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NEWGATE TECHNOLOGIES, INC. Installation & Operations Manual MDR Series Refrigerated Air Dryers with Cold Coalescing Filter

Models MDR 010 ~ MDR 1250

Includes Safety Information Attention/Caution

Pressurized Equipment: Never exceed the maximum working pressure indicated on the dryer data tag. Ensure dryer is fully depressurized and all electrical power is disconnected before working on the dryer.

Electrical: Always install dryers in accordance with local electrical codes and standards. This dryer is not NEMA 4 or 7 rated and should not be installed in unprotected or potentially explosive areas.

Air for Respiration: The air treated by this dryer should not be used for human respiration (breathing air) without approved monitoring controls and may require further additional and or specific air purification and treatment. Consult the OSHA 1910.134 norm regarding the necessary quality of compressed air for respiration or contact NewGate Technologies, Inc. for breathing air applications. 1137 SW 7th Road, Ocala, FL 34474, USA

♦

Tel: (352) 351-9992

♦

Fax: (352) 351-9979

7/2001

Warranty This equipment is warranted for a period of 12 months from date of installation or 18 months from date of shipment (whichever occurs first) against defects in materials and workmanship. Call NewGate Technologies prior to performing all warranty work for authorization or return of product. This warranty covers all components of the dryer, with the following exceptions: -

Electrical components (motor, fans, pressure switches, etc.) are covered for 6 months. Electronic circuits including lamps and fuses are covered for 3 months. Field adjustments to dryers to meet local conditions and which are different from standard factory settings is considered normal maintenance and not covered by warranty.

The warranty is void if or for the following reasons: -

Dryer identification data tag is removed or altered. Repair or maintenance is performed without prior authorization by NewGate Technologies, and/or by unqualified personal. If installation and maintenance procedures are not strictly adhered to and as specifically outlined in this operations manual.

In the case of a manufacturing defect, call NewGate Technologies Inc. or your authorized dealer for repair or replacement. If authorization is given to return the product to NewGate Technologies Inc, the customer must pay the freight, whereas NewGate Technologies Inc will pay the return freight. If the dryer is not covered by warranty, or no warranty related defect is found, all freight costs are the responsibility of the customer. Total liability is limited to the total cost of the dryer only.

This warranty covers the replacement or repair of the equipment only. Any other incurred costs or losses associated whether directly or indirectly with a defect in the dryer, are not covered by this warranty. NewGate Technologies, Inc. dryers are manufactured to meet or exceed ISO-7183-B international standards.

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Index 1.0

DESCRIPTION

1.1 1.2 1.3.1 1.3.2 1.3.3 1.4 1.4.1 1.4.2 1.4.3 1.5

How it works Air circuit Refrigerant circuit Evaporator control Condenser control Electrical circuit MDR-010 to MDR-100 MDR-125 to MDR-300 MDR-400 to MDR-1250 Location of components

2.0

INSTALLATION

2.1 2.2 2.3 2.4 2.5

Inspection, Damage and Handling Location and Installation Electrical connection Water connection Condensate drain connection

3.0

OPERATION

3.1 3.2

Start up During operation

4.0

MAINTENANCE

4.1 4.1.1 4.1.2 4.2 4.3 4.4 4.5

Condensers Air-cooled condensers Water-cooled Condensers Internal Cold coalescing filter Drain system Filter Change-out Trouble shooting guide

5.0

GENERAL ARRANGEMENT DRAWINGS

6.0

ELECTRICAL SCHEMATICS

7.0

FLOWCHARTS

8.0

TABLES

8.1 8.2 8.3

Capacity correction table Control parameters table Power Consumption, Amperage & Water Consumption table

