Trident Coldspell Series Refrigerated Compressed Air Dryer MANUAL

MANUAL

INSTALLATION OPERATION MAINTENANCE

REFRIGERATED COMPRESSED AIR DRYER

Coldspell Series

PDF processed with CutePDF evaluation edition www.CutePDF.com

.

1.

1.1

1.2

2.

8.

8.1

8.2

9.

6.

6.1

6.2

7.

4.

4.1

4.2

4.3

3.

3.1

3.2

3.3

3.4

5.

5.1

5.2

5.3

5.4

Contents

Introduction

Design

Description

Specifications

Operational Details

Operating Principle

Pneumatic Section

Refrigeration section

Safety

Schematic Diagrams

Electrical

Bar Indicating Controller - Operation / Setting

LCD Controller - Operation / Setting

Wiring Diagram

Installation

Storage

Installation and Site Connections

Electrical Connections

Running the Installation

Operation

Operator

How to stop the Dryer

Maintenance

Condenser Cleaning

Air cooled condenser

Water cooled condenser

Amount of Gas to be charged

10.

Repair Work

11.

Recommended spares list for 5 years

This document may be modified without notice reproduction, even partial, forbidden without written authentication

6

13

2

2

3

14

15

16

16

17

20

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 +3 o C to +7 o C.

l l l l l l l l l l

1.2 Description

The dryer consists of :

Integrated Heat Exchanger

Refrigerant Compressor

Electronic controller

Condenser Assembly

Expansion Device

Pressure switch*

Refrigerant Suction & Discharge Pressure Gauges

Hot gas bypass valve

Auto drain valve

Canopy

2. Specifications

Operational Details

Medium

Inlet condition

Operating pressure*

Inlet temperature*

Inlet humidity

Ambient temperature

Pressure dew point

Cooling system

Max. Working pressure

Refrigerant compressor

: Compressed Air

: Free of dirt, oil, condensate and corrosive substances.

: 7 Kg/cm 2

: Max +45 o C

: Saturated at specified conditions

: Max +38 o C

: + 3 o C to 7 o C

: Air cooled / Water cooled

: 16 Kg/cm 2

: Hermetic sealed

* Optional

Reference : Manual Version 2

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 +3 o C 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

3.4 Schematic Diagrams

INSTRUCTION MANUAL -

Coldspell

CS TID 20 - 250 P & I DIAGRAM

AIR

IN

AIR

OUT

4

INTEGRATED HEAT EXCHANGER

AIR LINE

REFRIGERANT LINE

ELECTRICAL LINE

DEMISTER

PROBE

CS TID 300 - 500 P & I DIAGRAM

ADV

PRE BALANCE LINE

EXPANSION DEVICE

HP/LP

FREON

DRYER

DISCHARGE

PRESSURE

GAUGE

Expansion valve bulb

HOT GAS

BYPASS VALVE

REF. COMPRESSOR

PS

1

Reference : Manual Version 2

CS TID 650 - 2000 P & I DIAGRAM

This document may be modified without notice reproduction, even partial, forbidden without written authentication

5

INSTRUCTION MANUAL -

Coldspell

4. Electrical

4.1 Bar Indicating Controller - Operation / Setting (Used upto model CS800)

Status Indication Dryer ON/OFF Switch

Dew point temperature

Display in o C (default)

Refrigeration Dryer

°C 2 6 8

DRAIN

HOT GAS

COMPRESSOR

S 2 4 6 8 10

0

Drain ON time/HGBPV

ON temperature setting display

(Seconds/ C )

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 0 o C, 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 0 o C, refrigerant compressor switches ON automatically.

Reference : Manual Version 2

6

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 6 8

DRAIN

HOT GAS

COMPRESSOR

S 2 4 6 8 10

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

This document may be modified without notice reproduction, even partial, forbidden without written authentication

7

INSTRUCTION MANUAL -

Coldspell

4.2 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.

l l

Available Keys:

I/O

MENU

UP

DOWN

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 l

To move from one menu to other, press MENU key.

Press up & down keys to increase or decrease setting valves.

l l l

Features In Front Panel:

Compressor ON

Drain valve ON

Anti Recycle Delay

Reference : Manual Version 2

8

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

1 0

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

1 1

INSTRUCTION MANUAL -

Coldspell

CS TID 650 - 800 - Wiring Diagram

CS TID 1000 - 2000 - Wiring Diagram

1 2

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 l

If possible, let the dryer remain in its original packing (In particular, products fitted with marine packing with plastic film and dessicant).

