Contents Description Page Introduction 3 Warranty 3 Health and Safety 4 Machine Card 4 General Safety Instructions 5 Refrigerant R134a Safety Data 6 Installation 8 Installation – Electrical 9 Installation – Mechanical 9 Installation Recommendations 9 Commissioning 10 Start-Up Procedure 10 Description of Operation 10 Schematic Flow Diagram 11 General Arrangement Drawings 12 Technical Description of Components 17 Technical Data Tables 18 Electrical Description 20 Wiring D
Important The refrigerant available on the C series of Compressed Air Dryers is Refrigerant R134a or Refrigerant R407C. It is imperative that refrigerants are not mixed. A label is fixed to each compressor, which identifies the refrigerant being used within the unit, and that refrigerant ONLY should be used in the dryer. R134a & R407C are ozone benign refrigerants and meet the requirements of the revised “Montreal Protocol”.
Health and Safety Due regard shall be given to observing safe procedures when working with or on the equipment. It is the responsibility of the Installer / Operator / Customer to ensure that the “Health and Safety at Work Act (1974)” and Normal Safe Working Procedures are adhered to at all times.
General Safety Instructions IMPORTANT: THE FOLLOWING SAFETY PRECAUTIONS MUST BE READ AND UNDERSTOOD BEFORE REPAIR OR MAINTENANCE WORK IS ATTEMPTED. General Beware of the following danger areas within the dryer : a) Any rotating components (fan etc.) b) Sharp edges (coil fins, etc.) c) Hot refrigeration pipework d) Possible live electrical components or terminals The refrigeration and compressed air circuits can operate at high pressures and unauthorised tampering may cause injury or damage.
Refrigerant Safety Data Reactivity Data Stability Unstable Conditions to Avoid Use in presence of naked flames, red-hot surfaces. High moisture levels Stable YES Incompatibility (Materials and Conditions to Avoid) May react violently with sodium, potassium, barium or other alkali or alkaline earth materials. Magnesium and alloys containing more than 2% magnesium. All finely divided metals. Hazardous Decomposition Products Halogen acids formed by thermal decomposition.
Health Hazard Data and First Aid Short term effects of over exposure when: In contact with skin: Liquid splashes may cause freeze burns. No information found on irritancy or sensitisation. There is no known hazard due to absorption through the skin. In contact with eyes: Liquid splashes or vapour spray may result in freezing of tissue or eye fluids. Inhaled: Very high concentrations may produce anaesthetic effects and can act as an asphyxiant by limiting available oxygen.
Installation - General Storage The equipment should be stored in a secure frost free area with a maximum ambient of 55°C and maximum humidity of 90% non-condensing. Unpacking Carefully remove the unit from its packing and examine it for obvious defects or damage including: Paint damage. Case deformation. Integrity of electrical cable. Breakage of gauge glass (where applicable).
Installation - Electrical The C series Dryers require a 220/240 Volt 1 phase and neutral 50-60 Hz supply. A flying lead is installed on the dryer for convenience. The cable core colours are: Brown Live Blue Neutral Green / Yellow Earth If the unit is connected to a junction box, receiving its supply from another source (e.g., auxiliary contacts of a main starter, or a relay), then it is important that electrical protection is provided by means of a suitably rated H.R.C. fuse located in the line.
Commissioning The units are factory pre-set and commissioned and should not need any field adjustment. However, if after a period of time the unit is found to be operating poorly or incorrectly, this may be due to a range of faults or problems which may be analysed by reference to the Fault Finding section of this manual. Start-up Procedure Important Do not allow the compressed air to flow through the unit until the following checks have been made AND THE UNIT SWITCHED ON. 1.
PS1061-C-021
PS1061-C-001
PS1061-C-002
PS1061-C-003
PS1061-C-004
PS1061-C-005
Technical Description of Components 1. Compressor This is a fully hermetic, high back pressure single phase type; the internal components being mounted on springs to minimise vibration. 2. Heat Exchanger The heat exchanger is coil / tube design and incorporates an air / air and refrigerant / air heat exchanger with an integral moisture separator 3. Air Cooled Condenser A fan assisted air cooled condenser is used to remove the remaining heat from the refrigerant.
Technical Data Table Model Nominal Airflow † 3 m /min C9-1 C14-1 C19-1 C31-2 C39-2 C58-2 0.58 0.83 1.16 1.83 2.33 3.5 Nominal Pressure Drop bar 0.3 0.3 0.3 0.3 0.3 0.
Technical Data Table Model C92-3 C120-3 C147-3 C175-4 C238-4 m /min 5.5 7.16 8.83 10.5 14.33 Nominal Pressure Drop bar 0.3 0.3 0.3 0.3 0.
Electrical Description Description of Components 1. "ON / OFF" Switch This switches the live side of the power supply to the circuit. All models are fitted with a rotary type cam switch. 2. Compressor (complete with control box) The compressor is a single phase type and incorporates a "start" circuit to avoid risk of a stalled motor on startup. 3. General The air cooled condenser fan will run under the control of the controller sensing the temperature in the compressor discharge line.
Wiring Diagrams To assist understanding of the electrical circuitry the following wiring diagrams are included: Model Numbers Schematic Wiring Diagram Number C9-1, C14-1, C19-1 PS1061-C-011 C31-2, C39-2, C58-2 PS1061-C-012 C92-3, C120-3, C147-3 PS1061-C-013 C175-4, C238-4 PS1061-C-014
PS1061-C-011
PS1061-C-012
PS1061-C-013
PS1061-C-014
Control of Refrigerant Discharge By international agreement, the worldwide use of certain refrigerants will be reduced in stages. To this end, listed below are suggestions on how refrigeration engineers can contribute by the discontinuing of releasing any refrigerant gas to the atmosphere. Release of refrigerant to the atmosphere is an offence under Section 33 of the Environmental Protection Act 1990. DO NOT . . . DO . . . (1) Blow off refrigerants to atmosphere.
Routine Maintenance It is not normally necessary to open the refrigerant circuit. If a problem is suspected it is strongly recommended that unit maintenance or repair is undertaken by a CITY & GUILDS 2078 (or equivalent) COMPETENT REFRIGERATION ENGINEER. A City and Guilds 2078 (or equivalent) certificate will soon be mandatory. Daily Check that the "ON / OFF" switch/isolator is in the "ON" or " I " position. Check condenser fan for airflow. Weekly Check condensate drain operation.
Fault Finding The following fault finding chart relates various symptoms and faults of the refrigeration system. Before attempting to identify a refrigeration system fault it must first be established that the DESIGN CONDITIONS to the compressed air system are being met i.e. flow, pressure and temperature. Excessive overload will be caused by: 1. 2. 3. 4. Excessive compressed air inlet temperature. Compressed air pressure too low. Compressed air flow in excess of design. High ambient air temperature.
Fault Finding continued PROBLEM B Excessive drop in compressed air pressure. CAUSE Compressed air flow rate too high. Condensate is Frozen. Exchanger Tubes soiled by impurities in the compressed air. C Compressed air does not flow through the dryer. The condensate has frozen and blocked the passage as the probe is incorrectly positioned. The condensate has frozen and blocked the passage as the set point is programmed too low.
Fault Finding continued PROBLEM E High pressure switch stop working and have to control by manual CAUSE Fan motor stop working SYMPTOM Every LED at electronics control board doesn’t light so its similar to no electric in circuit The room temperature is higher than appropriate temperature to work.
Notes
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