Refrigerated Compressed

Air Dryers

operation instruction

One
 CONTENTS

Introduction …………………………………………………………2

Function Introductions ………………………………………………2

Compressed Air & Refrigeration System Flow ……………………3

Arranged Air Compress System ……………………………………4

Usage requirement of the Air Dryer ………………………………4

Installation of the Air Dryer …………………………………………5

Note item of the operation of the Air Dryer ………………………6

Adjust of the Air Dryer ……………………………………………6

General Maintenance Information ………………………………7

Trouble Shooting ……………………………………………………8

Electric Control circuit Diagram …………………………………12

Two
1. Introduction
The main purpose of this manual is teaching user how to make our equipment to be treated
in exact use and maintenance. This procedure can prolong equipment's used-life and reduce
trouble for assuring the quality of air dryer. This manual also offers the related data in
equipment for reference & inspection. It's important to be familiar with this manual prior to
starting this equipment; moreover, subject to the instruction in operation and maintenance for
avoiding caused trouble of equipment.

Note: Subject to principle exactly as follows, for avoiding dangerous. Maintenance.

 Do not exceed maximum operating pressure as shown on equipment serial number
tag.
 Make sure equipment is depressurized before working on or disassembling it for
servicing.
 Install equipment is compliance with national and local electrical codes. (220V+5%)
 Disconnect power supply to equipment when performing any electrical service work.

2. Function Introductions
The main function of refrigerated type compressed air dryers is to remove the moisture in
compressed air, lowering the compressed air temperature to 1.6oC at dew point temperature
by air-to-refrigerant heat exchanger (refrigeration evaporator), and then, most of the water
vapor condenses into liquid droplets which are separated out of the air stream by a separator
and condensed liquid is discharged to out of the unit by auto drain, then finishing the whole
drying process. If all conditions are normal, it just has about 0.59 g/m3 water vapor in dry
compressed air, and its percentage of water removed can reach 93%.

3. Compressed Air & Refrigeration System Flow

■ 3-1Compressed air flow
Compressed air enters the dryer, lowering the air temperature by passing air cooler (12) first,
next entering an heat exchanger (7), it can condense water vapor into liquid droplets and do
pre-cooling job, then entering the evaporator (6); moreover, increasing the dryer effect. Then
liquid droplets are removed from the air stream in the separator (9) and automatic drain (10).
Finally the dry compressed air passes through the heat exchanger where it is reheated by
the incoming air, refrigeration system flow. (See Diagram 1).

Three
■ 3-2Refrigeration system flow
Refrigerant turns into air refrigerant of high pressure and high temperature by refrigeration
compressor (1). Moreover, lowering the temperature of air refrigerant-by-refrigerant heat
exchanger (2) first, then enters into liquid refrigeration after heat dissipation by condenser (3).
The main function of drier (4) is to dry and filter out water and impurity from refrigeration pipe.
After high-pressure liquid refrigerant is expansion through capillary tube (5), then forming air
and absorbing heat from compressed air in evaporator lowering air temperature, water vapor
condenses into liquid droplets. Refrigerant flow returning to compressor side of inlet by
through pipe, then continues use it after compressed it, then forming return route. (See
Diagram 1)

Flow Schematic Diagram of Model XS- A (AH) Air Dryer

1. Refrigeration Compressor
2. Refrigerant Heat Exchanger
3. Air Cooled Condenser
4. Water Cooled Condenser
5. Service Valve
6. Irrigate Valve
7. Dry Filter
8. Electric Valve
9. Refrigeration Screen
10. Expand Valve
11. Capillary
12. Heating Passby Valve
13. Evaporator
14. Air-water Separator
15. Air Heat Exchange
16. Water-air Separator
17. Air-cooled Front Cooler
18. Water-cooled Front Cooler
19. High-pressure Jump Protect Switch
20. Pressure Control switch
21. Auto Drain
22. Cooler Filter
23. Water Adjust Valve
24. High-pressure Safety Valve
25. Air-inlet Pressure Meter

Four
 26. Air-outlet Pressure Meter
27. Refrigeration Low-pressure Meter
28. Refrigeration High-pressure Meter DIAGRAM 1

4. Arranged Air Compress System

It is necessary to arrange the Machine like the following Diagram. If have high requirement to
the Air Dryer, please order Absorb Dryer behind Lever 3 Filter. The order chosen of the
7*5*3*1 Lever Filter base on the technical requirement. Or consult with our technical work.