Check that air inlet and outlet are properly blocked in order to protect the system from foreign materials.

l l l

Check that the machine is properly protected from atmospheric dust or water.

Check that the store is frost protected.

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 38 o C.

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)

This document may be modified without notice reproduction, even partial, forbidden without written authentication

1 3

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 l l l

Pressure in Kg/cm 2

Flow in cfm

Dew points in o C

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

Reference : Manual Version 2

1 4

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

Visual

Spares replacement

Cleaning

D

-

-

D

-

H/R

W

-

M

Y

-

Y/R

D - Daily W - Weekly M - Monthly H - Half Yearly Y- Yearly R - As required

Inlet temperature

D

-

-

Dew point temperature

D

-

-

* Note : For water cooled condenser clean the condenser by recirculating dilute HCl if discharge pressure exceeds the value specified in Table 7.1.

Freon

Table 7.1

Discharge pressure in psig

R134a

R407c

160-200

240-320

This document may be modified without notice reproduction, even partial, forbidden without written authentication

1 5

INSTRUCTION MANUAL -

Coldspell

8. Condenser cleaning

8.1 Air Cooled l l

Switch OFF the dryer

Open the side doors, so that all dust removed while cleaning can be vented out of dryer through the side doors.

l l

Using compressed air and an air gun clean the dust accumulated on the condenser fins from outside the dryer.

Ensure that there is no dust inside the dryer and reassemble the doors.

8.2 Water Cooled l l l l l l

Switch OFF the dryer

Stop the water supply and close the inlet and outlet valves of the water supply

Open the door covering the condenser.

Drain the water completely.

Pass dilute HCl solution in the tube side at pressure for more than 1 hour

Reassemble all and switch ON the dryer.

9. Amount of Gas to be charged

Sl. No.

Model Refrigerant

12

13

14

15

16

9

10

7

8

11

17

3

4

1

2

5

6

20

40

50/60

80

100

150

200

250

300

400

500

650

800

1000

1250

1500

2000

This is for information only. If in doubt, contact Trident.

R134a

R134a

R134a

R134a

R134a

R134a

R134a/R407C

R134a/R407C

R134a

R134a

R134a

R407C

R407C

R407C

R407C

R407C

R407C

Quantity of refrigerant to be charged (in Kg)

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

Reference : Manual Version 2

1 6

10. Repair work

Trouble

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)

High Suction Pressure

&

High Discharge Pressure

Root cause

GENERAL SECTION

1. Loose Wiring Connections

2. Phase Preventer Trip (3 phase models)

3. Fuse Blown(3phase models)

4. Dryer ON/OFF switch failure.

Solution

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. Excess load to dryer than rated.

2. High Suction Pressure.

3. Refrigerant charge quantity is insufficient.

4. High Superheat setting on the expansion valve.

5. Temperature probe malfunction.

1. Operate the dryer below its rated capacity.

2. Reduce the suction pressure using

HGBV.

3. Charge sufficient quantity of refrigerant.

4. Reduce the superheat setting in the expansion valve.

5. Replace the probe.

1. Low load to dryer.

2. Low Suction Pressure.

3. Low superheat setting on the expansion valve.

4. Temperature probe malfunction.

1. Operate the dryer below its rated capacity.

2. Increase the suction pressure using

HGBV.

3. Increase the superheat setting in the expansion valve.

4. Replace the probe.

REFRIGERANT SECTION

1. Refrigerant overcharge.

2. Excess load to the dryer.

3. Hot Gas Bypass Valve setting high.

4. Condenser coil is clogged.

5. 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.

This document may be modified without notice reproduction, even partial, forbidden without written authentication

1 7

Trouble

High Suction Pressure

&

Low Discharge Pressure

Low Suction Pressure

&

Low Discharge Pressure

Low Suction Pressure

&

High Discharge Pressure

Compressor takes High Current

Compressor takes Low Current

Compressor not starting.

