CONTROL AIR DRYER

Instruction Manual
of
Refrigerated Type Control Air Dryer

120-2, JANGGOK-RO, JORI-EUP, PAJU-SI, GYEONGGI-DO, KOREA

TEL : 031) 963 - 0080 / 949 - 7210 / 949 - 7223 / 949 - 7203
FAX : 031) 962 - 0180

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 CONTROL AIR DRYER

CONTENTS

. INSTALLATION

. OPERATION

. MAINTENANCE

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 CONTROL AIR DRYER

. INSTALLATION
1. LOCATION
(1) THE DRYER SHOULD BE LOCATED 30 TO 50cm AWAY FROM ADJACENT WALLS

FOR GOOD SUCTION AND DISCHARGE AIR THROUGH CONDENSER.

(2) SHOULD BE VENTILATED WELL AS THE DRYER IS EQUIPPED WITH AIR COOLED

CONDENSER.

(3) EVADE DUSTY AREA, RADIATORS AND DO NOT EXPOSE TO DIRECT SUN RAY.

THIS MAY DECREASE THE COOLING CAPACITOR OF THE DRYER.

(4) IF THE AMBIENT AIR TEMPERATURE EXCEEDS 45 , INSTALL A DUCT FOR

PRESENTING FRESH AIR.

ESPECIALLY IF THE VESSLE PASSES TORRID ZONE LIKE THE EQUATOR

IT WOULD BETTER INSTALL A EXTRA FAN TEMPORAILY.

(5) FOUNDATION SHOULD BE FLAT, LEVEL AND STRONG ENOUGH.

IF BOLTING DOWN OF THE DRIER IS NEEDED, UTILIZE THE 12MM HOLES

PROVIDED AT THE BASE.

(6) WHEN INSTALLED OUTDOORS, CARE SHOULD BE TAKEN NOT TO BE EXPOSED TO

RAIN. THE LOCATION SHOULD BE PROPERLY DRAINED.

2. FIELD PIPING
(1) ATTACHED AUTO DRAIN TRAP TO THE DRAIN OUTLET.

FOR CONNECTION TO FIELD MAIN DRAIN PIPING, USE PIE RUN TUBES.

(2) INSTALL BY PASS VALVE IN THE AIR PIPING.

3. SPECIAL INSTRUCTIONS FOR PROPER PIPING

(1) FIELD PIPING SHOULD NOT BE SMALLER THAN AIR CONNECTION OF THE DRYER.

(2) SHORT RADIUS ELBOWS AND FITTING WHICH CAUSE MUCH PRESSURE DROPING SHOULD

NOT BE USED.

(3) CLEAN THE PIPING BEFORE INSTALLATION.

(4) VIBRATION FROM AIR COMPRESSOR SHOULD NOT BE TRANSMITTED TO THE DRIER.

(5) INSTALL A SUPPORTER PROPERLY SO THAT PIPING WEIGHT SHOULD NOT BE

IMPOSED TO THE DRYER.

4. POWER WIRING
(1) CHECK AVAILABLE CURRENT FOR MATCHING VOLTAGE.

DRYER NAMEPLATE SHOWS THE POWER SOURCE NEEDED.

VOLTAGE SHOULD BE WITHIN 10

IF VOLTAGE IS TOO LOW, INSTALL A POWER TRANSFORMER.

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 CONTROL AIR DRYER
(2) MAIN SWITCH OR NO FUSED BREAKER SWITCH SHOULD BE INSTALLED IN THE
POWER LINE TO THE DRYER.
(3) SIZE OF ELECTRIC WIRES AND EARTH WIRE MUST BE OF ENOUGH CAPACITY
FOR THE DRIER.
(4) SHOULD BE PROPERY GROUNDED.

.OPERATION
1. OPERATION PRINCIPLE
(1) THE HUMID AIR FLOWS INTO THE AIR INLET, AND PRE-COOLED IN THE
HEAT EXCHANGER, AND ENTERS THE EVAPORATOR.
(2) AS THE AIR PASSES THROUGH THE EVAPORATOR(2) WHITCH WAS COOLED BY
EVAPORATION OF LIQUID REFRIGERANT, TEMPERATURE DROPS DOWN TO 10 (MAX 4 )
DEW POINT TEMPERATURE, THEN THE MOISTURE IN THE AIR IS CONDENSED.
(3) CONDEDSED MOISTURE, NOW WATER, IS SEPERATED FROM AIR, AND PURGED OUT OF
THE SYSTEM BY DRAIN, AND DISCHARGED THROUGH OUTLET OF AUTO DRAIN TRAP.
(4) WHILE PASSING THROUGH EXPANSING VALVE, THE HIGH PRESSURE LIQUID REFRIGERANT
IS EVAPORATED IN THE EVAPORATOR AND PULLED TO COMPRESSOR, COMPRESSED AGAIN.
CONTINUING THE REFRIGERATION CYCLE.

2. START-UP
(1) BEFORE START-UP, CHECK THE FOLLOWING :
- PROPER LOCATION, AIR PIPING AND POWER WIRING.
- CLOSED THE VALVE IN AIR LINE BY- PASS PIPING.
- OPENED THE VALVE IN THE DRAIN PIPING.
- CHECK VALTAGE.
- CHECK FOR PROPER FUSE OR BREAKER.
- SERVICE VALVE OF RECEIVER TANK : TURN THE VALVE COUNTERCLOCKWISE TO THE END(THE
STATUS THAT THE BAR IS FULLY OUT) AND TURN THE VALVE TWO AND A HALF(2 2/1) CLOCKWISE.

