FR Refrigerated Air dryer

Content
 Refrigerants & Ozone Depletion
 Refrigeration dryer system
 Maintenance
 Trouble shooting
 Refrigerants & Ozone Depletion
The Problem
The ozone layer protects the Earth from
ultraviolet radiation.
Chlorine found in compounds such as refrigerant
gasses, can if leaked into the atmosphere,
damage the protective layer.
To tackle this problem, most major nations of the
world signed the “Montreal Protocol” to phase
out production & use of ozone depleting
substances.
The European Union has adopted a more rapid
phase out program.(Regulation 3093/94)
 European Regulation 3093/94/EC
about the HCFC refrigerants (R22)
Production of cooling systems

1 Jan 2001
End of production for cooling systems with refrigerating capacity > 100 kW
1 Jul 2002
End of production for all the cooling systems
1 Jan 2004
End of production of reversible systems (heat pumps)
1 Jan 2010
Virgin R22 is forbidden for service purpose
1 Jan 2015
Recycled R22 is forbidden for any purpose
 European Regulation 3093/94/EC
about the HCFC refrigerants (R22)

Use of HCFC as refrigerant

HCFC Supply cuts start 2004. The volume of refrigerant manufactured will be
reduced as follows ：
2004 - 35% cut
2007 - 60% cut
2010 - 80% cut
2013 - 95% cut
2015 - Phased Out
 Refrigerant Types

CFC
Chlorine Fluorine Carbon
Examples - R11 & R12

CFC’s are chlor-fluorocarbons.

They are among the most ozone depleting refrigerants produced. On a
scale of 0 to 1, they have an ozone depleting potential (ODP) of 1.
 Refrigerant Types

HCFC
Hydrogen Chlorine Fluorine Carbon
Example - R22
HCFC’s are partially halogenated chloro-fluorocarbons.
They contain a smaller amount of chlorine and have a lower ozone depleting
effect (ODP = 0.05).
R22 is probably the most commonly used refrigerant world wide.
 Refrigerant Types

HFC
Hydrogen Fluorine Carbon
Examples - R407C, R134a, R404a & R410A

HFC’s are hydrofluorocarbons.

They contain no chlorine and are believed not to have any damaging effect at
all on the ozone layer.
They are considered to be the long term solution.
 HFC Refrigerants : R134a

 Designed as a substitute for R12

 Can also be used in R22 applications.

 Has lower refrigerating effect (30%) per unit

volume compared to R22 requiring a larger
compressor & refrigeration circuit to achieve
similar performance.

 Larger compressor & refrigeration circuit leads to

an increase in absorbed power of up to 10% and
increases in product cost, weight & dimensions.
 HFC Refrigerants : R134a

 Suitable for direct expansion & flooded refrigeration

systems.

 No temperature glide during evaporation.

 Compressors & components widely available world-

wide

 Charging procedure as per R22

 HFC Refrigerants : R407C

 A true R22 substitute, unlike R134a and R404A.

 Does not require a larger compressor & refrigeration
circuit like R134a.

 Unlike R12, R22 & R134a, R407C is not a single

compound. It is a blend of 3 HFC’s.
52% R134a / 23% R32 / 25% R125

 R407C does not have a single boiling point at a given

pressure. The constituents of R407C evaporate at
different rates.
 HFC Refrigerants : R407C

 The difference between the temperature at which the

mixture starts to evaporate and the temperature at
which it finally evaporates is called the “temperature
glide”.

 Refrigeration systems using R407C must be designed

specifically to optimise the effect of this temperature
glide.

 Offers many benefits with a correctly designed

system.
 HFC Refrigerants : R404A
g Drop-in substitute for R502.
g Designed for low temperature applications.
g Ideal for water-cooled solutions in the range
200-500 kW at low temperatures.
g Also gives a good performance in normal
temperature applications.
g High condensing pressure compared to R22 (ca.
+20%) complicates design.
 HFC Refrigerants : R410A
g
Future alternative to R22 for normal temperature
applications.
g Performance 30 - 40% higher than R22, offering
potentially significant savings on overall dryer
design.
g Useful for low temperature applications.
g Glide of less than 1°C (a 50-50 mix of R32 and
R125).
 HFC Refrigerants : R410A

g Higher condensing pressure compared to R22 (ca.