Compressor trips on LP

Pressure switch

Compressor trips on HP

Pressure switch

1 8

INSTRUCTION MANUAL -

Coldspell

Root cause

1. Hot Gas Bypass valve setting High.

2. HGBV failure(always remains open).

3. Low Superheat setting.

4. Compressor Pumping failure.

Solution

1. Adjust the HGBV setting to reduce the suction pressure.

2. Replace the Valve.

3. Adjust the superheat setting(increase).

4. Replace the compressor.

1. Refrigerant Charge quantity less.

2. Expansion Valve bulb charge lost.

1. Hot gas bypass valve setting low.

2. Filter drier partially/fully clogged.

3. Expansion valve clogged.

4. Heat Exchanger (Ref Side) clogged.

1. Charge sufficient quantity of refrigerant.

2. Replace the Expansion Valve.

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. 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 of 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. Check and correct it.

2. Replace the switch.

3. Clean the condenser surface.

4. Set the trip pressure correctly.

Reference : Manual Version 2

Trouble Root cause Solution

Compressor trips on OverLoad Protector

(OLP) [compressor body too hot].

1. Compressor Internal winding overheated.

Compressor winding

Overheated.

1. Allow the compressor body to cool until it reaches ambient temperature.

1. High current consumption by the compressor.

2. Liquid floodback to the compressor(Lubrication failure).

1. Check and correct it.

2. Check and adjust the superheat setting in the expansion valve.

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

Transformer not working

Drain Valve failure

Phase Preventer Trip

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.

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.

1. Clogging due to no installation of Prefilter at dryer inlet(Dust entrainment).

2. Coil failure due to input voltage of manufacturing defect.

1. Ensure prefilter before the dryer,if the dryer environment is dusty.

2. Replace the coil.

1. Loose Wiring.

2. Inputs to preventer wrongly connected.

3. Under voltage, Over voltage,phase reversal, phase loss exists.

4. Preventer problem.

1. Check and correct it.

2. Connect the inputs properly.

3. Check and correct it.

4. Replace the problem.

This document may be modified without notice reproduction, even partial, forbidden without written authentication

1 9

INSTRUCTION MANUAL -

Coldspell

11. Recommended spares for 5 years trouble free operation

Recommended Spare List - CS TID 20 [PH191]

Sl.No Part No Description

1 CH113

2 CH004

3 CC022

4 CE603

Freon Drier 1/4”

Capillary Tube 0.055”

Pressure Gauge 0-500Psig

Dewpoint display

5 CE599 Rocker Switch (illumination)

6 AD1151 Integrated HX A5

7 CH238

8 CH321

Hotgas bpass valve-ADRIE (0-75)

Condenser Cover 11” X 10” X 2

9 CH211A Compressor KCE419HAG

10 CH163 Switch Pressure (R134a)

11 CH387

12 PE067

Fan Motor

CTD 11B (4mm Orifice)

Recommended Spare List - CS TID 50 [PH193]

Sl.No Part No Description

1 AD614

2 CH163

3 CH458

4 CE599

5 CC022

6 AD582

7 CH113

8 CH004

9 CE575

10 CE459

11 CH238

12 CE646

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]

Sl.No Part No Description

1 AD614

2 CH163

3 CH457

4 CE599

5 CE022

6 AD582

7 CH113

8 CH004

9 CE575

10 CE459

11 CH238

12 CE646

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

Recommended Spare List - CS TID 60 [PH194]

Sl.No Part No Description

1 AD614

2 CH163

3 CH458

4 CE599

5 CC022

6 AD582

7 CH113

8 CH004

9 CE575

10 CE459

11 CH238

12 CE646

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

Reference : Manual Version 2

2 0

11. Recommended spares for 5 years trouble free operation

Recommended Spare List - CS TID 80 [PH195]

Sl.No Part No Description

1 AD614

2 CH163

3 CE514

4 CH315

5 CE599

6 CC022

7 AD581

8 CH113

9 CH004

10 CE575

11 CE459

12 CH238

13 CE646

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 Description

1 AD614

2 CH163

3 CH072

4 CE599

5 CC022

6 AD535

7 CH113

8 CE575

9 CE459

10 CH238

11 CH004

12 CE646

13 CD020

14 CE515

15 CH359

16 AD556

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 100 [PH196]

Sl.No Part No Description

1 AD614

2 CH163

3 CE514

4 CH315

5 CE599

6 CC022

7 AD581

8 CH113

9 CH004

10 CE575

11 CE459

12 CH238

13 CE646

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 200 [PH198]

