Installation, Operation, Maintenance

Coldspell

WE REDEFINE COMPRESSED AIR TREATMENT SYSTEMS

Contents
1.
1.1 1.2

Introduction
Design Description

2. 3.
3.1 3.2 3.3 3.4

Specifications
Operational Details

3 4

Operating Principle
Pneumatic Section Refrigeration section Safety Schematic Diagrams

4. 5.
5.1 5.2 5.3 5.4

Wiring Diagrams Installation

Storage Installation and Site Connections Electrical Connections Running the Installation

9 12

6.
6.1 6.2

Operation
Operator How to stop the Dryer

14

7. 8.
8.1 8.2

Maintenance Condenser Cleaning

Air colled condenser Water cooled condenser

15 16

9. 10. 11.

Amount of Gas to be charged Repair Work Recommended spares list for 5 years
This Document may be modified without notice reproduction, even partial, forbidden without written Authentication

17 18 21
1

INSTRUCTION MANUAL - Coldspell

READ THIS MANUAL CAREFULLY BEFORE INSTALLING OR OPERATING THE EQUIPMENT These symbols warn you of any dangers and the measures to be taken to prevent them.

The most important points for the correct operation of your dryer are printed in bold type.

1. Introduction
1.1 Design Coldspell refrigeration dryer eliminates any water vapour remaining in the compressed air coming at the outlet of the compressor house. The dryers have been designed for nominal standard inlet conditions as per ISO 7183 in order to obtain a dew point under pressure of + 3oC. 1.2 Description The dryer consists of : Air to Air Heat exchanger Air to Freon Evaporator Demister Refrigerant Compressor Electronic controller Condenser Assembly Expansion Device Pressure switch* Refrigerant discharge pressure gauge* Hot gas bypass valve Auto drain valve Canopy

* Optional
Reference : Manual Version 2

2. Specifications
Operational Details Medium Inlet condition Operating pressure* Inlet temperature* Inlet humidity Ambient temperature Pressure dew point Cooling system Max. Working pressure Refrigerant compressor : Compressed Air : Free of dirt, oil, condensate and corrosive substances. : 7 Kg/cm2 : Max +45oC : Saturated at specified conditions : Max +38oC : + 3oC to 7oC : Air cooled / Water cooled : 16 Kg/cm2 : Hermetic sealed

* Optional
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INSTRUCTION MANUAL - Coldspell

3. Operating Principle
3.1 Pneumatic section The moist compressed air (dirt, oil and water vapor) enters into the Air/Air Heat Exchanger where it is precooled by the outgoing air and thereby conserving energy. The compressed air next passes through the evaporator. It is cooled up to +3oC by the Refrigerant. At this sub-cooled temperature, the moisture present in the air is condensed and removed by the Demister. The cool saturated air passes through the Air to Air Heat Exchanger where it precools incoming air and it gets heated up. Thus this system provides clean dry air at the Outlet. Efficient Filter and Automatic Drain Valve carry out the removal of moisture at Demister. The Heat Exchangers are designed in such a way that they are self-cleaning to maintain the constant heat transfer rate. 3.2 Refrigeration section (Freon) The Evaporator remove heat from compressed air by means of cold and low pressure freon. The heat removed from the system is dissipated to the atmosphere/water by the condenser. The high pressure refrigerant flows into the expansion valves where it changes into liquid phase at low pressure. The boiling of liquid refrigerant takes place in Evaporator and cold air leaves from the Evaporator. The low pressure, low temperature refrigerant passes into the compressor and the cycle repeats. The Refrigeration Dryer senses the Refrigerant suction pressure and accordingly varies the flow of Hot Gas Bypass inside the system and maintains constant Dew point at various heat loads.

Reference : Manual Version 2

3.3 Safety

Pressurised equipments may explode if used improperly. It is therefore essential to locate any pressurised equipment, in such a way that the risks relating to incorrect use are reduced to the absolute minimum.

The person responsible for the stuff who is going to install, operate and maintain the machines described in this manual must make sure that they have read and understood these instructions. In particular we draw your attention to the safety procedures which are described in this manual and which must be scrupulously adhered to. Observing these measures will allow you to install, operate and maintain your dryer without risk. Coldspell dryers are intended for the drying of compressed air. Under no circumstances should they be used to dry other gases before Trident has performed a preliminary study and provided special instructions. 3.4 Schematic Diagrams
Model :

Coldspell 10-60
EXPANSION DEVICE DISCHARGE PRESSURE GAUGE

AIR/AIR HEAT EXCHANGER

EVAPORATOR

HOT GAS BYPASS VALVE

REF. COMP.