+30-40%) makes the refrigerant circuit design
complicated and expensive.
g Engineer charging bottles will have a high nominal
pressure (45 - 48 bar).
g Currently not available on an industrial scale
foreseen for 2003-4.
 REFRIGERANTS COMPARISON
Input Conditions
Evaporator Temperature 3 °C (mid temp for R407C)
Condenser Temperature 45 °C
Capillary Inlet Temperature 40 °C
Cooling Duty 15 kW
R22 R407C R134a R404A R410A
Condenser Temperature °C 45 45 45 45 45
Evaporator Temperature °C 3 3 3 3 3
Condenser Pressure barg 16,29 17,66 9,60 19,64 26,45
Evaporator Pressure barg 4,48 4,52 2,26 5,69 7,86
COP 5,44 5,11 5,48 4,90 5,07
Cooling Duty kW 15 15 15 15 15
Compressor Power kW 2,85 3,01 2,86 3,23 3,11
Mass Flow Rate kg/s 0,10 0,10 0,10 0,14 0,10
Volumetric Flow Rate into
m³/hr 15,37 15,62 24,30 15,52 10,66
Compressor
Discharge Temperature °C 69,4 64,5 55,8 56,5 69,5
Suction Line Temperature °C 10 10 10 10 10
Temp Glide in Evaporator K 0 4,61 0 0,4 0
Temp Glide in Condenser K 0 4,94 0 0,31 0
 Refrigerants & the Environment
Volumetric
Ozone Depletion Global Warming Refrigeration
Potential (ODP) Potential (GWP) Capacity (kJ/dm3)

1 3.5 5

0.9 4.5
3
0.8 4
0.7 2.5 3.5
0.6 3
2
0.5 2.5
0.4 1.5
2
0.3 1 1.5
0.2
1
0.5
0.1
0.5
0 0
R407C

R404A

R410A
R134a
R407C

R404A

R410A
R134a

R407C

R404A

R410A
R134a
R12

R22
R12

R22

R12

R22
Compressed Air Treatment
 More about R407C
 Performance and COP almost identical to
R22. Gas phase “is not R407C”
 Refrigerant, compressors and components
widely available.
 Glide can risk freezing unless counter-
measures taken.
 Cannot be used in flooded evaporators.
 Charging must be by weighing-in and with
reference to pressure-temperature
 Charge must be with liquid refrigerant
 Refrigerant leaks difficult to find in the field.
 No oil acid test exists (other than smell).
 Oil is highly hygroscope and easy to Always charge
in liquid phase: R407C:
contaminate. 52% R134a+ 23% R32 + 25% R125
 More about R407C
 CONCERN #1
Our distributors are currently working with R22 and R134a.
They have a single reclaiming unit on each service truck
that they use for all of these refrigerants. Can they use the
same equipment also for R407C?

We suggest to use different reclaiming units for different refrigerants.

R134a, R407C, R404A are all HFC (chlorine free refrigerant) and ester
oil is only suitable for them.
R12 or R22 are CFC / HCFC so instruments and service equipment
must be separate from the “green refrigerants”.
 More about R407C
 CONCERN # 2
Our distributors are expressing concern over the disposal of
R407C refrigerant as it is a geotropic blend of three gases.
Is this concern valid?

R407C is a geotropic blend of R134a (52%), R125 (25%), R32 (23%).

We suggest in case of leakage on a small dryer to replace completely
the refrigerant charge.
Drop in could affect the percentage of some components.
 FR Refrigeration Dryers
Benefits
Montreal Protocol Compliant.

Use of R134a & R407C

environmentally friendly HFC
refrigerants ensures compliance with
the Montreal Protocol.

With no proposed ‘phase out’ of

these refrigerants, the dryer will not
have to be replaced prematurely.
 Common pressure and temperature
in the refrigeration circuit (R22)
14 - 18 bar
35 - 50°C

Condenser

Expansion by-pass
device device 14 - 18 bar
65 - 90 °C
4,2 bar
1-2°C

Compressor

Evaporator
4,2 bar
3 - 8 °C
 Common pressure and temperature
in the refrigeration circuit (R134a)
9 - 11 bar
35 - 45°C

Condenser

Expansion by-pass
device device 9-11 bar
50 - 70 °C
2.1 bar
1-2°C

Compressor

Evaporator
2.1 bar
3 - 8 °C
FR Refrigeration dryer
Air cooling
FR Refrigeration dryer
Water cooling
 Refrigeration Dryers
Energy Saving Feature

Air / Air Heat Exchangers

Models FR030 to FR1000 use a high
performance air to air Heat Exchanger.

