REFRIGERATED COMPRESSED AIR DRYER

INSTALLATION OPERATION MAINTENANCE

INSTRUCTION MANUAL
 Thank you for choosing——
refrigerated compressed air dryer.

General remarks

These refrigerated compressed air dryer documented in these operation

instructions has all requirements that can be expected from a modern device.

In order to obtain maximum benefit from using this dryer the user should have
sufficient information to ensure the unit is installed and operated correctly, enabling
the user to avoid accidents and retain the manufacturers warranty.

Correct maintenance will also help you to avoid accidents and to ensure that the
manufacturer’s warranty coverage is maintained.

Our technique improving and progress are uninterrupted, please take

subject to the final actual product. If there's any changes and amendments
to models, technical data as well as outline, we regret that we won't inform
hereof.

Notes:
1. The pressure should be gauge's pressure unless there's special indication in this
manual.
2. Please inform us the model no. and manufacture no. for maintenance and
service which will be found in the nameplate.

Model No.:

Manuf. No.:
Starting Date:
 SAFETY WARNINGS

Please read carefully prior to starting the air dryer

Safety notices:
1. Do remove the surrounding flammable objects, and preventing the welding spark
inters to the air dryer to burn out accessories.
2. The power line connected to the air dryer should be matched and you must install safety
devices such as air swith, fuse etc. It's required to install the earthing devices to ensure the
safety and steady running of the wiring, if necessary, please install the lightning conductor.
3. You must check if there's any forgettings and tools, and inform other person for attention.
4. You must check if it's default phase, under-voltage, normal phase protection of the initial
starting and changing of power line.
5. The air dryer can't work under the pressure which is higher than the indication of
nameplate, otherwise, it'll blowout or even explode, it'll damage to property and personal
safety. Please pay serious attention. Please contact CROWNWELL for high pressure
dryers if you needed.
6. Please don't startup force the air dryer if there's any faults or un-security factors, you
should cut of the power supply and marking remarkable objects.
7. They're fatalness of the compressed air and electrical appliance, please make sure the
power is cut when overhauling or maintenance, and make signals of "OVERHAULING" or
"NO SWITCHING ON" to prevent dangerous occurred.
8. Please don't maintain it unless the compressed air is being released absolutely, and try to
keep away from any ventilators, close corresponding isolation valves.
9. You should clear the accessories with non-corrosiveness solvent, and it's prohibited to use
inflammable, explosive and volatile abluent.
10. The auto-drain should be checked and cleaned timely to ensure it's smoothly and reliable
running, Normally twice per week. (Refer to 6--Maintenance directory to auto-drain).
11. Spare parts should be origin brand, refrigerant compressor oil should be the pointed
specified oil, and it's seriously prohibited to mix two brands, or it'll cause carbonization of
system to form major accident.
12. Please check regularly and make sure the alarm labels be clear, visible.
13. The conventional air dryer can't withstand corrosive compressed air, either it can work
under the corrosive environment, the pointed air will lead leakage of evaporator, and burn
out of compressor. (Welcome to check with us for special air needed, such as ammonia
gas, sulfur dioxide).
14. The air dryer should be operated by professional person who should read and understand
this manual, follow the procedures and maintenance criterion.

Warning:
It'll be very dangerous if you offend the safety notice!
 Refrigerated compressed air dryer instruction manual

Contents
Preface 1

1. Transport, Delivery and Checking of Goods Received 2

2. Installation and Mounting 3~5

3. The Requested Maintenance to Refrigerated Air Dryer 6~7

4. Operation to Refrigerated Air Dryer 8~11

5. Troubleshooting 12~15

6. Electrical Diagram 15

7. Maintenance Directory to Auto-drain 16~18

8. Warranty Condition 19
 Refrigerated compressed air dryer instruction manual

Preface

Dear valued user:

Thank you for choosing CROWNWELL brand

refrigerated air dryer---The reputable brand
with premium service.

We've inspected and tested all the equipments before

delivery. Please read this instruction manual carefully,
master the operation procedures and skills as so to
make sure the air dryer's work safely, reliable and wear.
Thank you!

