MANUAL
INSTALLATION OPERATION MAINTENANCE
REFRIGERATED COMPRESSED AIR DRYER
Coldspell Series
PDF processed with CutePDF evaluation edition www.CutePDF.com
.
Contents
1.
1.1
1.2
Introduction
Design
Description
2
2.
Specifications
Operational Details
2
3.
3.1
3.2
3.3
3.4
Operating Principle
Pneumatic Section
Refrigeration section
Safety
Schematic Diagrams
3
4.
4.1
4.2
4.3
Electrical
Bar Indicating Controller - Operation / Setting
LCD Controller - Operation / Setting
Wiring Diagram
6
5.
5.1
5.2
5.3
5.4
Installation
Storage
Installation and Site Connections
Electrical Connections
Running the Installation
13
6.
6.1
6.2
Operation
Operator
How to stop the Dryer
14
7.
Maintenance
15
8.
8.1
8.2
Condenser Cleaning
Air cooled condenser
Water cooled condenser
16
9.
Amount of Gas to be charged
16
10.
Repair Work
17
11.
Recommended spares list for 5 years
20
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
1
INSTRUCTION MANUAL -
!
Coldspell
READ THIS MANUAL CAREFULLY
BEFORE INSTALLING OR OPERATING THE EQUIPMENT
These symbols warn you of any dangers and the measures to be taken to prevent them.
The most important points for the correct operation of your dryer are printed in bold.
1. Introduction
1.1 Design
Coldspell refrigeration dryer eliminates any water vapour remaining in the compressed air coming at the outlet of the
compressor house. The dryers have been designed for nominal standard inlet conditions as per ISO 7183 in order to
obtain a dew point under pressure of +3oC to +7oC.
1.2 Description
The dryer consists of :
l
Integrated Heat Exchanger
l
Refrigerant Compressor
l
Electronic controller
l
Condenser Assembly
l
Expansion Device
l
Pressure switch*
l
Refrigerant Suction & Discharge Pressure Gauges
l
Hot gas bypass valve
l
Auto drain valve
l
Canopy
2. Specifications
Operational Details
Medium
: Compressed Air
Inlet condition
: Free of dirt, oil, condensate and corrosive substances.
Operating pressure*
: 7 Kg/cm2
Inlet temperature*
: Max +45oC
Inlet humidity
: Saturated at specified conditions
Ambient temperature
: Max +38oC
Pressure dew point
: + 3oC to 7oC
Cooling system
: Air cooled / Water cooled
Max. Working pressure
: 16 Kg/cm2
Refrigerant compressor
: Hermetic sealed
* Optional
2
Reference : Manual Version 2
3. Operating Principle
3.1 Pneumatic section
The moist compressed air (dirt, oil and water vapor) enters into the Air/Air section of Integrated Heat Exchanger where
it is precooled by the outgoing air and thereby conserving energy.
The compressed air next passes through the evaporator section of Integrated Heat Exchanger. It is cooled up to +3oC
by the Refrigerant. At this sub-cooled temperature, the moisture present in the air is condensed and removed by
the Demister section of Integrated Heat Exchanger.
The cool saturated air passes through the Air to Air section of Integrated Heat Exchanger where it precools incoming
air and gets heated up. Thus, this system provides clean dry air at the outlet. Efficient Filter and Automatic Drain
Valve carry out the removal of moisture at Demister. The Integrated Heat Exchangers are designed in such a way
that they are self-cleaning to maintain constant heat transfer rate.
3.2 Refrigeration section (Freon)
The Evaporator removes heat from compressed air by means of cold and low pressure freon. The heat removed from
the system is dissipated to the atmosphere/water by the condenser. The high pressure refrigerant flows into the
expansion valves where it changes into liquid phase at low pressure. The boiling of liquid refrigerant takes place in
the Evaporator and cold air leaves the Evaporator. The low pressure, low temperature refrigerant passes into the
compressor and the cycle repeats.
The Refrigeration Dryer senses the refrigerant suction pressure and accordingly varies the flow of hot gas bypass inside
the system and maintains constant dew point at various heat loads.
3.3 Safety
!
Pressurised equipments may explode if used improperly. It is therefore essential to locate any
pressurised equipment, in such a way that the risks relating to incorrect use are reduced to the
absolute minimum.
The person responsible for the staff who are going to install, operate and maintain the machines described in this
manual must make sure that they have read and understood these instructions.
In particular, we draw your attention to the safety procedures which are described in this manual and which must be
scrupulously adhered to. Observing these measures will allow you to install, operate and maintain your dryer without
risk.
Coldspell dryers are intended for drying of compressed air. Under no circumstances should they be used to dry other
gases before Trident has performed a preliminary study and provided special instructions.
