SAMKUN

AIR DRYER
MODEL : MAX-OG
(H,No : GSN-241)

FI NAL
2000 .10, 20
SAM.KUN CENfURY CO., LTD
reCUUCat OnStCt te.ttr,i

SHIP YARD : 21St CENTURY SHIPPING GO.,LTD.

DATE :2OO8. 10,20

SAMKUN CENTURY CO.,LTD

128_56, MAE_RI, SANGDONG_MYOEN, GIIVHAE, GYEONGNAM, SOUTH KOREA

TELI +82.55.338.3030 FAX)+82.55.332.7123

MM-46

rMo-9416795
Gontrol Air Dryer I

CUSTO[/ER
SPECIFICATIONS
21st CENTURY SHIPPING C0.,LTD.
l I

HULL No. CSN-241

QUANTITY r sEr/sHrP
MODEL [/AX-06 ,

IYPE REFRIGERATED AIR COOLED TYPE

3APACITY 60 Nm3/hr
CONDITION

- AIR INLET TEI,,IP. 50 'c

- AIR OUTLET TEMP. 18 'C
_ AIIB ENT TE[/P. 45 'C
- PRESS. DEW POINT 5 'C ot 7 kg/cm'
iEFRIGERANT R-404A
ArR PRESSURE / CONNECTTONS
...:iKING PRESSURE 7 kgfcn'z
....T CONNECTION JIS l OK_25A
:---:T CONNECTION JIS 1OK-25A
ELECTRIC DATA
r -.,._: SOURCE AC 220V x 1Ph x 60Hz
: : ,,._T !ONSU[/PTION 1.0 kw 1 MACHINERY
PAINTING COLOR
r..:_ TAINTING COLOR MUNSELL NO, 2,5 G 7 /2

DIMENSIONS / WEIGHT
450 mm
800 mm
870 mm
70 KG
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SPARE PARTS LIST / 1 MACHINERY
(for AIR DRYER, MAX-61
Hull No. r CSN.241

No DESCRIPTION SKETCH QUANTITY REMARK

- =..r Sf fF=-] 2 PCS

2 II =ro*. .ARTRTD.E
ron EVAPoRAToR 1 PCS FOR SAF4OOO

S'ARE CARTRIDGE
3 PCS FOR SAF6OOO

.OR AIR OUTLET FOR YARD

1 PCS WORKING

PILOT LAN/P G 3 PCS

SPARE PART BOX

with KEY
1 PCS

$. .]
'AMKUN
28_56, MAE_R],
.ENTuRY co.,LTD
SANGDONG_[/YOEN, G]N/IAE, GYEONGNAN/, SOUTH KOREA

TEL) +82.5s.338.3O3O FAX)+82-55'332,7123

 t
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INSTALLATION & OPERATING

MANUAL

Refrigerated

Compressed Air Dryer

 A. INTRODUCTION I
I
All ambient air entering compressors contain water vapor, tI
It is heated during compression then cools,
In the course ofthis altemating process, water vapor is precipitated
in the form of condensate and released
into the pipe work system.
)
t
There are up to 190 million contaminant particles in the ambient
air taken in by the compressor. with
I
a
compression for example to 9'3 bar, the concentration ofthese f
contaminants increases to up to 1.52 billion
particles.
The moisture becomes aggressive when combin,id with
oil, water and heat.

So aggressive that it corrodes your pipe system, damages

varves and other control devices, ruins youl toors,
hings machines to a standstill and pushes up the cost ofmaintenance
and spare parts.

Amtler outcome ofcontaminated compressed air is the cost ofcleaning

equipment which is covered with oil
rddht.

Dry compressed air is tlte most economical and safest forms

of energr in your works.

rtb manual contains information and recommendations for installing,

operating and servicing MAX Series
R.figerated Air Dryers. The systems are designed and manufactured
to the highest standard ofquality.
Tb self-contained units have been tested and inspected before
shipment from the factory. The manufacturer
rscrves the right to make changes without notice and without
incuning obligation. The customer should
rd rhis manual carefully before locating and installing the
equipment.
B. RECEIVING AND INSPECTION

Remove all packaging.

