Installation and maintenance

Refrigerant Dryer
F11LS
GB

Id.Nr. 100011527 / 00 Oktober 2006 (Press 10 07 08)

TABLE OF CONTENTS
I. Safety regulations

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1.1. Interpretation of the instructions

1.2. Positioning
1.3. Operation
1.4. Maintenance by an engineer
1.5. Maintenance by the user

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II. Introduction

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2.1. Manufacturer information

2.2. Purpose of the dryer
2.3. Dryer label
2.4. Working details
2.4.1. refrigerant circuit
2.4.2. compressed air circuit
2.4.3. refrigerant compressor
2.4.4. condenser
2.4.5. refrigerant circuit protection
2.4.6. refrigerant circuit controls
2.4.7. condensate drain trap assembly
2.4.8. modular design
2.4.9. accessories

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III. Operation

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3.1. Control panel

3.2. Start up and shut-down
3.3. During operation

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IV. Technical specifications

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V. Diagrams

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5.1. Flow diagram

5.2. Electrical diagram
5.3. General arrangements

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VI. Troubleshooting

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VII. Spare parts

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I. SAFETY REGULATIONS
1.1. Interpretation of the instruction
In addition to the usual safety instructions the following safety directives and measures are
of the most importance:
1. When operating the air dryer the operator must apply safe working methods and
observe all local safety instructions and relevant regulations.
2. Prior installation, the dryer and the compressed air system are to be depressurised and
disconnected from the electrical main supply.
3. The user is responsible for the safe operating conditions. Parts and accessories must
be replaced if inspection shows that safe operation cannot be assured.
4. Installation, operation, maintenance and repair are only to be performed by authorized,
trained and skilled engineers.
5. If any statement in this manual does not comply with the local legislation, the strongest
standard is to be applied.

1.2. Positioning
The AirStation must be installed horizontally. A minimum of 50 cm clearance around the
AirStation is necessary to allow a good ventilation and easy access for servicing.
The ambient temperature in the room should not exceed 45C and should not be below of
3C, taking care to the heat eliminated by the dryer (40 watt for each l/sec under ISO
7183-A condition or 18 watt for each scfm under ISO 7183-B condition).

1.3. Operation
Before operating the dryer, the following points are to be considered :
1. The piping must have the correct diameter and be adapted to the operating pressure
(see technical specification).
2. Never operate the dryer at pressure above the maximum specified on the dryer label
(check the technical specs too).
3, Safety devices, protecting covers or insulation in the dryer are never to be dismantled or
modified. Each pressure vessel or accessory installed outside the dryer with air above
atmospheric pressure must be fitted with the required pressure relief safety valves.

1.4. Maintenance by an engineer

1. Use only the appropriate tools for maintenance and repair.
2. Maintenance and repair are only to be performed when the air dryer is shut down and
depressurised and when the main power switch is turned off.
3. Before dismantling a part under pressure, disconnect the pressure sources and
depressurise the system.
4. Proceed carefully during maintenance and repair. Prevent dirt from entering by covering
parts and orifices with a clean cloth, paper or tape. A receiver is never to be welded or
modified in any way.
5. Never leave tools, loose parts or cleaning rags in or on the air dryer.
6. Before putting back the dryer into service, check the setting of the control and safety
devices as well as the pressure and the temperature of the compressed air circuit.

1.5. Maintenance by the user

1. Keep the dryer clean.
2. Regularly check the correct operation of the condensate drain trap.
3. Clean the air condenser as soon as its dirty or clogged. Check it every 6 months at
minimum.
4. Check the trouble-shooting list in case of maintenance troubles.
5. Check operating pressures, temperatures and time settings after maintenance. If
operating and safety devices function properly, the air dryer may be used.

II. INTRODUCTION
2.1. Manufacturer information
CompAir Drucklufttechnik GmbH
Argenthaler Strasse 11
55469 Simmern / Germany
Phone: + 49 6761 832 0
Fax: + 49 6761 832 409
www.Compair.com

2.2. Purpose of this dryer

This refrigerant compressed air dryer has been designed to remove water vapours from
industrial compressed air without any chemical agents. This dryer has been designed to
be operated indoor.
The minimum and maximum values stated must be observed, as well as the safety
precautions described in this chapter.

2.3. Dryer label

The following label is affixed on the cabinet of the refrigerant compressed air dryer.

CompAirDrucklufttechnik GmbH
Argenthaler Strasse 11
55469 Simmern

For technical specifications, see chapter IV.