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
3
INSTRUCTION MANUAL -
Coldspell
3.4 Schematic Diagrams
CS TID 20 - 250 P & I DIAGRAM
CS TID 300 - 500 P & I DIAGRAM
DISCHARGE
PRESSURE
GAUGE
PRE BALANCE LINE
DEMISTER
ADV
FREON
DRYER
EXPANSION DEVICE
AIR/AIR
HEAT EXCHANGER
IN
EVAPORATOR
HP/LP
AIR
HOT GAS
BYPASS VALVE
AIR
REF. COMPRESSOR
PS
Expansion valve
bulb
OUT
INTEGRATED HEAT EXCHANGER
PROBE
AIR LINE
REFRIGERANT LINE
ELECTRICAL LINE
4
Reference : Manual Version 2
1
CS TID 650 - 2000 P & I DIAGRAM
This document may be modified without notice
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5
INSTRUCTION MANUAL -
Coldspell
4. Electrical
4.1 Bar Indicating Controller - Operation / Setting (Used upto model CS800)
Status Indication
Dew point
temperature
Display in
o
C (default)
Refrigeration Dryer
°C 2
Drain ON
time/HGBPV
ON temperature
setting display
o
(Seconds/ C)
Dryer ON/OFF Switch
S
6
8
DRAIN
HOT GAS
COMPRESSOR
0
2 4 6 8 10
1
MANUAL
DRAIN
Drain ON time
setting
Manual Drain
Switch
Hot Gas By-Pass
Valve ON temperature
setting
Dryer ON/OFF:
The Air Dryer is switched ON/OFF using Dryer ON/OFF switch. The moment Dryer is switched ON, built in Anti-Recycling
timer delays the Dryer switching ON by 2 minutes. After 2 minutes Refrigerant Compressor and Condenser Fan switches
ON and Dryer starts functioning.
Status Indication:
The Status Indication LCDs shows Drain valve, Hot Gas By-Pass Valve & Compressor ON/OFF.
Dew point Indication:
The dryer dew point temperature is displayed in deg. C by default in increments of 2, starting from 2 deg C.
Safety Feature for Low Dew point:
The Controller comes with Built in Low dew point setting of 0oC, the moment dew point temperature reaches this
lower level, the controller switches OFF the Refrigerant Compressor. After 2 minutes if the dew point temperature is
greater than 0oC, refrigerant compressor switches ON automatically.
6
Reference : Manual Version 2
Manual Drain:
The drain valve can be manually switched ON by pressing the Manual Drain Switch. The Drain Valve will be ON till the
Manual Drain Switch is released after pressing.
Drain ON time setting:
Refrigeration Dryer
°C 2
S
6
8
2 4 6 8 10
DRAIN
HOT GAS
COMPRESSOR
The drain valve ON time (opening period) can be set,
by pressing drain ON time setting button as shown in
figure, pressing once will show the current setting in
seconds in the display, pressing again will shift the time
in increments of 2 seconds, and can be seen in Drain
ON time setting display in seconds. Drain valve cycles
on a fixed time of 2 minutes. The moment Drain ON
time setting switch is released, after few seconds the
dryer display returns to normal function.
MANUAL
DRAIN
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7
INSTRUCTION MANUAL 4.2
Coldspell
LCD Controller - Operation / Setting (For CS1000 and above)
Introduction:
The controller is used in Coldspell models from CS 1000 and above. The controller default display is dew point
temperature, Inlet temperature of the compressed air, Compressor running hours.
Available Keys:
I/O
MENU
UP
DOWN
l
l
Default display is dew point temperature, inlet temperature of the compressed air.
Compressor running hours are displayed at the right bottom corner of the display.
Menus available:
1. Drain valve ON/OFF cycle settings.
3. Compressor offset temperature settings.
How to ON/OFF the Dryer:
l
l
l
l
Press I/O button for one second to ON the
dryer/controller.
The Refrigeration compressor will switch ON after
2 minutes due to Anti Recycle Timer.
If the compressor trip occurs, the refrigeration
compressor will switch ON after 2 minutes.
Press I/O button for two seconds to switch
OFF the dryer/controller.
Menu Setting:
l
To move from one menu to other, press MENU
key.
l
Press up & down keys to increase or decrease
setting valves.
Features In Front Panel:
l
l
l
8
Compressor ON
Drain valve ON
Anti Recycle Delay
Reference : Manual Version 2
4.3 Wiring Diagram
CS TID 20 - Wiring Diagram
CS TID 40-60 - Wiring Diagram
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
9
INSTRUCTION MANUAL -
Coldspell
CS TID 80 - 100 - Wiring Diagram
CS TID 150 - Wiring Diagram
10
Reference : Manual Version 2
CS TID 200 - 250 - Wiring Diagram
CS TID 300 - 500 - Wiring Diagram
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
11
INSTRUCTION MANUAL -
Coldspell
CS TID 650 - 800 - Wiring Diagram
CS TID 1000 - 2000 - Wiring Diagram
12
Reference : Manual Version 2
5. Installation
!
Various risks (crushing, explosion, projection, noise,…): The installation operations described in this
chapter should be performed only by personnel qualified in the installation of electro-pneumatic
systems. Follow the procedure described below with care in order to prevent exposing personnel to
danger.
5.1 Storage
If your dryer is to be stored for a long time before installation and use, follow these instructions.
l
If possible, let the dryer remain in its original packing (In particular, products fitted with marine packing with
plastic film and dessicant).
l
Check that air inlet and outlet are properly blocked in order to protect the system from foreign materials.
l
Check that the machine is properly protected from atmospheric dust or water.
l
Check that the store is frost protected.
l
Make sure to archive correctly the attached documents.
5.2 Installation and site connections
Series-Coldspell
Refrigeration Dryer
TRIDENT
1. Install the dryer in a closed, clean and dry room protected from frost. Access to the room should be restricted
to personnel not qualified in unit maintenance and operation. The room must be adequately ventilated. The
dryer must not be directly exposed to sources of heat. The temperature of the room must not exceed 38oC.
2. Make sure that the dryer is not near any equipment which does not comply with the electromagnetic
compatibility directives and which may degrade dryer operation. There must be a minimum distance of 1 m
between the dryer and any other equipment, which uses electricity. Yellow lines demarcating the area are
preferred.