9.0

MICROPROCESSOR CONTROLLERS

9.1 9.2 9.2.1

Analog Controller Energy Controller Energy Controller Annunciation & Shutdown

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1.0 DESCRIPTION 1.1 How it works Compressed air leaving the compressor is very hot and is completely saturated (RH 100%). It therefore contains a large quantity of water in the form of vapor. As the air flows in the pipeline, its temperature continues to drop, and condensation in the form of liquid water occurs. A mechanical or coalescing condensate separator or filter must now remove this water, else it will cause problems to components downstream. However, none of these devices can remove the water vapor that is still present in the air. For most applications this is an unacceptable condition and the air needs to be dried. The most common form of drying is through the process of refrigeration. This procedure involves further cooling of the compressed air to a lowest possible temperature of about 38º F and then separating the resultant liquid condensate. Subsequently, the dry but cold air is re-heated by the incoming hot air, and is delivered to the plant. The mechanical separation of the liquid condensate from the air is a critical function and is accomplished in NewGate’s dryers with a our G Series cold coalescing filter rather than by relying on inexpensive and inefficient mechanical separation methods. The removal of liquid oil, which also drops out of vapor state along with the water, is also accomplished most efficiently at this stage by the coalescing filter. This is a significant benefit to our customers, and guarantees no further condensation of oil vapors will occur further down in the plant air stream. The air is now considered oil free for all practical purposes. All NewGate Technologies dryers are designed to International ISO standard 7183-B.

1.2

Air circuit (see also 7.0)

The cooling of the air is done in two stages. In the 1st stage air-to-air heat exchanger (pre-cooler/re-heater), the temperature of the hot incoming air is reduced by the cold outgoing air, which is at the same time re-heated during the heat exchange process. The incoming air then enters the 2nd stage air-to-refrigerant exchanger (evaporator), where the air temperature is further reduced to about 38ºF dew point. At this point, the maximum amount of water and oil is condensed and removed through the cold coalescing filter electronic drain valve. The dry air now re enters the air-to-air heat exchanger and is reheated to about 80ºF before exiting the dryer to the plant.

1.3 Refrigerant circuit (see also 7.0) After compression the refrigerant is a high pressure and high temperature gas. The refrigerant gas then enters the water or air cooled condenser where it changes to a liquid at high pressure. This liquid refrigerant then passes through a drying filter and through an expansion valve where the high pressure liquid is allowed to expand back to a gaseous state. It is then directed into the air-to-refrigerant heat exchanger (evaporator) at a temperature of approximately 28ºF. In the evaporator, the entire liquid refrigerant converts back into a low pressure gas and returned to the refrigerant compressor inlet. This cycle repeats itself. NewGate Technologies, Inc. uses only EPA approved R22, R134a and R404 refrigerants. 1.3.1 Evaporator control When a reduction of the thermal load occurs (because of reduction of incoming airflow or air temperature), the refrigerant temperature and pressure in the evaporator will also reduce, and this could lead to a potential freezing of the liquid water on the air side of the evaporator in the dryer system. To avoid this potential to freeze, a hot gas by-pass valve is utilized. This valve deviates hot gas from the compressor hot discharge directly into the evaporator (by-passing the condenser), resulting in an increase in the thermal load and

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effectively preventing freezing. This valve can be adjusted to attain the parameters of table 8.2, or to compensate for actual field conditions that may differ from factory set standards. 1.3.2 Condenser control In certain circumstances, if low ambient temperatures or low thermal loads occur, there is a tendency for the refrigerant discharge pressure (downstream of the condenser) to be reduced too much. In certain dryer models this reduction in the discharge pressure could compromise the functions of the expansion and hot gas by-pass valves. These models are therefore equipped with an additional control device. In dryers equipped with water-cooled condensers, this device consists of a valve installed at the water intake along with a refrigerant discharge pressure sensor. The valve turns on and off based on a pre-determined discharge pressure value. With the water off, the condenser cooling is reduced. This in turn increases the discharge pressure. A constant refrigerant discharge pressure is thus maintained. Air-cooled models are equipped with a pressure switch that controls the condenser cooling fan. Again, by turning the cooling fan on and off, a constant refrigerant discharge pressure is maintained.

1.4

Electrical circuit

1.4.1

MDR 010 to MDR 80 (See also 6.0)

These dryers are 115/1/60 models and are equipped with a standard power cord with a molded and grounded plug. The user is responsible for providing a fused electrical circuit with a capacity as outlined in Table 8.3 . Once the electrical power connected to the dryer, the dryer system can be turned on by pressing the Power-On button located on the front panel. The entire system comes on live, including the refrigerant compressor, fans, automatic drain etc. In certain models, the start up of the compressor is assisted by a capacitor and start relay. All models have a thermal overload protection switch in the event of high temperatures and electrical overload conditions. If actuated, it can take up to 2 hours for this protection device to reset. The condenser fan is automatically switched on when the dryer is started. The automatic drain consists of an electronic circuit that actuates a solenoid valve at intervals that can be adjusted. 1.4.2

MDR 100 to MDR 250 (See also 6.0)

