OWNER/OPERATOR MANUAL COMPONENTS, INSTALLATION, OPERATION AND SERVICE INSTRUCTIONS

Transcription

1 OWNER/OPERATOR MANUAL COMPONENTS, INSTALLATION, OPERATION AND SERVICE INSTRUCTIONS REFRIGERATED COMPRESSED AIR DRYER WRA-0050 WRA-0200 WARNING READ ALL INFORMATION IN THIS MANUAL BEFORE BEGINNING INSTALLATION OR OPERATION OF THE DRYER. BEFORE STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES, TURN OFF THE MAIN POWER TO THE DRYER AND COMPLETELY DEPRESSURIZE THE UNIT TO PREVENT PERSONAL INJURY. DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS UNDER PRESSURE. THIS DRYER USES REFRIGERANT R-22. COMPLY WITH ALL LOCAL, STATE, AND FEDERAL REGULATIONS CONCERNING REFRIGERANT WHEN PERFORMING ANY MAINTENANCE OR SERVICE ON THE REFRIGERATION SYSTEM. ALL REFRIGERATION SYSTEM REPAIRS OR MAINTENANCE NOT DETAILED IN THIS MANUAL SHOULD BE DONE BY A QUALIFIED REPAIR PERSON. NEVER OPERATE THIS DRYER ABOVE THE RATED OPERATING CONDITIONS. OPERATION ABOVE SPECIFIED CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO THE UNIT AND/OR PERSONAL INJURY , Rev D 4/97 Printed in the U.S.A.

2 Table of Contents Why you need a Refrigerated Air Dryer...Page 2 Dryer Dimensions and Air Accessories...Page 3 Installation Instructions...Page 4-5 Control Panel Components...Page 5 Cabinet Components...Page 6 Refrigeration Components...Page 7 Electrical Box Components...Page 8 Wiring Diagrams...Page 9-11 Trouble Shooting Guide...Page 12 Warranty...Page 13 Service Information...Page 14 Page 1

3 WHY YOU NEED A REFRIGERATED AIR DRYER Untreated compressed air will contain contaminants such as water, compressor oil, rust, chemical contaminants, and bacterial growth. All of these contaminants will cause corrosion and product contamination. With proper filtration and a refrigerated air dryer in used, contaminants will be reduced to a harm-less level. The end result will be that the equipment which comes in contact with dry, treated, compressed air will stay cleaner, will not corrode, and will last longer. Rejection rates of your end products will be reduced when using dry, treated air in your plant manufacturing operations. FIGURE 1: TYPICAL COMPRESSOR ROOM LAYOUT: TO PLANT Typical Compressor Room Layout Component Key 1 Air Compressor 2 Shut-off Valve 3 Flex Connector 4 Compressed Air Aftercooler 5 Flex Connector 6 Liquid Separator with Electric Drain 7 Receiver Tank 8 Prefilter 9 Electric Drain Valve 10 Flex Connector 11 Shut-off Valve 12 Flex Connector 13 Afterfilter 14 Refrigerated Air Dryer Page 2

4 FLOW SIZING AND RECOMMENDED FILTRATION Dryer Full Prefilter Recommended Recommended Model Inlet/Outlet Flow Type A Prefilter Type B Afterfilter Type C Weights Number Connections (SCFM) 5.0 Micron Micron 0.01 Micron lbs WRA " NPT 50 F26-04-F00 M21-03-FS0 M21-03-F WRA " NPT 75 F30-08-F00 M30-04-FS0 M30-04-F WRA " NPT 100 F30-08-F00 M30-08-FS0 M30-08-F WRA /2" NPT 150 F30-08-F00 M31-08-FS0 M31-08-F WRA /2" NPT 200 F30-08-F00 M32-0A-FS0 M32-0A-F NOTE: Recommended filters were selected on the basis of flow capacity not pipe size. DIMENSIONS FRONT VIEW FRONT VIEW AIR OUTLET AIR OUTLET AIR INLET AIR INLET AIR INLET OUTLET SIDE VIEW WRA-0150 & WRA-0200 WRA Page 3

