Basic

Refrigeration
Theory F-FX-FD
Ban Do 7-2024
Who we are ?
▪ Ngoc Hua – Service Manager

✓ Phone: +84903904349

✓ Email: ngoc.hua@atlascopco.com

▪ Ban Do – Technical Support Specialist

✓ Phone: +84396877036

✓ Email: ban.do@atlascopco.com
AGENDA

⚫ Dryer knowledge

⚫ Basic refrigeration dryer

⚫ Parts introduction

⚫ Notices of commissioning

⚫ Prevent Maintenance
A
 5

DRYER KNOWLEDGE
WHY AIR DRYER REQUIRED Rapid and destructive pipe
corrosion, which causes:​
Atmospheric pressure Compressed to 8 bar • Increasing pressure drops​
• Increasing running costs
through air leakage​
• Increasing piping repair bill

Water and corrosion entering

expensive equipment, leading
to: ​
• Reduced tool and machine
reliability​
• Reduced tool and machine
lifetime​
8m³ air at 60% rel. Humidity and 25°C = Still we have 109,60g but in 1 m³. At 35°C
13,70g/m³*8 bar=109,60g moisture the m³ can hold @100% rel. Humidity • Reduced tool and machine
max. 39,29g moisture. performance
So 109,60g -39,29g= 70,31g Dirt and contaminants mixing
(Dew point 25°C=22,830g/m³*0,6 RH) condensation water created with the product to cause:​
• Increased scrap/failed rate​
• Contaminated raw materials​

6
F range refrigeration dryer gen3.0 product launch
ATLAS COPCO REFRIGERATION DRYER

Lowest Life Premium

Cycle Costs No loss drain
Controller
FD/FDVSD Range Energy saving
Iso Class 4
Energy savings
+3°C PDP
Value for money
FX Range
No loss drain
PDP display PDP display
Pot free contact Iso Class 4-5

+3°C to +5°C PDP

Economical solutions
Update from F Range New F range
Lowest Gen 2.0 to Gen Timer drain
Investment Costs 3.0
Entry platform SP in Jan
PDP indicator
2022
+7°C PDP Iso Class 5

7
F range refrigeration dryer gen3.0 product launch
ATLAS COPCO REFRIGERATION DRYER

8/14/2024
8 F range refrigeration dryer gen3.0 product launch
 10

BASIC REFRIGERATION THEORY

Influence of pressure

▪ Low pressure  low boiling temperature

▪ High pressure  high boiling temperature
WATER 85°C
185°
F
ABOVE SEA LEVEL
(low pressure)

100°C 110°
C
212°F
230°
SEA LEVEL BELOW SEA LEVELF
(high pressure)
 11

BASIC REFRIGERATION THEORY

Important Remark

▪ Atmospheric pressure (sea-level)

= 0 bar(e) /psi(e) pressure-gauge
= 1 bar(a) /14.5psi(a) absolute pressure

▪ 2 bar(a) /29psi(a) absolute pressure

= 1 bar(e) /14.5psi(e) pressure-gauge
REFRIGERATION BASICS
Refrigerant compressor

▪ The compressor performs two important functions:

– It moves refrigerant through the system allowing it to carry heat energy
– It creates high pressure on one side of the refrigeration system (discharge), and low pressure on the
other (suction)
 Refrigerant compressor and
REFRIGERATION BASICS liquid separator

Refrigerant compressor
 16

REFRIGERANT DRYER COMPONENTS

Refrigerant compressor

Piston Rotary Scroll

Pro’s Lowest cost Low cost Robust
No phase protection required Robust Can handle some liquid
Can handle some liquid High COP
Medium COP Low vibrations
REFRIGERATION BASICS
Liquid separator or accumulator
REFRIGERATION BASICS
Condenser

▪ The condenser is a heat exchanger

▪ The refrigerant gas condensate → heat to discharge (@ constant P and T)
▪ The condenser releases heat to the outside ambient.
REFRIGERATION BASICS
Condenser

Condenser and fan

REFRIGERATION BASICS
Condenser

▪ The condenser is a heat exchange device similar to the

evaporator. The condensation has three steps:

– Desuperheat = in the first passes of the condenser the heat is

extract from a hot superheated vapor coming from the compressor

– Condense = the middle of the condenser rejects latent heat from

the saturated vapor, which is in the process of phase changing to a
saturated liquid.

– Subcool = the last passes of the condenser reject heat from

subcooled liquid, this further subcools the liquid to below its
condensing temperature. (in order to increase the cooling power
and reduce the flash gas effect)
REFRIGERATION BASICS
Condenser
Superheated gas
decrease its temperature
at constant pressure REMEMBER:
1. Main purpose is to condensate the gas
2. Changes happens at ~constant pressure

The
compressor
pump hot
superheated
gas State change
Vapor →
liquid

Gas became
liquid subcooled
REFRIGERATION BASICS
Condensing control

▪ The fan-cycling device is one method to maintain a correct

condensing pressure.
▪ We use two different devices:

– Fan pressure switch → with cut-in and cut-off pressure

– PDP device → temperature probe on the condenser outlet

REFRIGERATION BASICS
Metering device

▪ These devices restrict the flow of liquid refrigerant and cause

a reduction of pressure, in which reduces the boiling point.
REFRIGERATION BASICS
Metering device

Capillary and filter

REFRIGERATION BASICS
Metering device

▪ This device restricts the flow of liquid refrigerant and

cause a reduction of pressure, in which reduces the
boiling point.

