Owners Manual 2009 PRICE LIST DRYMAXTM. Compressed Air Treatment Products. Refrigerated Air Dryers

Transcription

1 3177 Ridgeway Ct. Commerce Twp., MI FAX Owners Manual 2009 PRICE LIST Compressed Air Treatment Products DRYMAXTM Refrigerated Air Dryers ENERGY SAVING RECYCLING REFRIGERANT DRYERS HIGH TEMPERATURE REFRIGERANT DRYERS NON-CYCLING DRYERS FILTERS DRAINS ORDERING INFORMATION 1. All prices are U.S. Dollars 2. Minimum order is $50.00 net 3. All prices are F.O.B. shipping point. 4. Payment Terms are 30 days from ship date. (Subject to credit approval) 5. MACAIR reserves the right to make partial shipments. 6. Shipping dates are MACAIR best estimate at the time the order is placed. MACAIR will not accept any liability for late shipments. 7. See back page for terms and condition of sale. IMPORTANT: READ 8. THIS For complete MANUAL warranty CAREFULLY. policy IT contact CONTAINS the factory INFORMATION or go to ABOUT SAFETY AND THE SAFETY OF OTHERS. ALSO BECOME FAMILIAR WITH THE PROPER INSTALLATION AND CONTROLS OF THE AIR DRYER BEFORE OPERATING. ONLY QUALIFIED, TRAINED AND LICENSED PERSONAL SHOULD SERVICE OR OPERATE THIS EQUIPMENT. CAUTION: THIS MACHINE CONTAINS HIGH PRESSURE GAS AND ELECTICITY Visit our - For brochures, manuals, drawings & technical data. w w w. m a c a i r 1. c o m

2 A. INTRODUCTION MAC SERIES DRYERS LIST PRICE 2 FILTER Model Inlet DRYER Watercooled Dryer Dryer Recommended Filter Thank MAC you for Capacity selecting an LIST DRYMAX Condenser HX series refrigerated Conn. Shipping air dryer from Filter MACAIR INC. Conn. The refrigerated SCFMair dryer PRICE is specifically Adder designed Size and (NPT) manufactured Wgt. Lbs for drying Model and purifying Size (NPT) compressed MAC55A-1 air generated 55 $2,150 by an air compressor. Please 3/4 read this 200 instruction CAF70-U manual carefully 3/4 before MAC75A-1 using the air 75 dryer. $2,498 3/4 200 CAF70-U 3/4 Please MAC100A-1 pay attention 100 to the $2,665 precautions in transportation, 1 1/2 installation 295 and CAF116-U operation that are 1 MAC125A $3, /2 300 CAF201-U 1 1/2 listed in this manual. MAC150A $4,325 $ /2 310 CAF201-U 1 1/2 Please MAC200A-2 use the dryer 200 according $4,998 to our $450 application guide 2 and be 600sure to CAF201-U perform the proper 1 1/2 MAC250A $5,792 $ CAF318-U 1 1/2 maintenance MAC250A-4 will 250 void the $5,792 air dryer warranty. $ CAF318-U 1 1/2 MAC300A $6,492 $ CAF318-U 1 1/2 at MAC300A-4 local refrigeration 300 wholesalers. $6,492 $ CAF318-U 1 1/2 MAC400A $8,325 $ CAF470-U 1 1/2 Direct any questions not covered in this manual to your distributor or call MACAIR MAC400A $8,325 $ CAF470-U 1 1/ MAC500A-3 Before 500 calling $9,083 with questions $450 always have 2 the air 710dryer CAF616-U model #, serial # and 2 pressure MAC500A-4 gauge readings. 500 $9,083 $ CAF616-U 2 Service MAC625A-3 and maintenance 625 $10,083 can be obtained $475 from your 3distributor. 725 If you CAF616-U do not know your 2 distributor MAC625A-4 please 625 contact $10,083 the factory. $ CAF616-U 2 MAC800A $12,167 $ CAF923-U 2 1/2 MAC800A $12,167 $ CAF923-U 2 1/2 MAC1000A $14,333 $ CAF1324-U 3 MAC1000A $14,333 $ CAF1324-U 3 MAC1200A $15,998 $ CAF1324-U 3 MAC1200A $15,998 $ CAF1324-U 3 Notes: Receiving 1. MAC Series and dryer Inspection inlet capacities are... based..... on 3 C.A.G.I. ADF100 standard for rating refrigerated air dryers. Inlet capacities are based on the following inlet conditions: a. Inlet temp: 100 F b. Inlet pressure: 100 PSIG c. Ambient temp: 100 F ENERGY SAVING CYCLING DYERS MADE IN USA preventative maintenance as recommended in this manual. Failure to perform the preventative Refrigeration used in this air dryer is environmentally friendly R134a or R404a and is available Authorization # must be obtained from MACAIR INC. before any parts or dryers are returned to the factory. MACAIR INC. will not be responsible for anything returned without authorization. Contents Page How the Dryer Works Installation b. Outlet dewpoint: 38 F PDP 2. Dryer list price does not include filter. See page 4 for filter prices. Installation 3. Available Voltages: Guide =. 115v-1ph-60hz, =.. 230v-1ph-60hz, 4 3 = 230v-3ph-60hz, 4 = 460v-3ph-60hz. Trouble Shooting Guide Data Label YEAR PARTS & Electrical LABOR WARRANTY Schematics Dryer Controls YEAR... 7 COMPRESSOR WARRANTY 5 YEAR HEAT EXCHANGER Maintenance WARRANTY Log Start Up Warranty Initial Run Procedure How to Set the Condensate Drain Time... 9 Contents Page How to Make Minor Refrigerant Suction Adjustments Normal Maintenance Auto-Drain Maintenance

