High Inlet Air
Temperature
Air Dryers
Installation & Operation
Maintenance
Manual
Model
CHI 20
CHI 40
CHI 75
CHI 25
CHI 55
CHI 110
CHIIOM 01-02 Rev. REL
Model Number:
Serial Number:
FILL IN COMPLETELY AT INSTALLATION
Coaire Technologies Corporation
12226 Coast Drive, Whittier, CA 90601 ◊ TEL.(562)463-3935 ◊ (562)463-4928
website: www.coaire.com ■ e-mail: sales@coaire.com/support@coaire.com
Printed in U.S.A.
FORM CM-AD01
FEB. 2002
STATEMENT OF WARRANTY TERMS & CONDITIONS
COAIRE’s refrigerated air dryers are warranted to be free of defects in materials and workmanship under proper use,
installation, and application. This warranty shall be for a period of 15 months from date of shipment from our factory
or other stocking facilities or 12 months from date of installation. Proof of installation date will be required. All dryers
outside the U.S. and Canada carry a parts only warranty.
ALL FREIGHT DAMAGE CLAIMS ARE NOT THE RESPONSIBILITY OF THE MANUFACTURER AND ARE NOT
COVERED UNDER WARRANTY AS ALL PRODUCTS ARE SHIPPED F.O.B. SHIPPER.
PLEASE DIRECT ALL FREIGHT CLAIMS TO THE SHIPPER IN QUESTION.
MAINTENANCE AND ADJUSTMENTS
ADJUSTMENTS TO THE HOT GAS AND MAINTENANCE OF FLOAT AND AUTOMATIC DRAINS AND
CONDENSER COILS ARE CONSIDERED TO BE ROUTINE MAINTENANCE AND THEREFORE NONWARRANTABLE ITEMS AND ARE THE SOLE RESPONSIBILITY OF THE END USER. CONSULT THE
INSTALLATION, OPERATION AND MAINTENANCE MANUAL FOR THE ADJUSTMENT AND MAINTENANCE
PROCEDURES.
This warranty does not apply to any unit damaged by accident, modification, misuse, negligence, or misapplication.
Damage to heat exchangers by exposure to ammonia, any other corrosive substance or sub-freezing environment
will be considered misuse.
Any refrigerated dryer part or material found defective will be repaired, replaced or refunded, at the sellers option free
of charge, provided that COAIRE is notified within the above stated warranty period. All returns of allegedly
defective equipment must have prior written authorization. Said authorization may be obtained through our
refrigerated dryer service department. All refrigerated dryers, parts, materials must be returned freight prepaid to the
Manufacturer’s factory within 30 days of return authorization date. Any shipment returned to the factory collect will be
refused.
If an item is found to be warrantable, the repaired item or replacement will be returned normal ground freight prepaid
within the continental United States and Canada. Expedited shipment costs are the responsibility of the requestor.
Any replacement part or material is warranted only to the extent of the remaining warranty period of the dryer or to
the extent as provided by the supplier, whichever is longer.
Identification Plate
The identification plate is located on the back of the dryer and shows all the primary data of the machine. Upon
installation, fill in the table on the previous page with all the data shown on the identification plate. This data should
always be referred to when calling the manufacturer or distributor.
The removal or alteration of the identification plate will void the warranty rights.
DISCLAIMER
The warranty does not cover any responsibility or liability for direct or indirect damages to persons, or equipment
caused by improper usage or maintenance, and is limited to manufacturing defects only. Refer to COAIRE Warranty
policy manual for travel, mileage and special charge considerations. The warranty will be immediately voided if there
are changes or alterations to the dryer.
WHO TO CONTACT IF YOU HAVE A WARRANTY CLAIM:
COAIRE Technologies, Corporation
Phone
(562) 463-3935
Fax
(562) 463-4928
All freight damage claims should be filed within 15 working days and should be directed to the carrier.
TABLE OF CONTENTS
1.
SAFETY RULES
1.1
1.2
1.3
2.
INSTALLATION
2.1
2.2
2.3
2.4
2.5
2.6
3.
Control Panel
Operation
Flow diagram-CHI20 -CHI 55
Flow diagram-CHI 75
Flow diagram-CHI110
Refrigeration Compressor
Condenser unit
Filter Drier
Capillary Tube
Evaporator
Liquid separator (CHI 75-CHI110)
Hot Gas By-pass Solenoid Valve
5 micron Filter
Aftercooler
Air -Air Exchanger
Condensate Separator
Fan Pressure switch PV (CHI 110)
DMC 11 Controller
Electrical Schematic-CHI20-CHI25
Electrical Schematic-CHI40-CHI75
Electrical Schematic-CHI 110
MAINTENANCE, REPLACEMENT PARTS
6.1
6.2
7.
Technical Specifications-CHI20 -CHI25
Technical Specifications-CHI40- CHI55
Technical Specifications-CHI75- CHI110
TECHNICAL DESCRIPTION
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
6.
