TOOLOTS Refrigerated Compressed Air Dryers Instruction Manual

Refrigerated Compressed
Air Dryers
operation instruction

Introduction

The main purpose of this manual is teaching user how to make our equipment to be treated n exact use and maintenance. This procedure can prolong equipment’s used-life and reduce rouble 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.

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%.

Compressed Air & Refrigeration System Flow

• 3-1Compressed air flow
  Compressed air enters the dryer, lowering the air temperature by passing air cooler (12) first, next entering an heat exchanger (7), it can condense water vapor into liquid droplets and do pre-cooling job, then entering the evaporator (6); moreover, increasing the dryer effect. Then liquid droplets are removed from the air stream in the separator (9) and automatic drain (10). 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 exchanger (2) first, then enters into liquid refrigeration after heat dissipation by condenser (3). The main function of drier (4) is to dry and filter out water and impurity from refrigeration pipe. After high-pressure liquid refrigerant is expansion through capillary tube (5), 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

Flow Schematic Diagram of Model XS- A (AH) 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 Pass by 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

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 3 Filter. The order chosen of the 753*1 Lever Filter base on the technical requirement. Or consult with our technical work.

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: ≤42℃ (Water cooler model not limited)
Inlet Temperature : XS- A≤45℃ XS- AH ≤80℃
Inlet Pressure: 0.2Mpa-1.0Mpa (Over than 1.0Mpa may to order the goods) Quantity of Cooler Water: Account on 0.18 t/h with every dealing 1Nm3/min Cooler Water Temperature: Inlet water temperature≤35℃ Cooler Water pressure: 0.2-0.4Mpa

Installation of the Air Dryer

1. Place smoothly on the ground

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.

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 0.2 Mpa than outlet water pressure. The diameter of the pipe must fit for the water flux. Inlet water temperature must lower than 32℃ 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.

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.

Note Item of the Operation of the Air Dryer

1. Check the five step fitting the requirement of the usage or not.

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.

6. 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.

7. Check the machine with the timing relay to set the delay time and the setting time data or not.

8. The air leave in the pipe is taken out or not.
   Air cooler to observer the fan having the auto turn on or off capacity:
   XS-06-1A(AH): turn on the fan (low pressure :0. 24 Mpa), off the fan (low pressure:0. 2Mpa) XS- A(AH)-Over 2A(AH): turn on the fan (low pressure:044Mpa or high-pressure 1.6Mpa), off the fan (low pressure:0. 4Mpa or high-pressure 1.4Mpa).
   Water cooler: the low-pressure data of refrigerate will stabilization between with the 0.4Mpa-0.45Mpa.And the high-pressure data of the refrigerate will stabilization between with the 1.4-1.6Mpa. After above condition we can take the Air Dryer as work normal. And after setup the air compressor and the saving air barrel pressure data to 0.7Mpa, can open slowly the compressor inlet-repairing valve to compress air and the pressure will add to the machine slowly. Forbid to open the inlet-repairing valve fierce to cause the shock wave inside the machine or to attain the Evaporator and so on elements. In addition, forbid to turn on or off the machine to many time to avoid attaining the compressor motor.

9. Order of the closing machine:
   Close the Air compressor and the inlet repairing valve first then to close the Air Dryer.

Adjust of the Air Dryer

Our entire machine pass adjusts before out of the factory. And In generate, the user of below 12A(W) can use the machine install and operation illustration directly to open the machine. Over 15A(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 company. And under leading of our technical worker adjust some valve. Forbid to operate blindness and cause to attain machine and the element.

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. Check the automatic drain is needed to prevent sludge and contamination everyday. If clog, please clean them by according to dissolve diagram

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 10-17℃)..

7. The environment temperature of the Air Dryer does not fit below to 10℃, to avoid attaining the compressor because of lacking the oil.

8. Clean the dust on the outside box usually.

Trouble Shooting

A) Pressure-drop is too much

completely
Pipe diameter is too small| Use larger pipe
Pipe is too long, so the pipe bend and connector are too much| Redesign pipe system
Improper pipe arrangement due to two or more air compressors share the same dryer| Redesign pipe system
Filter in pipe system has blocked| Clear filter or replace new one
Too much air leakage on pipe system’s bend connector| Check bend connector
Air flow exceed
rated value| Air flow is higher than compressors rated air discharge capacity and the pressure drops automatically| Replace compressor with larger air discharge capacity
---|---|---
Reduce air flow
The condensing
water in Evaporator is frozen| Temperature switch or pressure switch has faulty| Check and adjust switch or
replace new one
Error of expansion valve or heat-air bypass valve| 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

compressed      air source
Drain system is abnormal| Auto drain is wrong or drain valve has problem| Clean or replace new one
Auto drain’s front valve hasn’t opened| Confirm that the front valve is on full-open position
Display of Cooling Medium’s evaporating temperature is abnormal| Dew point is too high or too low| Adjust pressure switch, water flow switch, expansion valve and heat-air bypass valve
Atmosphere temperature and inlet temperature is too low| Keep        machine working continuous
Circumstance    air    is    too    dreggy, ventilation is no good| Select better position to place machine or improve ventilation
Cooling medium has leakage| Remove leakage and re-supply cooling medium

