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. 83-191-100, Rev D 4/97 Printed in the U.S.A.
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
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: 3 4 7 1 2 5 6 8 11 10 11 12 13 TO PLANT 9 9 9 11 14 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
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 0.5-1.0 Micron 0.01 Micron lbs WRA-0050 1" NPT 50 F26-04-F00 M21-03-FS0 M21-03-F00 280 WRA-0075 1" NPT 75 F30-08-F00 M30-04-FS0 M30-04-F00 300 WRA-0100 1" NPT 100 F30-08-F00 M30-08-FS0 M30-08-F00 325 WRA-0150 1 1 /2" NPT 150 F30-08-F00 M31-08-FS0 M31-08-F00 325 WRA-0200 1 1 /2" NPT 200 F30-08-F00 M32-0A-FS0 M32-0A-F00 650 NOTE: Recommended filters were selected on the basis of flow capacity not pipe size. DIMENSIONS 2.00 34.00 26.00 FRONT VIEW FRONT VIEW 3.25 4.19 AIR OUTLET 5.12 27.00 AIR OUTLET AIR INLET 5.50 17.79 AIR INLET 16.50 AIR INLET OUTLET SIDE VIEW WRA-0150 & WRA-0200 WRA-0050-0100 Page 3
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. 12.00 305 Inches millimeters 12.00 305 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
100 75 125 600 800 50 400 1000 150 200 1200 25 175 0 1400 200 100 75 125 600 800 50 400 1000 150 200 1200 25 175 0 1400 200 6 8 4 80 10 60 140 40 160 2 12 180 20 200 psi 14 bar 6 8 4 80 10 60 140 40 160 2 12 20 180 200 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 28 52.4 30 54.9 32 57.5 34 60.1 36 62.8 38 65.6 40 68.5 45 76.0 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. 1 2 1 Switch, ON/OFF WRA-0050-0200 87-379-000 2 Light, High Temperature WRA-0050-0200 87-382-000 (See Trouble Shooting) 3 Gauge, Inlet Air Pressure WRA-0050-0200 49-111-000 4 Gauge, Refrigerant WRA-0050-0200 49-093-000 Suction Press 5 Digital Display WRA-0050-0200 87-508-000 6 Selector Knob WRA-0050-0200 87-470-000 POWER ON HIGH TEMP. REFRIGERA TED AIR DR YER 3 4 adjusting nut POWER ON SYSTEM MONITOR 100 120 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 100 120 REFRIGERANT SUCTION PRESSURE TED AIR DR YER FIGURE 1 5 6 INCREASING THE SUCTION PRESSURE WILL RAISE THE EVAPORATOR TEMPERATURE. DECREASING THE SUCTION PRESSURE WILL LOWER THE EVAPORATOR TEMPERATURE. Page 5
CABINET COMPONENTS Part Item Description Model Number Number 1 Grill, Inlet WRA-0050 & WRA-0075 63-801-000 WRA-0100-0200 63-063-000 2 Grill, Exhaust WRA-0050-0100 63-802-000 WRA-0150 & WRA-0200 63-063-000 3 Panel, End, Exhaust WRA-0050-0100 63-803-000 WRA-0150 & WRA-0200 63-804-000 4 Panel, Rear WRA-0050-0200 63-075-000 5 Panel, End, Inlet WRA-0050-0200 63-089-000 6 Top WRA-0050-0200 63-130-000 7 Base WRA-0050-0200 15-153-000 Page 6
REFRIGERATION COMPONENTS AND PARTS LIST Item Description Voltage Model # Part # 1 Compressor 115-60-1 WRA-0050 51-120-100 208/230-60-1 WRA-0050 51-120-101 208/230-50-1 WRA-0050 51-120-102 115-60-1 WRA-0075 51-120-103 After S/N# 208/230-60-1 WRA-0075 51-003-000* 208/230-50-1 WRA-0075 51-120-105 115-60-1 WRA-0100 51-120-106 208/230-60-1 WRA-0100 51-120-107 208/230-60-3 WRA-0100 51-149-104 208/230-50-1 WRA-0100 51-120-108 115-60-1 WRA-0150 51-120-109 208/230-60-1 WRA-0150 51-120-110 208/230-60-3 WRA-0150 51-149-100 440/460-60-3 WRA-0150 51-149-101 208/230-50-1 WRA-0150 51-120-111 208/230-60-1 WRA-0200 51-120-112 208/230-60-3 WRA-0200 51-149-102 440/460-60-3 WRA-0200 51-149-103 2 Electrical Box 3 Separator WRA-0050-0100 WSA-08-F00 WRA-0150-0200 WS0-0B-000 4 Fan Guard WRA-0050-0100 51-150-100 WRA-0150-0200 51-150-101 5 Fan Blade WRA-0050-0075 51-137-100 WRA-0100 51-137-101 WRA-0150-0200 51-137-102 