Instruction Manual for TOOLOTS models including: RAD Series Refrigerated Air Dryer, RAD Series, RAD Series Air Dryer, Refrigerated Air Dryer, Air Dryer, Refrigerated Dryer, Dryer
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DocumentDocumentRefrigerated Air Dryer Operation & Maintenance Instruction ! 1! Contents ------------------------------------------------------ Chapter 1: Device system flow .............................3 Chapter 2: Device installation and testing ..............4 Chapter 3: Device instructions ............................5 3.1 Device working conditions .......................5 3.2 Operation instructions .......................... 6 3.3 Notes ............................ ..................7 3.4 Daily maintenance of device .....................7 Chapter 4: Trouble-shootings of common fault ............8 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 ! 2! Chapter1: Device system flowchart 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. ! 3! Chapter 2: Device installation and testing 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: Ø A clearance of no less than 1 meter should be left around the refrigeration dryer. Ø The refrigeration dryer can be installed without foundation, but the ground must be leveled. Ø T and A filters can be selected and fixed accordingly. Please refer to the user's manual of filter for installation. Ø 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. ! 4! Chapter 3: Instructions 3.1 Device working conditions Power supply Voltage115V 60HZ or 230V 60HZ Please refer to the nameplate for parameters as for special equipments Rated 0.8 MPa0.6 MPa ~1.0 MPa Working pressure 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 pressure0.2-0.5Mpa water inlet temperature31 water outlet temperature37 Water quality: neutral water with PH6.5~7.5, without observable solid impurities Environment Environmental temperature Air cooling typeA238 Water cooling typeW245 Environmental humidity 80% Above sea level less than1000m Surroundings: no caustic fumes around Installation method: indoor (installation without base is allowed) ! 5! 3.2 Operating instructions ACheck 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%. B 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 R134a R22 R410a High pressure gauge of cooling medium (MPa) 1.1 1.6 2.3 Low pressure gauge of cooling medium (MPa) 0.2 0.4 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. ! 6! 3.3 Notes 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 45for 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. 3.4 Daily maintenance of device ü Blow the dust, ash and fiber of the wind cooled condenser with compressed air regularly. ü Automatic drainer tends to be blockaded by pollutant in condensed water and please clean the stainless-steel filter screen regularly by water or soap. ü Clean the water condenser regularly. ü Routine inspection: power supply, water supply and gas supply conditions. Observe and keep the reading on the panel of the refrigeration dryer. ! 7! Chapter 4: Trouble-shootings of common faults The internal and external causes of faults of the desiccators are as follows. The causes and troubleshooting are presented here. (1) Pressure drop increase Cause analysis Cause analysis The pipe system valve is not open fully. Fully open the valve Too small diameters of pipes, too long pipe Pipe system fault 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 Fault or poor set valve of expansion valve and heated air bypass valve Reset or replace the valve of low-pressure switch. Reset or replace the valve The air volume exceeds the rating volume of desiccators Reduce the air flow Replace air compressor or refrigeration desiccators ! 8! (2) Refrigeration dryers start failure Cause analysis Corrective measures Power supply system fault External fault-line Fuse burning or air switch tripping Find out the cause and treat accordingly to restore power supply Find out the cause and treat accordingly to restore power supply Voltage abnormality The voltage shall be 115V±10% or 230V±10% Start failure with proper power supply Control circuit fault Control circuit fault Poor electric contact Reset failure after protection system tripping Compressor fault Internal MP action of compressor Replace with a new one Find out the cause and treat accordingly Fix or replace with a new one Find out the cause of tripping, treat accordingly and then reset Check the compressor and treat accordingly Reset when the compressor gets cool (3) Poor automatic drain system Cause analysis Corrective measures Working pressure is lower than 0.15Mpa Proper working pressure of automatic water drainer is within 0.2~1.0Mpa Drain failure or poor drain Filter screen blockage in water drainer The preceding ball valve of water drainer is not opened Drainpipe blockage Clean the filter screen Open the filter screen Clean the pipe Draw off valve damage Replace the float ball inside water drainer or replace the water drainer ! 9! (4) Poor drainage Cause Analysis Corrective measures Bypass valve fails to close or to be closed fully Close the bypass valve The air doesn't pass through the dryer Poor installation and piping system The dryer is not leveled in installation Loped automatic drainer Open the inlet valve Horizontalization Horizontalization The drainage system is higher than automatic drainer Redesign the drainage pipe system Ball valve of drainer fails to open Poor drain system Open the ball valve Water drainer blockage of damage Too high cooling medium condensing pressure Clean or replace drainer Adjust the water flow governing valve, expansion valve, hot-gas bypass valve or pressure switch Cooling medium Too high air inlet temperature system fault Add a rear condenser Cooling medium leakage Compressor fault Decide the leakage, fix the leakage, and refill cooling medium Check the compressor ! 10! (5) 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 Cooling medium pipe blockage Expansion valve or hot-gas bypass valve fault Decide & fix the leakage & refill cooling medium Replace cooling medium desiccant, vacuumize and refill cooling medium Reset or replace the valve Poor evaporating pressure gauge Too low cooling water temperature Too high air inlet temperature Replace it Reduce the cooling water flow Install rear condenser to reduce atmospheric temperature Too high indication valve of cooling medium evaporating pressure gauge Too high indication valve of cooling medium condensing pressure gauge 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 Cooling medium pipe blockage Condenser scaling or blockage Too high cooling water temperature or too small water flow Pressure gauge damage Check pipe system and treat accordingly Clean the condenser Adjust the water flow governing valve preset valve to improve cooling water conditions Replace the pressure gauge Pressure gauge damage Check compressor and treat accordingly Too high air inlet temperature Install rear condenser Overload running Too much air process capacity Reduce the load or replace the device Cooling medium leakage Decide the leakage, fix it and refill cooling medium ! 11! (6) Bad operation of compressor after starting Cause analysis Corrective measures Voltage abnormality Trip soon after start Find out the fault and treat accordingly Start failure with proper electric system Poor contact of cooling medium pressure switch Overload tripping caused by too large load Replace pressure switch Decrease the load and restart Condenser scaling or blockage Clean the condenser 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 Frequent tripping of Poor environment ventilation and too Take measures to improve overload relay high temperature environment conditions Too low preset values of overload relay Set the value again Take measures to bring down the Too high cooling water temperature water temperature ! 12!macOS Version 12.0.1 (Build 21A559) Quartz PDFContext Word