C) Can’t operation

Fuse has broken

| Check the condition of earth connection, check if the fuse has broken or there is short circuit.
Wire has broken| Find the broken point and repair

The power supply works normally but can’t startup machine

| Voltage is abnormal| Make the input voltage on the range shown on nameplate
Switch has faulty| Replace
Connector has faulty| Replace
Over Current Relay has faulty| Replace
High-low voltage switch has faulty| Replace
Startup Breaker has faulty| Replace
Capacitor has faulty| Replace
Temperature Switch, Flow Switch has faulty| Replace
Compressor has faulty| Replace

Switches are all normal, but still can’t startup machine

| High-low voltage switch or over-current relay hasn’treset after jumping off.| Find the reason for jumping off, then reset the switch or relay
Compressor has faulty| Replace
**** Wire has loosen| Find the   loosen   place   and fasten

D) Running is not good after startup

be 3 minutes
Compressor has overloaded| Reduce air flow
Circumstance temperature or air dryer’s inlet temperature| Improve ventilation or add cooling device
Fuse has broken| Replace
Contactor has faulty| Replace
Cooling water hasn’t recycled| Check cooling water

E) Normal operation but bad effect in drain

Close the valve tightly
Air flow doesn’t flow thru dryer| Open all valves at inlet to dryer
Dryer is not laid flat| Lay flat the unit
Incorrect compressed air| Over flow rate| Add dryer
High inlet temp. (Over 80oC)| Add aftercooler or increase HP, improve ventilation
High ambient temp. (Over 40oC)| Improve ambient temp.
Incorrect air pressure| Normal valve: 2-25kg/cm2
Incorrect cooling system| Leaky refrigerant| Remedy the leak, re-charge
refrigerant
Damaged valves| Replace
Refrigerant pipe lines are clogged| Replace drier, vacuumize and re-change refrigerant
Breakdown of pressure switch| Replace
Breakdown of condenser or cooler
motor fan| Replace
| Condenser fins clogged| Clean
---|---|---
Incorrect auto-drain
system| Drain valves are breakdown or not fully opened| Renew or open valves
Incorrect working pressure| Back to normal pressure 2-25 kg/cm2
Auto drain declined| Lay flate & reset
Strainer is clogged| Clean (refer to maintenance
items)
Drain lines clogged| Clean
Drain lines are higher than auto drain’s| Reset the drain lines
Trouble of drain float| Replace

F) Auto Drain has faulty

Auto Drain has
faulty| Working pressure is belowl.5kg/cm2| Increase working pressure
Pipe has blocked| Clean
Drain damage or not open completely| Replace or open it completely
Drain is incline| Adjust position and fix it
Drain’s filter has blocked| Clear
Working pressure is too high| Decrease working pressure
Drain pipe has blocked| Clean
Evaporators pipe has blocked or rusted| Beyond using life and replace

CT8893D User Guide Version: h160826

1. Technique Index
   • Temperature display range: -20～100℃（The resolution is 0.1℃)
   • Power supply: 220V±10% （ Product supply voltage to the product label shall prevail）
   • Temperature sensor: NTC R25=5kΩ,B(25/50)=3470K

2. Operating Guide
   2.1 Meaning of the index lights on the panel

compressor start delay pro
| Fan| Fanning| –
| Defrost| Defrosting| –
| Alarm| –| Alarm state

2.2 Meaning of the LED display
Alarm signal will alternate display temperature and warning code. (A xx)
To cancel the alarm need recharge the controller. Display code as follow:

parameter code “F50”
A21| The dew-point sensor fault| The dew-point sensor broken-line or short circuit (The dew-point temperature display “OPE” or “SHr”)
A22| Condensation sensor fault| The condensation broken-line or short circuit ( Press ” ” will display “SHr” or “OPE”)
A31| The dew-point temperature fault| If alarm occurred in the dew-point temperature higher than the set value, can choose whether closing down or not (F51).
| | The dew-point temperature alarm will not occurred when compressor starts in five minutes.
A32| Condensation temperature fault| If alarm occurred in the condensation temperature higher than the set value, can choose whether closing down or not.（F52）