AIR LINE REFRIGERANT LINE ELECTRICAL LINE

ELECTRONIC CONTROLLER

CHARGING VALVE

This Document may be modified without notice reproduction, even partial, forbidden without written Authentication

AIR COOLED CONDENSER

INSTRUCTION MANUAL - Coldspell

Model :

Coldspell 80 & 100

EXPANSION DEVICE DISCHARGE PRESSURE GAUGE

AIR/AIR HEAT EXCHANGER

EVAPORATOR

HOT GAS BYPASS VALVE

AIR COOLED CONDENSER M CHARGING VALVE

REF. COMP.

AIR LINE REFRIGERANT LINE ELECTRICAL LINE

ELECTRONIC CONTROLLER

Model :

Coldspell 150-250
DISCHARGE PRESSURE GAUGE EXPANSION DEVICE

AIR/AIR HEAT EXCHANGER

EVAPORATOR

HOT GAS BYPASS VALVE

AIR COOLED CONDENSER M CHARGING VALVE

REF. COMP.

ELECTRONIC CONTROLLER AIR LINE REFRIGERANT LINE ELECTRICAL LINE

Reference : Manual Version 2

Model :

Coldspell 300-500
DISCHARGE PRESSURE GAUGE EXPANSION DEVICE

AIR/AIR HEAT EXCHANGER

EVAPORATOR

HOT GAS BYPASS VALVE

AIR COOLED CONDENSER M CHARGING VALVE

DISCHARGE PRESSURE GAUGE AIR COOLED CONDENSER CHARGING VALVE M

REF. COMP.

AIR LINE REFRIGERANT LINE ELECTRICAL LINE

ELECTRONIC CONTROLLER

Model :

Coldspell 650-1000

EXPANSION DEVICE

AIR/AIR HEAT EXCHANGER

EVAPORATOR

HOT GAS BYPASS VALVE

REF. COMP.

AIR LINE REFRIGERANT LINE ELECTRICAL LINE

ELECTRONIC CONTROLLER

This Document may be modified without notice reproduction, even partial, forbidden without written Authentication

INSTRUCTION MANUAL - Coldspell

Model :

Coldspell 1200-2000 (Water Cooled)

DISCHARGE PRESSURE GAUGE EXPANSION DEVICE

AIR/AIR HEAT EXCHANGER

WATER COOLED CONDENSER

EVAPORATOR

WATER IN HOT GAS BYPASS VALVE

WATER OUT

REF. COMP.

ELECTRONIC CONTROLLER AIR LINE REFRIGERANT LINE ELECTRICAL LINE

CHARGING VALVE

Reference : Manual Version 2

4. Wiring Diagrams
Model :

Coldspell 10 to 100
L E COMPRESSOR K1
S C R

OLP

SW 16A POTENTIAL RELAY L N E

TOP
5 2 4

J4 1 2 3

J5-2

J3-2 J2-1 TEMPERATURE SENSOR

CONTROL CARD J2-2 J5-3 J3-3 J1-1 J1-2

DRAIN VALVE 24V DC

Starting Capacitor Running Capacitor

230V AC 50HZ, 1Ph

CONDENSOR FAN

JUNCTION BOX N N N

K1 :Hot gas bypass valve

Model :

Coldspell 150

1
SW 16A

A2
L2 T2
J4 L N E 1 2 3 J5-3 J3-3 J1-1 J1-2 DRAIN VALVE 24V DC CONTROL CARD J2-2 J2-1 TEMPERATURE SENSOR

L1

C1 A1
J5-2

K1

AC
T1 2

J3-2

230V AC 50HZ, 1Ph

COMPRESSOR

CONDENSOR FAN

N COMPRESSOR

N
N

OLP
3 1

POTENTIAL RELAY

K1 : Hot gas Bypass Valve C1 : Contactor Coil A1, A2 AC : Auxiliary Contactor PS : Pressure Switch

TOP
230V, 50Hz 1Phase Supply L
4 5 2 1

Starting Capacitor

JUNCTION BOX

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INSTRUCTION MANUAL - Coldspell

Model :