These dryers are 230/1/60 models, requiring electrical hook-up by a qualified electrician. An internal junction box is provided for this connection. The user is responsible for providing a fused electrical circuit with a capacity as outlined in Table 8.3. Once the electrical power connected to the dryer, the dryer system can be turned on by pressing the Power-On button located on the front panel. The entire system comes on live, including the refrigerant compressor, fans, automatic drain etc. In certain models, the start up of the compressor is assisted by a capacitor and start relay. All models have a thermal overload protection switch in the event of high temperatures and electrical overload conditions. If actuated, it can take up to 2 hours for this protection device to reset. The condenser fan is automatically switched on, when the dryer is started. The fan(s) of the air-cooled models are controlled by a pressure switch, which de-energizes the circuit when the pressure surpasses a certain value, and allows the fans to cycle (see table 8.2). The automatic drain consists of an electronic circuit, which actuates a solenoid valve at intervals that can be adjusted.

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1.4.3

MDR300 to MDR 1250 (see 6.0)

These dryers are 460/3/60 models, requiring electrical hookup by a qualified electrician. An internal junction box is provided for this connection. The user is responsible for providing a fused electrical circuit with a capacity as outlined in table 8.3. Once the electrical power connected to the dryer, the dryer system can be turned on by pressing the Power-On button located on the front panel. The entire system comes on live, including the refrigerant compressor, fans, automatic drain etc. In certain models, the start up of the compressor is assisted by a capacitor and start relay. All models have a thermal overload protection switch in the event of high temperatures and electrical overload conditions. If actuated, it can take up to 2 hours for this protection device to reset. The condenser fan is automatically switched on, when the dryer is started. The fan(s) of the air-cooled models are controlled by a pressure switch, which de-energizes the circuit when the pressure surpasses a certain value, and allows the fans to cycle (see table 8.2). The automatic drain consists of an electronic circuit, which actuates a solenoid valve at intervals and can be preprogrammed at the control panel. On models so equipped, power is continuously supplied to a crankcase heater, which ensures that no liquid refrigerant is ever present in the compressor before startup. Since liquid presence in the compressor can cause serious compressor damage or failure, power must always be maintained to the crankcase heater. Therefore never turn off your dryer at the disconnect (except to work on the dryer). Instead, simply push the dryer Off button on the dryer control panel, and leave the dryer energized. On initial start up, if the ambient temperature in the factory is below 60ºF, the dryer may not start until a satisfactory temperature is achieved at the crankcase heater. This lockout may take several hours. Be Patient! The compressor is also protected and controlled by the microprocessor panel and will be switched off automatically if a serious defect like high or low refrigerant pressure occurs. The high-pressure switch will automatically rearm after a period of time, which could take up to 2 hours. However if the dryer is shut down due to low refrigerant pressure, it must be manually reset.

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1.5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Location of components

Coalescing filter 2 pressure switches Capacitor Condenser fan Condenser Compressor Capacity control Electrical panel Drain valve Heat exchanger Compressed air inlet Outlet of dry compressed air

7

11

5 4

12

8

10

2

1

6 9

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2.0 INSTALLATION 2.1

Inspection, Damage and Handling

It is the sole responsibility of the customer to fully inspect all merchandise prior to accepting the products from the freight company and to immediately make a claim with the freight company for any damages found. NewGate Technologies, Inc. cannot accept any responsibility for any freight damage once the unit has left our facility. Unless otherwise specified, dryer models MDR 010 to MDR 160 are packed in corrugated cardboard boxes. Units should be unloaded with a forklift or an appropriate device.

2.2

Location and Installation

2.2.1

The need for filtration:

To avoid contamination of the dryer by liquid oil or water, and to prolong the life of the high efficiency 0.01 micron cold coalescing filter in the dryer, all MDR dryer installations are recommended to include a quality prefilter, like the NewGate Technologies, Inc General Purpose U Series 1 Micron filter. Remember, oil and water contamination is a common problem, and can seriously effect both the performance and overall life of the dryer. It is therefore prudent to always protect your investment and ensure it’s top performance. 2.2.1