3. Ensure that the dryer is installed in vertical position and kept level.
4. Fix the anchor points if necessary.
5. Install a system of by-pass valves between the dryer inlet and outlet so as to be able to service the installation
without having to interrupt the compressed air supply from the network. The upstream and downstream valves
must be closed during installation.
6. Connect the compressed air for processing to the dryer inlet with rust-free pipes.
7. Connect a drain pipe to the drain valve part connection (½''F)
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13
INSTRUCTION MANUAL -
Coldspell
8. Connect the processed compressed air to the dryer output with rust-free pipes.
9. Check that all the connectors are airtight and that the fittings are tight.
5.3 Electrical Connections
Connect the electrical power cable to the supply as specified in this manual, ensure the supply is well grounded.
!
Risk of electrical shock: When connecting the machine, cut off the power at the connecting point.
5.4 Running the installation
!
Various risks (explosion, projection, noise, ...): Do not pressurise until the installation procedure
has been completed.
For water-cooled condenser, ensure that the Water pump is switched on.
Switch ON the system with the ON/OFF switch provided in the front panel of the canopy.
6. Operation
6.1 Operator
Only a minimum level of experience in handling compressed air is necessary to operate a Coldspell refrigeration dryer and
he should be familiar in the following terminologies :
l
Pressure in Kg/cm2
l
Flow in cfm
l
Dew points in oC
l
Components of a fluid network: compressor, valves, drains, taps, pressure gauges, filters, tanks,...
6.2 How to stop the dryer
!
Various risks (projection, explosion, noise,...) : Whenever working on the dryer, it I esessential
to disconnect it from the network. Follow the procedure below :
1. Open the by-pass valve
2. Close the upstream valve
3. Close the downstream valve
4. Switch off the Dryer
5. Vent the air inside the dryer
14
Reference : Manual Version 2
7. Maintenance
!
Various risks (projection, noise, ...) : This operation should be performed by professionals of
Refrigeration.
Trident make Refrigeration dryers are robust, reliable machines. To ensure uninterrupted, problem-free operation, regularly
perform the inspections below.
Type of
inspection
Discharge
pressure
in refrigerant
line
Drain
valve
Air Cooled
condenser
surface
cleaning
Water
cooled
condenser
cleaning
using dilute
HCL
Inlet
temperature
Dew point
temperature
Visual
D
D
W
Y
D
D
Spares
replacement
-
-
-
-
-
-
Cleaning
-
H/R
M
Y/R
-
-
M - Monthly
H - Half Yearly
D - Daily
W - Weekly
Y- Yearly
R - As required
* Note : For water cooled condenser clean the condenser by recirculating dilute HCl if discharge pressure exceeds
the value specified in Table 7.1.
Table 7.1
Freon
Discharge pressure in psig
R134a
160-200
R407c
240-320
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15
INSTRUCTION MANUAL -
Coldspell
8. Condenser cleaning
8.1 Air Cooled
l
Switch OFF the dryer
l
Open the side doors, so that all dust removed while cleaning can be vented out of dryer through the side doors.
l
Using compressed air and an air gun clean the dust accumulated on the condenser fins from outside the dryer.
l
Ensure that there is no dust inside the dryer and reassemble the doors.
8.2 Water Cooled
l
Switch OFF the dryer
l
Stop the water supply and close the inlet and outlet valves of the water supply
l
Open the door covering the condenser.
l
Drain the water completely.
l
Pass dilute HCl solution in the tube side at pressure for more than 1 hour
l
Reassemble all and switch ON the dryer.
9. Amount of Gas to be charged
Sl. No.
Model
Refrigerant
Quantity of refrigerant
to be charged (in Kg)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
20
40
50/60
80
100
150
200
250
300
400
500
650
800
1000
1250
1500
2000
R134a
R134a
R134a
R134a
R134a
R134a
R134a/R407C
R134a/R407C
R134a
R134a
R134a
R407C
R407C
R407C
R407C
R407C
R407C
0.5
0.75
0.75
1.0
1.0
1.4
1.9/2.2
1.9/2.2
3.2
3.4
3.7
7.0
7.2
8.3
9.0
10.5
11.0
This is for information only.
16
If in doubt, contact Trident.
Reference : Manual Version 2
10. Repair work
Trouble
Root cause
Solution
GENERAL SECTION
Dryer not Switching ON.
(No indications on the
controller)
Air Pressure Drop (>0.3barg).
[Across the Dryer]
Moisture carryover at the
dryer outlet.
High Dewpoint Temperature
(>7ºC)
Low Dewpoint Temperature
(<3ºC)
1.
2.
3.
4.
Loose Wiring Connections
Phase Preventer Trip (3 phase models)
Fuse Blown(3phase models)
Dryer ON/OFF switch failure.
1. Correct the wiring.
2. Check the input voltage,phase
reversal.
3. Replace the fuse
4. Replace the Switch
1. Compressed air to the dryer IN/OUT
interchanged.
2. Air Flow to the dryer exceeds its rated flow.
3. Ice formation happens at the Air path inside
the heat exchanger due to freezing.
4. Drain Valve Clogged.
5. Heat Exchanger Clogged.
1. Make the connections correctly.
2. Operate the dryer below its rated load.
3. Increase the suction pressure of the
refrigerant.
4. Clean the drain valve.
5. Flush the Heat Exchanger with
compressed air.
1. Excess water enters at the dryer inlet than
specified.
2. Drain Valve(Heat Exchanger) not working.
3. Excess load given to dyer than its rated
specifications.
4. Air line bypass valve partially open.
5. Refrigeration Compressor not working.
1. Ensure Air receiver tank with drain
valve installation before the dryer.