Examine the unit for extemal and intemal shipping damage. Report damages to transportation agency at
once. This is the responsibility ofconsignee,

Standard reftigerated dryers are charged with refrigerant, tested and operated before leaving the factory.
I
Units are ready to run after connecting to the proper services.

i
 C. LOCATION AND PIPING

1. A refrigerated compressed air dryer is normally installed downstream ofthe receiver tank. A I
I
compressed air line should be connected from the receiver tank outlet to the air dryer inlet,

The outlet ofthe dryer is then piped inro the distribution line, A bypass line should always be installed

to permit operation ofthe compressed air system during dryer maintenance and servicing.

See installation schematic in Figure l.

Air in/out and bypass piping should be equal or larger than the in/out sizes provided on dryers.

necommrnoeD il{gTALLAnON
a O4erstlon

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a. Ba !fto to op.rih lha b. Ur *Frat. harildr ., Chldalltodrlh d, tfuelot<ackr rway
Alr dryct nhut.r10 r*lt h Lr ai tdlrllr.rrrllurht ftori hhf & dJrl.t;
,d lo cllnprEr {lrs.Ior: ltnlt,
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':* lrr.llq8 ll bou{rtru!
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rEur8 I. A RSUABLE COIIPEhES$ED AtR. E-Yg'IEil NSTAILAi|ON

D. START UP PROCEDURE
l. hior to installation and start up refrigerated air dryer, all compressed air piping shall be purged clean,
removing all pipe scale, rust and free moisture. In a newly installed piping system you may want to
change the pre-filter element(s) within a few days ofinstallation to remove weld sludge, rust, etc,

2. A qualified electrician should check nameplate voltage and amperage. Install the conect power leads

to the equipment. Power shall be supplied through a fused disconnect which is to be provided by the
customer.

3. After all power and fluid connecfions are completed, the dryer is ready for operation. Generally dryers

are shipped with a charge ofrefripierant with all refrigeration service ports closed.

4. Start the dryer and observe the refrigerant suction pressure gauge. The refrigerant suction pressure

normal range in 4-5.9 BARG for R-404 units

On units equipped with performance monitors the normal suction temperature range is 0 b - 10 t .

The name plate indicates the type of refrigerant in each system. After the dryer has ran for about ten
(I0) minutes open the compressed air inlet and outlet valves and close the bypass line valve. Allow
unit to run one (1) hour with air flow, adjustment ofhot gas bypass valve or refrigerant pressure may
be necessary at this time to obtain the desired refrigerant suction temperature regulator pressure.

5. Ifthe dryer is equipped with a timer operated drain to remove water from the moisture separator, the

drain "ON"(open) time is adjustable from I to 15 seconds. The "OFF"(closed) time is adjustable
from I to 100 minutes. The ''ON"(open) time shall be adjusted to exhaust water for approximately
805 ofthe "ON"(open) time and air for the remainder ofthe time, The "OFF"(closed) time shall be

adjusted to prevent condensate carry over or over accumulation ofcondensate.

Caution: if the dryer is started immediately without following the above instructions, the dryer may get

damaged.
 E. SRVICE CHECKS
Water in air lines? Check for the following :

Problem I
Close bypass valve open dryer in/out
i. System Bypass Open
valves.
Check the rated output capacity ofair
2. Excessive Air Flow
compressor, may need a larger system.
(Consult factory) You may need a larger
3. High inlet Air Temperature ,
system or an after cooler.
I
Disconnect dryer in & out and back flush
4. Dirty Heat Exchanger with steam cleaner and copper compatible
solvent.
5. Drain Malfunction Clean or replace.
Adjust "off'(close time) to smaller interval
6. Not Drainig All Moisture to drain more frequently and,/or adjust on
(open time) to larger interval.
a. Overloaded Unit Reduce load or install larger system.
Clean condenser, install filter for
b. Dirty Atmosphere condenser, relocate unit or convert to water
cooled condenser.
7. Refrigerant Compressor
Provide suitable ventilation or relocate unit,
Cycling On High Pressure c. High Ambient
consult factory for unit suitable for high
or Overload Temperature
ambient.
d. Condenser Fan Motor
Repai or replace
Failure
e. Bad Compressor Replace