Preliminary Operations
Initial Start Up
Operation and Shut-down
TECHNICAL INFORMATION
4.1
4.2
4.3
5.
Transporting the unit
Installation site
Installation layout & Correction factors
Connection to the Compressed Air System
Connection to the Main Power
Condensate Drain
START-UP
3.1
3.2
3.3
4.
Explanation of Convention Symbols Used in This Manual
Warnings
Proper Use of the Dryer
Maintenance Schedule
Replacement Parts
TROUBLESHOOTING
7.1
Troubleshooting
1.1 DEFINITION OF THE SAFETY SYMBOLS
Carefully read instruction manual before attempting any service or maintenance procedures on the dryer.
Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not followed properly.
Electrical hazard. Warning message indicates practices or procedures that could result in personal injury or fatality if not
followed correctly.
Danger hazard. Part or system under pressure.
Danger hazard. High temperature conditions exist during operation of system. Avoid contact until system or component
has dissipated heat.
Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may result if precautions are
not followed.
Danger hazard: In case of fire, use an approved fire extinguisher, Water is not an acceptable means in cases of
electrical fire
Danger hazard. Do not operate equipment with panels removed.
Maintenance or control operation to be performed by qualified personnel only 1.
ARIA
AIR
LUFT
AIR
Compressed air inlet connection point.
ARIA
AIR
LUFT
AIR
Compressed air outlet connection point.
Condensate drain connection point.
Operations that can be performed by the operator of the machine, if qualified 1.
NOTE:
Text that specifies items of note to be taken into account, does not involve safety precautions.
In designing this unit a lot of care has been devoted to environmental protection:
• CFC free refrigerants
• CFC free insulation parts
• Energy saving design
• Limited acoustic emission
• Dryer and relevant packaging composed of recyclable materials
This symbol requests that the user heed environmental considerations and abide with suggestions annotated with this
symbol.
1
Experienced and trained personnel familiar with national and local codes, capable to perform the needed activities, identify and
avoid possible dangerous situations while handling, installing, using and servicing the machine. Ensuring compliance to all
statutory regulations
1.2 WARNINGS
Compressed air is a highly hazardous energy source.
Never work on the dryer with pressure in the system.
Never point the compressed air or the condensate drain outlet hoses towards anybody.
The user is responsible for the proper installation of the dryer. Failure to follow instructions given in the “Installation” chapter will
void the warranty. Improper installation can create dangerous situations for personnel and/or damages to the machine could
occur.
Only qualified personnel are authorized to service electrically powered devices. Before attempting maintenance, the
following conditions must be satisfied :
Ensure that main power is off, machine is locked out, tagged for service and power cannot be restored during service
operations.
Ensure that valves are shut and the air circuit is at atmospheric pressure. De-pressurize the dryer.
Warranty does not apply to any unit damaged by accident, modification, misuse, negligence or misapplication.
Unauthorized alterations will immediately void the warranty.
1.3 PROPER USE OF THE DRYER
This dryer has been designed, manufactured and tested for the purpose of separating the humidity normally contained in
compressed air. Any other use has to be considered improper.
The Manufacturer will not be responsible for any problem arising from improper use; the user will responsible for any
resulting damage.
• Moreover, the correct use requires the adherence to the installation instructions, specifically: Voltage
and frequency of the main power.
• Pressure, temperature and flow-rate of the inlet air.
• Ambient temperature.
This dryer is supplied tested and fully assembled. The only operation left to the user is the piping connections
to the compressed air system in compliance with the instructions given in the following chapters.
The purpose of the machine is the removal of water and residual oil vapor present in compressed air. The dried air
cannot be used for respiration purposes or for operations leading to direct contact with food products.
This dryer is nor suitable for the treatment of dirty air or of air containing solid particles.
2.1 TRANSPORTING THE UNIT
Check for visible loss or damage, if no visible damage is found place the unit near to the installation point and unpack the
contents.
• Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid on its side or if
placed upside down.
• Store machine in a clean, dry environment, do not expose to severe weather environments.
The packaging materials are recyclable. Dispose of material in compliance with the rules and regulations in force in the
destination country.
2.2 INSTALLATION SITE
Failure to install dryer in the proper ambient conditions will affect the dryer’s ability to condense refrigerant gas. This can
cause higher loads on the compressor, loss of dryer efficiency and performance, overheated condenser fan motors,
electrical component failure and dryer failure due to the following: compressor loss, fan motor failure and electrical
component failure. Failures of this type will affect warranty considerations.
Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous gasses; steam heat, areas of
high ambient conditions or extreme dust and dirt.
In case of fire, use an approved fire extinguisher, Water is not an acceptable means in cases of electrical fire.
Minimal installation requirements:
• Select a clean dry room, free from dust, and protected from atmospheric disturbances.