2. Check and repair the drain valve.
3. Operate the dryer below the its rated
capacity.
4. Completely close the bypass valve.
5. Check and correct the compressor.
1.
2.
3.
4.
5.
1. Operate the dryer below its rated
Excess load to dryer than rated.
capacity.
High Suction Pressure.
2. Reduce the suction pressure using
Refrigerant charge quantity is insufficient.
HGBV.
High Superheat setting on the expansion valve.
3. Charge sufficient quantity of
Temperature probe malfunction.
refrigerant.
4. Reduce the superheat setting in the
expansion valve.
5. Replace the probe.
1.
2.
3.
4.
1. Operate the dryer below its rated
Low load to dryer.
capacity.
Low Suction Pressure.
Low superheat setting on the expansion valve. 2. Increase the suction pressure using
HGBV.
Temperature probe malfunction.
3. Increase the superheat setting in the
expansion valve.
4. Replace the probe.
REFRIGERANT SECTION
High Suction Pressure
&
High Discharge Pressure
1.
2.
3.
4.
5.
Refrigerant overcharge.
Excess load to the dryer.
Hot Gas Bypass Valve setting high.
Condenser coil is clogged.
Heat Exchanger Leak(internal).
1. Charge the refrigerant with referance
to compressor current.
2. Operate the dryer below its rated
capacity.
3. Adjust the HGBV setting to reduce the
suction pressure.
4. Clean the condenser coil surface.
5. Replace the Heat Exchanger.
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17
INSTRUCTION MANUAL -
Trouble
Coldspell
Root cause
1. Adjust the HGBV setting to reduce the
suction pressure.
2. Replace the Valve.
3. Adjust the superheat setting(increase).
4. Replace the compressor.
High Suction Pressure
&
Low Discharge Pressure
1.
2.
3.
4.
Low Suction Pressure
&
Low Discharge Pressure
1. Refrigerant Charge quantity less.
2. Expansion Valve bulb charge lost.
1. Charge sufficient quantity
refrigerant.
2. Replace the Expansion Valve.
Low Suction Pressure
&
High Discharge Pressure
1.
2.
3.
4.
1. Adjust the HGBV Setting(increase).
2. Replace the filter drier.
3. Clean the expansion valve with dry
nitrogen and reuse.
4. Flush the HX with dry nitrogen.If
problem exists replace the HX.
Compressor takes High Current
Compressor takes Low Current
Compressor not starting.
Compressor trips on LP
Pressure switch
Compressor trips on HP
Pressure switch
18
Hot Gas Bypass valve setting High.
HGBV failure(always remains open).
Low Superheat setting.
Compressor Pumping failure.
Solution
Hot gas bypass valve setting low.
Filter drier partially/fully clogged.
Expansion valve clogged.
Heat Exchanger (Ref Side) clogged.
of
1. Voltage imbalance or higher voltage exists.
2. Compressor relay,capacitor fails.
3. Refrigerant not reaches its idle pressure before starting(R407C).
4. Loose wiring.
5. Compressor failure.
1. Check and correct the voltage.
2. Replace necessary compressor
accessories.
3. Allow the refrigerant to reach its idle
pressure before the compressor starts.
4. Correct the wiring.
5. Replace the compressor.
1. Refrigerant charge quantity very less.
2. Compressor pumping failure
1. Charge sufficient quantity
refrigerant.
2. Replace the Compressor.
1. Loose wiring connection.
2. External OLP trip due to overheating(1phase
models).
3. Internal OLP trip due to overheating (3phase
models).
4. Relay,Capacitor.OLP failure.
5. Dewpoint Temperature lies between -3ºC to
0ºC.
6. HP/LP Switch trip.
1. Check and correct wiring.
2. Allow the compressor body
temperature to cool until it reaches
ambient.
3. Allow the compressor body
temperature to cool until it reaches
ambient
4. Replace
5. Adjust the HGBV to increase the
dewpoint temperature to safe limit.
6. Reset the switches.
1. Low suction pressure setting in the HGBV.
2. Trip pressure setting kept high in LP Switch.
3. No refrigerant gas inside the system.
1. Increase the Suction pressure using
HGBV.
2. Set the trip pressure correctly.
3. Check and arrest the leak before
charging the refrigerant in the system.
1. Adjust the HGBV Setting (increase).
2. Replace the filter drier.
3. Clean the expansion valve with dry nitrogen
and reuse.
4. Flush the HX with dry nitrogen.If problem exists replace the HX.
1.
2.
3.
4.
Reference : Manual Version 2
Check and correct it.
Replace the switch.
Clean the condenser surface.
Set the trip pressure correctly.
of
Trouble
Root cause
Solution
1. Allow the compressor body to cool until
it reaches ambient temperature.
Compressor trips on OverLoad Protector
(OLP) [compressor body too hot].
1. Compressor Internal winding overheated.
Compressor winding
Overheated.
1. High current consumption by the compressor. 1. Check and correct it.
2. Liquid floodback to the compressor(Lubrication 2. Check and adjust the superheat setting
in the expansion valve.
failure).
Condenser Fan not running
1. Loose wiring.
2. Fan motor ronning capacitor failure.
3. Fan motor failure.
1. Check and correct it.
2. Replace the capacitor.
3. Replace the fan.
Pressure switches not working
1. Loose wiring connections.
2. No input supply to the switch.
3. Pressure switch failure.
1. Check and correct it.
2. Check and correct it.
3. Replace the switch.
Transformer not working
1. Loose wiring.
2. Wrong input supply.
3. Transformer failure due to manufacturing defect or higher voltage.
1. Check and correct it.
2. Check and correct it.
3. Replace the Transformer.
Drain Valve failure
1. Clogging due to no installation of Prefilter at 1. Ensure prefilter before the dryer,if the
dryer environment is dusty.
dryer inlet(Dust entrainment).