a. Low On Refrigerant
Inspect for leaks, repair, evacuate and
8. RefrigerantCompressor recharge unit.
Cycling On Low Pressure b. Low Pressure Control
Replace
Replace Malfunction
 F. REFRIGERATION COMPRESSOR TROUBLE SHOOTING GUIDE

l. Compressor will not start - no hum

In this case, there is no electrical power is reaching the hermetic motor. This can be caused by an open

line discoffIect switch, motor protector or temperature control as well as faulty wiring, Repairs should
be made to the electrical system or the cause of the overload trip identified.

2. Compressor will not start - hums - overload cycles.

Here electrical power is reaching the hermetic motor but the rotor does not move. This can be caused by

an elechical problem such as impioper wiring, an under voltage condition, defective start components or

damaged motor windings, a mechanical problem or liquid refrigerant in the compressor.

When replacing defective components, it is essential that the cause of failure be identified so that the
problem does not occur repeatedly.

3. Compressor stads - stays on starting winding

When a compressor starts but cannot reach normal running speed, it either means that the starting ability
ofthe motor has been impaired or the load is higher than anticipated. Motor starting ability is adversely
affected by miswiring, low voltage conditions, relay or run capacitor failure and winding damage. The

load will be a problem when the discharge pressure is too high or there is mechanical failure ofthe
compressor,

4. Compressor starts, runs - cycles on overload

This situation is similar to the previous problem although in this case, the motor has enough torque or
the load is low enough to maintain normal running speed for a short time. It is possible, though, that the
problem may exist elsewhere. The motor protector may be sensing currents and temperatures higher
than anticipated or the device itself may be defective.

Fan motors and system controls will cause the overload to tip prematurely if wired into the application
inconectly. Higher than normal return gas temperatures will cause the same problem.

5. Unit runs - cycles on thermostat, high/low pressure cut-out

Here, instead ofcycling on the motor protector, there are problems with other controls. The thermostat
will short cycle if the or/off temperatures are set too close together. The high pressure curout will
present a problem ifthere is insufiicient air over the condenser, an overcharge condition or

noncondensibles in the system. A system leak, an undercharge condition or condition or restricted

expansion device will cause the low pressure cut-out to short cycle.
 6. Unit operates continuously or for prolonged periods
This will occur ifcooling produced by the system is inadequate
ofthe temperature control is defective.
Improper cooing can be athibuted to a shortage ofrefrigerant,
overloading, poor system design,
I
restricted refrigerant flow or problems with the
evaporator or condenser.

Start capacitor open or shorted I

I
start capacitors are designed for intermittent duty. ,t
continuous operation will cause the capacitor to
fail. I
This sill occur if the relay contaets never open, if
there is continuous cycring on the start sinding
or the f
wrong capacitor is used.
An under voltage situation, use ofthe wrong relay or
a high starting load will prevent the hermetic
motor from reaching normar orating speed thus causing
cycling between the main and start windings.

3. Run capacitor open or shorted

Run capacitors are designed for continuous duty
at a maximum voltage m condition. Ifthe voltage rating
ofthe capacitor is too small or the line voltage is too
high, the capacitor will fall.

9. Defective relay
There are several important parameters that
are considered when choosing a potential
relay. contact
pick-up calibration, coil vortage rating and
mormting oonfiguration a, have an effect on
the proper
operation ofthe device' Ifan under or over voltage
condition exists the relay may not operate property
or may fail ifthe coil voltage rating is exceeded,
Excessive short cycling will cause the relay to exceed its life prematurely.
In addition, a run capacitor with an excessive microfarad rating may cause
the relay coil to fa,,

Space temperature too high

Too high a temperature in the area to be cooled

can be attributed to an improper control
setting, a system
problem or inadequate air circulation.

system considerations mentioned in this section

are the sizes ofthe expansion device and
evaporator
coil.

Suction line tosted or sweating

This probrem can be related to low suction line
temperatures. An over-sized or defective
expansion
valve, inadequate evaporation or system overcharge
can cause this situation to occur. Liquid
is probabry
flooding through the compressor as well.