TOOLOTS RAD Series Refrigerated Air Dryer Instruction Manual

TOOLOTS RAD Series Refrigerated Air Dryer

Device system flowchart

The device system flowchart provides an overview of the equipment and its components.

1. Refrigerant compressor
2.  Refrigerant heat exchanger(Under 6m’)
3. Air cooled condenser
4.  Water cooled condenser
5.  Placing a valve
6.  Device for drying and filtering
7.  Solenoid valve(More than 30m°)
8. Expansion valve(More than 15m°)
9. Capillary
10. Hot gas bypass valve(More than 8m’)
11. Evaporator
12. Gas-water separator
13. Air heat exchanger
14.  Liquid gas separator(More than 10m’)
15. Air cooled front cooler(HF type with)
16.  Water cooled front cooler(HW type with
17. High voltage trip protection switch
18.  Pressure control switch
19. Automatic drainer
20.  Safety valve
21. Air inlet pressure valve
22. Air outlet pressure valve
23.  Refrigerant low pressure meter
24. Refrigerant high pressure meter

Saturated compressed air of higher temperature enters the pre-cooler of cold dryer to exchange heat with the cold dry air from evaporator and then enters the evaporated of refrigeration system when its temperature is reduced to exchange heat with cooling vapor for the second time to reduce its temperature to the evaporating temperature of cooling medium. During the two cooling courses, the water vapor in the compressed air is turned into liquid and flows into the vapor-liquid separator. The liquid separated in the separator is drained out of the equipment through automatic drainer (not charted). The compressed dry air of lower temperature enters the pre-cooler to exchange heat with the saturated air to increase its temperature and the compressed dry air of low moisture (dew point) and low relative humidity is obtained at the outlet. Pre-cooler, evaporator and vapor-liquid are the three major parts of the air flow system in cold dryer.

Device installation and testing

The C grade filter should be installed before the refrigeration dryer to avoid contamination on the heat exchanger surface of the refrigeration dryer caused by unfiltered compressed air. The power supply of the refrigeration dryer must be single phase 115V 60HZ or 230V 60HZ to guarantee proper operation. An individual electrical cabinet conforming to the power requirements must be installed.The following drawing shows the standard installation of the equipment. The C grade filter should be installed in principle to avoid the contamination on heat exchanger surface of refrigeration dryer caused by the unfiltered compressed air.

Notes:

•  A clearance of no less than 1 meter should be left around the refrigeration dryer.
•  The refrigeration dryer can be installed without foundation, but the ground must be leveled.
• T and A filters can be selected and fixed accordingly. Please refer to the user’s manual of filter for installation.
• If this equipment is to be used together with piston compressor, a buffering gas container should be installed before the refrigeration dryer to eliminate the effect of the pulsation of air source.

Warning：
The power supply of refrigeration dryer shall be single phase 115V 60HZ or 230V 60HZ. In order to guarantee the proper operation, individual electrical cabinet conforming to the power requirements must be installed.

Device instructions

 Device working conditions

The device requires a power supply voltage of 115V 60HZ or 230V 60HZ. The working pressure ranges from 0.6 MPa to 1.0 MPa and the inlet air temperature ranges from 38 to 80 degrees Celsius depending on the type of equipment. The cooling water pressure should be between 0.2-0.5Mpa, and the water inlet temperature should be 31 degrees Celsius while the water outlet temperature should be 37 degrees Celsius.

Power supply| Voltage：115V 60HZ    or    230V 60HZ
Please refer to the nameplate for parameters as for special equipments
---|---
Working pressure| Rated 0.8 MPa（0.6 MPa ~1.0 MPa）
Please refer to the nameplate for parameters as for high-pressure equipments
Inlet air temperature| Standard type: rated 38℃,maximum 45℃； High temperature type: rated65℃ maximum 80℃
Cooling water (Water cooling type)| water pressure：0.2-0.5Mpa water inlet temperature：31℃ water outlet temperature：37℃
Water quality: neutral water with PH6.5~7.5, without observable solid impurities
Environment| **** Environmental temperature：
Air cooling type （A）：≥2℃，≤38℃ Water cooling type （W）：≥2℃，≤45℃ Environmental humidity： 80%
Above sea level： less than1000m
Surroundings: no caustic fumes around Installation method: indoor (installation without base is allowed)

 Operating instructions

1. Start the dryer for 3~5 minutes.
2. Start the inlet air valve.
3. Start the outlet air valve according to the load rate until it reaches the rated load.
4. Check the inlet/outlet pressure gauge (the difference of the two readings within 0.03MPa is acceptable).
5. Check the status of the automatic drainer.
6. Keep a record of the working condition of dryer, inlet/outlet air pressure, cooling medium high pressure, low pressure, etc.
7. To stop the equipment, first stop the outlet air valve; secondly, close the inlet air valve; and finally, press the stop button.