Coldspell 200 to 250

L L L E

1
SW 16A

3 L2 T2 4
L N E J4 1 2 3

A2 1 PS 4
J5-2 J3-2

L1

C1 A1

K1

AC
T1 2

J2-1 TEMPERATURE CONTROL CARD J2-2 SENSOR

J5-3

J3-3 J1-1 J1-2 DRAIN VALVE 24V DC

L L N E 230V AC 50HZ, 1Ph

N N

COMPRESSOR

CONDENSOR FAN

COMPRESSOR

K1 : Hot gas Bypass Valve C1 : Contactor Coil A1, A2 AC : Auxiliary Contactor PS : Pressure Switch

230V, 50Hz 1Phase Supply

N L Starting Capacitor

Model :

Coldspell 300
L L E

A2
1
SW 16A

3 L2 T2 4 1

C1 A1
J5-2 J4 L N E 1 TEMPERATURE 2 3 J5-3 J1-1 J1-2 DRAIN VALVE 24V DC CONTROL CARD SENSOR

L1

AC
T1 2

PS
4

L L N E 230V AC 50HZ, 1Ph

N N

COMPRESSOR

CONDENSOR FAN

COMPRESSOR

C1 : Contactor Coil A1, A2 AC : Auxiliary Contactor PS : Pressure Switch

230V, 50Hz 1Phase Supply

N L Starting Capacitor

10

Reference : Manual Version 2

Model :

Coldspell 400 to 500

L3 N

L3

1 L1
SW 16A

3 L2

5 L3 PS 1 4
J5-2 J4 L N E 1 2 3 J5-3 J1-1 J1-2 DRAIN VALVE 24V DC CONTROL CARD J2-2 J2-1 TEMPERATURE SENSOR

AC T1 2 T2 4 T3 6

L1 L1 L2 L3 N

L2

L3

L3

415V AC 50HZ, 3Ph

COMPRESSOR

CONDENSOR FAN N

C1 : Contactor Coil A1, A2 AC : Auxiliary Contactor PS : Pressure Switch

Model :

Coldspell 650 to 800

L3 N

L3 N

L3

1 L1
SW 23A

3 L2

5 L3

21
N/O

A2 1 PS C1 A1 4
J5-2 J4 L N E 1 2 3 J5-3 J1-1 J1-2 DRAIN VALVE 24V DC CONTROL CARD J2-2 J2-1 TEMPERATURE SENSOR

AC T1 2 T2 4 T3
N/O

6 22

L1 L1 L2 L3 N

L2

L3

L3

L3

415V AC 50HZ, 3Ph

COMPRESSOR

CONDENSOR FAN - 1

CONDENSOR FAN - 2 N

C1 : Contactor Coil A1, A2 AC : Auxiliary Contactor PS : Pressure Switch

COMPRESSOR * HEATER

* Compressor Heater Optional

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INSTRUCTION MANUAL - Coldspell

5. Installation

Various risks (crushing, explosion, projection, noise,): The installation operations described in this chapter should be performed only by personnel qualified in the installation of electro-pneumatic systems. Follow the procedure described below with care in order to prevent exposing personnel to danger.

5.1 Storage If your dryer is about to be stored during a long time before installation and use, take care to the following instructions: If possible, let the dryer in its original packing (In particular products fitted with marine packing with plastic film and dessicant) Check that air inlet and outlet are correctly blocked in order to protect the system from foreign materials Check that the machine is correctly protected from atmospheric dust or water. Check that the store is frost protected Make sure to archive correctly the attached documents. 5.2 Installation and site connections

Series-Coldspell
Refrigeration Dryer
TRIDENT

1. Install the dryer in a closed clean, dry room protected from frost. Access to the room should be restricted to personnel not qualified in unit maintenance and operation. The room must be adequately ventilated. The dryer must not be directly exposed to sources of heat. The temperature of the room must not exceed 43oC.
12

Reference : Manual Version 2

2. Make sure that the dryer is not near any equipment which does not comply with the electromagnetic compatibility directives and which may degrade dryer operation. There must be a minimum distance of 1 m between the dryer and any other equipment, which uses electricity. Yellow lines demarcating the area are preferred. 3. Ensure that the dryer is installed in vertical position and kept level. 4. Fix the anchor points if it's necessary. 5. Install a system of by-pass valves between the dryer inlet and outlet so as to be able to service the installation without having to interrupt the compressed air supply from the network. The upstream and downstream valves must be closed during installation. 6. Connect the compressed air for processing to the dryer inlet with rust-free pipes. 7. Connect a drain pipe to the Drain valve part connection (1/2''F) 8. Connect the processed compressed air to the dryer output with rust-free pipes. 9. Check that all the connectors are airtight and that the fixings are tight. 5.3 Electrical Connections Connect the electrical power cable to the supply as specified in this manual, ensure the supply is well grounded.

