January 2008 Edition Carefully read this manual before attempting to operate or perform maintenance on this equipment. Instruction Manual Of Refrigerated Air Dryer Hangzhou Kelin Aier Qiyuan Equipment Co., Ltd.
CONTENTS Introduction 1 Function Introductions 1 Compressed Air & Refrigeration System Flow 1 Arranged Air Compress System 3 Usage requirement of the Air Dryer 3 Installation of the Air Dryer 4 Note item of the operation of the Air Dryer 5 Adjust of the Air Dryer 6 General Maintenance Information 6 Trouble Shooting 7 Electric Control circuit Diagram 12 1
1. Introduction The main purpose of this manual is teaching user how to make our equipment to be treated in exact use and maintenance. This procedure can prolong equipment's used-life and reduce trouble for assuring the quality of air dryer. This manual also offers the related data in equipment for reference & inspection. It's important to be familiar with this manual prior to starting this equipment; moreover, subject to the instruction in operation and maintenance for avoiding caused trouble of equipment. Note: Subject to principle exactly as follows, for avoiding dangerous. Maintenance. Do not exceed maximum operating pressure as shown on equipment serial number tag. Make sure equipment is depressurized before working on or disassembling it for servicing. Install equipment is compliance with national and local electrical codes. (220V+5%) Disconnect power supply to equipment when performing any electrical service work. 2. Function Introductions The main function of refrigerated type compressed air dryers is to remove the moisture in compressed air, lowering the compressed air temperature to 1.6oC at dew point temperature by air-to-refrigerant heat exchanger (refrigeration evaporator), and then, most of the water vapor condenses into liquid droplets which are separated out of the air stream by a separator and condensed liquid is discharged to out of the unit by auto drain, then finishing the whole drying process. If all conditions are normal, it just has about 0.59 g/m3 water vapor in dry compressed air, and its percentage of water removed can reach 93%. 3. Compressed Air & Refrigeration System Flow 3-1Compressed air flow Compressed air enters the dryer, lowering the air temperature by passing air cooler (17) first, next entering an heat exchanger (15), it can condense water vapor into liquid droplets and do pre-cooling job, then entering the evaporator (13); moreover, increasing the dryer effect. Then liquid droplets are removed from the air stream in the separator (9) and automatic drain (21). Finally the dry compressed air passes through the heat exchanger where it is reheated by the incoming air, refrigeration system flow. (See Diagram 1). 3-2Refrigeration system flow Refrigerant turns into air refrigerant of high pressure and high temperature by refrigeration compressor (1). Moreover, lowering the temperature of air refrigerant-by-refrigerant heat 2
exchanger (2) first, then enters into liquid refrigeration after heat dissipation by condenser (3). The main function of drier (7) is to dry and filter out water and impurity from refrigeration pipe. After high-pressure liquid refrigerant is expansion through capillary tube (11), then forming air and absorbing heat from compressed air in evaporator lowering air temperature, water vapor condenses into liquid droplets. Refrigerant flow returning to compressor side of inlet by through pipe, then continues use it after compressed it, then forming return route. (See Diagram 1) Flow Schematic Diagram of Model ADL (H) Air Dryer 1. Refrigeration Compressor 2. Refrigerant Heat Exchanger 3. Air Cooled Condenser 4. Water Cooled Condenser 5. Service Valve 6. Irrigate Valve 7. Dry Filter 8. Electric Valve 9. Refrigeration Screen 10. Expand Valve 11. Capillary 12. Heating Passby Valve 13. Evaporator 14. Air-water Separator 15. Air Heat Exchange 16. Water-air Separator 17. Air-cooled Front Cooler 18. Water-cooled Front Cooler 19. High-pressure Jump Protect Switch 20. Pressure Control switch 21. Auto Drain 22. Cooler Filter 23. Water Adjust Valve 24. High-pressure Safety Valve 25. Air-inlet Pressure Meter 26. Air-outlet Pressure Meter 27. Refrigeration Low-pressure Meter 28. Refrigeration High-pressure Meter DIAGRAM 1 4. Arranged Air Compress System It is necessary to arrange the Machine like the following Diagram. If have high requirement to the Air Dryer, please order Absorb Dryer behind Lever A Filter. The 3
order chosen of the T*A*F*H Lever Filter base on the technical requirement. Or consult with our technical work. Air saving barrel Air comprossor Back condenser C T A Cooling hopper dryer 5. Usage requirement of the Air Dryer 1) Base on the four item of arrange to choose the back Cooler of Air Compressor, Saving Barrel, Filter and the Air Dryer. During these, the Back Cooler and Saving Barrel is necessary and it must install between the Air Compressor and Air Dryer. The Lever C Filter must be placed and other Filters only refer with your necessary. 2) Usage of work station: Environment Temperature: 100.4 (Water cooler model not limited) Inlet Temperature : 113 Inlet Pressure: 29Psi-145Psi (Over than 145Psi may to order the goods) 6. Installation of the Air Dryer 1) Place smoothly on the ground (Over than 400W can add the ground-foot bolt). 2) Deal scaling with the outlet of the Air Compressor to the inlet of the Air Dryer's pipe, and can't use the easy saving water bend pipe. 4