Location

The installation area must be well ventilated in order to avoid elevated ambient temperatures, which will negatively effect the performance of the dryer, especially the air-cooled models. All dryers must be permanently covered from the elements and from freezing temperatures at all time. Only equipment specially designed for outside installation can be placed outdoors without protection. Enclosed compressor rooms are natural dryer installation sites, but be cautious and ensure that these areas are properly ventilated and have ambient temperatures not exceeding 100ºF. The unit should be installed on a firm, level base or floor. Tall units should be bolted permanently to the floor or base utilizing the bolt holes provided. Connecting piping should be free of vibration. Where vibration exists, special flexible connections should be used and installed. Always leave adequate space around the unit for proper operation, maintenance and cooling. Insure adequate cross flow ventilation at all times. It is a good practice to install a bypass around the dryer to allow for routine maintenance without interrupting the process airflow. Any by-pass valves utilized ideally should have a special device to avoid the accidental opening of it. 2.2.3

Install the dryer in following sequence: Air compressor After-cooler Separator Air receiver NewGate G Series Filter NewGate MDR Dryer

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2.3

Electrical connection

Dryer models come in different voltages and amperage ratings and should be supplied with a dedicated and properly fused power supply. Follow all local electrical codes and utilize a qualified electrician for all electrical connections. Verify the electrical requirements for each dryer against the electrical diagram in this manual and as indicated on the data tags on every dryer.

Proper electrical grounding is a must in order to prevent electrical shock that could result in death or serious injury.

2.4 Water Dryers with water cooled condensers should use only good quality cooling water, and have a temperature rating between 70°F and 85°F and a pressure differential of 18 PSI. It is advisable to place a temperature and pressure gauge on the inlet of the water supply. Additionally, it is a good engineering practice to install an alarm and power cutoff feature should water pressure drop below minimum or fail completely.

2.5 Condensate & Drain system On smaller units, the automatic drain valve comes with a plastic tube for piping away liquid condensate. On larger units one can use clear plastic or PVC, copper or steel tubing to drain the condensate from the area. This condensate will contain coalesced oils and should be treated based on local and state codes for condensate discharge. It is critically important that liquid condensate is properly and freely removed from the dryer, else re-entrainment will occur. Therefore, continuously inspect and monitor dryer for proper electronic drain valve operation and for clogged or damaged/bent discharge piping.

3.0 OPERATION 3.1

Start up

On initial start-up on models MDR 010-250, allow the unit to warm up for at least 10 minutes prior to allowing airflow through the unit. When opening or closing the compressed air valves, always do so slowly, in order to avoid shock or damage to the heat exchangers and coalescing filters, and piping system. Models MDR 300 and larger must be energized at least 1 hour prior to start up. This allows the crankcase heater to fully warm up the compressor oil and ensures that no liquid refrigerant is present in the compressor before running Failure to follow these instructions immediately voids dryer warranty.

3.2

During Operation

Regularly check the automatic drain valve(s) operation and ensure that condensate is being discharged normally. Since there is generally a fairly large amount of water being discharged on a continuous basis, watch this operation. On models with a condenser control device, the fans start and stop suddenly during normal operation. During very hot days they may operate constantly. Use caution when in and around these dryers during normal operation.

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4.0 MAINTENANCE Your dryer will require very little maintenance, however, it is recommended you inspect them at least once a day. An authorized NewGate Technologies serviceman must carry out more comprehensive maintenance. Ensure that on air-cooled models the condensers are kept clean and free from debris or become blocked. This is the most common and most serious form of dryer failure and is easily preventable.

4.1

Condensers

CAUTION! Fans start automatically Disconnect power before any maintenance/service. 4.1.1

Air-cooled condenser

Always disconnect the dryer from the power supply before working on the dryer, and to avoid injury from rotating fan blades. Inspect and clean the condensers and free any debris from the coils. Be sure not to bend the aluminum fins on the condenser coil. Caution: If it is necessary to remove the fan blade, be sure to mark its direction and position so that you can reinstall it to the original factory settings. Reversed fan blades will cause serious performance problems and reduce the life of the unit. 4.1.2

Water-cooled condenser

Always disconnect dryer from the power supply before working on the dryer. Regular cleaning of the condenser is advised and the interval is dependent on the water quality. The tube in tube condensers (MDR - 250 to MDR 1250) should be cleaned chemically, if the discharge pressure is above normal.

4.2

Internal Cold Coalescing Filter

All MDR models come equipped with an internally installed Cold Coalescing Filter as standard. The first element replacement should be made within the first 900 hours of operation. Subsequently, replace the element every 4000 - 6000 hours or when the filter change out indicator on the control panel located on the front of the dryer lights up. Considering the possible chemical degradation of the filter element components, it is always advisable to change out the element at least once a year.

