Pahwa Group Delair RD 220, Operating, Installation And Maintenance Manual

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Page 2: ...with care to give you excellent service The Air Dryer has been manufactured to the designs and engineering of Delair the world leaders in this field Ultimate customer satisfaction is generally dependent upon the compromises made during the installation effort Your Delair Air Dryer utilises tested engineering principles and has passed through inspection for quality of workmanship and function Since...

Page 3: ...ection 2 3 Installation types 2 4 Placing the equipment 2 5 Installation 2 6 Electric connection 3 Operation 3 1 Start up 3 2 Switching on and off 3 3 Fault indication 3 4 Safety measures improper methods of Operation 4 Maintenance 5 Trouble shooting 6 Drawings 6 1 Unit outline 6 2 General arrangement G A 6 3 Electrical wiring diagram 6 4 Flow sketch 6 5 Foundation detail 7 Annexure LOG SHEET ...

Page 4: ... as applicable Liquid separator Insulated Heat Exchanger contains Air to refrigerant heat exchanger Air to air heat exchanger Moisture Separator Electrical Microprocessor based delsmart display Control PCB Sensor Water separator is an automatic drain separator mounted inside the Dryer The water being separated gets collected in the bowl which is periodically drained automatically through a drain v...

Page 5: ...5 1 1 About RD series Compressed Air Dryer Figure 1 will help you to identify various components of the RD series Compressed Air Dryer along with various safety and controls Figure 1 ...

Page 6: ...RYER FILTER COMPRESSOR AUTO DRAIN SEPARATOR WATER VALVE EXPANSION SYSTEM ON OFF POWER ON COMPRESSOR OVERLOAD FAILURE AUTO DRAIN HIGH AMBIENT HIGH INLET AIR TEMP M LIQUID RECEIVER SIGHT GLASS FAN CONDENSER RD Aircooled Dew Point 4 C HEAT EXCHANGER AIR HOT GAS BYPASS VALVE RD SERIES delair ...

Page 7: ... c resulting in condensation of moisture present in the air This air with the condensate is made to pass through the water separator where the condensed water is collected in the separator bowl The dried air free of moisture comes through the outlet point The dew point indication on electronic display card Microprocessor based delsmart card is digital showing the air temperature just at the water ...

Page 8: ...r of the Dryer The electrical consists of Miniature Circuit Breaker MCB Microprocessor based delsmart card Power Supply Card PCB Control contactor for comp On Off Starting kit for compressor For 1Phase supply High pressure switch Low pressure switch w r t Dryer model Fan control pressure switch ...

Page 9: ... fault indication Indicates the Dryer when compressor Are overheating or low gas condition High ambient fault indication Indicates the Dryer when ambient Temperature high from the set point Auto drain failure fault indication Indicates the Dryer when auto Drain valve clogged High inlet air temp Fault indication Indicates the Dryer when air inlet temp High from the set point ...

Page 10: ...side to a variable speed fan control for ensuring that the condensing pressure does not drop too low especially in cold weather insert fan pressure control switch image Single phase preventer motor protection relay in case of 3 phase supply unit Is located in the control panel box It is help motor protection in Following conditions Overloading condition Phase failure condition Phase reversal condi...

Page 11: ...thermocol panels from around and top of the unit Remove mounting bolts clamping down the unit to the wooden base of the packing and gently lift the machine free from the pallet Remove the side steel panels by unscrewing the screw clean the interior of the machine lock back the side panels in position The machine is now ready for installation ...

Page 12: ...chanical connections 3 Check incoming power supply 220 v or 415 v ac 50 hz 4 Check earthing vs neutral 0 to 1v 5 Check setting of phase sequence relay 6 Check the capacity of Dryer and Compressor 7 Check all connection of air and water supply 8 Check for indoor installation and proper ventilation 9 Check air compressor condensoris not facing the Dryer ...

Page 13: ...r Inlet temperature Dryer outlet temperature of after cooler Option B Dryer after Air Receiver Flow through Dryer can be more than maximum flow of Compressor Inlet temperature Dryer lower than outlet temperature of After cooler Filter installation Considerations Installation proposal with Refrigeration Dryer ...