The air to air heat exchanger is a pre-cooler /

re-heater. It pre-cools the hot, saturated,
incoming air by transferring heat to cold air is
returning from the stainless steel water
separator . This part of the process also has
the effect of re-heating the cold air before
distribution to the compressed air system,
reducing the likelihood of external pipeline.
 Refrigeration Dryers
Energy Saving Feature

Evaporator
The air to refrigerant heat exchanger takes
the pre-cooled air from the air to air
exchanger and cools it down to the required
dewpoint by transferring heat into the
evaporating refrigerant. After being cooled,
the air enters directly into the high efficiency
stainless steel water separator to remove the
condensed water.
 Refrigeration Dryers
Energy Saving Feature

Compressors
Dryer models (FR005 to FR600) are
fitted with piston compressors

Dryer models (FR750 to FR1000) are fitted with energy

efficient Scroll compressors. Scroll compressors consume
20% less energy than an equivalent output piston
compressor, increasing energy efficiency even further.
 Refrigeration Dryers
Energy Saving Feature

Piston Compressor Scroll Compressor

Electrical consumption with piston compressor 3.60 kW

Electrical consumption with scroll compressor 2.63 kW

The scroll compressor in this example uses 27% less energy

Reference conditions: condensation 50°C; evaporation 0°C; suction gas 25 °C; sub-cooling. 0°C; ref. R22
 Refrigeration Dryers
Energy Saving Feature
Condenser
It changes the gas refrigerant into liquid
phase, rejecting all the heat coming from
the evaporator and from the compression.

Water cooling type, the condenser is a

shell & tube. The cooling water flow is
regulated by a pressostatic valve which
allows to keep the condensation pressure
at a constant value despite of the change
of thermal load.
 Refrigeration Dryers
Energy Saving Feature

Inside the air outlet there is a Secondary condenser

Air / Freon heat exchanger
which works as an economiser,
subcooling the liquid refrigerant.
The economiser increases the
refrigerating capacity of the
system.
 Refrigeration Dryers
Energy Saving Feature

hot gas valve

When the thermal load is lower than
100% of the nominal value, the “hot
gas valve” injects superheated vapour
in the evaporator to maintain a boiling
temperature never lower than 0°C. In
this way we avoid the formation of ice
inside the tubes where the air is
flowing and the condensation of is
happening.
 Refrigeration Dryers
Energy Saving Feature
It keeps the level of liquid refrigerant inside the evaporator constant,
he floating device SV controls the lamination valve
 Refrigeration Dryers
safety devices

Anti-freezing pressure switch

It stops the compressor when the low pressure
switch does not trip and the system reaches a
temperature under -7°C.

High pressure switch

HP It suddenly stops the compressor when the
ALP discharge pressure is over a set limit. To reset
the it the pressure must go down to a certain
value. The reset is manual; beware to eliminate
the cause before resetting it.
 Maintenance

Desiccant filter

Remove the water and acid in the

refrigerant.

Refrigerant filter

Remove the solid particle in the

refrigeration system.
 Trouble shooting
Low refrigerant pressure (LP alarm)
Low charge in the system Oil found outside, Stop the dryer, intercept the
clear leak somewhere leaking point, call the service
in the refrigerating
circuit
Discalibrated hot by The pipe on the low Bypass the compressed air.
pass valve pressure side of the Adjust the valve with a
valve remains cold precision manometer

The injection of liquid The liquid pipe is quite Bypass the compressed air
refrigerant into the cold. No liquid flow can and call the service
evaporator is not working seen through the sight
glass on the line.
 Trouble shooting
High refrigerant pressure (HP alarm)

Poor water flow Condenser really By pass compressed air.

to the condenser hot: condensation Increase the water flow
pressure available at the condenser.
very high Close the bypass.
Water pressostatic Condenser really hot: Set the valve
valve miscalibrated condensation correctly
pressure very high

Fouled condenser Water delta T on By pass the air flow.

the condenser is of Clean the condenser.
few degrees
FR Refrigeration dryer selection
Type FR75WP FR100WP FR150WP FR200WP FR250WP FR300WP FR400WP FR500WP FR600WP FR750WP FR1000WP