Sl.No Part No Description

1 AD614

2 CH265

3 CH204

4 CE564

5 CE599

6 CC022

7 AD535

8 CH215

9 CH004

10 CE575

11 CE459

12 CH238

13 CE646

14 CD020

15 CE515

16 CH250

17 AD556

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

2 1

INSTRUCTION MANUAL -

Coldspell

11. Recommended spares for 5 years trouble free operation

Recommended Spare List - CS TID 250 [PH199]

Sl.No Part No

1 AD614

2 CH265

3 CH204

4 CE564

5 CE599

6 CC022

7 AD535

8 CH215

9 CH004

10 CE575

11 CE459

12 CH238

13 CE646

14 CD020

15 CE515

16 CH250

17 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”

Recommended Spare List - CS TID 400 [PH170]

Sl.No Part No Description

1 AD614

2 CH163

3 CH196

4 CE599

5 CC022

6 AD596

7 CH215

8 CE575

9 CE459

10 CH496

11 CH426

12 CH106

13 CE646

14 CD020

15 CE515

16 CH517

17 CH491

18 CH492

19 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 300 [PH169]

Sl.No Part No Description

1 AD614

2 CH163

3 CH508

4 CE599

5 CC022

6 AD596

7 CH215

8 CE575

9 CE459

10 CH496

11 CH426

12 CH106

13 CE646

14 CD020

15 CE515

16 CH278

17 CH491

18 CH492

19 AD556

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”

2 2

Recommended Spare List - CS TID 500 [PH171]

Sl.No Part No Description

1 AD614

2 CH163

3 CH196

4 CE599

5 CC022

6 AD596

7 CH215

8 CE575

9 CE459

10 CH496

11 CH426

12 CH106

13 CE646

14 CD020

15 CE515

16 CH517

17 CH491

18 CH492

19 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”

Reference : Manual Version 2

11. Recommended spares for 5 years trouble free operation

Recommended Spare List - CS TID 650 [PH186]

Sl.No Part No Description

1 AD614

2 CH265

3 CH226

4 CE599

5 CC022

6 CC468

7 AD596

8 CH382

9 CE575

10 CE459

11 CH374

12 CH431

13 CH106

14 CE646

15 CD020

16 CE515

17 CH278

18 CH491

19 CH492

20 AD556

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 Description

1 AD614

2 CH265

3 CH225

4 CE599

5 CC022

6 CC468

7 AD596

8 CH308

9 CE575

10 CE459

11 CH374

12 CH427

13 CH125

14 CE646

15 CD020

16 CE515

17 CH278

18 CH491

19 CH492

20 AD556

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”

This document may be modified without notice reproduction, even partial, forbidden without written authentication

Recommended Spare List - CS TID 1000 [PH188]

Sl.No Part No Description

1 AD614

2 CH265

3 CH225

4 CC022

5 CC468

6 CE599

7 AD596

8 CH308

9 CE575

10 CE459

11 CH374

12 CH427

13 CH125

14 CE646

15 CD020

16 CE515

17 CH517

18 CH491

19 CH492

20 AD556

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 Description

1 AD614

2 CH265

3 CH230

4 CC022

5 AD596

6 CE599

7 CH308

8 CC468

9 AH045

10 CE459

11 CH374

12 CH427

13 CH125

14 CE646

15 CD020

16 CE515

17 CH522

18 CH491

19 CH492

20 AD556

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”

2 3

INSTRUCTION MANUAL -

Coldspell

11. Recommended spares for 5 years trouble free operation

Recommended Spare List - CS TID 1500 [PH190]

Sl.No Part No Description

1 AD614

2 CH265

3 CH523

4 CC022

5 CC468

6 AD596

7 CH308

8 AH045

9 CE459

10 CH377

11 CH466

12 CH381

13 CE646

14 CD020

15 CE515

16 CH522

17 CH491

18 CH492

19 AD556

20 CE599

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

Recommended Spare List - CS TID 2000 [PH202]

Sl.No Part No

1 AD614

2 CH265

3 CH525

4 CC022

5 CC468

6 AD596

7 CE599

8 CH308

9 AH045

10 CE459

11 CH377

12 CH482

13 CH381

14 CE646

15 CD020

16 CE515

17 CH526

18 CH491

19 CH492

20 AD556

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”

2 4

Reference : Manual Version 2

Date :

INSTALLATION & COMMISSIONING REPORT FOR COLDSPELL TID

Customer Name & Address : Dryer model :

Dryer serial No :

Phone : Contact Person :

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

6

7

2

3

4

5

During installation

1 Is the air from the outlet of the air compressor flowing to the dryer inlet?

Is there an air tank/air receiver in between the air compressor outlet & dryer inlet?