5. Usage requirement of the Air Dryer

1) Base on the four item of arrange to choose the back Cooler of Air Compressor, Saving
Barrel, Filter and the Air Dryer. During these, the Back Cooler and Saving Barrel is
necessary and it must install between the Air Compressor and Air Dryer. The Lever C Filter
must be placed and other Filters only refer with your necessary.

Five
 2) Usage of work station:
Environment Temperature: ≤42℃ (Water cooler model not limited)
Inlet Temperature : XS- A≤45℃ XS- AH ≤80℃
Inlet Pressure: 0.2Mpa-1.0Mpa (Over than 1.0Mpa may to order the goods)
Quantity of Cooler Water: Account on 0.18 t/h with every dealing 1Nm3/min
Cooler Water Temperature: Inlet water temperature≤35℃
Cooler Water pressure: 0.2-0.4Mpa

6. Installation of the Air Dryer

1) Place smoothly on the ground
2) Deal scaling with the outlet of the Air Compressor to the inlet of the Air Dryer's pipe, and
can't use the easy saving water bend pipe.
3) Keep machine separate the environment for over 1 meter to ensure easy operate and fix
and daily maintain. Air cooler ensures airness expediting and Water cooler ensure the inlet
water pressure over 0.2 Mpa than outlet water pressure. The diameter of the pipe must fit
for the water flux. Inlet water temperature must lower than 32℃ and must be clean (fit for
filter in the water inlet).
4) Air Dryer is a machine for refrigeration. So it mute be avoid the strong shake and lean when
it to be moved, loaded or installed.
5) To add the Repairing valve and Bypass valve on the inlet of the Air Dryer. As the following
diagram:
6) To avoid shaking and impulse need to add the saving barrel to the back of Air compressor.
7) Water cooler should be place the signal pipe, and forbid to using one pipe together with
other Water Cooler machine.

8) Installation of the electric

A. Only set on power switch and don't use the setup switch together with other machine
B. The pressure wave should near 5%.
C. The place pipe should to avoid the section too small or long to cause the pressure
voltage drop.

Six
 D. Install a set of electric element beside of the power, for example the setup switch and
the air switch and the fuse and so on.
E. To touch the ground rightly.

7. Note Item of the Operation of the Air Dryer

1) Check the five step fitting the requirement of the usage or not.
2) Check the power: the voltage and the phase fit for the requirement or not, and the electric
touch line right or not.
3) Air cooler: the airness of the condenser is expedite or not.
Water cooler: the water pipe is expedite or not and the water pressure and the quality or
the temperature fitting for the requirement or not.
4) The Filter of the Air Dryer install right or not.
5) The Bypass valve and the inlet repairing valve is closed or not and the outlet repairing is
opened or not.
6) The Auto Drain ball valve is opened or not.
7) Check the machine with the refrigerate pressure meter to look the data of the machine is
normal or not and on the normal the data of high-pressure meter and the low-pressure
meter is equal or not.
8) Check the machine with the timing relay to set the delay time and the setting time data or
not.
9) The air leave in the pipe is taken out or not.
Air cooler to observer the fan having the auto turn on or off capacity:
XS-06-1A(AH): turn on the fan (low pressure :0. 24 Mpa), off the fan (low pressure:0.
2Mpa)
XS- A(AH)-Over 2A(AH): turn on the fan (low pressure:044Mpa or high-pressure 1.6Mpa),
off the fan (low pressure:0. 4Mpa or high-pressure 1.4Mpa).
Water cooler: the low-pressure data of refrigerate will stabilization between with the
0.4Mpa-0.45Mpa.And the high-pressure data of the refrigerate will stabilization between
with the 1.4-1.6Mpa. After above condition we can take the Air Dryer as work normal. And
after setup the air compressor and the saving air barrel pressure data to 0.7Mpa, can open
slowly the compressor inlet-repairing valve to compress air and the pressure will add to the
machine slowly. Forbid to open the inlet-repairing valve fierce to cause the shock wave
inside the machine or to attain the Evaporator and so on elements.
In addition, forbid to turn on or off the machine to many time to avoid attaining the
compressor motor.
10) Order of the closing machine:
Close the Air compressor and the inlet repairing valve first then to close the Air Dryer.

