Dryer Manual - ELRD 10 To 345
Dryer Manual - ELRD 10 To 345
Model
Fab No.
Customer
Printed in India
Price : INR-500/-
Compiled by :
Quality
F O R E W O R D
Congratulations! Now you are the proud owner of Elgi Refrigerant drier. This drier has been
designed and manufactured with utmost skill and care, with maximum reliability and high quality
standards as per the requirements and specifications conforming to International Standards.
This manual has been prepared and compiled with utmost care to help the user to know the
various systems involved in the drier thoroughly and to operate it to his best advantage. It
incorporates detailed description of all systems and working conditions with relevant diagrams and
drawings.
Before attempting to use the drier, the user shall go through this book carefully to get
acquainted with this equipment to ensure best results. Under normal working conditions and with
regular prescribed periodic preventive maintenance, excellent, trouble free service can be
guaranteed for serveral years. In case of necessity, our service can always be counted upon.
C O N T E N T S
Foreward --------------------------------------------------------------------------------------------------------------- 3
Installation --------------------------------------------------------------------------------------------------------------- 8
Instruction ------------------------------------------------------------------------------------------------------------- 22
Specifications--------------------------------------------------------------------------------------------------------- 23
Warning ----------------------------------------------------------------------------------------------------------------- 25
3
W A R R A N T Y
Elgi warrants that all its products will conform to the description there of contained in Elgi order
acknowledgement form including amendments thereto: and that it will be free from defects under
normal use and service in material and workmanship which are not commercially acceptable. Upon
receipt of material within one year from the date of commissioning or 18 months from the date of
supply whichever is earlier with transportation charges prepaid which Elgi examination shall
disclose to its satisfaction to have been defective,Elgi will at its option:
2. Issue credit to the original purchase only covering all or part of the purchase price,
as the case may be.
This shall be the buyers and user’s exclusive remedy and in no event shall Elgi be liable for breach
of any warranty or negligence of any nature in an amount exceeding the price it received for the
item. Elgi neither assumes nor authorises any other person to assume for it, any other liability of
any nature in connection with the sale of said item.
a. All or any of the chemical and physical characteristics of the environment in which the
product was actually operated (which was required in order to properly select the
materials of construction) was not included with the original order.
b. The environment in which product was operated different from the details of that
environment which were included with the order or recommended by Elgi.
c. All or any part of the product design or materials was selected and / or specified by parties
other than Elgi or was not approved by Elgi.
d. In the judgement of Elgi the product was subject to misuse, neglect, accident,
unauthorised alteration or was installed in equipment which was mechanically deficient.
4
PRINCIPLE OF
O P E R A T I O N
The Compressed air drying circuit uses an air-to-air exchanger, which acts as a precooler/
reheater, and an air-to refrigerant heat exchanger. Both heat exchangers use the latest Tube
in Tube design that gives superior heat transfer. The tubing in both heat exchangers is copper
to increase heat transfer, better service life and reduce corrosion.
Warm, saturated air first enters the air-to-air heat exchanger where it is precooled. By
precooling the incoming air, energy is saved through reduction of the heat load imposed on
the refrigerant compressor and condenser. Saturated air then enters the air to refrigerant
heat exchanger further reducing the air temperature to specified dew point 3oC water is
condensed as the air is cooled to the specified dew point.
The cold air then flows through a moisture separator where the condensed water
is removed and discharged from the drier through the automatic drain.
The chilled air then- re-enters the air-to-air heat exchanger where it is reheated. Reheating
of air does not affect the dew point of air. The incoming air flows through the air-to-air heat
exchanger in a opposite direction.
Refrigerant Circuit :
The gaseous refrigerant from the evaporator is sucked by the refrigeration compressor
and pumped into the condenser. It is then cooled and liquified by the motor driven fan. The
liquid refrigerant feeds into evaporator after passing thro’ the drier/filter and Thermostatic
expansion valve.
Because of the thermal exchange with the compressed air which passes thro’ the evaporator
in an up stream direction, the refrigerant vaporises and returns to the compressor to restart
a new cycle.