2.4. Working details

2.4.1. Refrigerant circuit
The refrigerant circuit can be divided in 3 parts :
* Low pressure section with :
- an evaporator (heat exchanger)
* High pressure section including :
- a condenser
- a liquid receiver
- a filter dryer
* Motor & control devices between high and low pressure including :
- a refrigerant compressor
- an expansion valve
- a fan pressure switch
It operates as follows :
- The compressor compresses gaseous refrigerant to a high temperature
- The hot refrigerant condenses in the condenser. Being liquefied, it is stored in the
liquid .
- The liquid is taken out of the storage vessel and injected into evaporator (heat
exchanger) by an automatic expansion valve. This expansion valve is protected by
a filter which holds the particles and humidity that could be in the circuit.
- The injected liquid fills in the refrigerant section of the air to refrigerant heat
exchanger and evaporates by taking out the calories from the compressed air. The
gaseous refrigerant is sucked in the compressor and the cycle carries on.
2.4.2.Compressed air circuit
The saturated hot compressed air flows into the economizer where it is pre-cooled by the
out flowing dry chilled air. In the cold zone of the air refrigerant section, it continues to cool
down to dew point and enters the separator where condensates are collected. The
outgoing chilled air is then warmed up in economizer by the hot incoming air.
The condensates are collected after centrifugal separation and drained out through the
automatic trap.
As long as the compressed air temperature does not drop below dew point, there will be
no condensation in the air circuit anymore.
2.4.3. Refrigerant compressor
Being of the hermetic type, it requires no servicing.
2.4.4. Condenser
The air condensers are equipped with a helicoidal fan controlled by a pressure switch
maintaining the right refrigerant high pressure at the condenser refrigerant level.

2.4.5. Refrigerant circuit protection

A. Klixon
This single phase compressor is equipped with a klixon which is a thermal sensitive
switch controlling the temperature of the compressor and a possible over current. In case
of malfunction, the klixon trips and switches on again automatically as soon as the
compressor has cooled down.
B. Filter drier
A refrigerant circuit is a closed circuit and total water removal in the refrigerant circuit is
paramount in order to obtain a correct functioning.
To avoid problems, the refrigerant circuit must be vacuumed before loading the refrigerant.
It is equipped with a filter drier, which also traps any solid particles which may have
migrated in the circuit during assembly.
2.4.6. Refrigerant circuit controls
A. Liquid refrigerant injection
The liquid refrigerant is injected into the evaporator by a pressostatic valve maintaining a
constant pressure of the refrigerant into the evaporator .
2.4.7. Condensate drain - trap assembly
Dismantling the drain for cleaning is easy. The drain has to be depressurised before being
dismantled.
2.4.8. Modular design
The dryers are equipped with a compact monobloc module. This assembly has been
specially designed to dry compressed air and is made of :
- an economizer which pre-cools the entering hot air with the out flowing cold air
- an air-refrigerant exchanger cooling down the compressed air
- a centrifugal separator concentrating all condensates and requiring no maintenance.
2.4.9. Accessories
Dew point indicator
Located on the control panel, it displays the value of the pressure dew point.

III OPERATION
3. Control panel

The control panel of the dryer includes the following elements :

1 : Power - on rocker switch
2 : Dew point indicator

3.2 Start up and shut-down

Warning : Avoid leaving the dryer stopped when compressed air flows through.
The start up is done by pushing On the rocker switch. The green led included into the
switch will light on and the temperature shown on the dew point indicator will decrease.
The shut down of the dryer is obtained by pushing Out the rocker switch.

3.3. During operation

Regularly check the position of the dew point indicator. The reference line has to be in the
green zone. If not, read the appropriate action in the trouble-shooting section VI.

IV. TECHNICAL SPECIFICATION OF THE DRYER

F11LS
Airflow
(m3/min at 7.5 bar)

1,14

Air ports (G)

3/4

Airflow at condenser
(m3/h)
Absorbed Power
(Kw)

BSP

370
0.2

Refrigerant

R134A

Quantity of refrigerant
(kg)
Maximum amperage
(Amp)
Fuse Am
(Amp)

0.75
1.6
2

Maximum pressure

16 bar

Maximum ambient temperature

45C

Minimum ambient temperature

3C

Maximum inlet temperature

50C

V. DIAGRAMS
5.1. Flow diagram

AIR CIRCUIT :
-A: air/refrigerant exchanger
-B: refrigerated separator
-C: float drain
-D: manual isolating valve and drain