Seven
8. Adjust of the Air Dryer
Our entire machine pass adjusts before out of the factory. And In generate, the user of below
12A(W) can use the machine install and operation illustration directly to open the machine.
Over 15A(W) model machine should let our technical worker to adjust the machine for you.
The operation people should take in our operation train first. During the using, if the machine
having abnormal phenomena, should relate with our company. And under leading of our
technical worker adjust some valve. Forbid to operate blindness and cause to attain machine
and the element.
9. General Maintenance Information
1) Clean the Air-cooling condenser usually to avoid the bott effect on the heating efficiency.
Clean way like following diagram
2) Check the automatic drain is needed to prevent sludge and contamination everyday. If clog,
please clean them by according to dissolve diagram
3) Clean the Water-cooling with the clean water and note to clean the filter to avoid the pipe
jam and can't expedite. The clean way like diagram 4. (If there is no water filter, should add
a filter net on the inlet of the pipe. If the auto drain doesn't work, can use the drain by hand
but it must exhaust the water in time to avoid the water inlet the air.
4) Note the three phases electric run with no phase.
5) Note to listen the compressor run in clam and no noise or not.
6) Note to touch the air inlet and outlet temperature with different temperature. (Normal
condition is near 10-17℃)..
7) The environment temperature of the Air Dryer does not fit below to 10℃, to avoid attaining
the compressor because of lacking the oil.
8) Clean the dust on the outside box usually.

Eight
10. Trouble Shooting

A) Pressure-drop is too much

Symptom Possible Cause Corrective Action
Pipe valve hasn't open complete Open the pipe valve completely
Pipe diameter is too small Use larger pipe
Pipe is too long, so the pipe bend and
Redesign pipe system
connector are too much
Improper pipe arrangement due to two
Pipe system is error
or more air compressors share the Redesign pipe system
same dryer
Filter in pipe system has blocked Clear filter or replace new one
Too much air leakage on pipe system's
Check bend connector
bend connector

Nine
 Air flow is higher than compressor's Replace compressor with larger
Air flow exceed rated air discharge capacity and the air discharge capacity
rated value pressure drops automatically
Reduce air flow

Temperature switch or pressure switch Check and adjust switch or

has faulty replace new one
The condensing
Check to see the pipe system
water in Evaporator Error of expansion valve or heat-air
has blocked or not, adjust switch
is frozen bypass valve
or replace new one
Air flow is too small Enlarge air flow

B) Air Dryer's water removing result isn't good

Symptom Possible Cause Corrective Action
Bypass valve hasn't closed Close bypass valve
The air hasn't passed through air dryer Open air dryer's air inlet completely
Pipe system is Air dryer isn't placed parallelly Place air dryer parallelly
abnormal Auto Drain has incline Place auto drain vertically
Pipe for draining is higher than auto
Redesign draining pipe
drain
Air flow is too much Redesign compressed air
Pressure-drop is too much large
large source
Auto drain is wrong or drain valve has
Clean or replace new one
Drain system is problem
abnormal Confirm that the front valve is on
Auto drain's front valve hasn't opened
full-open position
Adjust pressure switch, water
Dew point is too high or too low flow switch, expansion valve and
Display of Cooling heat-air bypass valve
Medium's Atmosphere temperature and inlet Keep machine working
evaporating temperature is too low continuous
temperature is Circumstance air is too dreggy, Select better position to place
abnormal ventilation is no good machine or improve ventilation
Remove leakage and re-supply
Cooling medium has leakage
cooling medium

Ten
 C) Can't operation
Symptom Possible Cause Corrective Action
Check the condition of earth
connection, check if the fuse
The power supply Fuse has broken
has broken or there is short
can't supple voltage
circuit.
Wire has broken Find the broken point and repair
Make the input voltage on the
Voltage is abnormal range shown on
nameplate
Switch has faulty Replace
Connector has faulty Replace
The power supply
Over Current Relay has faulty Replace
works normally but
High-low voltage switch has faulty Replace
can't startup machine
Startup Breaker has faulty Replace
Capacitor has faulty Replace
Temperature Switch, Flow Switch has
Replace
faulty
Compressor has faulty Replace
High-low voltage switch or over-current Find the reason for jumping off,
Switches are all relay hasn'treset after jumping off. then reset the switch or relay
normal, but still can't Compressor has faulty Replace
startup machine Find the loosen place and
Wire has loosen
fasten
D) Running is not good after startup