▪ There are two main types of metering devices we

use
– Capillary Tube
– Thermostatic Expansion Valve (TXV)

▪ Manly you will see Capillary Tube: this device

basically create the ∆p between the outlet of
condenser and the inlet of HE using the Venturi
effect
REFRIGERATION BASICS
Metering device

▪ The Venturi effect is the reduction in fluid pressure

that results when a fluid flows through a constricted
section of pipe.
▪ The Venturi effect is a jet effect; as in a funnel the
speed of the fluid increases as the cross sectional
area decreases, with the static pressure
correspondingly decreasing.
▪ According to the laws governing fluid dynamics, a
fluid's speed must increase as it passes through a
constriction to satisfy the principle of continuity,
while its pressure must decrease to satisfy the
principle of conservation of mechanical energy.
REFRIGERATION BASICS
Filter drier

▪ Absorbing moisture → preventing acids:

– The ability to remove water from a refrigeration system is
the most important function of a refrigerant filter.
– This is accomplished by the use of desiccants within the
filter-drier.
– The three most commonly used desiccants are
molecular sieve, activated alumina, and silica gel.
REFRIGERATION BASICS
Evaporator or Heat exchanger

▪ The evaporator is a heat exchanger

▪ Liquid refrigerant gas boiling (evaporate) → cooling effect (@
constant P and T)
▪ Heat transfer from the compressed air to cool surface.
REFRIGERATION BASICS
Evaporator or Heat exchanger

Evaporator
REFRIGERATION BASICS
Evaporator or Heat exchanger

▪ While the condenser releases heat to the outside air, the evaporator
absorbs heat from the inlet air and release it to refrigerant.
▪ The evaporator also relies on two key principles of heat transfer:
– Heat energy always moves from "hotter" to "colder"
– Heat energy transfers faster between objects having a larger T difference

▪ PC Brendola use two types of

HE:
– Aluminum block
– Brazed zinc plate
REFRIGERATION BASICS
Evaporator or Heat exchanger

▪ Heat exchanger: Air to Air

– Pre-cools the incoming wet compressed air prior to drying and re-heats the dried compressed air prior to
discharging it to the compressed air system. Why: Saving of energy. Pre cooled inlet air requires less
refrigeration energy / outlet air is warmed up to avoid condensation of the outlet pipes.

▪ Heat exchanger: Air to Refrigerant (Evaporator)

– The refrigerant boils (evaporates) and draws heat from the wet compressed air thus reducing the air
temperature. This reduction in compressed air temperature causes the moisture in the air to condense.

▪ Condensate trap
– Condensed moisture from the compressed air is collected from the air to air and the refrigerant to air
exchangers and drained either through an automatic or manual drain valve.
REFRIGERATION BASICS
Evaporator or Heat exchanger
▪ We always have some steps in all the
designs:
Air in
– Pre cool exchange area
Air out ▪ In this area the air coming from the outside is
cooled down by simply heat exchange with
5
Refrigeran outgoing (already cooled) air.
t out ▪ Remember cooler air contains less humidity
– Thermal exchange area
▪ Here there is the real heat transfer, air release
4
1 heat to refrigerant and temperature decrease
allowing water droplets to condensate in water
Refrigeran – Condensate discharge area
t in ▪ Here the water is mechanically removed from a
2
mesh filter made in aluminum and is collected to
discharge pipe and then to the drain
– Post heat exchange area
3
▪ Cooled air is warmed up when face the warm inlet
air
– Air outlet
REFRIGERATION BASICS
Evaporator or Heat exchanger

▪ Zinc plate heat exchanger

Refrigerant out
Not visible
Refrigerant out
Air out
Air in

Refrigerant in

Air out Refrigerant in

Not visible
Air in

Drain

Drain
REFRIGERATION BASICS
Drain

FILTER MUST BE CLEANED EVERY WEEK

End customer maintenance

Drain
REFRIGERATION BASICS
Drain

▪ There are two types of drain we use.

▪ Drain with a floater system it is a typical drain system with zero loss
of compressed air.
ED12 LD200

REGULAR MAINTENANCE IS ESSENTIAL (every 6/12 months)

REFRIGERATION BASICS
Drain
TEST button

▪ ED12 is a basic drain with a PCB MPM connector

▪ It works automatically with floater/reed system

▪ It can be tested with test button

▪ Floater issue → no automatic, test button OK

▪ Test button KO → PCB or solenoid failed

FILTER ▪ Drain stuck open → dirty membrane/piston or electrical

failure
Always check this point in case of failure
REFRIGERATION BASICS
Drain

▪ LD200 is an advanced drain with a logic controller

– It works automatically with floater/reed system
– It can be tested with test button
– It has auto cleaning routine