REFRIGERANT CIRCUIT :
SAFETY DEVICES :
-1: hermetic compressor
-t: compressor thermo-switch : klixon
-2: air cooled condenser
-w: fan pressure switch
-3: condenser fan
-4: liquid receiver
-5: filter dryer
-6: thermostatic expansion valve
-8: hot gas by-pass valve (only in F36LS)

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5. Electrical Diagram

M1:

Compressor

- a:
- b:
- c:

M4:
Rp:
C1:
C2:
S1:
ET:
P1:
EV1:

Fan motor
Current relay
Start condensator
Run capacitor
Main switch
Electronic timer
Fan pressure switch
Drain valve

run winding
start winding
motor protector

5.3. General arrangements

P
w2

w1

1
h2

F11LS

Weight
(kg)
42

High
(mm)
479

Lenght
(mm)
677

h1

Rear face

L
Model

Wide
(mm)
410

11

h1
(Inlet)
356

w1
(Inlet)
234

h2
(Outlet)
439

w2
(Outlet)
148

VI. TROUBLESHOOTING
Before beginning maintenance or repair on the dryer, the mains switches and the on/off
switch must be turned off. Also, the compressed air must be vented from the system.
TROUBLE

PROBABLE CAUSE

CORRECTIVE ACTIONS

The dryer does not start.

Dryer is not powered.

Check voltage at supply of the dryer

The refrigerant compressor start

but does not produce enough cold

The internal thermo protection

(klixon) of the compressor motor
has tripped.
The top of the refrigerant
compressor is really hot

Condenser fan stopped

Open electrical circuit at fan motor

level, fan blades stuck or tripped
fan thermo-switch

The pressure drop is too high.

The dryers capacity is exceeded.

Clogged heat exchanger(s).

Freezing.

The pressure dew point is too high. The air inlet temperature is too
high.
The ambient temperature is too
high

The air inlet pressure is too low.

The dryers capacity is exceeded.

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Check voltage at the outlet of

rocker switch
Check for right voltage and current.
The compressor will restart
automatically when klixon will be
cold.
There is no enough refrigerant in
the circuit
A fridge engineer must check the
refrigerant circuit tightness and
repair eventual leak prior adjusting
the quantity of refrigerant up to the
level stated on the dryer label plate.
Eliminate mechanical resistance,
repair electrical circuit or replace
fan motor if necessary.
Check correct functioning of fan
pressure switch
Reduce the air inlet flow. When this
is not possible, increase the air inlet
pressure.
Please contact the maintenance
service.
Stop the dryer long time enough to
allow ice to melt.
Subsequently reset the evaporation
pressure higher at by-pass valve.
(for F36LS)
Check and set it lower. Install a
pre-cooler when required.
Check and make it lower. Move
the dryer if required or move the
cooling air suction pipe to a cooler
location.
Increase the air inlet pressure.
Reduce the air inlet flow. Consider
purchasing a second or a larger
dryer as a final solution.

Too high dew point.

Refrigerant pressure in the

condenser is too high.

Some air does not flow through the

dryer.
Condensates are not fully drained
out.
Clogged drain trap(s).
Water entering the dryer.

Check your compressed air by-pass

valve and / or inlet valve.
Clean the drain assembly and
readjust drain time if applicable.
Cleaning.
Leave the dryer the time to get rid
of water. This can be speeded up
by increasing the drain time with
timer operated drain
Set it back to normal time.
Refrigerant evaporation pressure
Unscrew the by-pass valve by 1/4
too high.
of a turn at a time. Let the system
Caution : the evaporation pressure stabilize and repeat if necessary.
manometer installed on the dryer
Avoid going < 0C : freezing !
does not give accurate reads out.
Only a refrigerant manifold will
show actual pressure.
Fan motor protection has tripped.
Automatic restart after cooling
down.

VII. SPARE PARTS

Spare Parts Kit

F11LS Kit Content

Ident No.

One year kit

Drain valve and timer

100015515

One year kit

Optional Bekomat drain

100012735

3 year kit / refrigeration technician

High pressure security switch, fan on/off

switch, thermostatic gauge, on/off button

100015516

3 year kit for fan

Fan motor with blades

100015517

5 year kit / refrigeration technician

Dryer hydrator, expansion valve

100015518

Upon request / refrigeration technician

Refrigerant gas, compressor, condensor,

heat exchanger

On request

CompAir Drucklufttechnik GmbH

Argenthaler Str. 11
55469 Simmern
Deutschland
Tel. ++49 (0)6761 832-0
Fax ++49 (0)6761 832-409

www.compair.com
email: sales@compair.com

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