Page 14: ...14 2 4 Placing the equipment We recommend a minimum 600 mm of space be provided for future service and proper air ventilation Also ensure that ambient and other inlet parameters are as per design ...

Page 15: ...to the Dryer inlet via moisture separator pre filter in that order Connect the inlet and outlet points figure 2 2 to the respective points in the pipe lines all the pipe connections should be leak proof and such that these do not stress the Dryer outlet and inlet pipes Figure 2 2 figure 2 3 Check the manual water drain valve figure 2 3 and ensure it to be closed Your Dryer is now ready for operati...

Page 16: ...50hz w o n Other option System operating on other voltage can be supplied on request please check the name plate for correct voltage number of phases and frequency Wire cable sized can be selection on the basis of maximum amperage by electrical items 3 phase wire connection Single phase wire connection Caution Electrical connection should be made by a qualified electrician only ...

Page 17: ... will be on On position if fault has come and not been removed attended The machine is a continuous working type and its compressor keeps running and trips if exceptional overload occurs If the compressor trips due to overload or power failure it will restart after five minutes of pressure equalization If system trip due to gas high pressure then given fault should be acknowledge by client restart...

Page 18: ...aults Five types of faults i e High pressure Compressor overload High inlet air temperature High ambient water temperature Auto drain failure will be indicated on electronic display card Microprocessor based Delsmart card in the faults block It will be in on position if fault has occurred and has not been removed attended to Refer to troubleshooting for necessary action 1 High pressure fault compr...

Page 19: ...r shall be established first neutral conductor second and phase line hot conductor last 2 Protection of equipment Equipment has been provided with an MCB of 230 415v both as a supply disconnecting device as well as over current protection device In case of replacing the MCB it shall always be replaced only with standard MCB of 230 415v It is not uncommon to replace MCB of incorrect rating and if t...

Page 20: ...the condensate from the moisture separator and air receiver figure 4 2 Function of compressor Weekly Working of fan Monthly Mounting bolts of the compressor condenser and vla figure 4 1 De scaling of water cooled condenser Yearly Quantity of refrigerant gas figure 4 1 figure 4 2 ...

Page 21: ...on tubing from the bottom of the seperator Disconnect the solenoid valve and clean with air pressure Connect the valve and tube And open ball valve of auto drain valve Start the Dryer Weekly Since this machine has an air cooled condenser care should be taken that mud should not be allowed to clog the fins of condenser coil This will lower the efficiency of the machine and shall cause the dew point...

Page 22: ...repair or replace e Check lead if lead is ok replace motor 4 Compress or starts but motor will not get off starting winding a Low line voltage b Improperly wired c Defective relay d Defective run capacitor e High discharge pressure f Motor has winding open or shorted g Starting capacitor weak h Tight compressor a Voltage must be within 10 of voltage listed on identification plate b Check wiring ag...

Page 23: ...mpressor suction or discharge valves inefficient indicated by high head c Defective fan control d Inlet air temperature too low a Repair leak and recharge b Repair or replace c Repair adjust or replace d Unit should be shut down when inlet air is 40 deg F or lower Air may be passed thru unit 10 Auto Drain Failure a Loose connection b Due to dust contamination in valve c Low voltage a Proper connec...

Page 24: ...ure low Pre cooler and or evaporator clogged b Incorrect piping c Air overload d Unit too small e Excess water in unit a Increase pressure b Reverse flush using mild detergent c Increase line size and or correct piping as required d Reduce overload e Add another unit or replace with larger unit 17 Unit runs but air flow erratic or zero a Freeze up b Pre cooler and or evaporator clogged c Restricti...

Page 25: ...25 Annexure i ...

Page 26: ..._______________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ________________________________________________________________________________ ____________________________________...

Page 27: ... com West South Delair India Pvt Ltd 319 T V Tower Industrial Estate Worli Mumbai 400030 Contact Mr S R Dhuri Phone 022 24935155 Fax 022 24931020 Mobile 09820601382 E Mail delairservicew pahwa com Delair India Pvt Ltd Harrington chambers Block a 3rd floor door no 2 1 7 Abdul Razack Street Saidapet Chennai 600 015 Contact phone 044 42693761 62 fax 044 42693764 mobile 09840087130 e mail delairservic...