2. Coil failure due to input voltage of manufac- 2. Replace the coil.
turing defect.
Phase Preventer Trip
1. Loose Wiring.
2. Inputs to preventer wrongly connected.
3. Under voltage, Over voltage,phase reversal,
phase loss exists.
4. Preventer problem.
1.
2.
3.
4.
Check and correct it.
Connect the inputs properly.
Check and correct it.
Replace the problem.
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reproduction, even partial, forbidden without written authentication
19
INSTRUCTION MANUAL -
Coldspell
11. Recommended spares for 5 years trouble free operation
Recommended Spare List - CS TID 20 [PH191]
Recommended Spare List - CS TID 50 [PH193]
Sl.No Part No
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
CH113
CH004
CC022
CE603
CE599
AD1151
CH238
CH321
CH211A
CH163
CH387
PE067
Description
Freon Drier 1/4”
Capillary Tube 0.055”
Pressure Gauge 0-500Psig
Dewpoint display
Rocker Switch (illumination)
Integrated HX A5
Hotgas bpass valve-ADRIE (0-75)
Condenser Cover 11” X 10” X 2
Compressor KCE419HAG
Switch Pressure (R134a)
Fan Motor
CTD 11B (4mm Orifice)
1
2
3
4
5
6
7
8
9
10
11
12
AD614
CH163
CH458
CE599
CC022
AD582
CH113
CH004
CE575
CE459
CH238
CE646
Description
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KFE 444HAG/ECZ444HG
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model A2
Freon Drier 1/4”
Capillary Tube 0.055”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Transformer 30VA
Recommended Spare List - CS TID 40 [PH192]
Recommended Spare List - CS TID 60 [PH194]
Sl.No Part No
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
20
AD614
CH163
CH457
CE599
CE022
AD582
CH113
CH004
CE575
CE459
CH238
CE646
Description
Solenoid valve-24V
Switch Pressure (R134a)
Compressor KFE 432HAG/ECZ431HG
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX A2
Freon Drier 1/4”
Capillary Tube 0.055”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Transformer 30VA
1
2
3
4
5
6
7
8
9
10
11
12
AD614
CH163
CH458
CE599
CC022
AD582
CH113
CH004
CE575
CE459
CH238
CE646
Reference : Manual Version 2
Description
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KFE 444HAG/ECZ444HG
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model A2
Freon Drier 1/4”
Capillary Tube 0.055”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Transformer 30VA
11. Recommended spares for 5 years trouble free operation
Recommended Spare List - CS TID 80 [PH195]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
AD614
CH163
CE514
CH315
CE599
CC022
AD581
CH113
CH004
CE575
CE459
CH238
CE646
Description
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KCJ467HAG
Fan Motor
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model A0
Freon Drier 1/4”
Capillary Tube 0.055”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Transformer 30VA
Recommended Spare List - CS TID 100 [PH196]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
AD614
CH163
CE514
CH315
CE599
CC022
AD581
CH113
CH004
CE575
CE459
CH238
CE646
Description
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KCJ467HAG
Fan Motor
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model A0
Freon Drier 1/4”
Capillary Tube 0.055”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Transformer 30VA
Recommended Spare List - CS TID 150 [PH197]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
AD614
CH163
CH072
CE599
CC022
AD535
CH113
CE575
CE459
CH238
CH004
CE646
CD020
CE515
CH359
AD556
Description
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KCJ498HAG
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model B0
Freon Drier 1/4”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Capillary tube 0.055”
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Drain Valve-1/2”
Recommended Spare List - CS TID 200 [PH198]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
AD614
CH265
CH204
CE564
CE599
CC022
AD535
CH215
CH004
CE575
CE459
CH238
CE646
CD020
CE515
CH250
AD556
Description
Solenoid valve-24V
Pressure Switch (R407C)
Compressor RE277VHSMT
Capacitor 40MFD 440V
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model B0
Freon Drier 3/8”
Capillary tube 0.055”X2.2m
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Drain Valve-1/2”
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
21
INSTRUCTION MANUAL -
Coldspell
11. Recommended spares for 5 years trouble free operation
Recommended Spare List - CS TID 250 [PH199]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
AD614
CH265
CH204
CE564
CE599
CC022
AD535
CH215
CH004
CE575
CE459
CH238
CE646
CD020
CE515
CH250
AD556
Sl.No Part No
Description
Solenoid valve-24V
Pressure Switch (R407C)
Compressor RE277VHSMT
Capacitor 40MFD 440V
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model B0
Freon Drier 3/8”
Capillary tube 0.055”X2.2m
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-ADRIE (0-75)
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Drain Valve-1/2”
Recommended Spare List - CS TID 300 [PH169]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
22
AD614
CH163
CH508
CE599
CC022
AD596
CH215
CE575
CE459
CH496
CH426
CH106
CE646
CD020
CE515
CH278
CH491
CH492
AD556
Recommended Spare List - CS TID 400 [PH170]
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