50Hz/60Hz
10.7 14.4 21.4 28.5 34.2 42.7 59.5 70.8 79.3 106.2 141.4
Max.capacity(m3/min)
50℃ （ Max 80℃)(Capacity varies with different pressure)
Air inlet temperature

32℃ （ Max 40℃)(Capacity varies with different pressure)

Ambient temperature
Dewpoint 2 ～ 10℃ at 7 kg/cm2
Dewpoint

7 kg/cm2G(Capacity varies with different pressure), Max. pressure:10 kg/cm2G (Higher pressure available upon request)
Operating pressure
R-407C
Refrigerant
50Hz 2.1 2.8 2.8 4.1 5.3 6.1 7.8 8.9 10.3 13.5 16.3

Power 60Hz 2.5 3.4 3.4 4.9 6.4 7.3 9.4 10.7 12.4 16.2 19.6
Consumption
Single phase 220V 50/60Hz 3-phase 220V/380V/440V 50/60Hz
Power supply
DN80 DN80 DN80 DN100 DN100 DN125 DN125 DN150 DN150 DN200 DN200
Air piping size
L 1130 1130 1130 1290 1290 1580 1580 1700 1700 1870 1870
Dimensions
(mm) W 740 740 940 1070 1070 1200 1200 1250 1250 1400 1400
H 1500 1500 1700 1900 1900 2000 2200 2200 2500 2500 3000

Net weight (Kg) 260 300 350 500 550 800 900 1000 1100 1400 1600
 Dryer selection
Correct
Correct factor
factor
Temperature(℃) A/W 30 35 38 40 42 45

Pressure(MPa)
AP/WP 45 50 55 60 70 80

0.4 1.06 0.87 0.77 0.71 0.67 0.61

0.5 1.12 0.92 0.82 0.75 0.71 0.64

0.6 1.17 0.96 0.85 0.79 0.74 0.67

0.7 1.22 1 0.89 0.82 0.77 0.7

0.8 1.24 1.02 0.9 0.84 0.79 0.71

0.95 1.29 1.06 0.94 0.87 0.82 0.74

For example ： inlet temperature 40℃ ， operation pressure 0.6MPa
the dryer correct factor is 0.79.
 Dryer selection
Air cooling
Parameters Needed:
Maximum compressed air flow rate
Minimum compressed air pressure
Maximum compressed air temperature
Dewpoint requirement
Ambient temperature
Selection Example
Maximum Inlet Flow Rate : 6.5m3/min
Minimum Inlet Pressure : 6kg/cm2
Maximum Temperature : 40oC
Dewpoint requirement : 2~10oC
Ambient temperature : 35oC
 Dryer selection
Ambient
Ambient temperature
temperature correct
correct factor
factor
Ambient temperature(℃) A/AP 30 32 35 40

Correct factor 1.03 1 0.96 0.9

Cooling
Cooling water
water temperature
temperature correct
correct factor
factor
Cooling water temperature(℃) W/WP 30 32 34

Correct factor 1 0.97 0.94

 Dryer selection
Air cooling

Inlet flow requirement Minimum drying

= capacity requirements
CFT & CFP x CFAT

6.5m3/min
= 8.57m3/min
0.79 X 0.96
Dryer Size ？ FR075A
 Dryer selection
Water cooling
Parameters Needed:
Maximum compressed air flow rate
Minimum compressed air pressure
Maximum compressed air temperature
Dewpoint requirement
Cooling water temperature
Selection Example
Maximum Inlet Flow Rate : 10m3/min
Minimum Inlet Pressure : 6kg/cm2
Maximum Temperature : 40oC
Dewpoint requirement : 2~10oC
Cooling water temperature : 34oC
 Dryer selection
Ambient
Ambient temperature
temperature correct
correct factor
factor
Ambient temperature(℃) A/AP 30 32 35 40

Correct factor 1.03 1 0.96 0.9

Cooling
Cooling water
water temperature
temperature correct
correct factor
factor
Cooling water temperature(℃) W/WP 30 32 34

Correct factor 1 0.97 0.94

 Dryer selection
Water cooling

Inlet flow requirement Minimum drying

= capacity requirements
CFT & CFP x CFAT

10m3/min
= 13.46m3/min
0.79 X 0.94
Dryer Size ？ FR100W