POWER led

ALARM led

TEST button
REFRIGERATION BASICS
Maintenance

▪ All technicians can do dryer service on:

▪ Drain
– ED12
▪ Install wear kit p/n 2200902017 every 12m or 2000h
▪ Replace ED12 drain every 24 months
– LD200
▪ Install wear kit p/n 2200902017 every 12m or 4000h

▪ Condenser
– Every compressor maintenance

WEAR KIT IS THE SAME

▪ Also end customer has to do regular maintenance following FOR ED12 & LD200
instruction manual
REFRIGERATION BASICS
Hot Gas Bypass Valve

▪ Our refrigerant dryer use a bypass valve

▪ This component recirculate part of the
gas in case of partial load

HGB
V
REFRIGERATION BASICS
Hot Gas Bypass Valve

▪ The refrigeration circuit in a dryer is sized

to cool the full inlet capacity to a certain
temperature typically 3°C.
▪ If for some reason there is only a partial
load on the dryer, the refrigerant circuit
over cools the air, which causes the water
to not only condense, but to freeze.
▪ The HGBP automatically regulate itself
based on a pressure input from the
refrigerant circuit
▪ As the pressure in the refrigerant circuit
decreases, the valve opens, allowing
some of the refrigerant to bypass the
metering device, which eliminates the
problem of overcooling.
REFRIGERATION BASICS
Hot Gas Bypass Valve

Hot gas bypass valve

REFRIGERATION BASICS
Hot Gas Bypass Valve

5 Main parts:
1) Bulb
2) Regulation screw
3) Inlet (from compressor discharge)
4) Outlet (to compressor suction)
5) Balancing pipe (take pressure at HE inlet)
 52

PRODUCT INTRODUCTION
F330-410A
• 220V Power supply

• Cooling fan controlled by

temperature sensor

• High pressure switch

• Overload protector

• R410 Gas

• High dewpoint warning

• Capillary tube + HGB valve

• Timer Drain
F330-410W
• 220V Power supply

• Water cooler

• High pressure switch

• Overload protector

• R410 Gas

• High dewpoint warning

• Capillary tube + HGB valve

• Timer Drain
F600-1250A
• 380V Power supply

• Fan pressure switch

• High pressure switch

• Overload protector/phase sequence relay

• R410 Gas

• High dewpoint warning

• Expansion valve+ HGB valve

• Timer Drain
F600-3300W
• 380V Power supply

• Water valve

• High/low pressure switch

• Overload protector/phase sequence relay

• R410 for F600-1250

• R407C for F1670-3300

• High dewpoint warning

• Expansion valve+ HGB valve

• Timer Drain
F4170-6600W
• 380V Power supply

• Water valve

• High/low pressure switch

• Overload protector/phase
sequence relay

• High dewpoint warning

• Expansion valve+ HGB valve

• Timer Drain

• PLC controller
F4170-6600
F4170-6600 WATER VALVE REGULATE

4mm
CONTROLLER & PDP GAUGE

▪ PDP indicator

➢ F330-410 display + fan control

➢ Above F410 showing dewpoint only

64
 CONTROLLER

控制器 故障诊断

65
 66

NOTICES OF COMMISSIONING
调试 COMMISSIONING
▪ 压缩空气和冷却水（水冷机型）进出口是否连接正确 Load connection direction
▪ 电源是否连接正确 (已加热10小时以上) Power supply
▪ 电控部分联线是否有松动 Control cable connection
▪ Cooling water flow (prefer AML) important
▪ 点动风扇看起转向与箭头标识是否一致 Fan rotation direction (3 phase)
▪ 检查机器内部连接处是否有油渍 Any oil stain(oil means leakage possibly)
▪ 检查环境温度、进气温度 Check ambient/load inlet temp
▪ 以上如无问题请启动机器 Start if ok
▪ 确认转向正确后观察压缩机是否有异响风扇是否转动 Any nosie, fan status
▪ 排水阀是否工作正常 Auto drain valve status
▪ 检查露点温度为2-5℃空载标况（螺杆机需要检查油位）No load PDP should be 2-5 ℃
运行及维护注意事项 NOTICE

▪ 建议先开干燥机，等待10分钟后再缓慢打开干燥机进、出气阀以求系统平稳运行
Start dryer for several minutes, then slowly open the ball valve of dry load inlet/outlet
▪ 每周检查排水阀工作状态；系统运行初期可能会由于管道脏的因素堵塞排水阀内置滤芯，请拆开
清洗； 排水阀是否动作可按TEST键，如排水不畅可更换排水阀过滤网圈KIT号码2205677963
Check drain valve every week;
inside filter may get block during first running period, open and clean;
Press “TEST” button to check drain function;
Service kit for drain valve inside filter.
▪ 每月检查并清洁干燥机冷凝器翅片，可采取压缩空气吹扫方式
Check and clean fins of condenser, blew by compressed air
 150

PREVENT MAINTENANCE
 PREVENT MAINTENANCE
- LD kit: 4000hrs/1 year
- Prefer technical data in IB
 COMMITTED TO
SUSTAINABLE PRODUCTIVITY.