3 RECEIVING AND INSPECTION 1. The dryer cannot be tilted on its side or upside down during shipping. 2. Use forklift from the bottom of the dryer when installing or moving. 3. Dryers are shipped F.O.B. factory. Immediately upon arrival check the dryer for possible damage. If damage is found, report it to the carrier and file a damage claim. 4. Check dryer data label to be sure you have the right dryer. Check the data labels voltage and amperage to be sure it is correct and the one you ordered. 5. Check the refrigeration gauges for pressure. If gauges read 0 PSIG STOP. Do not start dryer. Call your distributor for service. This could mean there is a leak and the refrigerant has leaked out. HOW THE AIR DRYER WORKS HX Series refrigerated compressed air dryers use refrigeration cooling to condense entrained moisture out of the compressed air stream. Warm saturated air enters the air-to-air heat exchanger at the dryer inlet. (1) In the air to- air heat exchanger the inlet air is pre-cooled by the outgoing cold air. The pre-cooled air then enters the air to refrigerant heat exchanger (3) were it is cooled to its lowest point by the refrigeration in the evaporator. As the air is cooled moisture in the air changes from a vapor to a liquid. The liquid condensate is removed from the airstream by the separator (4) and discharged from the dryer by the automatic drain valve. (5) The cold air is reheated by incoming warm air as it passes back through the air-to-air heat exchanger. Pre-cooling the inlet air reduces the heat load on the refrigerant compressor, permitting the use of a smaller refrigerant compressor. (2) The out going cold air is reheated by the in coming hot air. As a result the outlet air is warmed up as it leaves the dryer. This prevents the outlet pipe from sweating. The air exits the dryer and is now clean and dry, ready for use. 3