• The supporting plate must be smooth, horizontal and able to hold the weight of the dryer.
• Minimum ambient temperatures 34°F see the data plate for maximum temperature.
• Allow at least 40 inches of clearance on each side of the dryer for proper ventilation and to facilitate maintenance
operations.
The dryer doesn't require to be fixed to the supporting surface. Locks will be required for special installations (on brackets,
hanging, etc.).
2.3 INSTALLATION LAYOUT
3
2
4
1
6
7
7
7
5
3
2
4
1
6
7
7
7
5
1 AIR COMPRESSOR
2 PRE-FILTER
3 COMPRESSED AIR TANK
4 AFTERFILTER
5 DRYER
6 BY-PASS
7 CONDENSATE DRAIN
Type A installation is suggested when the compressor operates at reduced intermittence and the total consumption
equals the compressor flow rate.
Type B installation is suggested when the air consumption can consistently change with peak values highly exceeding the
flow rate of the compressors. The capacity of the tank must be sized in order to compensate for more demanding
conditions (peak air consumption).
Correction factor for inlet air pressure changes:
Inlet air pressure psig
80
Factor
1.25
100
1.00
150
.87
200
.83
230
.80
Correction factor for ambient temperature changes (Air cooled only):
85
100
Ambient Temperature °F
Factor
.91
1.00
105
1.10
110
1.22
Correction factor for inlet air temperature changes:
125
Air Temperature °F
Factor
.85
180
1.00
200
1.11
150
.91
2.4 CONNECTION TO THE COMPRESSED AIR SYSTEM
Operations to be performed by qualified personnel only. Never work on compressed air piping under pressure. The
user is responsible to ensure that the dryer will never be operated with pressure exceeding the maximum pressure
rating on the unit data tag. Over pressurizing the dryer could be dangerous for both the operator and the machine.
The air temperature and the scfm entering the dryer must comply with the limits reported on the data nameplate. The
system connecting piping must be kept free from dust, rust, chips and other impurities, and must be consistent with the
flow-rate of the dryer.
In order to perform maintenance operations, it recommended that by-pass piping be installed, as shown in illustration 1.1.
Illustration 1.1
Particular measures have been taken to reduce the amount of vibration that could occur during the operation.
Therefore, we recommend the use of connecting pipes that are able to insulate the vibration. (Flexible hoses,
vibration damping fittings, etc.)
2.5 Electrical Connections
Qualified personnel should carry out connections to the main power. Be sure to check the local codes in your
area.
Before connecting the unit to the electrical supply, verify the data nameplate for the proper electrical
information. Voltage tolerance is +/- 5%.
115/1/60 dryers are supplied with a standard North American power cord and plug assembly (two poles and a
ground.
230/1/60 is supplied with a junction box. Be sure to provide the proper fuses or breakers based on the data tag
information located on the back of the unit. The main power receptacle must be protected with a thermal
overload relay (I∆n+0.03A), rated to the power consumption of the dryer (refer to data nameplate for nominal
values). The power supply cord must meet or exceed ratings for the total amp draw of the unit.
Connect to a properly grounded utlet. Improper connection of the equipment-grounding conductor can result in
risk of electric shock. Do not use adapters on the plug receptacle- if it will fit the outlet, have a proper outlet
installed by a qualified electrician.
2.6 CONDENSATE DRAIN
Discharge is at system pressure. Drain line should be secured.
Never point the condensate drain line towards anybody.
The dryer comes with a flexible plastic drain tube (1/4”in diameter and 60in long) for the connection to suitable drain.
Removal of the condensate occurs through a solenoid valve protected with a mechanical filter. In order to avoid clogging
of the solenoid valve, the condensate from the cyclone separator is previously filtered, than discharged. An adjustable
electronic timer operates the solenoid valve coil.
The drain cannot be connected to pressurized systems.
Condensate may contain oil. Comply with applicable laws concerning disposal.
A water-oil separator should be installed before the air inlet to the dryer for the purpose of removing
condensate drainage coming from compressors, dryers, tanks, filters, etc.
3.1 PRELIMINARY OPERATION
Verify that the operating parameters match with the nominal values reported on the data nameplate of the dryer
(voltage, frequency, air pressure, air temperature, ambient temperature, etc.).
This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unit could be
damaged during transportation, check the integrity of the dryer during initial start-up and monitor operation during the first
hours of operation.
Qualified personnel must perform the initial start-up.
When installing and operating this equipment, comply with all National Electrical Code and any applicable
federal, state and local codes.
3.2 INITIAL START-UP
This procedure should be followed on initial start-up, after periods of extended shutdown or following
maintenance procedures.
Qualified personnel must perform the start-up.
Sequence of operations:
• Ensure all steps of the “Installation” chapter have been followed.
• Confirm that all piping and electrical connections are proper.
• Ensure condensate drain lines are properly fastened and connected to a suitable drain system.