• Check the following items before starting the device

1. All valves on the pipe network shall be at the ready-to-work condition pipe system:
2.  Turn on the cooling water valve and maintain the pressure within 0.2—0.5MPa and the temperature below 31℃.
3. The indications of high-pressure gauge and low-pressure gauge of cooling medium on the panel are normal and approximately equal (note: there is only low-pressure gauge for small equipment)
4. Examine the power supply and make sure the rated value doesn’t exceed ±10%.
   •  If the above-mentioned items are normal, start the equipment.
5.  Press the “start” button, and the cooling medium compressor will start thereafter:
6.  Observe the panel, when the type of refrigerant is R22 ，the high pressure gauge of cooling medium should slowly increase to about 1.6MPa and the low pressure gauge of cooling medium should slowly reduce to about 0.4MPa. The equipment has now entered the normal working condition:
   Other common cooling medium shown in the following table:

Refrigerant Type| High pressure gauge of cooling medium (MPa)| Low pressure gauge of cooling medium (MPa)
---|---|---
R134a| 1.1| 0.2
R22| 1.6| 0.4
R410a| 2.3| 0.7
7. First, start the dryer for 3~5 minutes; secondly, start the inlet air valve; finally, start the outlet air valve according to the load rate until it reaches the rated load. 8. Check the inlet/outlet pressure gauge (the difference of the two readings within 0.03MPa is acceptable) 9. Check the status of the automatic drainer. 10. Keep a record of the working condition of dryer, inlet/outlet air pressure, cooling medium high pressure low pressure etc. 11.  Stop steps: first, stop the outlet air valve; secondly, close the inlet air valve: and finally, press the “stop” button.

Notes

During usage, avoid long-term operation without load. Do not start the cooling medium compressor again and again and do not start it over 6 times within an hour. To guarantee air quality, strictly follow the start and stop steps.
Please pay close attention to the following issues when using the refrigeration dryer:

1. Avoid long term operation without load.

2.  Don’t start the cooling medium compressor again and again and don’t start over 6 times within an hour.

3.  In order to guarantee the air quality, please carrying out the start and stop steps strictly. Start: run the dryer for 3~5minutes before starting the air compressor or inlet valve.
   Stop: turn off air compressor or outlet valve and then turn off the dryer.

4. Make sure the bypass valve connecting the inlet and outlet pipe is turned off in operation to avoid the unprocessed air flow into the low reach pipe network.

5. The air pressure shall not exceed 0.95MPa. (As for high-pressure equipment, please refer to the nameplate of the machine)

6.  The inlet air temperature shall not exceed 45℃for standard type and 80℃ for high-temperature type.

7. The temperature of cooling water shall not exceed 31℃.

8. Don’t start the equipment when the temperature is less than 2℃

9. The delay of the relay in the electrical control cabinet shall not be set less than 3 minutes.

10.  Normally, only the start or stop button shall be used.

11. Wind-type refrigeration dryer cooling fan is controlled by pressure switch when the refrigeration dryer works in a low temperature environment, it is normal if the fan doesn’t work. The fan will start automatically as the pressure of cooling medium increases.

Daily maintenance of device

Perform daily maintenance of the device to ensure proper functioning. Check for oil leaks and water leaks in the refrigeration system. Clean the air filter and replace it if necessary. Check the fan belt tension and adjust it if necessary.
Lubricate the fan motor bearings and other moving parts.

• Blow the dust, ash and fiber of the wind cooled condenser with compressed air regularly.
• Automatic drainer tends to be blockaded by pollutant in condensed water and please clean the stainless-steel filter screen regularly by water or soap.
• Clean the water condenser regularly.
•  Routine inspection: power supply, water supply and gas supply conditions. Observe and keep the reading on the panel of the refrigeration dryer.

Trouble-shootings of common fault

If you encounter any issues with the equipment, refer to Chapter 4 for troubleshooting tips.
Dear user, in order to use this equipment properly, please read this manual carefully and carry out the steps described in this manual strictly. If the equipment fails, please examine the equipment according to the troubleshooting list in this manual carefully, or contact agents authorized by our company, of dial our after-sale service hotline for assistance. If you maintain the equipment regularly, you will bring out its best performance. We hope that this product will facilitate your work and thank you very much for using this machine！
The internal and external causes of faults of the desiccators are as follows. The causes and troubleshooting are presented here.