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 Refrigerated compressed air dryer instruction manual

Transport, Delivery and

Checking of Goods Received
1.1 Transport
The refrigeration compressed air dryer is prepared for transport with a fork-
lift truck. When installing the dryer, move it with a fork-lift truck or another
suitable device.The refrigeration compressed air dryer must by no means
be lifted at the compressed air inlet or outlet connections. Severe damage
may result from such handling. It is not allowed to tip the dryer onto its
side.

1.2 Delivery
The refrigeration compressed air dryer is thoroughly checked and packed,
before it leaves the factory. It has been handed over to the forwarding
agent in perfect condition.

1.3 Checking at Receipt

Upon receipt please check immediately the packing for visible damage. In
case of visible damage of the packing, please insist upon a respective note
on the delivery sheet of the forwarding agent. Please also check the dryer
for hidden damages. If a refrigeration compressed air dryer is delivered
with apparently undamaged packing but with hidden damage, see to it, that
the forwarding agent is informed at once and have the dryer inspected.

The manufacturer is not responsible for damages occurred during

transport.

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 Refrigerated compressed air dryer instruction manual

Installation and Mounting

2.1 Installation
Installation standard: Straight and even floor, and set drainage trench.

2.2 Clearance
Keep more than 1 meter space to other equipments and the wall for
ventilation and maintenance (Chart 1).

2.3 Location and Mounting

2.3.1 Please avoid the heat conducting and negative pressure if there are
several air dryers parallel installed in one room.

2.3.2 Please do avoid installing air dryer outdoor with solarization, drench,
high temperature, poor ventilation and dusty environment absolutely.
(Chart 2, please contact CROWNWELL for outdoor needed)
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Caution:
When installing the dryer ensure, all connections are even and no pressure is placed on
inlet and outlet connections.

Check all compressed-air connections to ensure, that they are firm and free of leaks.

2.4 Connection to the Compressed Air System

Please install by-pass valves above air inlet and outlet for convenience of
maintenance, and try to avoid long, curve, narrow pipelines to avoid
pressure drop.
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 Refrigerated compressed air dryer instruction manual
2.5 Power Supply
Pay special attentions to power supply:
➢ Rated voltage 士 5%.
➢ Wire path-line size should be subject to the current and length.

2.6 Cooling Water Requirement (Water-cooled Type)

Cooling (circling) water pressure should be ;;0.2MPa, while temperature
s32C, and it should be softening to meet the requirement of general
industrial water needed.

2.7 Set an Air Compressor Station

2.7.1 It's better to install a pipeline air filter (HF7) before air inlet, in this way
to avoid the pollution (;;3u particles) to the heat exchanger, and improve
the efficiency of air dryer.

2.7.2 It's better to install the air dryer behind the after-cooler and air tank to
reduce its inlet temperature, improve its performance and pre-long its life.
You're welcome to consult with us for typical project.

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 Refrigerated compressed air dryer instruction manual

The Requested Maintenance

to Refrigerated Air Dryer
It is necessary to maintain the air dryer. It will not only meet the using
requirements but also extend its life if you operate and maintain it correctly.

3.1 Maintenance to the Exterior:

Clean the air dryer’s external regularly with damp cloth and than dry cloth,
avoid water-spraying directly. So that the electrical appliance won’t be
damaged and the insulativity won’t be reduced. Moreover, avoid using the
volatile oil (e.g. gasoline), diluents and others chemical drugs to clean it.
Otherwise, it will be caused the fading, deformation and paint peeling.

3.2 Maintenance to the Auto-drain

Check the drainage situation every day and clean the filter net, valve core
and floater, etc. to avoid the losses of drain function and bring about
always exhausting. Please pay special attention: Use soap-suds or
cleanser essence to clean it, it’s prohibited to use aggressive agents such
as gasoline, methylbenzene, resin water, etc. (Refer to Chapter 7,
Maintenance directory to auto-drain)

3.3 Maintenance to the Drain Valve

If the air dryer installs a drain valve, at least it must be drained twice every
week regularly. Particularly for the new pipeline, drain it once per day in the
first couple of months. Keep non-blocking of drainage from the welding
slag of the pipeline and barrel.
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 Refrigerated compressed air dryer instruction manual

3.4 Clean the Condenser

Air cooled type condenser, it’s
only 2-3mm of the fins space, it
is easy to be blocked by dust
and bring about badness of
radiating. So it should be
cleaned regularly. Generally
using compressed air to spray
or brush with copper brush.