5 INSTALLATION Air-Cooled Condenser The dryer should be installed in a well-ventilated area. Ambient air should flow freely into the condenser opening (right side of dryer). Do not block or restrict this opening. There should be at least 12" (305 mm) clearance at the back and both sides of the dryer. The condenser fins and surfaces should be regularly cleaned with an air blow gun. The grill can easily be removed to access the condenser coil. BY-PASS VALVE FLEXIBLE LINE (RECOMMENDED) Ambient temperature should never be above 110 F (43 C) or below 40 F (4.4 C). Compressed Air Piping Pipe air in and out as indicated on dryer. Compressor induced vibration (or any other vibration) should be dampened by installing flexible piping between the dryer and compressor, or vibration dampeners on dryer floor legs. Prolonged vibration will damage dryer and void warranty. If piping incorporates a bypass circuit (recommended), make sure in and out shut-off valves are normally wide open and bypass valve completely closed. Do not undersize these valves. Before Start-Up The gauge readings BEFORE START UP will be: 1. REFRIGERANT SUCTION PRESSURE: Indicates the refrigerant pressure. 2. INLET AIR TEMPERATURE: Indicates the temperature of the air as it enters the dryer. (Gauge reading should be ambient temperature). 3. INLET AIR PRESSURE: Indicates the pressure of the air as it enters the dryer Inches millimeters Start-Up DO NOT START WITH A LOAD ON THE DRYER Bypass the flow of air around the dryer before pushing the start button. 1. After pushing the start button, the power indicating light will illuminate. Dryer is designed to run continuously and must not be cycled with the air compressor. The fan on air-cooled units will cycle in accordance with head pressure. LEFT VIEW FRONT VIEW 2. The refrigerant suction pressure gauge reading AFTER START UP AND WHILE OPERATING UNDER RATED LOAD WILL BE: R-22 (57-65 PSIG). Care Of Outside Of Dryer This dryer is protected and decorated with the highest quality paint for lasting attractive appearance. To clean these surfaces, use a sponge, mild soap and warm water. Dry with a clean cloth. Do not use any abrasives or solvents. Page 4

6 psi 14 bar psi 14 bar Running Operation 1. The non-cycling operation of the refrigerated dryer is controlled by an automatic expansion valve (AXV). The fan control is used in conjunction to maintain head pressure during light or no load running condition. 2. The automatic expansion valve is preset at the factory. The suction pressure gauge should indicate 65 PSIG for R-22. If adjustment is necessary refer to Figure 1. Control Panel Components Item Description Model Number Part # AXV USED AS EITHER AN EXPANSION VALVE OR Temperature-Pressure Chart (R-22) TEMPERATURE PRESSURE F PSIG AS A HOT GAS BY-PASS. Use a 3/8" wrench or socket to turn the adjusting nut. Turn clockwise to increase the suction pressure. Turn counterclockwise to decrease the suction pressure to the normal range Switch, ON/OFF WRA Light, High Temperature WRA (See Trouble Shooting) 3 Gauge, Inlet Air Pressure WRA Gauge, Refrigerant WRA Suction Press 5 Digital Display WRA Selector Knob WRA POWER ON HIGH TEMP. REFRIGERA TED AIR DR YER 3 4 adjusting nut POWER ON SYSTEM MONITOR HIGH TEMP. INLET PRESSURE REFRIGERANT SUCTION PRESSURE REFRIGERA TED AIR DR YER 3 4 INCREASE DECREASE POWER ON HIGH TEMP. TEMPERA TURE 83 F 1 INLET AIR TEMPERATURE 2 AMBIENT AIR TEMPERATURE 3 REFRIGERANT COMPRESSOR DISCHARGE TEMPERATURE 4 OUTLET AIR TEMPERATURE SYSTEM MONITOR INLET PRESSURE REFRIGERA REFRIGERANT SUCTION PRESSURE TED AIR DR YER FIGURE INCREASING THE SUCTION PRESSURE WILL RAISE THE EVAPORATOR TEMPERATURE. DECREASING THE SUCTION PRESSURE WILL LOWER THE EVAPORATOR TEMPERATURE. Page 5