Is there any air leakage at the dryer inlet & outlet connections?

Is proper electrical input supply provided to the dryer from the customer side?

Has the refrigerant gas pressures been idealized before starting the dryer (Check the pressure gauges)?

Is the drain valve outlet hose connected?

Is the dryer provided with pre-filter? Is there 1000 metre minimum clearance provided around the dryer?

(Yes/No)

6

7

8

9

4

5

During dryer operation

1

2

3

Is the Controller/Display switched on? (Visual observation)

Is the Contactor Switch energized during refrigeration compressor operation?

Does the Phase preventer switch show LED indication (yellow & red) during operation of the dryer?

(only for 3-phase models)

Is the refrigeration compressor working?

Is there any abnormal sound from the refrigeration compressor?

Is the drain valve working?

Are there any leakage in the drain valve hoses?

Has the condenser fan cut-ON/cut-OFF at regular intervals?

Are the condenser fins & tubes free from dust?

Observations

2

3

Notes for the service engineer:

1 All the parameters mentioned below must be checked.

4

Note the values of voltage in RY in case of 1-Phase.

Note the values of amperage in R in case of 1-Phase.

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

2 5

.

Date :

INSTALLATION & COMMISSIONING REPORT FOR COLDSPELL TID

Customer Name & Address : Dryer model :

Dryer serial No :

Phone : Contact Person :

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

6

7

2

3

4

5

During installation

1 Is the air from the outlet of the air compressor flowing to the dryer inlet?

Is there an air tank/air receiver in between the air compressor outlet & dryer inlet?

Is there any air leakage at the dryer inlet & outlet connections?

Is proper electrical input supply provided to the dryer from the customer side?

Has the refrigerant gas pressures been idealized before starting the dryer (Check the pressure gauges)?

Is the drain valve outlet hose connected?

Is the dryer provided with pre-filter? Is there 1000 metre minimum clearance provided around the dryer?

(Yes/No)

6

7

8

9

4

5

During dryer operation

1

2

3

Is the Controller/Display switched on? (Visual observation)

Is the Contactor Switch energized during refrigeration compressor operation?

Does the Phase preventer switch show LED indication (yellow & red) during operation of the dryer?

(only for 3-phase models)

Is the refrigeration compressor working?

Is there any abnormal sound from the refrigeration compressor?

Is the drain valve working?

Are there any leakage in the drain valve hoses?

Has the condenser fan cut-ON/cut-OFF at regular intervals?

Are the condenser fins & tubes free from dust?

Observations

2

3

Notes for the service engineer:

1 All the parameters mentioned below must be checked.

4

Note the values of voltage in RY in case of 1-Phase.

Note the values of amperage in R in case of 1-Phase.

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

2 7

.

S.No

Parameters

1 Input supply to the Dryer (from Customer side)

2 Dryer input Voltage (RY) V Refer specification chart

Dryer input Voltage (YB)

Dryer input Voltage (RB)

3 Dryer running hours

4 Refrigerant Used

5 Refrigerant idle pressure (Before switching on the dryer)

6 Dryer inlet air flow (Check air compressor's rated flow)

7 Dryer inlet air pressure (measured by pressure gauge)

8 Pressure drop between dryer inlet & outlet (measured by pressure gauge)

9 Dryer inlet air temperature(measured using temperature gun or temperature probe)

10 Ambient temperature

11 Dewpoint temperature (from dryer display)

12 Compressor Suction Pressure (measured by pressure gauge)

Values

13 Compressor Discharge Pressure (measured by pressure gauge)

14 Compressor Amperage (R) (measured by clamp meter)

Compressor Amperage (Y) (measured by clamp meter)

Compressor Amperage (B) (measured by clamp meter)