3.5 Clean the Water Filter

The purpose of installing water filter is to prevent the cooling water solids
impurity entering to the condenser to effect its heat transferring. So you
should clean the filter net regularly so as to avoid the insufficience of water
flow, bring about the badness of radiation.

3.6 Maintenance to the Interior

Make cleaning and dust absorption of internal parts during the air dryer
stopped working.

3.6 Maintenance to the Complete Dryer

Keep the air dryer away from sunshine and heat producer, ensure a good
ventilation.

3.7 Protect to the Refrigeration System

Please be sure to protect the refrigeration system and avoid damage in the
maintenance process.

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 Refrigerated compressed air dryer instruction manual

Operation to Refrigerated
Air Dryer
4.1 Check Before Start-up
4.1.1 Check if the power supply and voltage is in normal.
4.1.2 Check the refrigerant system--refrigerant high-low pressure gauges,
the figures of two gauges should be balance in certain pressure. The
balance figure is depend on the ambient temperature. Generally, it should
be about 0.5MPa~1.0MPa.
4.1.3 Check if the air pipeline is in normal. Air inlet pressure and
temperature should not be excess than the rated value of the nameplate.
4.1.4 If it's a water-cooled type air dryer, you should also check if it is in
normal (water pressure should be 0.2MPa~0.4MPa, water temperature
s32C).

Caution:
The refrigerated compressed air dryer has to be supplied with operating voltage 24
hours prior to start-up. During this time, refrigerant, which has been condensed in the
refrigerant compressor, is vaporized by the crankcase heater. This prevents damage to
the refrigerant compressor.

The refrigerated compressed air dryer is ready for operation, when:

•The device has been installed in accordance with Chapter2 “Installation and mounting”.
• All inlet and outlet lines have been correctly connected.
•The required forms of energy (electricity, compressed air) are available.
• The shut-off devices (e.g. butterfly valve, ball valve) in the compressed air inlet and
outlet lines are closed (if installed).
• The compressed air by pass is open (if installed).
• The condensate is able to flow through the condensate discharger without obstruction
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(Ball valve upstream the condensate drain/s is/are open).
• The device has been supplied with the appropriate operating voltage for 24 hours prior
to start-up.

4.2 Air Dryer Operation:

4.2.1 I type and II type control panel description:
1 2 3

(I type)

4 5 6 7 8 9

1 2 3 10

(II type)

4 5 6 7 8 9

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句--REF LOW PRESSURE gauge. Indicating the refrigerant saturation pressure value
in the evaporator.
® --REF HIGH PRESSURE gauge. Indicating the condensate pressure value of
refrigerant.
@--AIR OUTLET PRESSURE gauge. Indicating the pressure value of air outlet.
@--START button, press it to start the air dryer.
®--STOP button, press it to sop the air dryer.
@--POWER indicator, it lights when the power supply is connecting.
(])--RUN indicator, it lights during the air dryer's running.
®--O.C.TRIP indicator, it lights when overload current to compressor, and the overload
relay tripped off, the air dryer need to be stopped for checking.
®--H.L.P.TRIP indicator, it lights when the high-low pressure protection switch tripped
off, the air dryer need to be stopped for checking.
®--AIR INLET PRESSURE gauge. Indicating the pressure value of air inlet.

4.2.2 III type and IIII type control panel description:

1 2
2

4
5
4 5

6 6

(III type) (IIII type)

句 --REF HIGH PRESSURE gauge. Indicating the condensate pressure value of

refrigerant.
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 Refrigerated compressed air dryer instruction manual
®--REF LOW PRESSURE gauge. Indicating the refrigerant saturation pressure value
in the evaporator.
@--POWER indicator, it lights when the power supply is connecting.
@--OPERATION indicator, it lights during the air dryer's running.
®--START button, press it to start the air dryer.
@--STOP button, press it to sop the air dryer.