4 INSTALLATION AND LOCATION 1. Ventilation Install dryer only in a well-ventilated clean, dry area only and keep at least 3 feet between the dryer, other equipment and the walls. 2. Dryer Location Make sure there is approximately 3 feet around the dryer for service and maintenance purposes. Do not install the dryer outside. The air dryer must not be exposed to direct sunlight, rain or snow. Do not install the dryer in an environment with fire, high temperatures or low temperatures. Make sure the dryer is installed in an environment that is clean and dry. Dust and dirt particles will clog the air-cooled condenser. A clogged and dirty condenser will reduce the performance of the dryer and will eventually cause damage to the dryer. 3. Ambient Temperatures Suitable ambient temperature for the refrigerant dryer is a minimum of 35 F to a maximum of 110 F. The performance of the dryer will be significantly decreased when the air dryer is subject to temperatures higher than 110 F. For installations with ambient temperatures higher than 110 F it is recommended to use a water-cooled condenser on the dryer. Contact your dealer for details. 4. Selecting Proper In and Out Piping and Piping Design Pipe diameter should be sized according to air flow requirements. Do not mix the air inlet and outlet air flow. It is recommended that a vibration absorber be installed on the dryer inlet and outlet to eliminate vibration from the compressor. Do not use the inlet and outlet of the air dryer to support the weight of the air piping valve bypass and Isolation valves - should be installed on the air dryer outlet and inlet ports to allow for bypassing, depressurizing, and proper maintenance and servicing of the air dryer. 6. Condensate Drains Condensate drains must be properly piped from the dryer to prevent moisture re-entrainment. The dryer is equipped with an automatic drain valve that controls the discharge of the condensate and a manual valve to manually drain condensate. The user must run a drain line to an environmentally approved condensate collection/disposal system. 7. Electrical Installation The dryer data label lists the electrical power requirements for the air dryer. The user must confirm that the line voltage matches the voltage listed on the data label. (Warning Operating the air dryer with improper line voltage will void the warranty.) Provide the proper size wire, disconnect switches and fuses in accordance with applicable codes. Field wiring must comply with local and national fire safety and electrical codes. Standard dryer s enclosures and controls are designed to meet NEMA 1 Type 1 electrical standards. All wiring is complete. Connect power leads as indicated in the electrical schematic. Ground the frame properly. Once power is connected turn the power on to the dryer. Leave the power on for 6 hours before you turn the dryer on. This will energize the crank case heater and boil off any liquid refrigerant in the crank case. Failure to do this may damage the refrigerant compressor and will void the warranty. 4

5 IMPORTANT NOTE: DRYMAX HX series dryers that are 460v-3ph-60hz and 230v-3ph-60hz voltages have Scroll Refrigerant Compressors. These compressors must be wired for proper rotation with the proper phases L1, L2, L3. To check if dryer is wired properly turn dryer on and observe the REFRIGERANT SUCTION PRESSURE GAUGE, immediately after the dryer is switched on the pressure on this gauge should drop. If after seconds the pressure does not drop switch the dryer off. This could mean the dryer is wired wrong. Switch any 2 leads and repeat. 8. Maximum Working Pressure - HX10 thru HX psig. 9. Breathing Air Applications - This dryer has not been tested for breathing air applications. The owner is advised to do its own testing and use for breathing air applications at owns risk. 5

6 DATA LABEL DATA LABEL The data label is affixed to the outside of the cabinet. This label identifies the The data label is affixed to air the dryer s outside model of the and cabinet. serial This number label and identifies important the technical air dryer s data. model Before and installing the dryer check all the information on the data label for the correct serial number and important technical data. Before installing the dryer check all the information on model and voltage. If the model number and voltage are incorrect do no the data label for the correct install model the and dryer. voltage. Do not If put the model power to number the dryer. and voltage Call your are local incorrect distributor. do no install the dryer. Do not put power to the dryer. Call your local distributor. Model Serial # Date of MFG. DATA LABEL HX v-3ph- 60hz Voltage Voltage Range RLA 3.4 LRA 25 Min Circuit Ampacity 4.9 Max Fuse Size 15 Maximum Inlet Air Temp - F 110 Min/Max. Ambient Temp - F 110/45 Ref. System Design - PSI 350/150 Suction/Discharge - PSI 70/225 Maximum Pressure (PSIG) 232 Ref. Compressor HP 1 1/2 Refrigerant Type R404a Refrigerant Charge 7.5 lbs MACAIR INC. REFRIGERATED AIR DRYER DRYER CONTROLS 1. On/Off switch Turns the refrigerant compressor on 2. Power On Light Indicates there is power to the dryer. 3. High Temp Warning Light Indicates there may be a problem with the dryer. 4. Dew-point Indicator Indicates the approximate dew point temp of the compressed air. 5. Hot Gas Bypass Valve Controls the evaporator pressure 6. Fan Cycling Switch Cycles the condenser fan on and off based on the condensing pressure (See FIG. 1) 7. Programmable Electronic Auto-Drain Valve Automatically controls the draining of liquid condensate removed by the dryer. 5 6