• If a by-pass is installed around the dryer, close the inlet and outlet isolation valves, open the by-pass valve.
• Verify that the manual valve mounted on condensate drain circuit is open.
• Remove all packaging and other material that could obstruct the area around the dryer.
• Turn on the main power to the unit
POSITION 1
POSITION 2
• Move the rocker “ON/OFF” switch to the “ON” position (in the on
ON
position the switch should be illuminated), the “ON” led located on
the control panel (pos. 1) should be lit.
• Compare amp draw to nominal values on the data nameplate.
• Verify the operation of the condensate drain circuit - wait for first
activation.
• Allow the dryer temperature to stabilize at the pre-set value.
• Slowly open the air inlet valve.
• Slowly open the air outlet valve.
• Slowly close the central by-pass valve of the system
• Check the piping for air leakage.
3.3 START-UP AND SHUT DOWN
Operation :
• Check the condenser for cleanliness.
• Verify power to the system.
• Move the rocker “ON/OFF” switch to the “ON” position.
• Check that the “ON/OFF” switch and the LED
on the DMC11 are both illuminated.
• Wait a few minutes, verify that the DewPoint displayed on the DMC11 is correct and that the condensate drains actuates regularly.
• Turn on the air compressor.
• A hot gas by-pass solenoid valve is utilized to prevent evaporator and drain freeze-ups during low load conditions; valve activation is
detected by illumination of the
display on the DMC11 (pos. 2).
Switching off :
• Verify that the DewPoint displayed on the DMC11 is correct.
• Switch off the air compressor.
• After few minutes, Move the rocker “ON/OFF” switch of the dryer to the “OFF” position.
During operation, the refrigeration compressor, the condenser fan and the Aftercooler fan will be on continuously. On the 110 SCFM
model, the PV pressure switch controls the condenser fan.
4.1 TECHNICAL SPECIFICATIONS CHI20-CHI25
21.25
20.00
17.75
CHI20
CHI25
4.2 TECHNICAL SPECIFICATIONS CHI40-CHI55
23.25
35.50
19.25
CHI40
CHI55
40
R134a
55
❘
R404a
4.3 TECHNICAL SPECIFICATIONS CHI75-CHI110
CHI75
CHI110
75
110
5.1 CONTROL PANEL CHI20-CHI110
The control panel illustrated below is the only operator interface.
2
1
1
0
ON
set
set
3
1
R o c k e r S w i t c h O n / O f f ( I l l u m i n a t e d wh e n O n )
2
DMC11 Air Dryer Controller
3
K
Air and refrigerating gas flow diagram
5.2 OPERATION
Operating principal-The dryer models described in this manual operate all on the same principal. The hot moisture laden
air enters an air to air heat exchanger. The air then goes through the evaporator, also known as the air to refrigerant heat
exchanger. The temperature of the air is reduced to approximately 35-39 degrees Fahrenheit, causing water vapor to
condense to liquid. The liquid is continuously coalesced and collected in the separator for removal by the condensate
drain. The cool moisture free air then passes back through the air to air heat exchanger to be reheated to within fifteen
degrees of the incoming air temperature as it exits the dryer.
Refrigerant circuit - Refrigerant (R-134a or R-404) gas is cycled through the compressor and exits at high pressure to an
air condenser where heat is removed causing the refrigerant to condense to a high pressure liquid state. The liquid is
forced through a metering device (capillary tube or thermal expansion valve) where the resulting pressure drop allows the
refrigerant to boil off at a predetermined temperature. Low pressure liquid refrigerant enters the heat exchanger where
heat from the incoming air is transferred causing the refrigerant to boil; the resulting phase change produces a low
pressure, low temperature gas.
The low pressure gas is returned to the compressor, where it is re-compressed and
begins the cycle again. During those periods when the compressed air load is reduced the excess refrigerant is bypassed automatically back to the compressor via the hot gas by-pass valve circuit.
5.3 FLOW DIAGRAM
1 REFRIGERATION COMPRESSOR
2 CONDENSER
3 FILTER DRYER
4 CAPILLARY TUBE
5 EVAPORATOR
6 LIQUID SEPARATOR (75-110 SCFM)
7 HOT GAS VALVE
8 AFTERCOOLER
9 BY-PASS (RECOMMENDED)
10 5 MICRON FILTER
5.4
11
12
13
14
15
16
17
18
19
20
ELECTRIC DRAIN
AIR-AIR HEAT EXCHANGER
CONDENSATE SEPARATOR
CONDENSATE DRAIN SERVICE VALVE
CONDENSATE FILTER
CONDENSATE DRAIN SOLENOID VALVE
CONDENSER FAN
CONDENSER FAN PRESSURE SWITCH (110 SCFM)
AFTERCOOLER FAN
AIR DRYER CONTROLLER PROBE
Flow Diagram for Model Series CNC20-CNC55
5.4 REFRIGERATION COMPRESSOR
The refrigeration compressor is the pump of the system where the gas coming from the evaporator (low pressure side) is
compressed up to the condensation pressure (high pressure side). The compressors utilized are manufactured by primary
companies and are designed for applications where high compression ratios and wide temperature changes are present.
