Maxair MAX-11.000, MAX-17.800, MAX-1800, MAX-8500 Operating Manual

OPERATING MANUAL FOR REFRIGERANT COMPRESSED AIR DRYER MAX-900/160.000
Contents
1.1 Transportation
1.2 Placement
1.3 Installation
1.4 Maintenance
2 General Information
2.1 Manufacturer information
2.2 Nameplate information
2.3 Operating principle
3 Operating
3.1 Front panel
3.2 On-off
3.3 Equipment characteristics
4 Technical specifications
5 Settings
6 Fault codes and troubleshooting
7 Warranty certificate and warranty conditions
1.1 TRANSPORTATION
Air dryers should be transported by an appropriate forklifet. The equipment should be lifted at
the market points and should not be turned down.
1.2 PLACEMENT
 Air dryer should be definitely placed on a flat surface horizontally.
 Air dryer should not be directly exposed to rain, sunlight and outdoor conditions.
 A clearance of minimum 50cm should be left around the air dryer to allow access for service
and ventilation.
 Hot air discharged from the air compressor should not reach the dryer. The ambient air
temperature should be in the range of +4oC and +45oC and air circulation should be assured.
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Chemicals that may be harmful for copper and aluminium (e.g. ammonia gas, etc.) should be
sept and stored in the environment. The air dryer should not be subject to rainwater and
direct sunlight.
1.3 INSTALLATION
 Air dryer should be installed only by a trained and authorized personnel.
 Installation should comply with the operating pressure indicated on the nameplate of the air
dryer.
 Air dryer should be supplied by voltage indicated on its nameplate.
 Safety elements and protection covers and materials on the equipment should never be
removed or modified.
 Power connection f the air dryer should not be used in common with the board of another
equipment.
 Necessary safety valve should be connected to each pressure tank and accessories of the air
dryer.
 An appropriate air installation and line filters should be used and by-pass line should be
installed for cutting off the air during maintenance-repair operations.
1.4 MAINTENANCE
 Air dryer should be switched off, power should be cut off and compressed air in the system
should be released prior to maintenance.
 Condenser should be regularly cleaned with compressed air.
 The filter in the drain valve should be regularly cleaned with clean water and air.
 The interior elements of the filter at the air inlet and outlet lines should be replaced
regularly.
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2
Filter no. 5 should be cleaned with compressed air and water regularly. Otherwise, the drain
solenoid valve may cause failure.
GENERAL INFORMATION
2.1 Manufacturer Information
Maksimum Makine Soğutma Sanayi ve Dış Tic. Ltd. Şti.
İkitelli O.S.B. Aykosan San Sit. No.:22 Başakşehir / İstanbul
Tel: +90 212 809 19 19
Fax: +90 212 809 19 18 www.maxdryer.com [email protected]
2.2 Nameplate of the air dryer
2.3 Operating Principle of the Air Dryer
a) When the dryer is switched on, it delivers the coolant to the system under high pressure and
temperature and the compressor operates continuously without fail.
b) The hot coolant is cooled down by fan in the condenser to make it liquid. And fan operation
is controlled by the pressure switch or heat sensor mounted at the condenser outlet.
c) The liquefied gas is stored in the liquid tank. And the coolant stored in liquid Is sprayed from
the liquid tank to the heat exchanger by means of expansion valve or capillary piping. This
expansion valve and capillary piping are protected by the particle-retaining filter coupled
with the dryer filter and body.
d) The coolant thus sprayed takes over the heat of the air passing through the heat exchanger
to cool it. While the compressed air is cooled down, the coolant in liquid form is converted
back to the gas phase and suctioned by the compressor. This closed circuit gas cycle
continues constantly.
e) In order to keep constant the pressure and temperature of the coolant in the heat
exchanger, hot gas is delivered from the hot gas delivery line of the compressor to the hot
gas return by means of a by-pass valve. And in case of some dryers, the pressure of the heat
exchanger is controlled by the expansion valves (regulator).