6 Air Circuit WRA-0050-0075 ARP-96-949 Assembly Item Description Voltage Model # Part # Air Circuit WRA-0100 ARP-96-950 Assembly Cont. WRA-0150-0200 ARP-96-948 7 Refrigerant Service Valve ALL 52-090-000 8 Fan Cycle Control ALL 87-121-000 9 High Pressure Control ALL 87-120-000 10 Filter Dryer ALL 54-071-000 11 Hot-Gas ByPass Valve WRA-0050-0100 52-000-000 WRA-0150-0200 52-165-000 12 Accumulator ALL 54-121-000 13 Exchanger, Suction, Liquid ALL ARP-96-947 14 Fan Motor 115 WRA-0050 51-130-100 208/230 WRA-0050 51-130-102 115 WRA-0075 51-130-100 208/230 WRA-0075 51-130-102 115 WRA-0100 51-130-101 208/230 WRA-0100 51-130-102 115 WRA-0150-0200 51-130-103 208/230 WRA-0150-0200 51-130-104 440/460 WRA-0150-0200 51-130-105 15 Condenser WRA-0050-0075 50-121-100 WRA-0100 50-121-101 WRA-0150-0200 50-121-102 16 Base ALL 15-153-000 *NOTE: See electrical box components for run components before and after serial number 3-12-1997-511. Page 7
ELECTRICAL BOX COMPONENTS Item Description Voltage Model # Part # 1 Electrical Box ALL 63-753-000 2 Electrical Box Cover ALL 63-754-000 3 Transformer ALL 87-044-000 4 Contactor ALL 87-063-000 5 Start Relay 115-60-1 WRA-0050 87-600-100 208/230-60-1 WRA-0050 87-600-101 208/230-50-1 WRA-0050 87-600-101 115-60-1 WRA-0075 87-600-100 208/230-60-1 WRA-0075 87-600-103 Before S/N# 208/230-60-1 WRA-0075 87-600-104* After S/N# 208/230-60-1 WRA-0075 87-600-109* 115-60-1 WRA-0100 87-600-100 208/230-60-1 WRA-0100 87-600-100 208/230-60-3 WRA-0100 N/A 208/230-50-1 WRA-0100 87-600-104 115-60-1 WRA-0150 87-600-107 208/230-60-1 WRA-0150 87-600-105 208/230-60-3 WRA-0150 N/A 440/460-60-3 WRA-0150 N/A 208/230-50-1 WRA-0150 87-600-106 208/230-60-1 WRA-0200 87-600-108 208/230-60-3 WRA-0200 N/A 440/460-60-3 WRA-0200 N/A 6 Start Capacitor 115-60-1 WRA-0050 87-610-100 208/230-60-1 WRA-0050 87-610-100 208/230-50-1 WRA-0050 87-610-100 115-60-1 WRA-0075 87-610-100 Before S/N# 208/230-60-1 WRA-0075 87-610-100* After S/N# 208/230-60-1 WRA-0075 87-610-102* 208/230-50-1 WRA-0075 87-610-100 115-60-1 WRA-0100 87-610-100 Item Description Voltage Model # Part # 6 Start Capacitor 208/230-60-1 WRA-0100 87-610-100 Cont. 208/230-60-3 WRA-0100 N/A 208/230-50-1 WRA-0100 87-610-100 115-60-1 WRA-0150 87-610-100 208/230-60-1 WRA-0150 87-610-100 208/230-60-3 WRA-0150 N/A 440/460-60-3 WRA-0200 N/A 208/230-50-1 WRA-0150 87-610-102 208/230-60-1 WRA-0200 87-600-100 208/230-60-3 WRA-0200 N/A 440/460-60-3 WRA-0200 N/A 7 Run Capacitor 115-60-1 WRA-0050 87-613-100 208/230-60-1 WRA-0050 87-613-100 208/230-50-1 WRA-0050 87-613-100 115-60-1 WRA-0075 87-613-100 208/230-60-1 WRA-0075 87-613-100 208/230-50-1 WRA-0075 87-613-100 115-60-1 WRA-0100 87-613-101 208/230-60-1 WRA-0100 87-613-100 208/230-60-3 WRA-0100 N/A 208/230-50-1 WRA-0100 87-613-100 115-60-1 WRA-0150 87-613-100 208/230-60-1 WRA-0150 87-613-101 208/230-60-3 WRA-0150 N/A 440/460-60-3 WRA-0150 N/A 208/230-50-1 WRA-0150 87-613-100 208/230-60-1 WRA-0200 87-613-102 208/230-60-3 WRA-0200 N/A 440/460-60-3 WRA-0200 N/A 8 Junction Box ALL 87-104-000 9 Junction Box, Cover ALL 87-110-000 *NOTE: See electrical box components for run components before and after serial number 3-12-1997-511. Page 8
WIRING DIAGRAM (Optional) VOLTAGE -1 SINGLE PHASE WIRING DIAGRAM Page 9
WIRING DIAGRAM VOLTAGE - 2 & - 6 SINGLE PHASE WIRING DIAGRAM Page 10
WIRING DIAGRAM VOLTAGE - 3- & - 4 - THREE PHASE WIRING DIAGRAM Page 11
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
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
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