The fully sealed construction is perfectly gas tight, so ensuring high-energy efficiency and long useful life. Dumping
springs supports the pumping unit, in order to consistently reduce the acoustic emission and the vibration diffusion.
The electric motor is cooled by the aspirated refrigerating gas, which goes through the coils before reaching the
compression cylinders. The thermal protection protects the compressor from over heating and over currents. The
protection is automatically restored as soon as the nominal temperature conditions are reached.
5.5 CONDENSER UNIT
The condenser is the element in which the gas coming from the compressor is cooled down and condensed becoming a
liquid. Mechanically, a copper tubing circuit (with the gas flowing inside) forms it immersed in an aluminum fin package.
The cooling operation occurs via a high efficiency fan, which, in applying pressure on the air contained within the dryer,
forces it into the fin package. It’s mandatory that the temperature of the ambient air will not exceed the nominal values. It
is also important TO KEEP THE UNIT FREE FORM DUST AND OTHER IMPURITIES.
5.6 FILTER DRIER
Traces of humidity and slag can accumulate inside the refrigeration circuit, or long periods of use can produce sludge,
could limit the lubrication of the compressor and clog the expansion valve or capillary tube.
The function of the filter drier, located before the capillary tubing, is to stop the impurities, avoiding their circulation within
the system.
5.7 CAPILLARY TUBING
It consists of a piece of reduced cross section copper tubing located between the condenser and the evaporator and acts
as a metering device to reduce the pressure of the refrigerant. Reduction of pressure is a function of the temperature to
be reached within the evaporator: the smaller the capillary tube outlet pressure, the lower the evaporation temperature.
The length and interior diameter of the capillary tubing is accurately sized with the performance to be reached by the
dryer; no maintenance or adjustment is necessary.
5.8 EVAPORATOR
Also called an air-refrigerant exchanger. The liquid refrigerant formed in the condenser is evaporated in this part of the
circuit. In the evaporation phase the refrigerant side of the evaporator tends to absorb heat from the compressed air
present in the other side of the exchanger. The evaporator is immersed in the cabinet base of the dryer and insulated with
non-CFC expanded insulating foam. The part is entirely constructed in copper and the cooler goes in the opposite
direction to the air, thus contributing to limited pressure loss and to provide efficient thermal exchange.
5.9 LIQUID SEPARATOR (CHI75 & CHI110 only)
It prevents the return of liquid refrigerant to the compressor separating droplets not evaporated from the gas flow.
5.10 HOT GAS BY-PASS SOLENOID VALVE
This valve is located between the pressure side of the compressor and the terminal side of the evaporator.
Its purpose is to avoid conditions of low thermal charge in the dryer (low air flow or relatively cold air)
The temperature inside the evaporators will drop below 32ºF. Temperature below 32ºF would eventually allow the
formation of ice inside the evaporator, with the consequent blockage of air flow and, in the worst of the cases, the rupture
of the evaporator itself. The DMC11 Controller activates the coil of the solenoid valve.
5.11 5-MICRON FILTER
Positioned at the outlet of the Aftercooler, the 5-micron filter ensures a good degree of purification of the treated air. The
filter unit is embodied in the container so as to ensure rapid and easy replacement.
5.12 AFTERCOOLER
The air Aftercooler is the component where the hot air entering the dryer undergoes preliminary cooling down. It consists
of a circuit of copper tubing, supporting the circulation of compressed air, immersed in an aluminum body provided with
cooling fins. A high efficiency axial fan moving ambient air onto these blades provides the necessary cooling down of the
system. It is mandatory that the ambient temperature will not exceed the nominal value for the dryer. It is equally
important to KEEP THIS SYSTEM FREE FROM DUST AND FOREIGN MATERIALS eventually introduced by the fan.
5.13 AIR/AIR EXCHANGER
The purpose of this exchanger is the transmission of the heat of the incoming air to the exiting cold air. The benefits of this
solution are basically twofold: the incoming air is partially cooled down. Therefore the chilling system can be sized for a
lower thermal drop, thus allowing a 40-50% energy saving; moreover, cool air will never reach the compressed air circuit
and condensate will not form on the external surface of the piping.
5.14 CONDENSATE SEPARATOR
The cold air exiting the evaporator goes through the "demister" type condensate separator featuring a stainless steel net.
As the condensate transported by the air gets in contact with the metallic net of the "demister" it is separated and expelled
by means of the draining device. The resulting cold and dry air is then conveyed into the air/air exchanger.
The "demister" type separator offers the benefit of being highly efficient, even with variable flow rates and does not require
special maintenance.