A "A" 막힘
bar

e) Normal setting of the bar : f-1) The status that the bar is fully out :
Status that all of A, B, and C are opened. A- Locked, B and C - Opened
f-2) Phenomenon - The pressure doesn't go Through
the low pressure part of Dual Pressure Switch.
f-3) Result - Trip occurs because the value lowers than
the set value of low pressure part.

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 CONTROL AIR DRYER

"B" 막힘

g-1) The status that the bar is fully in :

A and B - Opened, C - Closed
g-2) Phenomenon - As the flow of refrigerant is cut off by
receiver tank, the high pressure part can't go up.
g-3) Result - As there is no flow of refrigerant, the
Ref. compressor is burned out by overload.

(2) START-UP
- IF ABOVE CONDITION IS ALL RIGHT, TURN ON THE OPERATING SWITCH,
WITHOUT SUPPLYING COMPRESSED AIR TO THE DRYER.
- AFTER STARTING, INDICATING LAMP LITS, AND IT IS NORMAL
IF THE REFRIGERANT PRESSURE GAGUE INDICATES GREEN AREA AFTER 5 TO 10
MINUTES OPERATIONS. (Low Pressure : 3~6kg/cm 2, High Pressure : 12~25kg/cm 2)
- ALLOWS THE COMPRESSED AIR INTO THE DRYER.
DRYER
- AUTO DRAIN TRAP WILL BE AUTOMATICLLY DRAIN CONDENCED WATER WHICH
IS FROM EVAPORATOR.

. MAINTENANCE
1. GENERAL
(1) IF THE GAGUE INDICATES AREA ABOVE THE GREEN, IT MEANS THE DRYER

IS OVER-LOADED.

CHECK FOLLOWING.

- IS TEMPERATURE OF ENTERING COMPRESSED AIR TOO HIGH?

- IS AMBIENT AIR TEMPERATURE TOO HIGH?

- IS CONDENSER FAN RUNNING?

- DOES CONDENSER HAVE DIRTY WITH DUST, SO RESTRICT AIR FLOWING?

- IS AIR FLOW INTO CONDENSER WELL?

- ISN'T VOLTAGE IS LOW?

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 CONTROL AIR DRYER

(2) IF THE DRYER STOPS OPERATION BY ONE OF ABOVE REASON,

REF-COMP LAMP TURNS OFF AND ALARM LAMP LIGHTS.

FOR RE-STARTING, AFTER CORRECTION OF TROUBLE, RESET THE PRESSURE

SWITCH AND START OPERATION.

(3) The Way to exchange a compressor and refrigerant injection procedure.

- Turn off the Control Air Dryer.

- Release the refrigerant from Check Joint instralled in the unit.

- Separate the discharge and suction copper tube from the old Ref. Compressor

by using oxygen welding or copper cutter.

- Remove the old Ref. Compressor.

- Install new one and connect to the discharge/suction line.

- Using a Vacuum Pump to make vacuum state.

If you can not make vacuum state, check the welding part to find leak point.

- After completing of vacuum generating, Connect Refrigerant Gas to Check Joint

by using Manifold Gauge.

- Turn on the Control Air Dryer to recharge the refrigerant appox. 0.8kg.

- The refrigerant injection procedure.

1) The proper level of refrigerant liquid is around a half degree at sight glass.

2) The proper temperature of the suction line of compressor is cold enough

not to be frozen.

3) The high side pressure is 13~26 kg/ , low side pressure is 3~6 kg/ is
suitable pressure on working.

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2. TROUBLESHOOTING
PROBLEM CAUSE SOLUTION

1. INDICATING LAMP IS OFF 1. POWER IS OFF 1. TURN ON POWER

2. SWITCH OR LAMP ARE INACTIVE 2. REPLACEMENT

2. TURNS ON THE POWER 1. PRESSURE SWITCH CUT OFF 1-1. HIGH PRESSURE

BUT COMPRESSOR IS NOT - FIND THE REASON OF ABNORMAL

OPERATING HIGH PRESSURE AND RESET

1-2. LOW PRESSURE

- CHECK LEAKAGE POINT OF

REFRIGERANT

2. STARTING RELAY OR 2. REPLACEMENT

STARTING CAPACITOR FAILURE

3. DEW POINT TEMPERATURE IS 1. EVAPORATOR IS FROZEN 1. ADJUST HOT GAS BY-PASS V/V

LOW, BUT NO DRAIN ( PRESSURE GAGUE INDICATES

BELOW GREEN AREA )

2. BLOCKED DRAIN TRAP 2. CLEAN IT

4. DEW POINT TEMPERATURE IS 1. HIGH TEMPERATURE INLET AIR 1. LOW IS THROUGH

HIGH, WATER SHOW UP AT AIR AFTER COOLER

OUTLET 2. EXCESSIVE AIR FLOW 2. ADJUST AIR QUANTITY

3. LOWERED COOLING 3. CHARGE REFRIGERANT

CAPACITY

4. HIGH AMBIENT TEMP. 4. MAKE LOW TEMP. BY VANTILATION

5. CONDENSER IS BLOCKED 5. CLEAN IT

5. ABNORMAL NOISE OF 1. OVERCHARGED 1. PURGE IT AT PROPER PRESSURE

COMPRESSOR REFRIGERANT

6. REFRIGERANT COMPRESSOR AND 1. BLOCKED HOT GAS BY-PASS 1. CHECK HOT GAS BY-PASS VALVE

LOW-PRESSURE LINE ARE FROST VALVE - ADJUST OR REPLACE

2. BLOCKED FILTER DRYER 2. REPLACEMENT

7. LOW PRESSURE OF OUTLET AIR 1. EVAPORATOR IS FROZEN 1. ADJUST HOT GAS BY-PASS V/V

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