Other considerations: Filter elements become progressively blocked over time, and therefore require more compressor energy to drive the air through them. A simple calculation based on your cost of energy per kilowatt-hour can help determine the right time to change filter elements in your compressed air system. NewGate Technologies’s engineering staff can assist with this analysis, and help you save valuable energy costs.

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4.3

Drain system

The electronic drain should be inspected once a week. If it does not drain correctly, it might be blocked with dirt. Dismantle the solenoid valve and clean it with compressed air or water.

CAUTION! The dryer is under pressure Before dismantling the solenoid valve close the ball valve.

CAUTION! Always disconnect the power supply before any maintenance or electrical work is performed. 4.4

Filter change-out

All dryers have an LED readout located on the control panel, indicating when the coalescing filter should be changed. The very high cost of pressure drop should also be considered in determining when filters should be changed out. Typically, the ideal time to change is when the cost of pressure drop exceeds the cost of the replacement filter element. This will vary depending on location and energy costs in your area. Contact NewGate Technologies, Inc. for assistance and guidance. Filter element replacement for models MDR 010 to MDR 1250:

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4.5

Troubleshooting Guide

High pressure drop across dryer Dryer design capacity exceeded Saturated coalescing Filter Internal freeze up Low inlet air pressure

1 5 6 25

Water in compressed air, High dew point A. MDR dryer is cooling properly Capacity too high 1 Pulsating flow 3 Drain not functioning 4 Coalescing filter by-passed 7

Refrigerant compressor does not run Pressure switch A/B closed Blown control fuse Power switch off Broken electrical circuit Broken switch

16 17 18 17

B. MDR dryer is not cooling properly Refrigerant compressor is not running

Refrigerant compressor is running Low refrigerant Cooling flow blocked Incorrectly adjusted hot gas by-pass valve Air flow too high High inlet air temperature Dirty condenser Expansion valve damaged Dirty filter(s) Ambient temperature too high

11 9 12 1 8 10 13 24 2

Broken compressor Thermal protection activated Blown control fuse Broken/loose wiring

Refrigerant compressor has no power Pressure switch A/B open (Possible Reason for A/B open)

Pressure switch A/B open

Loss of refrigerant Adjust pressure switch

Reset pressure switch If the problem repeats:

20 21 Fan(s) stopped Broken fan motor(s) Adjust pressure switch Broken electrical circuit

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14 15 15 18

Fan(s) running 22 23 18

High ambient temp. High air inlet temp. High Inlet air flow rate Blocked ventilation Dirty condenser

2 8 1 9 10

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1. High inlet air flow rate (Capacity too high) Check the actual flow conditions against rated capacity. See Correction factors in Table 8.1. 2. High ambient temperature Make sure temperatures are not above 100/110°F. See Correction factors in Table 8.1 3. Pulsating flow If the use of air is very inconsistent and fluctuates, an air receiver of adequate size should be installed after the MDR dryer. 4. Drain is not operating Check timer or the solenoid valve. If the coil is energized, the problem could be inside the valve. Disassemble the valve and clean it internally with compressed air or water. 5. Coalescing filters saturated Replace coalescing filter element, using OEM approved elements only. 6. Internal freeze-up Call NewGate Technologies or authorized dealer for technical assistance. 7. Air by-passing the coalescing filters The filter elements may be damaged or incorrectly installed. Check, reposition or replace. 8. High compressed air temperature Check if the compressed air temperature is above 250°F. 9. Condensers air flow blocked The MDR dryer should be installed in such a way that the inlet and outlet of both cooling airflows are not obstructed. The inlet should receive clean and fresh air. If necessary, relocate the dryer. 10. Dirty After-Cooler/Condenser Clean the condenser as explained in Chapter 4.1. 11. Low refrigerant pressure Call NewGate Technologies or authorized dealer for assistance. 12. By-pass valve out of adjustment Call NewGate Technologies or authorized dealer for assistance. 13. Damaged expansion valve Call NewGate Technologies or authorized dealer for assistance. 14. Compressor failure Call NewGate Technologies or authorized dealer for assistance. 15. Thermal protection/overload actuated Wait for up to 2 hours. Try to restart. If the compressor terminals are energized and the compressor does not start, it is probably broken/seized. Call NewGate Technologies or authorized dealer for assistance. 16. Control fuse blown Replace control fuse. If fuse repeats to blow, look for a short circuit in the control system (drain, temp. indicator, alert lights, etc.). 17. Power On/Off switch not working The power On/Off switch may be switched off or interrupted. If off, switch it on. If faulty, replace the switch. 18. Electric short circuit There could be a short or loose wire/connector in the wiring control circuit. Check and repair. 20. Refrigerant low or out Call NewGate Technologies or authorized dealer for assistance. Also check for signs of refrigeration compressor oil leaks that indicate location of leak. 21. Pressure switch needs adjusting Call NewGate Technologies or authorized dealer for assistance. 22. Broken fan motor If the fan receives power but does not rotate, replace motor. 23. Pressure switch for condenser control defective Call NewGate Technologies or authorized dealer for assistance. 24. Refrigerant filter/dryer ice up If the filter/dryer shows signs of icing, it may be blocked with dirt from a contaminated refrigerant system. Call NewGate Technologies or authorized dealer for assistance. 25. Low operating pressure Inlet pressure to the MDR dryer is below nominal and design conditions. Increase pressure at the inlet to the dryer.