5.15 COOLING FLUID PRESSURE SWITCH PV (CHI110 only)
To safeguard a safety operation and the integrity of the dryer, a pressure controller has been installed on the refrigerating
gas circuit.
PV: Condenser fan control switch located on the inlet side on the compressor keeps the condensation
temperature/pressure constant within preset limits.
Setting pressure: R 404A Stop 232 psi/104ºF - Restart 290 psi/115ºF
5.16 DMC11 AIR DRYER CONTROLLER
Button
-
Access set-up functions.
Button
-
LED
LED
-
Condensate drain-push to test / change drain
interval setting.
Illuminated = power on.
Flashing = set-up condition.
Hot-gas solenoid valve activated.
LED
-
Condensate drain solenoid valve activated.
ON
set
se t
DISPLAY
The DMC11 device controls the operation of the dryer, and allows adjustment to the operating parameters. A
temperature-dependent semiconductor probe located at the end of the evaporator controls the hot-gas solenoid
valve activation. An electronic timer drives the condensate drain solenoid valve at regular intervals.
OPERATION - During the dryer operation, the LED
is illuminated.
The LED display (consisting of ten LED’s) indicates the current operating DewPoint. The LED’s illuminate
sequentially from left to right, refer to the tri-colored gradient decal directly above the LED display itself.
•
•
•
Blue section - the DewPoint of the dryer is too low: risk of freeze-up.
Green section – acceptable operating conditions ensuring an optimal DewPoint ;
Red section – The DewPoint is too high, air is not being properly treated.
PARAMETERS AND ADJUSTMENTS
Activation of the hot-gas solenoid valve occurs when the DewPoint drops below 37.4°F - 3°C (refer to table-Set point) LED illuminates - valve is deactivated when the DewPoint rises above 40°F - 4.5°C (Set point + ∆t) The condensate drain solenoid valve activates for 2 seconds (refer to table-TON) (refer to table-TOFF).
Depress the
LED off.
LED on – in 60 second intervals
button to perform manual test of the condensate drain.
SET-UP - The DMC11 is preset to factory specifications for typical use. The following parameters can be changed to meet
specific user requirements:
• Set point - activation temperature of the hot-gas solenoid valve (fix hysteresis - ∆t equal to 2.7°F - 1.5°C).
• TON - condensate drain solenoid valve activation duration time.
• TOFF – Interval time between activation of the condensate drain solenoid valve.
To access set-up, depress and hold the
button for 2 seconds, the
LED flashing confirms the command.
Parameters cycle in sequence, the Set Point parameter is first, followed by TON, then TOFF. Depress the
access the next parameter. The current value for the parameter is shown as a single flashing LED.
button to
To change the value of the selected parameter, while pressing the
button use the
button to toggle through
available settings. For the value range and the resolution (value of each single LED), see the following table:
Description
Set point
TON
TOFF
Activation of the hot-gas
solenoid valve
Activation time of the condensate drain
solenoid valve
Pause time of the condensate
drain solenoid valve
Display
Synchronous flashing
+ LED
LED
Synchronous flashing
Value
range
Resolution
Set
value
35.6 - 43.7 °F
2.0 - 6.5 ºC
1.0 °F
0.5 ºC
37.4 °F
3 ºC
1 - 10 sec
1 sec
2 sec
1 - 10 min
1 min
1 min
+ LED
LED
Non-synchronous flashing
LED
+ LED
The "out of scale" conditions are indicated by the intermittent flashing of the first and the last LED of the display, depicts a
chosen setting out of acceptable range.
To exit the set-up condition at any time, press the
system returns to operation function.
button. If no operations are performed for a 2-minute period, the
5.17 ELECTRICAL SCHEMATIC CHI20-CHI/25
LEGEND:
IG - ON/OFF SWITCH
K - REFRIGERATION COMPRESSOR
KR – COMPRESSOR START RELAY
KM – COMPRESSOR MOTOR
KT – COMPRESSOR THERMAL PROTECTION
V - CONDENSER/AFTERCOOLER FAN
PR – AIR CONTROLLER PROBE
EVB – HOT GAS VALVE
EVD – CONDENSATE DRAIN SOLENOID VALVE
5.18 ELECTRICAL SCHEMATIC CHI40-CHI75
LEGEND:
IG - ON/OFF SWITCH
K - REFRIGERATION COMPRESSOR
KR – COMPRESSOR START RELAY
KM – COMPRESSOR MOTOR
KT – COMPRESSOR THERMAL PROTECTION
VC - CONDENSER FAN
VA - AFTERCOOLER FAN
PR – AIR CONTROLLER PROBE
EVB – HOT GAS VALVE
EVD – CONDENSATE DRAIN SOLENOID VALVE
5.19 ELECTRICAL LAYOUT 110 SCFM
LEGEND:
IG - ON/OFF SWITCH
K - REFRIGERATION COMPRESSOR
KR – COMPRESSOR START RELAY
KM – COMPRESSOR MOTOR
KT – COMPRESSOR THERMAL PROTECTION
PV – COOLING FLUID PRESSURE SWITCH
VC - CONDENSER FAN
VA - AFTERCOOLER FAN
PR – AIR CONTROLLER PROBE
EVB – HOT GAS VALVE
EVD – CONDENSATE DRAIN SOLENOID VALVE
6.1 MAINTENANCE SCHEDULE
Only qualified personnel should perform maintenance operations.