4.3 The air dryer operation precess:

4.3.1 Turn on the air switch, connect power supply, the panel’s POWER
indicator (yellow) lights, and the lubricating oil of the compressor is being
heated.
4.3.2 If it's a water-cooled type air dryer, please open the in-out valve of
cooling water.
3.3.3 Press START button, the contactor actuate, RUN indicator (green)
lights, the compressor begins to run.
4.3.4 Check if the compressor keeps normal running, e.g. Normal/extreme
noise, the refrigerant high-low pressure is normal/abnormal.
4.3.5 If everything is normal, you can open the air compressor or in-out
valve for transferring gas to air dryer, and close the air by-pass valve. For
the time being, the outlet pressure value will be shown on the air outlet
pressure gauge.
4.3.6 After 5~10min running, the finished air will meet the requirement.
Meanwhile the refrigerant low pressure gauge indicates (Winter--
0.3~0.5MPa, Summer--0.4~0.7MPa); The refrigerant high pressure gauge
indicates (Winter--1.4~1.6MPa, Summer--1.4~2.0MPa)
4.3.7 Open the ball valve of auto-drain, the condensed water will be
drained out by the auto-drain.
4.3.8 Please do close the air supply first, than press STOP button to turn
off the air dryer. Cut of power supply, and open the drain valve to drain out
the remaining condensate water thoroughly.

4.4 Attentions for operation

4.4.1 Avoid the air dryer to run for a long time under non-load.
4.4.2 It's prohibited to continuously start-stop in a short time to avoid the
damaging to refrigerant compressor.

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 Refrigerated compressed air dryer instruction manual

Troubleshooting
The main faults of air dryer is from the circuitry and refrigeration system.
The final results will be as follows: unable to start of compressor; the
decline of refrigeration capacity and damage of equipment. The right
judgment, reasonable and efficient measures to the faults, it not only
requires speculative knowledge of electrical and refrigeration technician,
moreover, it also need to have the practical skill. Some of the faults is
caused by several reasons. Please analyze comprehensively so as to get
the best resolvent. On the other hand, some faults is caused by incorrect
operation and maintenance. It is said "false faults".
Therefore, We can only find out the real faults and right measures through
practical operation.
Follows as some fairly faults and its troubleshooting of the air dryer.

➢ Excessive pressure drop

Malfunction Reason Troubleshooting
The piping valves don’t be fully
Open the valve fully
opened
The pipe(s)is too slim Enlarge the pipe(s)
Large differential Pipeline is too long, lots of elbow and
Re-configurate the piping system
pressure tie-in
Much leakage of the piping
Check the elbows and connections
connections
Block of the piping filters Change the filter element(s)
Shortage of the Actual using capacity exceeds the air Change larger compressor
air using compressor rated capacity Reduce air capacity
Ice over of the Fault of temperature switch Change temperature switch
evaporator Invalidation of expansion value Change expansion value

➢ Badness of draining
Malfunction Reason Troubleshooting
Liquid water The air by-pass valve does not be
Close the by-pass valve
content fully closed.

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 Refrigerated compressed air dryer instruction manual

Compressed air don’t go through the Open the inlet & outlet valves of air
air dryer dryer

excessive flow rate and low pressure
Badness of the drain
The drain culvert is higher than the
auto-drain
The selection of dryer is not matched
Too high evaporating temperature
The ambient air pollution or badness
Abnormity of the of ventilation
evaporating Block of the expansion valve
gauge indicator
leakage of refrigerant
Spoiling of the gauge
Re-design the compressor system
Clean or change a new one
Re-set the drain culvert
Re-setup the air compressor or air
dryer
Reduce air capacity using
Improve the ventilation and ambient
conditions
change the expansion valve
Check the leakage point(s) and
infuse some refrigerant
Change the gauge