7 CABINET COMPONENTS Part Item Description Model Number Number 1 Grill, Inlet WRA-0050 & WRA WRA Grill, Exhaust WRA WRA-0150 & WRA Panel, End, Exhaust WRA WRA-0150 & WRA Panel, Rear WRA Panel, End, Inlet WRA Top WRA Base WRA Page 6

8 REFRIGERATION COMPONENTS AND PARTS LIST Item Description Voltage Model # Part # 1 Compressor WRA / WRA / WRA WRA After S/N# 208/ WRA * 208/ WRA WRA / WRA / WRA / WRA WRA / WRA / WRA / WRA / WRA / WRA / WRA / WRA Electrical Box 3 Separator WRA WSA-08-F00 WRA WS0-0B Fan Guard WRA WRA Fan Blade WRA WRA WRA Air Circuit WRA ARP Assembly Item Description Voltage Model # Part # Air Circuit WRA-0100 ARP Assembly Cont. WRA ARP Refrigerant Service Valve ALL Fan Cycle Control ALL High Pressure Control ALL Filter Dryer ALL Hot-Gas ByPass Valve WRA WRA Accumulator ALL Exchanger, Suction, Liquid ALL ARP Fan Motor 115 WRA /230 WRA WRA /230 WRA WRA /230 WRA WRA /230 WRA /460 WRA Condenser WRA WRA WRA Base ALL *NOTE: See electrical box components for run components before and after serial number Page 7

9 ELECTRICAL BOX COMPONENTS Item Description Voltage Model # Part # 1 Electrical Box ALL Electrical Box Cover ALL Transformer ALL Contactor ALL Start Relay WRA / WRA / WRA WRA / WRA Before S/N# 208/ WRA * After S/N# 208/ WRA * WRA / WRA / WRA-0100 N/A 208/ WRA WRA / WRA / WRA-0150 N/A 440/ WRA-0150 N/A 208/ WRA / WRA / WRA-0200 N/A 440/ WRA-0200 N/A 6 Start Capacitor WRA / WRA / WRA WRA Before S/N# 208/ WRA * After S/N# 208/ WRA * 208/ WRA WRA Item Description Voltage Model # Part # 6 Start Capacitor 208/ WRA Cont. 208/ WRA-0100 N/A 208/ WRA WRA / WRA / WRA-0150 N/A 440/ WRA-0200 N/A 208/ WRA / WRA / WRA-0200 N/A 440/ WRA-0200 N/A 7 Run Capacitor WRA / WRA / WRA WRA / WRA / WRA WRA / WRA / WRA-0100 N/A 208/ WRA WRA / WRA / WRA-0150 N/A 440/ WRA-0150 N/A 208/ WRA / WRA / WRA-0200 N/A 440/ WRA-0200 N/A 8 Junction Box ALL Junction Box, Cover ALL *NOTE: See electrical box components for run components before and after serial number Page 8

10 WIRING DIAGRAM (Optional) VOLTAGE -1 SINGLE PHASE WIRING DIAGRAM Page 9

11 WIRING DIAGRAM VOLTAGE - 2 & - 6 SINGLE PHASE WIRING DIAGRAM Page 10

12 WIRING DIAGRAM VOLTAGE - 3- & THREE PHASE WIRING DIAGRAM Page 11

13 TROUBLE SHOOTING GUIDE Symptom Dryer not running Power ON light is ON Dryer not running Power ON light is OFF Cause a. Low voltage to the dryer b. Contactor not pulling in c. Compressor over-load open d. Defective compressor start components (single phase) e. Compressor windings open a. Switch not turned on b. No power c. Circuit breaker or fuse d. Improperly wired e. ON/OFF switch defective High discharge pressure (Above 335 psig) a. Fan not operating b. Dirty or blocked condenser c. High ambient conditions d. Excessive air load exceeding the capacity of the dryer High suction pressure a. Excessive air load exceeding the capacity (62 to 72 normal) of the dryer b. Hot gas bypass valve setting too high c. High ambient temperature Low suction pressure a. Low or no air load (62 to 72 normal) b. Fan not cycling at low load c. Hot gas bypass valve setting too low d. Refrigerant leak e. Low ambient temperature and fan not cycling Moisture in air system downstream High pressure drop in dryer air circuit a. Dryer over loaded (air flow) b. Separator drain not functioning c. Bypass valve open d. Refrigeration system not operating e. Improper air piping a. Dryer over loaded (air flow) b. Heat exchanger clogged c. Frozen evaporator coil High temperature light ON (Refrigerant compressor OFF) a. Air inlet temperature too high b. Refrigerant shortage c. Blocked condenser Page 12