Prior to performing any maintenance or service, be sure that:
• Ensure that the power is off and the unit is at atmospheric pressure.
• Main power circuit breaker is in the off position per lock out/tag out procedures.
• Ensure that maintenance personnel have read and understand the safety and operations instructions in
this manual.
High temperature conditions exist during operation of system. Avoid contact until system or component
has dissipated heat.
DAILY
• Verify that the DewPoint displayed on the DMC11 is correct.
• Check the proper operation of the condensate drain system.
• Inspect the condenser for cleanliness.
EVERY 200 HOURS OR MONTHLY
• Blow entire unit out with compressed air (Max. 30 psig - 2 barg)
• Blow condenser coils out with compressed air.
• Close the manual condensate drain valve, remove the mechanical filter and clean it with compressed air
and a brush. Reinstall the filter, make sure it is tight, and open the manual valve.
• Verify operation of the machine.
EVERY 1000 HOURS OR YEARLY
• Tighten all electrical connections. Look for broken, cracked or bare wires.
• Inspect refrigeration circuit for signs of oil and refrigerant leakage.
• Measure and record amperage. Verify that readings are within acceptable parameters as listed in
specification table.
• Inspect condensate drain flexible hoses, and replace if necessary.
• Verify operation of the machine.
YEARLY OR MORE FREQUENTLY IF NECESSARY
•
Disconnect the 5-micron filters from the relevant condensate drain circuit.
•
Unscrew the clogged cartridges.
•
Lubricate with silicon grease the gaskets of the new cartridge.
•
Hand tighten the cartridges on the head of filters.
•
Connect the respective condensate drain circuits.
6.2 SPARE PARTS
Model
Part Description
Condenser
Fan Motor
Fan Blade
Aftercooler Condenser
Aftercooler Fan Motor
Aftercooler Fan Blade
Compressor
Filter Drier
By-Pass Solenoid Valve
(+) By-pass Solenoid Coil
DMC11 Controller
DMC11 Probe
Green Indicator Switch
Shut Off Ball Valve 3/8"
Y- Strainer 3/8"
Auto Drain Trap ATD02
Condensate Solenoid Valve 1/4"
(+) Condensate Solenoid Coil
(+) Replacement Spin on Filter 5 Micron
Front Panel
Back Panel
Side Panels (Right & Left)
Top
* Parts not required on model.
(+) Recommended Spare Parts
CHI20
Qty Part Numbers
1 5821005005
1 5210135015
1 5215000022
1
*
1
*
1
*
1 5015135005
1 6650SSS005
1 64120SS005
1 64N22MM055
1 5620130100
1 5625NNN020
1 5450SZN010
1 64130MF150
1 64355FF011
1 2230ATD002
1 64320FF005
1 64N22MM035
1 1500LFP006
1 680TH005ANDF
1 680TH005PSTF
1 680TH005LTRF
1 680DF003CPRF
Spare Parts List
CHI25
CHI40
Part Numbers
Part Numbers
5821005005
5810010005
5210135015
52100135015
5215000022
5215000022
*
5820010005
*
5210135015
*
5215000022
5015135007
5015135010
6650SSS005
6650SSS005
64120SS005
64120SS005
64N22MM055
64N22MM055
5620130100
5620130100
5625NNN020
5625NNN035
5450SZN010
5450SZN010
64130MF150
64130MF150
64355FF011
64355FF011
2230ATD002
2230ATD002
64320FF005
64320FF005
64N22MM035
64N22MM035
1500LFP012
1500LFP012
680TH005ANDF
680TH010ANDF
680TH005PSTF
680TH010PSTF
680TH005LTRF
680TH010LTRF
680DF003CPRF
680TH010CPRF
CHI55
Part Numbers
5810010005
52100135015
5215000022
5820010005
5210135015
5215000022
5025135003
6650SSS005
64120SS005
64N22MM055
5620130100
5625NNN035
5450SZN010
64130MF150
64355FF011
2230ATD002
64320FF005
64N22MM035
1500LFP018
680TH010ANDF
680TH010PSTF
680TH010LTRF
680TH010CPRF
CHI75
Part Numbers
5810020005
5210135020
5215000025
5820020005
5210135020
5215000025
5025135005
6650SSS005
64120SS005
64N22MM055
5620130100
5625NNN035
5450SZN010
64130MF150
64355FF011
2230ATD002
64320FF005
64N22MM035
1500LFP023
680TH020ANDF
680TH020PSTF
680TH020LTRF
680TH020CPRF
CHI110
Part Numbers
5810030005
5210135020
5215000025
5820030005
5210135020
5215000025
5025135015
6650SSS005
64120SS005
64N22MM055
5620130100
5625NNN035
5450SZN010
64130MF150
64355FF011
2230ATD002
64320FF005
64N22MM035
1500LPF045
680TH020ANDF
680TH020PSTF
680TH020LTRF
680TH020CPRF
7.1 TROUBLESHOOTING
The troubleshooting and the eventual checks have to be worked out by qualified personnel. Pay particular attention
in entering the refrigerating circuit. The refrigerant if under pressure, while expanding could cause burns and
serious damage to the eyes, should it gets in contact with them.