2.3 Temperature display
After power on self-test, the LED display the dew-point temperature value. When press on“ ”, it will display the temperature of condenser. Reverse will back to display the dew-point temperature.
2.4 Cumulative working hours display
Pressing on the“ ”at the same time, will display the compressor accumulated operational time. Unit: hours
2.5 Higher level operation
Long press “M” 5 seconds to enter parameter setting condition. If have set the command, will display word “PAS” to hint import the command. Using press“ ”to import the command. If the code is right, it will display parameter code. Parameter code as followed table:

Category| Code| Parameter name| Setting
range| Factory
setting| Unit| Remark
---|---|---|---|---|---|---
| F51| i he x% a) o1 dealing with dew-point temperature alarm.| 0 – 1| 1| –| 0 : Only alarm, not close.
1: Alarm and close.
F52| The way of dealing with condensation temperature alarm.| 0 – 1| 1| –| 0 : Only alarm, not close.
1: Alarm and close.
System means| F80| Password| OFF
0001 —
9999| of I| | OFF means no password
0000 System means clearing password
---|---|---|---|---|---|---
F83| Switch machine state memory| YES – NO| YES| |
F85| Display the compressor accumulated operational time| | | Hour|
P86| Reset compressor accumulated operational time.| NO — YES| NO| | NO: not reset YES: reset
| F88| Reserved|
Testing| F98| Reserved|
F99| Test-self| This function can attract all relays in turn, and please don’t use it when the controller is running!
| End| Exit|

Basic Operating Principle

3.1 Compressor control
After controller powered on, the compressor will delay for a moment to protect itself (F21).
The indicator light will flicker at the same time. If checked external input is alarming, the compressor will stop.
3.2 Fan control
Fan default under control of condensing temperature. It will open when temperature is higher than (including) set point (F42) , closed when lower than the set point – return difference (F43) . If condensation sensor fails, the fan output along with the compressor.
3.3 External alarm
When external alarm occurs, stop the compressor and fan. External alarm signal has 5 modes (F50): 0: without external alarm, 1: always open, unlocked, 2: always open, locked; 3: always closed, unlocked; 4: always closed, locked. “Always open” means in normal state, external alarm signal is open, if closed, the controller is alarm; “Always closed” is on the contrary. “Locked” means that when external alarm signal becomes normal, the controller is still in the alarm state, and it needs to press any key to resume.
3.4 Command
In order to prevent irrespective persons from changing the parameters, you can set a password (F80), and if you have set a password, the controller will hint you to enter the password after you press the key “M” for 5 seconds, you must enter the correct

Category| Code| Parameter name| Setting
range| Factory
setting| Unit| Remark
---|---|---|---|---|---|---
Temperature| 0.00E+00| dew-point temperature warning point| 10 – -1| | C| It will warning when the temperature
higher than the set value.
F12| Condensation temperature warning point| 42 – 70| 65| °C
F18| Dew-point sensor amendment| -20.0 —
20.0| 0.0| °C| Amend dew-point
sensor error
F19| Condensation sensor
amendment| -20.0 –
20.0| 0.0| °C| Amend condensation sensor error
Compressor| F21| Sensor delay time| 0.0 — 10.0| 1.0| Min
ute|
Fan/ Antifreezing| ****

F31

| Start antifreezing demand temperature| -5.0 – 10.0| **** 2.0| **** ℃| It will start when dew-point temperature lower than the set value.
---|---|---|---|---|---|---
**** F32| Antifreezing return difference| 1 – 5| 2.0| ℃| It will stop when dew-point temperature higher than F31+F32.
F41| The second way the output mode.| OFF 1-3| 1| –| OFF: close fan

1.   The fan under the control of condensation temperature.
2.   Fan worked at the same time with compressor.
3.   Antifreezing outpu mode.

F42| Fan start temperature| 32 – 55| 42| ℃| It will start when condensation temperature higher than the set value. It will close when lower than set return difference.
F43| Fan close temperature return difference.| 0.5 – 10.0| 2.0| ℃
Alarm| F50| External alarm mode| 0 – 4| **** 0| **** –| 0: without external alarm
1  : always open, unlocked
2  : always open, locked
3: always closed, unlocked
4: always closed, locked
---|---|---|---|---|---|---

password, and then you can set the parameters. If you don’t need the password, you can set F80 to “0000”. Notice that you must remember the password, and if you forget the password, you can not enter the set state.

Wiring Diagram

Notes

• Please use the temperature sensor allocated by our company.
• If compressor power is less than 1.5HP, can direct control by internal relay. Otherwise need to connect ac contactor.
• Fan loaded with no more than 200w.
• We have installed a 460V transformer to 220V, and the customer is connected to the 460V/60hz power supply, which can be directly used

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