5
S C H E M A T I C
D I A G R A M
6
PROCEDURE FOR
COMMISSIONING
THE DRIER
1. Proper ventilation is necessary where the drier is installed since machine is air cooled.
2. Recommend the customer to arrange bye pass line for the drier with isolation valves.
3. Ensure the pipe line connections (inlet & outlet) to the drier are given properly and level the unit
properly and place it on firm ground and ensure proper foundations.
5. Recommend the customer to connect the drier electrical line with MCB.
6. Check the loose connections in all the electrical parts like Temperature Controller, Start & Run
Capacitor and Relay by opening the doors of the drier.
8. Please check whether Relay is fixed exactly TOP Arrow Mark position up.
9. Check the power supply as mentioned in the drier i.e., 220 V or 415 V.
10. Check the gas pressure in the system in pressure gauge on the discharge side of the drier.
11. Check the current rating of the drier and compressor before running and confirm the rated amps
of the compressor.
12. Check the capacity of the drier and compressor. The capacity of the drier should be more for
equal. (PI. check selection of drier based on Inlet Tenp and Room Ambient Temp)
14. Please check leakage of the joints by using soap solution before start up.
15. If there is any leakage of gas found due to transit damage, ensure that the leak is identified,
rectified, system pressurised and vacumised and change right quantity of gas before running the
system.
16. If there is any major damage due to transit, take the help of local refrigeration mechanic to do the
above procedure before start up or contact our nearest service point to attend the damage.
17. Please ensure sufficient time is given for service engineer to attend.
18. If as a major break down compressor fails, then replacement of the same can be obtained at any
of the regional offices of Kirloskar Copeland, by using our purchase invoice copy as a warranty
claim document. The compressor may be fixed by taking the help of local refrigeration mechanic
or ELGI authorised service engineers.
7
INSTALLATION
Elgi air drier is a self contained unit with all accessories provided on the skid. A closed room
protected from rain, moisture and dust is preferable. The Compressor room will be an ideal
location.
The air to the drier should be sufficiently cool (25 Deg.C to 40 Deg.C) to get the best performance,
so an after cooler is necessary. check if your compressor has one in good working condition.
This type of installation is recommended when the use of air is very little intermittence and
the total consumption, at its maximum, is equal to the delivery of the compressor. In this
condition the load of the drier is constant.
This type of installation is recommended when the use of air is very variable and with
instantaneous consumption which can be much more or much less than the compressor
delivery.
Drier should be mounted vertical level and free from any transmitted vibration. The
surroundings temperature should not be abnormally high (above 40 Deg.C). Air
pressure must not be less then 60 psi (4 Kg/Sq.cm.) not more than 175 psi (12 Kg/cm2) for
ELRD Models and must not be less than 25 kg/cm2 not more than 42 kg/cm2 for ELHD Models.
8
T R O U B L E
S H O O T I N G
Compressor do not start N Power supply not correct N Check supply power
N Check the Voltage
Excessive pressure drop N Too low inlet pressure N Check pressure and
across unit flow rate
High discharge pressure N Air or non-condensible gas N Purge the foul gas
in the system from the condenser.
9
Problem Problem Cause Solution
Note : Before investigating the causes of the symptom or difficulty experienced make sure
that all pressure gauges and all cut outs are functioning satisfactory.
10
MAINTENANCE TIPS
Do not exceed driers rated design flow and inlet temperature to avoid poor dew point.
Keep the drier in clean and ventillated room. there should not be any dust and other
contaminants which may block the condenser unit.
Do not adjust/tamper any of the components in the drier. They are factory set and should be
adjusted only by the authorised service persons.
Do provide a good after cooler. This will bring down the inlet air temperature of
compressed air.
To claim warranty the above inspection and maintenance schedule must be strictly followed.
For any doubt or clarification consult factory.
11
RECOMMENDED SPARES FOR 5 YEARS TROUBLE FREE OPERATION
8. Ref. Compressor 1 No
NB : Please mention your drier model no and serial no. Without fail while ordering for spares.