3) Keep machine separate the environment for over 1 meter to ensure easy operate and fix and daily maintain. Air cooler ensures airness expediting and Water cooler ensure the inlet water pressure over 29 Psi than outlet water pressure. The diameter of the pipe must fit for the water flux. Inlet water temperature must lower than 113 and must be clean (fit for filter in the water inlet). 4) Air Dryer is a machine for refrigeration. So it mute be avoid the strong shake and lean when it to be moved, loaded or installed. 5) To add the Repairing valve and Bypass valve on the inlet of the Air Dryer. As the following diagram: 6) To avoid shaking and impulse need to add the saving barrel to the back of Air compressor. 7) Water cooler should be place the signal pipe, and forbid to using one pipe together with other Water Cooler machine. Bypass valve Compressed air 1 3 Inlet repairing valve Outlet repairing valve C.G T.G A.G Cooling hopper dryer 8) Installation of the electric A. Only set on power switch and don't use the setup switch together with other machine B. The pressure wave should near 5%. C. The place pipe should to avoid the section too small or long to cause the pressure voltage drop. D. Install a set of electric element beside of the power, for example the setup switch and the air switch and the fuse and so on. E. To touch the ground rightly. 7. Note Item of the Operation of the Air Dryer 1) Check the five step fitting the requirement of the usage or not. 5
2) Check the power: the voltage and the phase fit for the requirement or not, and the electric touch line right or not. 3) Air cooler: the airness of the condenser is expedite or not. Water cooler: the water pipe is expedite or not and the water pressure and the quality or the temperature fitting for the requirement or not. 4) The Filter of the Air Dryer install right or not. 5) The Bypass valve and the inlet repairing valve is closed or not and the outlet repairing is opened or not. 6) The Auto Drain ball valve is opened or not. 7) Check the machine with the refrigerate pressure meter to look the data of the machine is normal or not and on the normal the data of high-pressure meter and the low-pressure meter is equal or not. 8) Check the machine with the timing relay to set the delay time and the setting time data or not. 9) The air leave in the pipe is taken out or not. In addition, forbid to turn on or off the machine to many time to avoid attaining the compressor motor. 10) Order of the closing machine: Close the Air compressor and the inlet repairing valve first then to close the Air Dryer. 8. Adjust of the Air Dryer Our entire machine pass adjusts before out of the factory. And In generate, the user of below 120F(W) can use the machine install and operation illustration directly to open the machine. Over 150F(W) model machine should let our technical worker to adjust the machine for you. The operation people should take in our operation train first. During the using, if the machine having abnormal phenomena, should relate with our copsiny. And under leading of our technical worker adjust some valve. Forbid to operate blindness and cause to attain machine and the element. 9. General Maintenance Information 1) Clean the Air-cooling condenser usually to avoid the bott effect on the heating efficiency. Clean way like following diagram 2. 2) Check the automatic drain is needed to prevent sludge and contamination everyday. 6
If clog, please clean them by according to dissolve diagram 3. 3) Clean the Water-cooling with the clean water and note to clean the filter to avoid the pipe jam and can't expedite. The clean way like diagram 4. (If there is no water filter, should add a filter net on the inlet of the pipe. If the auto drain doesn't work, can use the drain by hand but it must exhaust the water in time to avoid the water inlet the air. 4) Note the three phases electric run with no phase. 5) Note to listen the compressor run in clam and no noise or not. 6) Note to touch the air inlet and outlet temperature with different temperature. (Normal condition is near 50-62.6 ).. 7) The environment temperature of the Air Dryer does not fit below to 50, to avoid attaining the compressor because of lacking the oil. 8) Clean the dust on the outside box usually. 10. Trouble Shooting A) Pressure-drop is too much Symptom Possible Cause Corrective Action 7
Pipe system is error Pipe valve hasn't open complete Pipe diameter is too small Pipe is too long, so the pipe bend and connector are too much Improper pipe arrangement due to two or more air compressors share the same dryer Filter in pipe system has blocked Open the pipe valve completely Use larger pipe Redesign pipe system Redesign pipe system Clear filter or replace new one Air flow exceed rated value Too much air leakage on pipe system's bend connector Air flow is higher than compressor's rated air discharge capacity and the pressure drops automatically Check bend connector compressor with larger air discharge capacity Reduce air flow The condensing water in Evaporator is frozen Temperature switch or pressure switch has faulty Error of expansion valve or heat-air bypass valve Check and adjust switch or replace new one Check to see the pipe system has blocked or not, adjust switch or replace new one Air flow is too small Enlarge air flow B) Air Dryer's water removing result isn't good Symptom Possible Cause Corrective Action Pipe system is abnormal Bypass valve hasn't closed The air hasn't passed through air dryer Close bypass valve Open air dryer's air inle completely 8