AD614
CH163
CH196
CE599
CC022
AD596
CH215
CE575
CE459
CH496
CH426
CH106
CE646
CD020
CE515
CH517
CH491
CH492
AD556
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KCM519CAL
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model C0
Freon Drier 3/8”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-TEN 2
Expansion Valve Orifice 3mm
Hot Gas KVC-12
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
Recommended Spare List - CS TID 500 [PH171]
Sl.No Part No
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KCM514CAL
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model C0
Freon Drier 3/8”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-TEN 2
Expansion Valve Orifice 3mm
Hot Gas KVC-12
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
AD614
CH163
CH196
CE599
CC022
AD596
CH215
CE575
CE459
CH496
CH426
CH106
CE646
CD020
CE515
CH517
CH491
CH492
AD556
Reference : Manual Version 2
Description
Solenoid valve-24V
Pressure Switch (R134a)
Compressor KCM519CAL
Rocker Switch
Pressure Gauge 0-500Psig
Integrated HX-Model C0
Freon Drier 3/8”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-TEN 2
Expansion Valve Orifice 3mm
Hot Gas KVC-12
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
11. Recommended spares for 5 years trouble free operation
Recommended Spare List - CS TID 650 [PH186]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
AD614
CH265
CH226
CE599
CC022
CC468
AD596
CH382
CE575
CE459
CH374
CH431
CH106
CE646
CD020
CE515
CH278
CH491
CH492
AD556
Description
Solenoid valve-24V
Pressure Switch (R407C)
Compressor NE56YDNMT
Rocker Switch
Pressure Gauge 0-500Psig
Pressure Gauge-suction 0-300psig
Integrated HX-Model C0
Freon Drier 1/2”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-TEZ 2
Expansion Valve Orifice 4mm
Hot Gas KVC-12
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
Recommended Spare List - CS TID 800 [PH187]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
AD614
CH265
CH225
CE599
CC022
CC468
AD596
CH308
CE575
CE459
CH374
CH427
CH125
CE646
CD020
CE515
CH278
CH491
CH492
AD556
Description
Solenoid valve-24V
Pressure Switch (R407C)
Compressor BE82YFEMT
Rocker Switch
Pressure Gauge 0-500Psig
Pressure Gauge suction 0-300Psig
Integrated HX-Model C0
Freon Drier 5/8”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-TEZ 2
Expansion Valve Orifice 5mm
Hot Gas KVC-15
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
Recommended Spare List - CS TID 1000 [PH188]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
AD614
CH265
CH225
CC022
CC468
CE599
AD596
CH308
CE575
CE459
CH374
CH427
CH125
CE646
CD020
CE515
CH517
CH491
CH492
AD556
Description
Solenoid valve-24V
Pressure Switch (R407C)
Compressor BE82YFEMT
Pressure Gauge 0-500Psig
Pressure Gauge suction 0-300Psig
Rocker Switch
Integrated HX-Model C0
Freon Drier 5/8”
Bar Indicator Controller
NTC Dewpoint Probe
Expansion Valve-TEZ 2
Expansion Valve Orifice 5mm
Hot Gas KVC-15
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
Recommended Spare List - CS TID 1250 [PH189]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
AD614
CH265
CH230
CC022
AD596
CE599
CH308
CC468
AH045
CE459
CH374
CH427
CH125
CE646
CD020
CE515
CH522
CH491
CH492
AD556
Description
Solenoid valve-24V
Pressure Switch (R407C)
Compressor BE96YFEMT
Pressure Gauge 0-500Psig
Integrated HX-Model C0
Rocker Switch
Freon Drier 5/8”
Pressure gauge suction 0-300psig.
LCD Controller
NTC Dewpoint Probe
Expansion Valve-TEZ 2
Expansion Valve Orifice 5mm
Hot Gas KVC-15
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
23
INSTRUCTION MANUAL -
Coldspell
11. Recommended spares for 5 years trouble free operation
Recommended Spare List - CS TID 1500 [PH190]
Sl.No Part No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
24
AD614
CH265
CH523
CC022
CC468
AD596
CH308
AH045
CE459
CH377
CH466
CH381
CE646
CD020
CE515
CH522
CH491
CH492
AD556
CE599
Description
Recommended Spare List - CS TID 2000 [PH202]
Sl.No Part No
Solenoid valve-24V
Pressure Switch (R407C)
Compressor ZR108-KCE TFD-522
Pressure Gauge 0-500Psig
Pressure gauge suction 0-300psig.
Integrated HX-Model C0
Freon Drier 5/8”
LCD Controller
NTC Dewpoint Probe
Expansion Valve-TEZ 5
Expansion Valve Orifice 2mm
Hot Gas KVC-22
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
Rocker Switch
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
AD614
CH265
CH525
CC022
CC468
AD596
CE599
CH308
AH045
CE459
CH377
CH482
CH381
CE646
CD020
CE515
CH526
CH491
CH492
AD556
Reference : Manual Version 2
Description
Solenoid valve-24V
Pressure Switch (R407C)
Compressor ZR144-KCE TFD-522
Pressure Gauge 0-500Psig
Pressure gauge suction 0-300psig.
Integrated HX-Model C0
Rocker Switch
Freon Drier 5/8”
LCD Controller
NTC Dewpoint Probe
Expansion Valve-TEZ 5
Expansion Valve Orifice 3mm
Hot Gas KVC-15
Transformer 30VA
Ball Valve 1/2”
Contactor 16Amps
Fan Motor
Low Pressure Trip Switch-KP1
High Pressure Trip Switch-KP5
Drain Valve-1/2”
Date :
INSTALLATION & COMMISSIONING REPORT FOR COLDSPELL TID
Customer Name & Address :
Dryer model :
Dryer serial No :
Contact Person :
Phone :
Designation :
Mail :
Initial check
Notes for the service engineer :
1
The below parameters must be checked during installation & operation.