➢ Out of work
Malfunction Reason Troubleshooting
Check if the power is default phase
The fuse blew out or
or short circuit
Out of power trip of the fuse switch
Check the fuse
supply
Find out the point, examine and
Open circuit
repair
Reverse phase sequence Change
Abnormity of voltage or too slim of Please choose voltage according to
the power wire(voltage drop) the rated power on the name plate
Badness of switch Change

Power supply is Badness of contactor Change

in normal, but it Overload protection won't be Reset the overload relay
can’t start restoration

Badness of capacitance Change

Badness of pressure switches Change
Badness of compressor Change
Trips of high-low pressure and don’t Check the reason of trips , press
All switches are in be restoration “RESET”
normal, but it High pressure switch don’t be
Check and press “RESET”
can’t start restoration
Badness of compressor Change

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 Refrigerated compressed air dryer instruction manual

➢ Faults of refrigerant high-low pressure

Malfunction Reason Troubleshooting
Too low load to make the condensed
Increase air flow-rate, close the
water frozen, form ice blockage, air
pre-cooler,open the by-pass valve
pressure drop apparently

Lower of Evaporation temperature is too low

Change
evaporating (Badness of low pressure gauge)
temperature Block of the expansion valve Change
indicator
Too low setting value of the
Please adjust the setting
temperature and pressure switches
Check the leakage point(s) and
Leakage of refrigerant
infuse some refrigerant
Improve the ambient temperature,
Ambient temperature is too high
keep good ventilation
Reduce the cooling water inlet
Cooling water inlet temperature is too
temperature and increase the
high or pressure is too low
pressure

High condensate Air-cooled condenser accumulated

temperature dust, oil; Clean the condenser
indicator Water-cooled condenser blocked
Invalidity of the thermal by-pass value Adjust or change
Failure to the fan Change
Too high capacity and low working re-setup the air compressor or air
pressure dryer
Refrigerant excessive Relieve some

➢ Abnormity of compressor
Malfunction Reason Troubleshooting
No power supply Connect power
Change the power phase
Phase sequence protection
sequence
Badness of contactor, no actuation Change contactor
High-low pressure protective switches
Make them restoration
don't be restoration
Unable to start
Thermal overload relay don't be
Make it restoration
restoration
Capacitor fault Change
Loosen of control circuit Re-impose line
Compressor mechanical fault,
Change
e.g.clamping cylinder

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 Refrigerated compressed air dryer instruction manual
Failure of phase sequence protection
Adjust phase sequence and
device, or
change protection device
Compressor reversion
Check the leakage point(s), and
Abnormal sound Leakage of refrigerant
infuse some refrigerant
and hot of
Excessive capacity Reduce
compressor
Too large opening to the by-pass valve Adjust
The foundation uneven, compressor
Adjust the foundation
eccentric shaft
Zero line and ground line sharing Separate them

➢ Badness of the drainage system

Malfunction Reason Troubleshooting
Normal working pressure should be
The using pressure is under 0.2MPa
0.8MPa
Spoiling of ball valve Change
Slant or breakage of the drain Correction ,fasten or change
Clean the filter net and dredge the
Badness of Block of the filtering of the drain
pipe
drainage
Copper ball valve not open or
Change
damaged
The air by-pass valve not be
closed, compressed air don't pass Close the by-pass pipe
the air dryer.

The air dryer is composed of a compressor, condenser, evaporator, expansion valve

(capillary) and many accessories. It’s a complex system that interconnected and
interactive. Therefore, we should focus on the whole system but not a typical part
should there’s some problems, comprehensive check and analyze. Eliminate doubts
and eventually find the real reasons of the faults.

Electrical Diagram
(Electrical diagram is stuck in the back of the electric control box for the
convenience of examination and repair. Please refer to it.)

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Maintenance Directory
to Auto-drain
7.1 Clean and maintain guide of electronic drain
7.1.1 The fairly faults and troubleshooting to electronic drain:
Malfunction Reason Troubleshooting
Drainage coil burned out Change
Time control relay burned out Change
No drainage
The valve core be seized-up by
Clean the filter net and valve core
impurity substance, it can't work
The valve core be seized-up by
Always
impurity substance, it can't be Clean the filter net and valve core
exhausting
restoration for sealing.