! !

Risk of electrical shock: When connecting the machine, cut off the power at the connecting point.

5.4 Running the installation

Various risks (explosion, projection, noise, ...): Do not pressurise until the installation procedure has been completed.

For water-cooled condenser, ensure that the Water pump is switched on. Switch ON the system with the ON/OFF switch provided in the front panel of the canopy.

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13

INSTRUCTION MANUAL - Coldspell

6. Operation
6.1 Operator Only a minimum level of experience in handling compressed air is necessary to operate a Coldspell refrigeration dryer and he should be familiar in the following terminologies : Pressure in Kg/cm2 Flow in cfm Dew points in oC Components of a fluid network: compressor, valves, drains, taps, pressure gauges, filters, tanks,... 6.2 How to stop the dryer

Various risks (projection, explosion, noise,...) : Whenever working on the dryer, it I esessential to disconnect it from the network. Follow the procedure below :

1. Open the by-pass valve 2. Close the upstream valve 3. Close the downstream valve 4. Switch off the Dryer 5. Vent the air inside the dryer

14

Reference : Manual Version 2

7. Maintenance

Various risks (projection, noise, ...) : This operation should be performed by professionals of Refrigeration.

Trident make Refrigeration dryers are robust, reliable machines. To ensure uninterrupted, problem-free operation, regularly perform the inspections below. Type of inspection Discharge pressure in refrigerant line Drain valve Air Cooled condenser surface cleaning Water cooled condenser cleaning using dilute HCL Y Y/R Inlet temperature Dew point temperature

Visual Spares replacement Cleaning D - Daily

D W - Weekly

D H/R M - monthly

W M H - Half Yearly Y- Yearly

D -

D -

R - As required

* Note : For water cooled condenser Clean the condenser by recirculating dilute HCL if discharge pressure exceeds the value specified in Table 7.1.

Table 7.1
Freon R22 R134a Discharge pressure in psig 300 180

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INSTRUCTION MANUAL - Coldspell

8. Condenser cleaning
8.1 Air Cooled Stop the dryer Open the side doors, so that all dust removed while cleaning can be vent out of dryer through the side doors Using compressed air and an air gun clean the dust accumulated on the condenser fins from outside the dryer. Ensure that there is no dust inside the dryer and reassemble the doors. 8.2 Water Cooled Stop the dryer Stop the water supply and close the inlet and outlet valves of the water supply Open the door covering the condenser. Drain the water completely. Pass dilute HCL solution in the tube side at pressure for more than 1 hour Reassemble all and start the dryer.

16

Reference : Manual Version 2

9. Amount of Gas to be charged

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 Capacity (cfm) 40 60 80 100 150 200 / 250 / 300 400 500 650 800 1000 Gas Used R134a R134a R134a R134a R134a R22 R22 R22 R22 R22 R22 Amount of gas to be charged (in gm) 350 400 450 600 700 1500 2250 2750 2850 3750 4100

This is only information. If any doubt contact factory.

This Document may be modified without notice reproduction, even partial, forbidden without written Authentication

17

INSTRUCTION MANUAL - Coldspell

10. Repair work

Trouble 1 Dewpoint Root cause High flow or low pressure of compressed air Discharge pressure high or low Large quantity of hot gas bypassed High return gas entry in to the refrigeration compressor (suction line ice formation) Low gas Expansion device block (Ice formation on the inlet line to heat exchanger) 2 Low dewpoint or dew point lesser than 10C 3 Compressor not running Less quantity of hot gas bypassed Thermal over road relay tripped Winding broken Winding short Pumping failure, compressor is running Freon pressure is not increasing Wiring problem 4 Controller display not coming Power supply connection loose or disconnected Controller failure Solution Correct the flow and pressure Refer point no.05 Close the hot gas bypass valve Open the hot gas bypass valve Charge gas to maintain the suction pressure Service the expansion device / replace Open the hot gas bypass Allow the compressor to cool and restart, clean the condenser Replace the compressor Replace the compressor Replace the compressor

Check wiring Correct the connection Replace the controller

18

Reference : Manual Version 2

Trouble 5 High Discharge pressure R22 Gas : Above 280 PSI incase of water cooled.