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5.0 GENERAL ARRANGEMENT DRAWING Models MDR 010 to 160

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5.0 GENERAL ARRANGEMENT DRAWING Models MDR 200 to 500

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5.0 GENERAL ARRANGEMENT DRAWING Models MDR 600 to 1250

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6.0 ELECTRICAL SCHEMATIC Models MDR 010 to 250

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6.1 ELECTRICAL SCHEMATIC Models MDR 300 to 1250

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7.0 FLOWCHART Models MDR 010 to MDR 500

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7.0 FLOWCHART Models MDR 600 to MDR 1250

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8.0 TABLES 8.1 CAPACITY CORRECTION TABLES AMBIENT TEMPERATURE Temp. °F

50°

75°

100°

105°

110°

115°

FA

1.20

1.15

1.00

0.97

0.94

0.91

INLET AIR TEMPERATURE Temp. °F

80°

90°

100°

105°

110°

120°

FI

1.46

1.23

1.00

0.91

0.84

0.70

OPERATING PRESSURE Press. Psig

70

85

100

115

130

150

175

FP

0.88

0.95

1.00

1.05

1.09

1.14

1.18

CF = Corrected Flow NF = Nominal Dryer Flow CF = NF x FA x FI x FP

8.2 CONTROL PARAMETERS TABLE MDR-010 to MDR-080

MDR-100 to MDR-160

MDR-200 to MDR-250

MDR-300 to MDR-1250

28 to 30

58 to 60/ 72 to 74

58 to 60/ 72 to 74

58 to 60/ 72 to 74

High pressure switch (PSIG)

--

--

--

350/380

Low pressure switch (PSIG)

--

--

--

50/64 dif. 9

Condenser fan switch (PSIG)

--

--

265/320 dif. 40

265/320 dif. 40

Suction superheat (°F)

5 to 11

5 to 11

5 to 11

5 to 11

Liquid sub-cooling (°F)

18

18

18

18

Water valve (Condenser) (PSIG)

--

--

205/250

205/250

R134a

R22/R404a

R22/R404a

R22/R404a

N/A

N/A

N/A

N/A

Parameter Suction pressure (PSIG)

Refrigerant Inlet, second stage (PSIG)

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8.3

POWER CONSUMPTION, AMPERAGE, WATER CONSUMPTION TABLE

MODEL

FLOW @ 100 psig

POWER CONSUPTION (WATTS)

(SCFM)

460/3/60

WATER CONSUMPTION (GPM) @ 85°F

AMPERAGE (AMPS) 115/1/60

230/1/60

MDR-010

20

300

3.2

--

--

MDR-020

20

300

3.2

--

--

MDR-040

40

450

6.0

--

--

MDR-060

60

650

6.0

--

--

MDR-080

80

650

9.0

--

--

MDR-100

100

1400

7.0

--

--

MDR-125

125

1400

7.0

--

--

MDR-160

160

1400

7.0

--

--

MDR-200

200

1800

9.0

--

--

MDR-250

250

2400

12.0

--

5.55

MDR-300

300

2900

--

4.66

6.66

MDR-400

400

2900

--

4.66

8.88

MDR-500

500

3400

--

5.34

11.10

MDR-600

600

3750

--

7.12

13.32

MDR-800

800

4820

--

9.16

17.76

MDR-1000

1000

5760

--

9.48

22.20

MDR-1250

1250

6310

--

10.34

27.75

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9.