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COMPRESSED AIR CIRCUIT
When the compressed air passes through the initial cooling circuit in the heat exchanger, it is mixed
with the compressed air cooled down to +3oC to perform initial cooling process. After passed the
initial cooling circuit, the air is cooled down to the intended temperature of 3oC at the section where
gas-air comparison is made. The compressed air cooled down Is discharged at the water separator by
the time-regulated drain valve.
Figure. Heat exchanger of he air dryer
3.1 FRONT PANEL
3.2 ON/OFF
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Press on-off button ( ) and hold for 3 seconds to switch on the equipment. When the button
is held pressed, it counts 1---2---3 seconds on the display and the statement (open) ( )
appears on the display. To switch off the equipment, hold o-off button for 3 seconds again.
When the equipment is switched off, the statement (OFF) appears on the display and the
equipment is closed. When the equipment is closed, this statement appears on the display.
When you press the button (Drain Test) on the front panel, the equipment drains manually.
To have access to the set values of the equipment, press the buttons ( ) together for 3
seconds. In this menu:
TH: Setting the drain time. It drains each minute by the times set by means of the up-down
arrows (in seconds).
SR: The safety temperature value measured by the heat protection sensor is set. This setting
is made during the production stage at the plant!! (Temperature should be set according to
the type of the gas charged.)
SET: Operating set value of the equipment is adjusted. It may be set between 3oC and 10oC.
The default setting is set 3oC at the plant.
PRG: is selected in case of all versions.
3.3 CHARACTERISTICS OF THE AIR DRYER
Max series air driers have microprocessor controlled electronic board. 2 heat exchanger on this
board performs measurement continuously. The 1st sensor controls the dew temperature. And the
2nd sensor controls the condenser temperature of the equipment and, in some version, the
temperature of the refrigerating compressor to ensure the equipment to operate safely.
1. On the control board of the dryer, failure-warning contact output is achieved by FREE
contact.
2. In case of any failure, it gives audio alarm and the fault code appears on the display.
Air dryer is equipped with the control equipment to prevent any possible failure in the
occurrence of the following faults:
(Versions between 900-3700 l/min.)
 Condenser heat control sensor
(Versions above 5500 l/min)
 Compressor heat control sensor
(All versions)
 Klixon high temperature switch
(All versions 5500 l/min and above)
 Low pressure switch
(All versions 5500 l/min and above))
 Condenser high pressure switch
(All versions 17,000 l/min. and above)
 Phase failure relay
(All versions 25,000 l/min and above)
 Compressor control switch
(All versions 25,000 l/min and above)
 Fan control switch
Air dryer warns the user against the following faults by audio-visual warning on the front
panel
(All versions)
 High pressure warning alarm
(All versions)
 Sensor failure alarm
(All versions)
 Cooling failure alarm
(All versions)
 Freezing warning alarm
(All versions)
 Service-maintenance time alarm
(all versions 5500 l/min. and above)
 Low pressure warning alarm
4. TECHNICAL SPECIFICATIONS AND DIAGRAMS
8. SETTINGS

Setting the condensate drain time:
Press and hold for 3 seconds ( ) together on the front panel of the dryer and enter the TH
parameter value by means of the arrows on the display.
Click the button ( ) and increase-reduce the value that appears by using the arrows. (setting
can be made in the range of 2 – 15 seconds.

Setting the evaporation gas pressure:
Evaporation gas pressure can be set by Allen screw on the automatic expansion/hot gas bypass valve. Turn clockwise to increase the pressure and turn anticlockwise to reduce it.
R-134 a gas pressure: 2.1 bar
R-407 c gas pressure: 5.5 bar

Setting the temperature protection value of the compressor: (max. 5500-160,000)
Go through the menu on the display to the display where SR parameter value appears and
click on-off button to view the set value. Set the value by using the up-down keys.
Default setting: 45oC
9. FAULT CODES AND TROUBLESHOOTING
FAULT CODES ARE INDICATED ON THE DISPLAY OF THE AIR DRYER AND OPERATOR IS WARNED BY
AUDIO ALARM.