SYMPTOM
POSSIBLE CAUSE - SUGGESTED ACTION
The machine doesn't start.
Check for power failure.
Verify the electric wiring.
The compressor doesn’t work.
Activation of the internal protection - wait for 30 minutes, then retry.
Verify the electric wiring.
Replace the internal protection.
If present, replace the start-up relay.
If present, replace the start-up capacitor.
If present, replace the run capacitor.
If the compressor still doesn’t work, replace.
Verify the electric wiring.
The PV pressure switch is faulty (25 SCFM) -contact refrigeration engineer to
replace it.
If the fan still doesn’t work, replace.
Verify the electric wiring.
If the fan still doesn’t work, replace.
The fan of the condenser doesn’t work.
The fan of the final refrigerant
Doesn’t work.
The dryer doesn’t drain the
condensate.
The dryer continuously drains
condensate.
Verify the electric wiring.
The condensate drain mechanical filter is clogged- remove and clean.
The drain solenoid valve is jammed - remove and clean.
The coil of the condensate drain solenoid valve burned out - replace.
Air Dry Controller doesn’t work - replace.
The DewPoint is too low - the condensate is frost - see the specific section.
The drain solenoid valve is jammed - remove and clean.
Air Dryer Controller doesn’t work - replace.
Water within the line.
The dryer is off - switch it on.
Untreated air flows through the by-pass unit (if installed) - close the by-pass.
The dryer doesn’t drain condensate - see the specific section.
DewPoint too high - see the specific section.
DewPoint too high.
The dryer is off - switch it on.
The refrigerating compressor doesn’t work - see the specific section.
The fan of the condenser doesn’t work - see the specific section.
The fan of the Aftercooler doesn’t work - see the specific section.
The inlet air is too hot - restore the nominal conditions.
The inlet airflow rate is higher than the rate of the dryer - reduce the flow rate restore the normal conditions.
The ambient temperature is too high or the room ventilation is insufficient provide proper ventilation.
The condenser is dirty - clean.
The Aftercooler is dirty - clean.
The dryer doesn’t drain the condensate - see the specific section.
LED
of the Air Dry Controller is always on - see specific paragraph.
The set point of the Air Dry Controller is very high - see SET-UP of the Air Dry
Controller.
There is a leak in the refrigerating circuit - contact a refrigerating systems
engineer.
SYMPTOM
POSSIBLE CAUSE - SUGGESTED ACTION
Excessive pressure drop within the dryer.
The dew point is too low - the condensate is frost and blocks
the air -see the specific section.
Check for restriction in the flexible connection hoses.
DewPoint too low.
Verify the electric wiring of the Air Dry Controller.
Verify the wiring of the hot gas by pass solenoid valve.
The coil of the hot gas by-pass solenoid valve burned out replace.
The probe of the Air Dry Controller does not properly detect
the temperature of the evaporator - push the probe until it
reaches the bottom of the measurement well.
The set point of the Air Dry Controller is very low - see
paragraph SET-UP of the Air Dry Controller.
Air Dryer Controller doesn’t work - replace.
The hot gas solenoid valve is blocked - contact a refrigerating
systems engineer.
LED
Verify the electric wiring of the probe of the Air Dry Controller.
The first and the last led of the display of Air Dry Controller
blink simultaneously, the probe doesn’t work - replace.
Air Dryer Controller doesn’t work - replace.
of the Air Dry Controller is always on.
Excessive pressure drop within the dryer.
the air -
The dew point is too low - the condensate is frost and blocks
see the specific section.
5 micron filters is clogged - replace the cartridges.
Check for throttling the flexible connection hoses.
For complete line of additional product information, please contact your local COAIRE
distributor.
DISTRIBUTED BY
COAIRE Technologies reverse the right to make changes, at any time without notice
as a result of our commitment to continuous improvement.
Coaire Technologies, Corporation
12226 Coast Drive, Whittier, CA 90601 ◊ TEL.(562)463-3935 ◊ (562)463-4928
website: www.coaire.com ■ e-mail: sales@coaire.com/support@coaire.com
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