Root cause Water cooled model, water supply or cooling tower not proper Water cooled model, scale formation in the condenser tubes Refrigeration line block, after the condenser or Expansion device block Condenser dirty

Solution Correct the water supply

Clean the tubes with dil HCI Clean the block

Clean or blow off condenser dust Close hot gas by pass valve Charge gas to maintain the suction and discharge pressure Replace the compressor Arrest the leak & charge the gas Clean condenser dust Charge gas Purge gas to maintain the suction and discharge pressure Clean the block Close the hot gas by pass valve Clean the after cooler Correct the flow rate
19

6 Compressor thermal overload relay trip or compressor getting off and not getting on

Less return gas in the suction line Less return gas in the suction line Winding open Gas leak in the system Condenser dirty

7 Compressor head is hot and less return gas in the suction line

Low gas High gas

Expansion device block Hot gas bypass valve opened more Inlet temperature high Inlet flow rate high

This Document may be modified without notice reproduction, even partial, forbidden without written Authentication

INSTRUCTION MANUAL - Coldspell

Trouble 8 Pressure drop against the dryer or no air at the outlet Root cause Inlet compressed air flow higher than the rated Dewpoint less than 10C Demister element choke 9 Water at the outlet Inlet compressed air flow higher than the rated Inlet compressed pressure lower than the rated Inlet temperature is higher than the rated Demister drain valve is not working Air inlet and outlet connected wrongly given Bypass line partially open Contact your authorised service center for any assistance. Solution Correct the flow rate Increase dewpoint setting Clean or replace the demister element Correct the flow Correct the pressure Correct the temperature Service or replace the drain valve Correct the connection Close the bypass valve properly

20

Reference : Manual Version 2

11. Recommended spares for 5 years trouble free operation

Sl. No. 1 2 3 4 5 6 7 8 9 Description of Spares Dew point temperature controller with sensor High Pressure Gauge High Pressure Switch (Fan Control) Gas cylinder (6 Kg) Auto drain valve seal kit Auto Drain Timer Ref. Compressor Compressor Electrical Accessories Hot gas Bypass Valve Qty 1 No. 1 No. 1 No. 1 No. 1 Set 1 No. 1 No. 1 Set 1 No.

This Document may be modified without notice reproduction, even partial, forbidden without written Authentication

21

WARRANTY
Products of Trident Pneumatics Pvt Ltd are guaranteed to be free from defects in materials and workmanship when installed and operated in accordance with the instructions outlined in the Instruction Manual. Trident Pneumatics Pvt. Ltd.'s obligation under this warranty shall be limited to repair or replacement (at the discretion of Trident) of defective goods returned to Trident's plant within one (1) year from the date of commissioning. Product Model Serial No. : : : :

___________________________

Quality Assurance Dept.

5/232, K.N.G Pudur Road, Somayampalayam, Coimbatore 641 108. Ph : 0422 2400492, 2401373 Fax : 0422 2401376 e-mail : [email protected] Website : www.tridentpneumatics.com

Trident Pneumatics Pvt Ltd

INSTALLATION & COMMISSIONING REPORT REFRIGERATION DRYER

1. INSTALLATION
Customer : Model Sl.No Contact person : Designation i) Installed at ii) Inlet air temperature iii) 1000mm clearance provided around the dryer : Phone Fax : : : :

Before / After receiver Normal / High Yes / No

2. COMMISSIONING POWER ON STATUS

i) Inlet air temperature ii) Inlet air pressure iii) Amps iv) Voltage Installation : v) vi) Discharge pressure (Freon) Outlet pressure

vii) Set pressure viii) Drain valve settings Date of completion : Date of completion :

Commissioning :

Signature & Name of installing Engineer

Dealers Signature & Seal

Customer's Signature & Seal

5/232, K.N.G. Pudur Road, Somaiyampalayam P.O., Coimbatore - 641 108, India. Ph : +91-422-2400492 Fax : +91-422-2401376 e-mail : [email protected] Website : www.tridentpneumatics.com

TRIDENT PNEUMATICS PVT LTD