FAULT
DESCRIPTION
REMOVAL
CODE
HPR
High condenser
 If the ambient temperature of the air dryer is above 45oC, you
temperature/pressure
should ensure ventilation of the environment to reduce the
alarm
temperature.
 Condenser fin spacing may be clogged/dirty. Clean by
compressed air.
 Condenser cooling fan may not operate. Remove the failure.
 In case of versions max 5500 and above, the gas return
temperature of the cooling compressor is very high. Set from
expansion valve/hot gas by-pass valve.
LPR
Low gas pressure
 Evaporation gas pressure might have reduced. Increase it from
alarm
the expansion valve/hot gas by-pass valve.
 The ambient temperature of the equipment may be below
5oC. Ensure the ambient temperature to be between 5-45o
 Gas leakage in the cooling system. Contact with an authorized
personnel/plant about gas failure.
SRU
Service/maintenance  Service time for the internal elements of the air line filters.
time alarm
Replace the internal element and reset the timer.
ESH
Cooling sensor failure  The sensor measuring dew temperature is broken or short
alarm
circuited.
 Inspect the sensor socket connections.
 Replace the sensor if it is broken.
CSH
SH
Temperature
protection sensor
failure alarm
Failure arm in the
cooling system
Possible faults
Pressure is law
Water in the system
 Sensor measuring temperature is broken or short circuited.
 Inspect the sensor socket connections.
 Replace the sensor if it is broken.
 If the temperature info from the sensor measuring the heat
exchanger although the equipment has operated for 30
minutes, then the microprocessor stops the system given
warning for problem in the cooling system.
 Inspect the compressor contactor and wiring connections.
 Inspect the coolant level.
 Dew temperature of the air dryer is low and freezing occurs.
Increase the temperature setting from the expansion
valve/hot gas by-pass valve.
 Inlet and outlet line filters are clogged. Replace the internal
elements of the filter.
 By-pass valve connecting the air inlet and outlet may be open.
Close it.
 Filter of the valve in the drain system of condensate may be
clogged. Clean by compressed air and water.
 Condensate drain solenoid valve may be broken. Remove the
failure.
 Water accumulation in the compressed air installation and
charge into the dryer. Drain the water in the system and
attach water separator to the line.
 May be high dew point. Reduce the temperature from
expansion valve/hot gas by-pass valve.
 Condensate drain time may be insufficient. Extend the drain
duration.
 Air inlet-outlet connection of the air dryer may be reverse.
Correct the connection.
Dryer does not operate
 Control the wiring connections of the equipment. Make sure it
is powered.
 If the equipment is 3-phase, then perhaps the phase control
relay does not give output. Correct the phase direction.
 Fuse on the electronic control board of the equipment is
burnt. Replace it.
!!! ELECTRICAL PARTS ON THE DRYER ARE EXCLUDED FROM THE WARRANTY. FOR THIS REASON,
MAKE SROU THE MAINS IS REGULAR.
10. WARRANT CERTIFICATE AND CONDITIONS
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If the air dryer is used under the conditions recommended by Maksimum Makine, the
manufacturer, it is under warranty against manufacturing and workmanship defects for 24
months. The warranty term starts on the date of invoice received by the customer.
Maximum repair term of the air dryer is 30 days. This term starts upon notification of the
failure to the service centre, dealer and manufacturer.
For validity of the warranty, the conditions of installation, usage, maintenance and
environment specified in the operating manual should be observed. Any defects arising from
the misuse are excluded from the warranty.
Any defects arising from the electric installation are excluded from the warranty.
Defects arising from natural disaster, transportation and damage are excluded from the
warranty.
Any defects arisen under the warranty may be intervened only by the authorized service
centres and technicians of Maksimum. Any intervention and replacement by the
unauthorized persons is exclude from the warranty.
If the periodical maintenance of the equipment is not made, any failure of the drain system
of the air dryer is excluded from the warranty.
In case the air dryer fails, the customer is liable to send the equipment to the regional service
centre the factory.
Warranty granted to the user is limited to removal of the failure and replacement of the
parts. Other costs arising from the failure cannot be included in the scope of the warranty.
The warranty may not be assigned to any third parties.