All the above spares to be replaced only on failure of the same.
12
MAINTENANCE OF CONDENSATE DRAIN
During the first few days of operation some impurities (rust, dirt, etc.,) may reach the drain
valve and block the way. We therefore suggest disassembling the drain valve (Open the top
and bottom cover of valve) and clean it thoroughly, particularly the seating area and ‘O’ ring
seal. This operation must be carried out at least once or twice after starting up. After that the
drain valve need only be dismantled and cleaned once a six month.
For the unit to work efficiently it is absolutely essential that the design limits of the unit are
not exceeded. These are the some limits compressed air temperature and the ambient
temperature. (Refer name plate)
Many small problems can easily be avoided by following the instruction given in this guide. In
case of difficulties however it is advisable to consult a qualified service engineer in the following
address.
13
HIGH PRESSURE CONTROL (Fan Control)
The high pressure control is a pressure controlled electric switch makes and breaks
circuit to fan motor respectively to pressure values.
Setting
Fan Motor
Refrigerant used
On Off
Setup Procedure
Step 1 : Adjust the screw (A) for setting the High pressure value (fan motor will be ON when
the system reach this setting Pressure.)
Step 2 : Adjust the screw (B) for setting the pressure difference (fan motor will be OFF after
this pressure difference.)
Operating Procedure :
Setting
Suction Compressor
Refrigerant used
Pressure dew point
14
WIRING DIAGRAM
15
16
17
18
19
20
21
SPARES PART No. LIST FOR ELRD SERIES OF AIR DRIERS – AIRCOOLED
S.NO NAME OF THE PART ELRD010 ELRD020 ELRD030 ELRD040 ELRD050 ELRD064 ELRD080
COMPRESSOR
1 % % % % B000500010119 B000500010119 B680103
EMERSON/DANFOSS
2 HEAT EXCHANGER ASSY B100101 B100101 B100102 B100102 B100103 B100103 B100103
8 HOT GAS SOLENOID VALVE % % % % % % %
22
12 CAPILARY TUBE B010300010001 B010300010001 B010300010004 B010300010004 B010300010002 B010300010002 B010300010002
13 HAND SHUT OF VALVE B011000010001 B011000010001 B011000010001 B011000010001 B011000010001 B011000010001 B011000010001
15 EXPANSION VALVE NA NA NA NA NA NA NA
17 OVER LOAD PROTECTOR B000500010129 B000500010129 B000500010098 B000500010098 B000500010099 B000500010099 B000500010100
20 AUTO DRAIN COIL B009400010101 B009400010101 B009400010101 B009400010101 B009400010101 B009400010101 B009400010101
21 AUTO DRAIN TIMER B720101 B720101 B720101 B720101 B720101 B720101 B720101
COMPRESSOR
1 B680103 B680103 B680103 B000500010120 B000500010120 B000500010120 B000500010120
EMERSON/DANFOSS
2 HEAT EXCHANGER ASSY B100103 B100104 B100104 B100104 B100105 B100105 B100105
8 HOT GAS SOLENOID VALVE % % % % % % %
23
11 HIGH PRESSURE SWITCH NA NA NA NA NA NA NA
13 HAND SHUT OF VALVE B011000010001 B011000010001 B011000010001 B011000010001 B011000010001 B011000010001 B011000010001
15 EXPANSION VALVE NA NA NA NA NA NA NA
16 RUNNING CAPACITOR NA NA NA NA NA NA NA
20 AUTO DRAIN COIL B009400010101 B009400010100 B009400010100 B009400010100 B009400010100 B009400010100 B009400010100
21 AUTO DRAIN TIMER B720101 B720101 B720101 B720101 B720101 B720101 B720101
COMPRESSOR
1 B000500010120 B000500010121 B000500010121 B000500010121
EMERSON/DANFOSS
16 RUNNING CAPACITOR NA NA NA NA
18 STARTING CAPACITOR NA NA NA NA
19 STARTING RELAY NA NA NA NA
24
Procedure for Temperature Controller Setting:
1. Set Menu
b. Push the button (1) or the button (3) and find that parameter you want to change.
d. Push the button (1) or the button (2) and select the new value.