2
If the answer for any of the below parameters are NO, then use the Troubleshooting chart for solution.
S.No
Parameters
(Yes/No)
During installation
1
Is the air from the outlet of the air compressor flowing to the dryer inlet?
2
Is there an air tank/air receiver in between the air compressor outlet & dryer inlet?
3
Is there any air leakage at the dryer inlet & outlet connections?
4
Is proper electrical input supply provided to the dryer from the customer side?
5
Has the refrigerant gas pressures been idealized before starting the dryer (Check the pressure gauges)?
6
Is the drain valve outlet hose connected?
7
Is the dryer provided with pre-filter? Is there 1000 metre minimum clearance provided around the dryer?
During dryer operation
1
Is the Controller/Display switched on? (Visual observation)
2
Is the Contactor Switch energized during refrigeration compressor operation?
3
Does the Phase preventer switch show LED indication (yellow & red) during operation of the dryer?
(only for 3-phase models)
4
Is the refrigeration compressor working?
5
Is there any abnormal sound from the refrigeration compressor?
6
Is the drain valve working?
7
Are there any leakage in the drain valve hoses?
8
Has the condenser fan cut-ON/cut-OFF at regular intervals?
9
Are the condenser fins & tubes free from dust?
Observations
Notes for the service engineer:
1
All the parameters mentioned below must be checked.
2
Note the values of voltage in RY in case of 1-Phase.
3
Note the values of amperage in R in case of 1-Phase.
4
If measured values are out of range, then use the troubleshooting chart to find the root cause & take corrective actions.
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
25
.
Date :
INSTALLATION & COMMISSIONING REPORT FOR COLDSPELL TID
Customer Name & Address :
Dryer model :
Dryer serial No :
Contact Person :
Phone :
Designation :
Mail :
Initial check
Notes for the service engineer :
1
The below parameters must be checked during installation & operation.
2
If the answer for any of the below parameters are NO, then use the Troubleshooting chart for solution.
S.No
Parameters
(Yes/No)
During installation
1
Is the air from the outlet of the air compressor flowing to the dryer inlet?
2
Is there an air tank/air receiver in between the air compressor outlet & dryer inlet?
3
Is there any air leakage at the dryer inlet & outlet connections?
4
Is proper electrical input supply provided to the dryer from the customer side?
5
Has the refrigerant gas pressures been idealized before starting the dryer (Check the pressure gauges)?
6
Is the drain valve outlet hose connected?
7
Is the dryer provided with pre-filter? Is there 1000 metre minimum clearance provided around the dryer?
During dryer operation
1
Is the Controller/Display switched on? (Visual observation)
2
Is the Contactor Switch energized during refrigeration compressor operation?
3
Does the Phase preventer switch show LED indication (yellow & red) during operation of the dryer?
(only for 3-phase models)
4
Is the refrigeration compressor working?
5
Is there any abnormal sound from the refrigeration compressor?
6
Is the drain valve working?
7
Are there any leakage in the drain valve hoses?
8
Has the condenser fan cut-ON/cut-OFF at regular intervals?
9
Are the condenser fins & tubes free from dust?
Observations
Notes for the service engineer:
1
All the parameters mentioned below must be checked.
2
Note the values of voltage in RY in case of 1-Phase.
3
Note the values of amperage in R in case of 1-Phase.
4
If measured values are out of range, then use the troubleshooting chart to find the root cause & take corrective actions.
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
27
.
S.No
Parameters
1
Input supply to the Dryer (from Customer side)
2
Dryer input Voltage (RY) V Refer specification chart
Values
Units
Range
---
1Phase / 3Phase
Dryer input Voltage (YB)
V
Dryer input Voltage (RB)
3
Dryer running hours
hrs
4
Refrigerant Used
5
Refrigerant idle pressure (Before switching on the dryer)
--
---
R134a / R407C
psi(g)
Refer specification chart
6
Dryer inlet air flow (Check air compressor's rated flow)
cfm
< Dryer capacity
7
Dryer inlet air pressure (measured by pressure gauge)
bar (g)
6 – 16
8
Pressure drop between dryer inlet & outlet (measured by pressure gauge)
bar (g)
< 0.3
9
Dryer inlet air temperature(measured using temperature gun or temperature probe)
o
C
< 40
C
3–7
C
< 45
10
Ambient temperature
o
11
Dewpoint temperature (from dryer display)
o
12
Compressor Suction Pressure (measured by pressure gauge)
psi(g)
28-33 (R134a)
& 60-70 (R407c)
13
Compressor Discharge Pressure (measured by pressure gauge)
psi(g)
140-180 (R134a)
& 240-320 (R407c)
14
Compressor Amperage (R) (measured by clamp meter)
A
Refer specification chart
Compressor Amperage (Y) (measured by clamp meter)
Compressor Amperage (B) (measured by clamp meter)
15
Drain Valve ON/OFF ming (measured by stopwatch)
s
--
16
Phase preventer OV & UV Setting
%
OV=5%, UV=10%
Comments :
Customer’s name and signature :
Service engineer name and signature :
Name :
Name :
Customer Feedback
1) Have we responded fast to your enquiry?
4) How is the quality of our packing?
2) Are you happy with our order processing method?
5) Does the dryer work as per your expectation?
3) Was the delivery as promised?
6) Suggestions _________________________________________
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
29
Release date: 30th Sep 2016
1. Poor 2. Fair 3. Good 4. V. Good 5. Excellent
.