Symptom Possible Cause Corrective Action

After startup, the circuit is short and Reset circuit and switch, find the
Voltage is abnormal
cause adust smell reason of abnormal voltage
High-voltage witch Voltage switch or temperature switch
Replace switch
jump off. After reset, has faulty to cause fan stop working
the machine can't The fan has faulty Replace

Eleven
 startup Overload switch jump off Check
Condenser is too dirty Clean
Capacitor has faulty Replace
Voltage switch or temperature switch
Replace
has faulty to cause fan stop working
Hydraulic switch has faulty Replace
The interval between two startup
Continuous startup for several times
should be 3 minutes
Over Current Replay
Compressor has overloaded Reduce air flow
jumps off
Circumstance temperature or air dryer's Improve ventilation or add
inlet temperature cooling device
Fuse has broken Replace
Contactor has faulty Replace
Cooling water hasn't recycled Check cooling water

E) Normal operation but bad effect in drain

Symptom Possible Cause Corrective Action
Hot gas by-pass valve isn't closed fully Close the valve tightly
Incorrect pipe
Air flow doesn't flow thru dryer Open all valves at inlet to dryer
arrangement system
Dryer is not laid flat Lay flat the unit
Over flow rate Add dryer
Add aftercooler or increase HP,
Incorrect High inlet temp. (Over 80oC)
improve ventilation
compressed air
High ambient temp. (Over 40oC) Improve ambient temp.
Incorrect air pressure Normal valve: 2-25kg/cm2
Remedy the leak, re-charge
Leaky refrigerant
refrigerant
Damaged valves Replace
Incorrect cooling Replace drier, vacuumize and
Refrigerant pipe lines are clogged
system re-change refrigerant
Breakdown of pressure switch Replace
Breakdown of condenser or cooler
Replace
motor fan

Twelve
 Condenser fins clogged Clean
Drain valves are breakdown or not fully
Renew or open valves
opened
Back to normal pressure 2-25
Incorrect working pressure
kg/cm2
Incorrect auto-drain Auto drain declined Lay flate & reset
system Clean (refer to maintenance
Strainer is clogged
items)
Drain lines clogged Clean
Drain lines are higher than auto drain's Reset the drain lines
Trouble of drain float Replace

F) Auto Drain has faulty

Symptom Possible Cause Corrective Action
Working pressure is below1.5kg/cm2 Increase working pressure
Pipe has blocked Clean
Drain damage or not open completely Replace or open it completely
Auto Drain has Drain is incline Adjust position and fix it
faulty Drain's filter has blocked Clear
Working pressure is too high Decrease working pressure
Drain pipe has blocked Clean
Evaporator's pipe has blocked or rusted Beyond using life and replace

Thirteen
 CT8893D User Guide Version: h160826

1 Technique Index
 Temperature display range: -20～100℃（The resolution is 0.1℃)
 Power supply: 220V ± 10% （ Product supply voltage to the product label shall
prevail）
 Temperature sensor: NTC R25=5kΩ,B(25/50)=3470K

2 Operating Guide
2.1 Meaning of the index lights on the panel
Index
Name Light Flash
light
Ready to refrigerate, in the state of
Refrigeration Refrigerating
compressor start delay pro
Fan Fanning -
Defrost Defrosting -
Alarm - Alarm state
2.2 Meaning of the LED display
Alarm signal will alternate display temperature and warning code. (A xx)
To cancel the alarm need recharge the controller. Display code as follow:
Code Meaning Explain
Alarm from external alarm signal, refer to the internal
A11 External alarm
parameter code “F50”
The dew-point The dew-point sensor broken-line or short circuit（The
A21
sensor fault dew-point temperature display “OPE” or “SHr”)
Condensation The condensation broken-line or short circuit（Press “” will
A22
sensor fault display “SHr” or “OPE”）
The dew-point If alarm occurred in the dew-point temperature higher than the
A31
temperature fault set value, can choose whether closing down or not (F51).