Pressure drop increase

open the valve
Too small diameters of pipes, too long pipe length or too many elbows.| Redesign the piping system.
Pipe system filter blockage| Clean or replace the filter medium
Pipe system leakage| Decide the leaking point and fix it.
Condensed water frozen inside evaporator| Poor set or control of low- pressure switch| Reset or replace the valve of low-pressure switch.
Fault or poor set valve of expansion valve and heated air bypass valve| Reset or replace the valve
The air volume exceeds the rating volume of desiccators| Reduce the air flow
Replace air compressor or refrigeration desiccators

Refrigeration dryers start failure

and treat accordingly to restore power supply
Fuse burning or air switch tripping| Find out the cause and treat accordingly to restore power supply
Start failure with proper power supply| Voltage abnormality| The voltage shall be 115V±10% or 230V±10%
Control circuit fault| Replace with a new one
Control circuit fault| Find out the cause and treat accordingly
Poor electric contact| Fix or replace with a new one
Reset failure after protection system tripping| Find out the cause of tripping, treat accordingly and then reset
Compressor fault| Check the compressor and treat accordingly
Internal MP action of compressor| Reset when the compressor gets cool

Poor automatic drain system

Proper working pressure of automatic water drainer is within 0.2~1.0Mpa
Filter screen blockage in water drainer| Clean the filter screen
The preceding ball valve of water drainer is not opened| Open the filter screen
Drainpipe blockage| Clean the pipe
**** Draw off valve damage| Replace the float ball inside water drainer or replace the water drainer

Poor drainage

Cause Analysis

|

Corrective measures

---|---
Poor installation and piping system| Bypass valve fails to close or to be closed fully| Close the bypass valve
The air doesn’t pass through the dryer| Open the inlet valve
The dryer is not leveled in installation| Horizontalization
Loped automatic drainer| Horizontalization
The drainage system is higher than automatic drainer| Redesign the drainage pipe system
Poor drain system| Ball valve of drainer fails to open| Open the ball valve
Water drainer blockage of damage| Clean or replace drainer
Cooling medium system fault| Too high cooling medium condensing pressure| Adjust the water flow governing valve, expansion valve, hot-gas bypass valve or pressure switch
Too high air inlet temperature| Add a rear condenser
Cooling medium leakage| Decide the leakage, fix the leakage, and refill cooling medium
Compressor fault| Check the compressor

Bad working performance with proper operation of dryer

Cause analysis

|

Corrective measures

---|---
Too low indication value of cooling medium evaporating pressure gauge| Cooling medium leakage| Decide & fix the leakage & refill cooling medium
Cooling medium pipe blockage| Replace cooling medium desiccant, vacuumize and refill cooling medium
Expansion valve or hot-gas bypass valve fault| Reset or replace the valve
Poor evaporating pressure gauge| Replace it
Too low cooling water temperature| Reduce the cooling water flow
Too high indication valve of cooling medium evaporating pressure gauge| Too high air inlet temperature| Install rear condenser to reduce atmospheric temperature
Expansion valve or hot-gas bypass valve fault| Reset or replace the valve
Condenser blockage| Clean the condenser
Too high cooling water temperature| Improve the cooling water temperature
Cooling medium compressor fault| Check compressor and treat accordingly
Too high indication valve of cooling medium condensing pressure gauge| Cooling medium pipe blockage| Check pipe system and treat accordingly
Condenser scaling or blockage| Clean the condenser
Too high cooling water temperature or too small water flow| Adjust the water flow governing valve preset valve to improve cooling water conditions
Pressure gauge damage| Replace the pressure gauge
Pressure gauge damage| Check compressor and treat accordingly
Overload running| Too high air inlet temperature| Install rear condenser
Too much air process capacity| Reduce the load or replace the device
Cooling medium leakage| Decide the leakage, fix it and refill cooling medium

Bad operation of compressor after starting

accordingly
Start failure with proper electric system| Poor contact of cooling medium pressure switch| Replace pressure switch
Overload tripping caused by too large load| Decrease the load and restart
Condenser scaling or blockage| Clean the condenser
Frequent tripping of overload relay| Poor oil pressure switch or oil pressure failure| Adjust of replace with a new one
Compressor overload| Reduce the air process flow
Air inlet temperature too high| Install rear condenser to reduce temperature
Poor environment ventilation and too high temperature| Take measures to improve environment conditions
Too low preset values of overload relay| **** Set the value again
Too high cooling water temperature| Take measures to bring down the water temperature

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