S.No
Parameters
1
Input supply to the Dryer (from Customer side)
2
Dryer input Voltage (RY) V Refer specification chart
Values
Units
Range
---
1Phase / 3Phase
Dryer input Voltage (YB)
V
Dryer input Voltage (RB)
3
Dryer running hours
hrs
4
Refrigerant Used
5
Refrigerant idle pressure (Before switching on the dryer)
--
---
R134a / R407C
psi(g)
Refer specification chart
6
Dryer inlet air flow (Check air compressor's rated flow)
cfm
< Dryer capacity
7
Dryer inlet air pressure (measured by pressure gauge)
bar (g)
6 – 16
8
Pressure drop between dryer inlet & outlet (measured by pressure gauge)
bar (g)
< 0.3
9
Dryer inlet air temperature(measured using temperature gun or temperature probe)
o
C
< 40
C
3–7
C
< 45
10
Ambient temperature
o
11
Dewpoint temperature (from dryer display)
o
12
Compressor Suction Pressure (measured by pressure gauge)
psi(g)
28-33 (R134a)
& 60-70 (R407c)
13
Compressor Discharge Pressure (measured by pressure gauge)
psi(g)
140-180 (R134a)
& 240-320 (R407c)
14
Compressor Amperage (R) (measured by clamp meter)
A
Refer specification chart
Compressor Amperage (Y) (measured by clamp meter)
Compressor Amperage (B) (measured by clamp meter)
15
Drain Valve ON/OFF ming (measured by stopwatch)
s
--
16
Phase preventer OV & UV Setting
%
OV=5%, UV=10%
Comments :
Customer’s name and signature :
Service engineer name and signature :
Name :
Name :
Customer Feedback
1) Have we responded fast to your enquiry?
4) How is the quality of our packing?
2) Are you happy with our order processing method?
5) Does the dryer work as per your expectation?
3) Was the delivery as promised?
6) Suggestions _________________________________________
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
31
Release date: 30th Sep 2016
1. Poor 2. Fair 3. Good 4. V. Good 5. Excellent
.
This document may be modified without notice
reproduction, even partial, forbidden without written authentication
33
Time
(Hours)
Dryer
Running
Period
°C
°C
Dew Point
Air Inlet
Temperature Temperature
(3-7°C)
(Less
than 45°C)
Kg/cm2
R134a
(25-35)
R407C
(55-65)
Air
Suction Pressure (Psig)**
Inlet/Outlet
Pressure
R134a
(140-180)
R407C
(240-320)
Discharge Pressure(Psig)**
(YES/NO)
Drain Valve
Working
Status
180 to 250
380 to 450
Voltage (Volts)
**Must be checked,when the dryer is in operation.
If any of the observed readings are either above or below the mentioned values,contact Service Excecutive for immediate solution.
Recommended Observation : Minimum once in a day.
Note :
(DD:MM:YY) (Hours:Mins)
Date
COLDSPELL REFRIGERATION DRYER DATA LOG SHEET
.
WARRANTY
Products of Trident Pneumatics Pvt. Ltd. are guaranteed to be
free from defects in materials and workmanship when installed
and operated in accordance with the instructions outlined in the
Instruction Manual.
Trident Pneumatics Pvt. Ltd.'s obligation under this warranty shall
be limited to repair or replacement (at the discretion of Trident)
of defective goods returned to Trident's plant within one (1) year
from the date of commissioning or 18 months from the date of
invoicing which ever is occurring earlier.
Product
:
Model
:
Serial No.
:
Refer Name Plate
:
___________________________
Quality Assurance Dept.
Trident Pneumatics Pvt Ltd
5/232, K.N.G Pudur Road,
Coimbatore 641 108. Ph : 0422 2400492, 2401373
e-mail : sales@tridentpneumatics.com
Website : www.tridentpneumatics.com
.
Trident sales and service network
Trident Pneumatics Private Limited
5/232, KNG Pudur Road, Somayampalayam P.O.
Coimbatore 641108, India
Telephone : +91-422-2400492 extension 223
Fax
: +91-422-2401376
E-mail
: sales@tridentpneumatics.com
Sales
A. Anil Kumar
Territory Manager - Andhra Pradesh
Mobile
: +91-9885445321
E-mail
: a_anilkumar@tridentpneumatics.com
Syed Yusha
Territory Manager - Mumbai
Mobile
: +91-9867367726
E-mail
: s_yusha@tridentpneumatics.com
Ramesh Kumar Singh
Territory Manager - Railways
Mobile
: +91-9811310726
E-mail
: rk_rameshkumar@tridentpneumatics.com
T. Saravanakumar
Product Manager - Drain Valves
Mobile
: +91-9994978928
Telephone : +91-422-2400492 extension 216
E-mail
: t_saravana@tridentpneumatics.com
Ramesh Kumar Singh
Territory Manager - Delhi
Mobile
: +91-9811310726
E-mail
: salesdelhi@tridentpneumatics.com
J. Nandha Kumar
Territory Manager - Tamil Nadu/Kerala
Mobile
: +91-9789480564
E-mail
: j_nandhakumar@tridentpneumatics.com
Service
M. Ragunath
Service Executive
Mobile
: +91-8870010565
Telephone : +91-422-2400492 extension 217
E-mail
: service@tridentpneumatics.com
TRIDENT PNEUMATICS PVT LTD
5/232, K.N.G. Pudur Road, Coimbatore - 641 108, India.
Ph : +91-422-2400492 Fax : +91-422-2401376
e-mail : sales@tridentpneumatics.com Website : www.tridentpneumatics.com