2. Set Temperature
b. Push the upper or the lower button to select the new value.
25
26
SPARE’S KIT NO’S FOR ELHD SERIES
Model ELHD010- ELHD010- ELHD050- ELHD085 ELHD105 ELHD126 ELHD191 ELHD227 ELHD267 ELHD345
Sr.No.
Name of the Part 20 040 064
27
5. High Pr.Switch
Part No. NIL NIL NIL B180101
6. Temp. Controller
sub zero
Part No. B710101 B710101 B710101
7. Auto drain timer
Part No. B720101 B720102
8. Hot gas valve
Part No. B750102 B750102 B750103
9. Auto Drain Valve
Part No. B131302 B131302 B131302
GENERAL SERVICE INSTRUCTIONS TO CUSTOMERS
1. Please make Service calls only to Elgi Spares & Service Division or Branches
and give adequate time to arrange service personnel for your call.
2. Please inform the serial No. and model No. of the Drier with Invoice details.
3. Please keep available the recommended spares with you prior to calling Service
personnel.
4. Please assist Elgi / Elgi Dealer service personnel for arranging local works & local
purchases.
6. In warranty claim materials have to be send to GME Spares & service Division on
Fright PAID basis.
1. Electrical Components.
2. Gas, Oil used in the systems except commissioning work.
28
SPECIFICATION SHEET – ELRD DRIER
Flow Max. Pressure Cooling Inlet / Outlet Weight in Rated Power Power Supply AC Volts /
Model L X B X H mm
(CFM) (Bar) Media Size Kgs in KW Hz / Phase
29
ELRD85 85 16 Air 1” NPT 500x600x730 95 0.70 220V / 50 Hz / 1 Phase
ELRD 100 100 16 Air 1” NPT 600x800x850 121 0.72 220V / 50 Hz / 1 Phase
ELRD 105 105 16 Air 1” NPT 600x800x850 121 0.72 220V / 50 Hz / 1 Phase
ELRD 126 126 16 Air 1" NPT 600x800x850 135 0.98 415V / 50 Hz / 3 Phase
ELRD 150 150 16 Air 1 ½” NPT 600x800x850 135 0.98 415V / 50 Hz / 3 Phase
ELRD 191 191 16 Air 1 ½” NPT 600x800x850 135 0.98 415V / 50 Hz / 3 Phase
ELRD 200 200 16 Air 1 ½” NPT 600x800x850 135 0.98 415V / 50 Hz / 3 Phase
ELRD 227 227 16 Air 1 ½” NPT 600x800x850 140 0.98 415V / 50 Hz / 3 Phase
ELRD 267 267 16 Air 1 ½” NPT 800x900x1150 200 1.60 415V / 50 Hz / 3 Phase
ELRD 300 300 16 Air 1 ½” NPT 800x900x1150 200 1.60 415V / 50 Hz / 3 Phase
ELRD 345 345 16 Air 1 ½” NPT 800x900x1150 200 1.60 415V / 50 Hz / 3 Phase
SPECIFICATION SHEET - ELHD DRIER
30
WARNING
1. Hazardous Voltage can cause severe injury or death. Disconnect main power before
servicing compressor/ Drier
2. This machine contains high pressure air can cause injury or death from flying parts.
Always release pressure from compressor and air receiver before removing caps, plugs,
fitting, covers etc.,
3. Flammable vapors, can cause a fire or an explosion and result in severe injury on death.
Sparks from the motor’s electrical contacts can ignite flammable vapours from ogosoline
Natural gas or solvents.
4. Compressed air can propel dirt, sand, Metal shaving etc., and result in severe injury.
Never point any air nozzle or air towards any parts of the body or towards another person.
Always wear safety glasses or goggles.
5. Moving parts, can cause severe injury. The electric motor air compressor models are
designed to cycle automatically when the power is on. Doing services or repair work, this
automatic cycling can cause severe injury.
31
INSPECTION AND SERVICE RECORD