7 DRYER CONTROLS 1. On/Off switch Turns the refrigerant compressor on 2. Power On Light Indicates there is power to the dryer. 3. High Temp Warning Light Indicates there may be a problem with the dryer. 4. Dew-point Temp Indicator Indicates the approximate dew point temp of the compressed air. 5. Refrigerant Suction Pressure Gage 6. Refrigerant Discharge Pressure gage 7. Hot Gas Bypass Valve Controls the evaporator pressure 8. Fan Cycling Switch Cycles the condenser fan on and off based on the condensing pressure (See FIG. 1) 9. High Pressure Shutdown 10. Low Pressure Shutdown 11. Programmable Electronic Auto-Drain Valve Automatically controls the draining of liquid condensate removed by the dryer. 7

8 START UP The following procedure must be followed to start your air dryer. Failure to follow this start up procedure will void your warranty. If problems occur during start up, contact your distributor. 1. Turn off the On/Off switch. 2. Verify the main electrical supply voltage matches the voltage specified on the data label. 3. IMPORTANT: There is a WARM UP PERIOD for the 460v-3ph-60hz and 230v-3ph-60hz dryers. You must put the power on to the dryer for a minimum of 6 hours before you turn the dryer on. This energizes the crankcase heater and boils off any liquid refrigerant in the crankcase and suction lines. Failure to do this may damage the refrigerant compressor and will void the warranty. 4. Do not turn the dryer on during this warm up period. 5. Check the proper connection and support of the compressed air lines to the dryer: check dryer bypass and isolation valve system. 6. Confirm that the inlet and ambient air temperature, pressure and flow to the dryer meet the specified requirements. 7. Confirm that the condensate drain lines from the separator are properly piped to an environmentally approved disposal system INITIAL RUN PROCEDURE After start up and checks are complete and after the main electrical power to the dryer has been turned on for at least 6 hours (only for & dryers), follow the procedure below to put the dryer in operation: 1. Turn ON the dryer ON/OFF switch. 2. Let the dryer run for 15 minutes. (For & dryers After 15 seconds observe the refrigerant suction pressure gage. It should start to pull down immediately. (This will indicate that L1,L2,L3 is connected for proper rotation. If the pressure does not pull down switch 2 of the L1,L2,L3 leads.) 3. Check the refrigerant suction pressure gage: Should read: On R134a dryers. (28 psig to 34 psig) On R404a dryers. (72 psig to 80 psig) 4. Check the refrigerant discharge pressure gage: Should read: On R134a dryers. (120 psig to 200 psig) On R404a dryers. (220 psig to 350 psig) 5. Check the DEWPOINT TEMP INDICATOR. After about 15 minutes This should read 35 F to 39 F. 6. Verify that the condenser fan motor is operating. The fan will cycle on and off. 7. Confirm that condensate is discharging from the condensate drain. This may take minutes. 8