Air flow is too much large Drain system is abnormal Display of Cooling Medium's evaporating temperature is abnormal Air dryer isn't placed parallelly Auto Drain has incline Pipe for draining is higher than auto drain Pressure-drop is too much large Auto drain is wrong or drain valve has problem Auto drain's front valve hasn't opened Dew point is too high or too low Atmosphere temperature and inlet temperature is too low Circumstance air is too dreggy, ventilation is no good Cooling medium has leakage Place air dryer parallelly Place auto drain vertically Redesign draining pipe Redesign compressed air source Clean or replace new one Confirm that the front valve is on full-open position Adjust pressure switch, water flow switch, expansion valve and heat-air bypass valve Keep machine working continuous Select better position to place machine or improve ventilation Remove leakage and re-supply cooling medium C) Can't operation Symptom Possible Cause Corrective Action The power supply can't supple voltage Fuse has broken Wire has broken Check the condition of earth connection, check if the fuse has broken or there is short circuit. Find the broken point and repair 9
Voltage is abnormal Make the input voltage on the range shown on nameplate The power supply works normally but Switch has faulty Connector has faulty Over Current Relay has faulty can't startup High-low voltage switch has faulty machine Startup Breaker has faulty Capacitor has faulty Temperature Switch, Flow Switch has faulty Compressor has faulty Switches are all normal, but still can't startup machine High-low voltage switch or over-current relay hasn'treset after jumping off. Compressor has faulty Wire has loosen Find the reason for jumping off, then reset the switch or relay Find the loosen place and fasten D) Running is not good after startup Symptom Possible Cause Corrective Action Voltage is abnormal High-voltage witch jump off. After reset, the machine can't After startup, the circuit is short and cause adust smell Voltage switch or temperature switch has faulty to cause fan stop working The fan has faulty Overload switch jump off Reset circuit and switch, find the reason of abnormal voltage switch Check 10
startup Condenser is too dirty Clean Over Current Replay jumps off Capacitor has faulty Voltage switch or temperature switch has faulty to cause fan stop working Hydraulic switch has faulty Continuous startup for several times Compressor has overloaded Circumstance temperature or air dryer's inlet temperature Fuse has broken Contactor has faulty Cooling water hasn't recycled The interval between two startup should be 3 minutes Reduce air flow Improve ventilation or add cooling device Check cooling water E) Normal operation but bad effect in drain Symptom Possible Cause Corrective Action Incorrect pipe arrangement system Incorrect compressed air Incorrect cooling Hot gas by-pass valve isn't closed fully Air flow doesn't flow thru dryer Dryer is not laid flat Over flow rate High inlet temp. (Over 80oC) High ambient temp. (Over 40oC) Incorrect air pressure Leaky refrigerant Close the valve tightly Open all valves at inlet to dryer Lay flat the unit Add dryer Add aftercooler or increase HP, improve ventilation Improve ambient temp. Normal valve: 2-25kg/cm2 Remedy the leak, re-charge refrigerant 11
system Damaged valves Incorrect auto-drain system Refrigerant pipe lines are clogged Breakdown of pressure switch Breakdown of condenser or cooler motor fan Condenser fins clogged Drain valves are breakdown or not fully opened Incorrect working pressure Auto drain declined Strainer is clogged Drain lines clogged Drain lines are higher than auto drain's Trouble of drain float drier, vacuumize and re-change refrigerant Clean Renew or open valves Back to normal pressure 2-25 kg/cm2 Lay flate & reset Clean (refer to maintenance items) Clean Reset the drain lines F) Auto Drain has faulty Symptom Possible Cause Corrective Action Auto Drain has faulty Working pressure is below1.5kg/cm2 Pipe has blocked Drain damage or not open completely Drain is incline Drain's filter has blocked Working pressure is too high Drain pipe has blocked Increase working pressure Clean or open it completely Adjust position and fix it Clear Decrease working pressure Clean 12
5 5 6 7 6 3 7 2 3 2 8 1 8 1 Evaporator's pipe has blocked or rusted Beyond using life and replace 11. Electric Diagram only for Air Cooler 23~27m3 ordinary temperatures Circuit diagra 13.5~17m3 ordinary temperatures Circuit diagra CF1 0.7~14.5m3 ordinary temperatures Circuit diagra 13
5 6 3 7 8 2 1 5 6 3 7 2 8 1 5 5 6 3 6 7 8 3 2 1 7 8 2 1 34~55m3 ordinary temperatures Circuit diagra 13.5~17m3 ordinary temperatures Circuit diagra C F 300~500F high temperatures Circuit diagra 120~200F high temperatures Circuit diagra FR FR CF1 5~100F high temperatures Circuit diagra 14
DL Air Switch FR Heating Relay K Touch Exchange R Compressor Heater FU Fuse Protector COMP Refrigerate Compressor SS Setup Switch ST Stop Switch HPS High-pressure Jump Switch LPS Low-Pressure Jump Switch T Time Delay CF Fan Motor 15