it does not drain correctly, it might be blocked with dirt. Dismantle the solenoid valve and clean it with compressed air or water. CAUTION! The dryer is under pressure Before dismantling the solenoid valve close the ball valve. CAUTION! Always disconnect the power supply before any maintenance or electrical work is performed. Page 8 of 16

9 4.4 Filter Change-out All Synergy dryers have an LED readout located on the control panel, indicating when the cold coalescing filter should be changed. The very high cost of pressure drop should also be considered in determining when filters should be changed out. Typically, the ideal time to change is when the cost of pressure drop exceeds the cost of the replacement filter element. This will vary depending on location and energy costs in your area. Contact NewGate technologies, Inc. for assistance and guidance. See illustration on next page. Filter element replacement for models SYNERGY 010 to SYNERGY 125: Page 9 of 16

10 4.5 Troubleshooting Guide High pressure drop across dryer Water in compressed air, High dew point Dryer design capacity exceeded 1 Saturated coalescing Filter 5 A. SYNERGY dryer is cooling properly B. SYNERGY dryer is not cooling properly Internal freeze up 6 Low inlet air pressure 25 Capacity too high 1 Refrigerant compressor is running Refrigerant compressor is not running Pulsating flow 3 Drain not functioning 4 Low refrigerant 11 Broken compressor 14 Coalescing filter by-passed 7 Cooling flow blocked 9 Thermal protection activated 15 Incorrectly adjusted hot gas Blown control fuse 16 by-pass valve 12 Broken/loose wiring 18 Air flow too high 1 High inlet air temperature 8 Dirty condenser 10 Expansion valve damaged 13 Dirty filter(s) 24 Ambient temperature too high 2 Refrigerant compressor does not run Refrigerant compressor has no power Pressure switch A/B closed Pressure switch A/B open Pressure switch A/B open (Possible Reason for A/B open) Blown control fuse 16 Power switch off 17 Loss of refrigerant 20 Reset pressure switch Broken electrical circuit 18 Adjust pressure switch 21 If the problem repeats: Broken switch 17 Fan(s) stopped Fan(s) running Broken fan motor(s) 22 High ambient temp. 2 Adjust pressure switch 23 High air inlet temp. 8 Broken electrical circuit 18 High Inlet air flow rate 1 Blocked ventilation 9 Dirty condenser 10 Page 10 of 16

11 1. High inlet air flow rate (Capacity too high) Check the actual flow conditions against rated capacity. See Correction factors in Table High ambient temperature Make sure temperatures are not above 100/110 F. See Correction factors in Table Pulsating flow If the use of air is very inconsistent and fluctuates, an air receiver of adequate size should be installed after the SYNERGY dryer. 4. Drain is not operating Check timer or the solenoid valve. If the coil is energized, the problem could be inside the valve. Disassemble the valve and clean it internally with compressed air or water. 5. Coalescing filters saturated Replace coalescing filter element, using OEM approved elements only. 6. Internal freeze-up Call NewGate Technologies or authorized dealer for technical assistance. 7. Air by-passing the coalescing filters The filter elements may be damaged or incorrectly installed. Check, reposition or replace. 8. High compressed air temperature Check if the compressed air temperature is above 250 F. 9. Condensers air flow blocked The Synergy dryer should be installed in such a way that the inlet and outlet of both cooling airflows are not obstructed. The inlet should receive clean and fresh air. If necessary, relocate the dryer. 10. Dirty After-Cooler/Condenser Clean the condenser as explained in Chapter Low refrigerant pressure Call NewGate Technologies or authorized dealer for assistance. 12. By-pass valve out of adjustment Call NewGate Technologies or authorized dealer for assistance. 13. Damaged expansion valve Call NewGate Technologies or authorized dealer for assistance. 14. Compressor failure Call NewGate Technologies or authorized dealer for assistance. 15. Thermal protection/overload actuated Wait for up to 2 hours. Try to restart. If the compressor terminals are energized and the compressor does not start, it is probably broken/seized. Call NewGate Technologies or authorized dealer for assistance. 16. Control fuse blown Replace control fuse. If fuse repeats to blow, look for a short circuit in the control system (drain, temp. indicator, alert lights, etc.). 17. Power On/Off switch not working The power On/Off switch may be switched off or interrupted. If off, switch it on. If faulty, replace the switch. 18. Electric short circuit There could be a short or loose wire/connector in the wiring control circuit. Check and repair. 20. Refrigerant low or out Call NewGate Technologies or authorized dealer for assistance. Also check for signs of refrigeration compressor oil leaks that indicate location of leak. 21. Pressure switch needs adjusting Call NewGate Technologies or authorized dealer for assistance. 22. Broken fan motor If the fan receives power but does not rotate, replace motor. 23. Pressure switch for condenser control defective Call NewGate Technologies or authorized dealer for assistance. 24. Refrigerant filter/dryer ice up If the filter/dryer shows signs of icing, it may be blocked with dirt from a contaminated refrigerant system. Call NewGate Technologies or authorized dealer for assistance. 25. Low operating pressure Inlet pressure to the SYNERGY dryer is below nominal and design conditions. Increase pressure at the inlet to the dryer. Page 11 of 16

12 5.0 GENERAL ARRANGEMENT DRAWING Models SYNERGY 025 to 125 Page 12 of 16

13 6.0 ELECTRICAL SCHEMATIC Models SYNERGY 025 to 125 Page 13 of 16

14 7.0 FLOWCHART Models SYNERGY 025 to SYNERGY 125 Page 14 of 16

15 8.0 TABLES 8.1 CAPACITY CORRECTION TABLES AMBIENT TEMPERATURE Temp. F F A INLET AIR TEMPERATURE Temp. F F I OPERATING PRESSURE Press. Psig F P C F = Corrected Flow N F = Nominal Dryer Flow C F = N F x F A x F I x F P 8.2 CONTROL PARAMETERS TABLE Parameter SYNERGY-025 to SYNERGY-080 SYNERGY-100 and SYNERGY-125 Refrigerant Suction pressure (PSIG) 58 to to 60 Suction superheat ( F) 5 to 11 5 to 11 Refrigerant R134a R22/R404a 8.3 POWER CONSUMPTION & AMPERAGE TABLE MODEL 100 psig POWER CONSUPTION (WATTS) AMPERAGE (AMPS) (SCFM) 115/1/60 230/1/60 SYNERGY SYNERGY SYNERGY SYNERGY SYNERGY SYNERGY Page 15 of 16

16 9. MICROPROCESSOR CONTROLLER 9.1 ANALOG CONTROLLER (All Synergy Models) How it functions: The panel consists of 3 LEDs indicating the operation of the dryer and 1 test button for the drain system. The first LED (red) indicates if the equipment is switched on (lighted) or off. The second LED (green) indicates if the drain is activated or not. Each time the drain opens, this LED will light up. The third LED (red) indicates that the internal filter is saturated. For proper operation of the dryer it is necessary to replace the filter element when this lights up, as shown in 4.2. The Analog panel is illustrated below: Page 16 of 16