14 In an effort to maximize warranty support and minimize confusion concerning the Refrigerated Air Dryer warranty policy, the following is presented as a supplement to the standard Manufacturer's warranty policy. First, please note that the Manufacturer is not necessarily responsible for labor costs associated with a warranted part. It has been incorrectly assumed by many customers that the manufacturer would accept labor charges regardless of the claim submitted. This is not the case as indicated by the following clarifications. Problems such as plugged drains, burned out light bulbs, simple electrical trouble shooting, and minor adjustments will not be covered under warranty. It is our intent to work with the customer over the phone to correct such minor problems. For example: It is not uncommon for a hot-gas bypass valve to drift slightly out of calibration over a period of time. This simple adjustment can be performed by the customer under most circumstances. It requires no knowledge of refrigeration systems and will be supported by telephone and written documentation. This not only saves the customer time but also educates them on this common procedure so that it can be performed again when the dryer is not under warranty. Naturally, customers will not be expected to perform major repairs such as replacing a compressor or installing a heat exchanger. These tasks must be performed by a qualified technician. Along these lines, a customer may be asked to take ohm or amp readings to determine if a compressor needs to be replaced. At this point, it is not necessary to write down every task a customer may be asked to perform. These issues are better addressed on a case-by-case basis. Now that the written warranty policy has been reviewed and some examples given, the next step is to review the correct way to file a warranty claim. The following Warranty Procedure clearly outlines the obligations of the manufacturer and the procedure to be followed when processing a warranty claim. REFRIGERATED AIR DRYER WARRANTY These products are warranted to be free from defects in material and workmanship, under proper use, installation, application and maintenance in accordance with written recommendations and specification for a period of one year from the date of shipment from the factory (refrigerated dryers are warranted for 2 years). The obligation under this warrant is limited to, and the sole remedy for any such defect shall be, the repair or replacement (at manufacturer s option) of unaltered products returned and proven to have such defect, provided such defect is promptly reported within said one-year period. This is the only authorized warranty and is in lieu of all other express or implied warranties or representation, including any implied warranties of merchantability or fitness, or of any other obligations. Warranty claims must be submitted and shall be processed in accordance with established warranty claim procedure. In no event will manufacturer be liable for business interruptions, loss of profits, personal injury, costs of delay or for any other special, indirect, incidental or consequential losses, cost or damages. NOTE: Routine maintenance and minor adjustments to refrigerated compressed air dryers are not covered under this warranty. Prior to performing any possible warranty service or replacing a possible warranted part, the manufacturer must be notified. Failure to comply with this procedure will result in denial of warranty claim. Please fill in the Service Information Sheet prior to calling. Service Information Sheet 1. Dryer Model No. 2. Dryer Serial No. 3. Date Installed and Started Up 4. Prefilter Model No(s). (if no prefilters are present, so indicate) 5. Nature Of Problem Page 13

15 SERVICE INFORMATION We will be glad to assist with any service problems you may have. However, before contacting us, please have the following information available. 1. MODEL NUMBER 2. SERIAL NUMBER 3. What is the nature of the problem? 4. What is the Refrigerant Suction Pressure Gauge reading? OTHER INFORMATION NEEDED: A. AIR TEMPERATURES AND PRESSURES Inlet air temperature F ( C) Inlet air pressure psig (bar) Outlet air temperature F ( C) Outlet air pressure psig (bar) B. AIR FLOW What is H.P. of compressor? What is the air flow? scfm (Nm3/h) C. AMBIENT CONDITIONS AT DRYER INSTALLATION What is the ambient air temperature? F ( C) Is ambient air at dryer installation dusty? Has condenser been cleaned recently? Page 14