7.1.2 Electronic drain’s structure and how it works: (Chart 3)

The electronic drain is composed by valve body, coil and time relay, It
drain out the condensate water according to the setting time. When the
time relay transmits power to the coil, the coil gets electricity and produces
the electromagnetic force. It overcomes the elastic force of the valve spring,
actuate valve core to accomplish the draining process. When stops, the
coil power losses, the valve core is using the elastic force of the spring
itself to descend and seal to lock gas.

time coil

core

(Chart 3)

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 Refrigerated compressed air dryer instruction manual
7.1.3 Procedural decomposition of the dismantling and cleaning to
electronic drain:
Turn off the gas time relay
coil

1.normal operation --- 2. close the manual --- 3. dismantle the --- 4. dismantle the coil
condition valve time-relay and
cut of the power

valve stem core

sealed cap

--- 5.take down the --- 6. dismantle the --- 7. take down the --- 8.dismantle the
coil stem stem & core sealed cap of filter net

filter net --- 12. please

re-install as the
reverse
procedure after
cleaning.

--- 9.take down the 10. cleaning the stem --- 11. clean the filter net
filter net & core

7.2 Clean and maintain guide of floating drain

7.2.1 The fairly faults and troubleshooting to floating drain:
Malfunction Reason Troubleshooting
Floater be stuck by oil and dust, it
Clean
No drainage can’t rise
Block of the impurity substance Dredge
Always exhausting Damaged of seal ring Change

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 Refrigerated compressed air dryer instruction manual

7.2.2 Floating drainage structure and How it works

When the condensed water accumulates to a certain position, it will float
up by the buoyancy of water to finish the drainage process.

7.2.3 Procedural decomposition of the dismantling and cleaning to floater

drain:

cover handle
clamp

Filter net

float
connector
filter net
cup 句. fasten the drain clamp
®. screw the cover handle
cover @. take down the clamp
@. take down the filter net
float ®. discharge the float connector
connector @. take down the float connector

(]). Please use cleanser essence to clean the parts, it’s prohibited use the
corrosive liquid.

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 Refrigerated compressed air dryer instruction manual

Warranty Conditions
8.1 General
The manufacturer provides the purchaser of this device with a warranty for
perfect condition and performance for a period of 12 months from putting
into use or 14 months from the date of dispatch from manufacturer
whichever is earlier.
subject to the following conditions:
* The warranty covers the delivered device, on condition that it is employed in a proper and correct
manner in accordance with its specifications. Within the scope of this warranty, the manufacturer warrant
that the device is free of any manufacturing or material defects which would impair the performance
characteristics of the device as specified in these operating instructions.
* In the event of a malfunction or failure of the device, warranty coverage will be provided by replacing
or repairing the device or components of the device, according to the manufacturer's decision. Replaced
components of the device will be retained by the manufacturer, without separate compensation.
* The costs for materials and labor (normal working hours, no overtime) will be borne by the
manufacturer, provided that the work is carried out by the manufacturer and the required material is
supplied by the manufacturer. The costs for dispatch to the manufacturer are to be borne by the operator,
the costs for return dispatch will be born by the manufacturer.

8.2 Warranty period

The warranty period is to be twelve (12) months from putting into use, or fourteen (14)
months from the date of dispatch from the manufacturer, whichever is earlier, provided,
that the product has been properly protected against atmospheric influence such as
rain,snow, wind and sun.

8.3 Exclusion from warranty coverage

Warranty claims are excluded,
* If the device is damaged or destroyed due to force majeure or environmental effects (humidity,
electric shocks, etc.).
* For damage resulting from incorrect handling, in particular failure to comply with the operating and
maintenance instructions (cleaning of the condenser and the separation system, regular inspection of the
condensate discharger, etc.).
If the device has not been used in accordance with its specifications (see nameplate).
* If the device has been opened or repaired by workshops or other persons unauthorized for this
purpose and/or reveals any type of mechanical damage.

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 the expert compressed air treatments!

Expert compressed air treatment