15 Drain Valve ON/OFF ming (measured by stopwatch)

16 Phase preventer OV & UV Setting

Comments :

Units

---

V

Range

1Phase / 3Phase bar (g) bar (g) o C o C o C psi(g) hrs

---

--

R134a / R407C psi(g) Refer specification chart cfm < Dryer capacity psi(g)

6 – 16

< 0.3

< 45

< 40

3 – 7

28-33 (R134a)

& 60-70 (R407c)

140-180 (R134a)

& 240-320 (R407c)

A s

%

Refer specification chart

--

OV=5%, UV=10%

Customer’s name and signature : Service engineer name and signature :

Name : Name :

Customer Feedback

1. Poor 2. Fair 3. Good 4. V. Good 5. Excellent

1) Have we responded fast to your enquiry?

2) Are you happy with our order processing method?

3) Was the delivery as promised?

4) How is the quality of our packing?

5) Does the dryer work as per your expectation?

6) Suggestions _________________________________________

This document may be modified without notice reproduction, even partial, forbidden without written authentication

2 9

.

S.No

Parameters

1 Input supply to the Dryer (from Customer side)

2 Dryer input Voltage (RY) V Refer specification chart

Dryer input Voltage (YB)

Dryer input Voltage (RB)

3 Dryer running hours

4 Refrigerant Used

5 Refrigerant idle pressure (Before switching on the dryer)

6 Dryer inlet air flow (Check air compressor's rated flow)

7 Dryer inlet air pressure (measured by pressure gauge)

8 Pressure drop between dryer inlet & outlet (measured by pressure gauge)

9 Dryer inlet air temperature(measured using temperature gun or temperature probe)

10 Ambient temperature

11 Dewpoint temperature (from dryer display)

12 Compressor Suction Pressure (measured by pressure gauge)

Values

13 Compressor Discharge Pressure (measured by pressure gauge)

14 Compressor Amperage (R) (measured by clamp meter)

Compressor Amperage (Y) (measured by clamp meter)

Compressor Amperage (B) (measured by clamp meter)

15 Drain Valve ON/OFF ming (measured by stopwatch)

16 Phase preventer OV & UV Setting

Comments :

Units

---

V

Range

1Phase / 3Phase bar (g) bar (g) o C o C o C psi(g) hrs

---

--

R134a / R407C psi(g) Refer specification chart cfm < Dryer capacity psi(g)

6 – 16

< 0.3

< 45

< 40

3 – 7

28-33 (R134a)

& 60-70 (R407c)

140-180 (R134a)

& 240-320 (R407c)

A s

%

Refer specification chart

--

OV=5%, UV=10%

Customer’s name and signature : Service engineer name and signature :

Name : Name :

Customer Feedback

1. Poor 2. Fair 3. Good 4. V. Good 5. Excellent

1) Have we responded fast to your enquiry?

2) Are you happy with our order processing method?

3) Was the delivery as promised?

4) How is the quality of our packing?

5) Does the dryer work as per your expectation?

6) Suggestions _________________________________________

This document may be modified without notice reproduction, even partial, forbidden without written authentication

3 1

.

This document may be modified without notice reproduction, even partial, forbidden without written authentication

3 3

.

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 : [email protected]

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

E-mail

: +91-422-2401376

: [email protected]

Sales

A. Anil Kumar

Territory Manager - Andhra Pradesh

Mobile

E-mail

: +91-9885445321

: [email protected]

Syed Yusha

Territory Manager - Mumbai

Mobile : +91-9867367726

E-mail : [email protected]

Ramesh Kumar Singh

Territory Manager - Railways

Mobile

E-mail

: +91-9811310726

: [email protected]

T. Saravanakumar

Product Manager - Drain Valves

Mobile : +91-9994978928

Telephone : +91-422-2400492 extension 216

E-mail : [email protected]

Ramesh Kumar Singh

Territory Manager - Delhi

Mobile

E-mail

: +91-9811310726

: [email protected]

J. Nandha Kumar

Territory Manager - Tamil Nadu/Kerala

Mobile

E-mail

: +91-9789480564

: [email protected]

Service

M. Ragunath

Service Executive

Mobile : +91-8870010565

Telephone : +91-422-2400492 extension 217

E-mail : [email protected]

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 : [email protected] Website : www.tridentpneumatics.com