9 HOW TO SET THE CONDENSATE DRAIN OPEN & CLOSED TIME (LOCATE DRAIN VALVE) 1. The OPEN (ON) time is adjustable from 0.5 sec to 10 sec. Drains are set at factory to open for 6 sec. When drain opens the on light will light 2. The CLOSED (OFF) time is adjustable 0.5 min to 45 min. Drains are set at factory to stay closed for 10 min. When drain is closed the off light will light. You may increase or decrease this based on moisture levels in the air. Push the TEST button to manually open the drain valve. HOW TO MAKE MINOR REFRIGERANT SUCTION PRESSURE ADJUSTMENTS. 1. Keep dryer running under a no load by turning off or bypassing the compressed air. 2. Remove dryer top and locate the Hot Gas Bypass Valve. 3. Remove cap on Hot Gas Bypass Valve and using an allen wrench turn valve counter clockwise to decrease the suction pressure and clockwise to increase the suction pressure. Make ½ turn adjustments and wait 2 to 3 minutes for suction pressure to stabilize. Make more adjustments if needed. (Minor Pressure Adjustments not covered under warranty.) 9

10 NORMAL MAINTENANCE PROCEDURES AND CHECKS 1. Daily Maintenance Check the operation of the automatic drain valves at least once during each eight hour shift. Check Dewpoint Indicator to make sure it is the proper range Check suction pressures gauge to make sure it is the proper range. (HX250 and larger) Check discharge pressures gauge to make sure it is the proper range. (HX250 and larger) Make sure condenser coil is clean and unobstructed. Make sure the high temp warning light is not on. 2. Weekly Maintenance Clean Air cooled condenser coils - Blow off all dust and dirt that is on the condenser fins with a compressed air maintenance gun. While cleaning the condenser fins do not damage fins. WARNING - DRYER FAILURE DUE TO A DIRTY CONDENSER IS NOT COVERED UNDER WARRANTY 3. Condensate Drain Maintenance (Float Type) HX10 thru HX25 Bypass and depressurize the dryer. Remove separator bowl and then remove float drain. Clean drain with hot soapy water After cleaning shake drain. The drain should have a slight rattle of the float opening and closing. If there is no shaking sounds replace float drain with a new one. Repeat on a weekly basis. (Electronic Drain) HX40 and above Push the Push to Test Button to verify drain operation. Check the open time. Check the closed time. DANGER Dismantling or working on any component in the air dryer or the compressed air system under pressure may cause serious personal injury and equipment failure. Before dismantling any part of the air dryer or compressed air system completely vent the internal pressure to the atmosphere. Only qualified service persons should attempt to work on the air dryer. If drain is not opening the drain should be dis-assembled, cleaned and checked for defects. DANGER This should only be done by a qualified service technician. 10

11 Close the isolation valve before the drain. Remove the power unit and timer. Remove solenoid coil. Dis-assemble valve and check for debris and or defective spring or valve parts. Clean out any debris and re-assemble the valve. If there are defective or broken valve parts contact your distributor for a new drain valve. Trouble Shooting Guide 1. DRYER WILL NOT START Problem Cause Solution Disconnect switch off or faulty Replace disconnect or turn on. Power Supply Wrong voltage Connect proper voltage Connection problem Find bad connection and repair Disconnect is defective Repair or Replace Defective Electrical Componet Fuse is blown Repair or Replace On/Off switch defective Repair or Replace Compressor defective Repair or Replace Refrigerant Leaked Out Crack in refrigerant line Find leak and repair Refrigerant valve leaking 2. AFTER START UP DRYER SHUTS DOWN Problem Cause Solution High Pressure Switch Clean dirty or blocked condensr Fan motor failure Repair or Replace On/Off switch bad Repair or Replace Electrical Capacitor failed Repair or Replace Overload tripped Check connections, replace or reset Dryer overlaoded Correct inlet air flow, temp and pressure Poor ventilation Improve ventilation Ambient Temp to high Lower ambient temp. 3. WATER DOWNSTREAM OF DRYER Problem Cause Solution Auto Drain not set properly Increase drain on time. Condensate not draining Auto Drain defective Repair or replace Auto Drain clogged Clean drain valve. Evaporator Pressure to high Hot gas valve out of adjustment Set Evaporator Pressure to 55 psig Dryer overlaoded Reduce air flow and tempature Condeser pressure to low Low ambient temperature Consult your distributor Condeser clogged or blocked Clean condenser Condenser pressure to high Fan motor stopped Repair or replace Fan cycling switch not adjusted Adjust properly In and Out piping incorrect Condensate drain piping wrong Correct piping Bypass open Close bypass Inlet Temp to High Air compressor aftercooler clogged Clean or repalce Aftercooler drain not working Repair or replace 11