Fourteen
 The dew-point temperature alarm will not occurred when
compressor starts in five minutes.
Condensation If alarm occurred in the condensation temperature higher than
A32
temperature fault the set value, can choose whether closing down or not.（F52）
2.3 Temperature display
After power on self-test, the LED display the dew-point temperature value. When press
on“”, it will display the temperature of condenser. Reverse will back to display the dew-point
temperature.
2.4 Cumulative working hours display
Pressing on the“   ”at the same time, will display the compressor accumulated
operational time. Unit: hours
2.5 Higher level operation
Long press “M” 5 seconds to enter parameter setting condition. If have set the command,
will display word “PAS” to hint import the command. Using press“   ”to import the
command. If the code is right, it will display parameter code. Parameter code as followed table:
Setting Factory
Category Code Parameter name Unit Remark
range setting

The way of
dealing with 0 : Only alarm, not
F51 dew-point 0-1 1 - close.
temperature 1: Alarm and close.
alarm.
The way of
dealing with 0 : Only alarm, not
F52 condensation 0-1 1 - close.
temperature 1: Alarm and close.
alarm.

Fifteen
 OFF means no
OFF
password
F80 Password 0001 -- OFF -
0000 System means
9999
clearing password
Switch machine
F83 YES - NO YES -
state memory
System means Display the
compressor Hou
F85 - -
accumulated r
operational time
Reset compressor
NO：not reset
F86 accumulated NO - YES NO -
YES：reset
operational time.
F88 Reserved
F98 Reserved
Testing This function can attract all relays in turn, and
F99 Test-self
please don’t use it when the controller is running!
End Exit

3 Basic Operating Principle

3.1 Compressor control
After controller powered on, the compressor will delay for a moment to protect itself (F21).
The indicator light will flicker at the same time. If checked external input is alarming, the
compressor will stop.
3.2 Fan control
Fan default under control of condensing temperature. It will open when temperature is
higher than (including) set point (F42) , closed when lower than the set point - return difference
(F43) . If condensation sensor fails, the fan output along with the compressor.
3.3 External alarm

Sixteen
 When external alarm occurs, stop the compressor and fan. External alarm signal has 5
modes (F50): 0: without external alarm, 1: always open, unlocked, 2: always
open, locked; 3: always closed, unlocked; 4: always closed, locked. “Always
open” means in normal state, external alarm signal is open, if closed, the
controller is alarm; “Always closed” is on the contrary. “Locked” means that
when external alarm signal becomes normal, the controller is still in the alarm
state, and it needs to press any key to resume.
3.4 Command
In order to prevent irrespective persons from changing the
parameters, you can set a password (F80), and if you have set a
password, the controller will hint you to enter the password after
you press the key “M” for 5 seconds, you must enter the correct
Setting Factory
Category Code Parameter name Unit Remark
range setting

dew-point
F11 temperature 10 - 45 20 ℃ It will warning when
warning point the temperature
Condensation higher than the set
F12 temperature 42 - 70 65 ℃ value.
Temperature warning point
Dew-point sensor -20.0 – Amend dew-point
F18 0.0 ℃
amendment 20.0 sensor error
Condensation
-20.0 – Amend condensation
F19 sensor 0.0 ℃
20.0 sensor error
amendment
Min
Compressor F21 Sensor delay time 0.0 – 10.0 1.0
ute

Seventeen
 It will start when
Start antifreezing
-5.0 – dew-point
F31 demand 2.0 ℃
10.0 temperature lower
temperature
than the set value.
It will stop when
Antifreezing dew-point
F32 1-5 2.0 ℃
return difference temperature higher
than F31+F32.
OFF: close fan
1. The fan under the
control of
condensation
Fan/
The second way OFF temperature.
Antifreezing F41 1 -
the output mode. 1-3 2. Fan worked at the
same time with
compressor.
3. Antifreezing outpu
mode.
Fan start It will start when
F42 32 - 55 42 ℃
temperature condensation
temperature higher
Fan close than the set value. It
F43 temperature return 0.5 – 10.0 2.0 ℃ will close when lower
difference. than set return
difference.

Eighteen
 0: without external
alarm
1 : always open,
unlocked
External alarm 2 : always open,
Alarm F50 0-4 0 -
mode locked
3: always closed,
unlocked
4: always closed,
locked
password, and then you can set the parameters. If you don’t need the password,
you can set F80 to “0000”. Notice that you must remember the password, and if
you forget the password, you can not enter the set state.

4 Wiring Diagram

Nineteen
5 Notes
 Please use the temperature sensor allocated by our company.
 If compressor power is less than 1.5HP, can direct control by internal relay. Otherwise
need to connect ac contactor.
 Fan loaded with no more than 200w.

 We have installed a 460V transformer to 220V, and the customer is connected to the
460V/60hz power supply, which can be directly used

Twenty