12 12

13 13

14 14

15 MAINTENANCE LOG DATE CLEAN SERVICE AMBIENT SUCTION DISCHARGE AIR CONDENSER DRAIN TEMP PRESSURE PRESSURE PRESSURE DATE CLEAN SERVICE AMBIENT SUCTION DISCHARGE AIR CONDENSER DRAIN TEMP PRESSURE PRESSURE PRESSURE NOTES NOTES 15

16 MACAIR LIMITED REFRIGERATED AIR DRYER WARRANTY MACAIR (herein after referred to as the seller) refrigerated air dryers are warranted to be free of defect in materials and workmanship for a limited period of 5 YEARS from the date of shipment from the sellers warehouse to the distributors warehouse or end user (herein after called the buyer) provided the air dryers are applied, installed and maintained in accordance with sellers recommendations listed in the owner s manual. This warranty applies only to the original owner and is not transferable. The warranty covers materials and labor for the first year and materials only for the remaining four years for a total of 5 YEARS from the date of shipment. Normal maintenance items, customer maintained components and labor charges after the first year from the ship date from the seller are not covered by this warranty. The following is not covered by this warranty: Refrigerant leaks after the first 12 months, Condenser cleaning, maintaining the drain valve (Time adjustments and cleaning, auto-drains sticking open or closed due to debris, float drains sticking open or closed) fan motor lubrication, filter element changing and damage in shipping. After the first year from the ship date from the seller, the seller will not be responsible for the following incidental items: service call charges, refrigerant, filter driers, insulation, truck charges, torch charges, recovery/reclaim charges, disposal charges, mileage, miscellaneous fittings, or freight charges. The seller will only allow the amount of labor hours and pay the labor rates that are listed in the MACAIR WARRANTY & SERVICE GUIDELINES. In the event of a warranty issue the buyer must follow the warranty procedures listed in the MACAIR WARRANTY & SERVICE GUIDELINES or the warranty is void. If the buyer purchases replacement parts from a third party, the seller will not be responsible for the cost of the parts. The buyer will be invoiced for the new materials and must return the defective materials to the buyer. Upon inspection of the defective materials and if the materials are deemed defective, the buyer will be credited for the cost of the new materials. The buyer is responsible for all transportation costs of all materials that are shipped to the buyer and to the seller after the initial 12-month period. The seller will not be responsible for any consequential damage, economic loss, extra expense including payment for the loss of time, pay, inconvenience, storage, removal, reinstallation, loss of dryer use, dryer rental expense, lodging, meals, or other travel. The foregoing warranty is exclusive and in lieu of all other warranties, whether written, oral, or statutory, including implied warranties of merchantability or fitness for any particular purpose. This contract shall constitute the entire agreement between Buyer and Seller. All terms contained herein shall be deemed acceptable by the Buyer and The Seller and shall prevail over the terms of the Buyers purchase order. The seller s liability is limited solely to the repair or replacement of defective products at seller s option. Under no circumstances shall sell, the sellers distributor or agent be liable for any losses or consequential damages, costs or expenses of any kind incurred by the buyer, whether arising from breach of warranty, negligence or strict liability in tort. The seller makes no warranty or representation of any kind, expressed or implied as to the merchantability or of fitness for a particular purpose with respects to the products. This contract shall be governed and interpreted in accordance with the laws of the State of Michigan. Warranty only applies to equipment sold in the USA and Canada. MACAIR INC. SERVICE DEPARTMENT