MICROPROCESSOR CONTROLLERS

9.1 ANALOG CONTROLLER (Models MDR 010 to MDR 250)

How it functions:

The panel consists of 3 LEDs indicating the operation of the dryer and 1 test button for the drain system. The first LED (red) indicates if the equipment is switched on (lighted) or off. The second LED (green) indicates if the drain is activated or not. Each time the drain opens, this LED will light up. The third LED (red) indicates that the internal filter is saturated. For proper operation of the dryer it is necessary to replace the filter element when this lights up, as shown in 4.2. The Analog panel is illustrated below:

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9.2

As indicated in the flow chart, the following temperatures will display:

ENERGY CONTROLLER

(Models MDR 300 to MDR 1250)

1. 2. 3. 4.

Compressed air temperature at the coldest point. Compressed air temperature at inlet. Ambient air or condenser water temperature. Evaporation temperature of Freon.

After ten seconds the display returns to temperature 1. 1

Temperature Indication Ranges 2

3 4 5

6

1. 2. 3. 4. 5. 6.

6

Flowchart of dryer Temperature indicators Temperature display (in °F) Display of temperature selection Control buttons Indication LEDs

How it works When the equipment is connected to power but is switched off, the digital display will show the message “OFF” as indicated below:

1. Lowest air temperature 2. Inlet air temperature 3. Ambient temperature Condenser water temperature 4. Evaporating temp. of Refrigerant

32ºF 50ºF 50ºF 60ºF 32ºF

to to to to to

50ºF 100ºF 115ºF 85ºF 50ºF

The panel also controls the drain open time and the time interval between drain openings. To activate the drain manually, use the right arrow button on the panel. To program the interval time and/or the drain open time, press the right arrow button for 5 seconds. Following message will appear. To change the drain open time, press the t .L I G On/Off button once and change the values with the up/down buttons. The values are indicated in seconds. To change the interval between drain openings, press the On/Off button a second time. Message shown at the left will appear. Change the values with the up/down buttons. The values are indicated in t.D E S minutes. To finalize the program, press the On/Off button a third time. The display will return to the dryer’s temperatures indication. Annunciation & Shutdown

0 FF To switch the equipment on, just press the red button (ON/OFF) once. When switched on, the red led “Equipment Switched On” will light. The temperature display will indicate the temperature in ºF, as illustrated below: TEMPERATURE DISPLAY

TEMPERATURE SELECTION DISPLAY

003 To select the four available temperature indications, the UP control button should be pressed.

NEWGATE TECHNOLOGIES, INC.

A number of LEDs will indicate operational problems within the dryer. These are divided into two categories: Non-critical problems with Annunciation only, wherein the LEDs light up but the dryer continues to run and Critical problems with Annunciation + Shutdown, wherein the digital displays will show hyphens, and the dryer is switched off. Defective temperature sensor If a problem occurs with any temperature sensor, the display will show hyphens, as shown on left. The number indicated on the temperature selection display corresponds to the defective sensor. I & O Manual, MDR 010-1250 Page 24 of 25

7/2001

9.2.1 ENERGY CONTROLLER ANNUNCIATION & SHUTDOWN A) Annunciation only - Operational conditions Operational Conditions Equipment switched on

Probable Cause Equipment in operation. There exists no serious problem.

B) Annunciation only - Non-critical problems Problem Saturated filter

Probable reasons Saturated filter element High ambient

High dew point

(Lowest Air Temperature)

Warm water Compressed air too hot Compressed air flow higher than dryer capacity.

Remedy Replace filter element Check if cooling air temperature is adequate (see dryer’s manual) Use cooling water with adequate temperature Check if inlet air temperature is adequate (see dryer’s manual) Check if inlet air flow is adequate (see dryer’s manual)

C) Annunciation & Shutdown - Critical problems Problem

Probable reasons High ambient Warm water Dirty condenser Fans switched off Water valve closed

High refrigerant discharge pressure

Compressed air too hot

Low refrigerant suction pressure

Too much refrigerant Gas leakage Low pressure not calibrated By-pass valve not calibrated Ambient too low

NEWGATE TECHNOLOGIES, INC.

Remedy Check if cooling air temperature is adequate (see dryer’s manual) Use cooling water with adequate temperature Clean condenser Check fan wiring Open water valve Check if inlet air temperature is adequate (see dryer’s manual) Call technical service Call technical service Call technical service Call technical service Check if cooling air temperature is adequate (see dryer’s manual)

I & O Manual, MDR 010-1250 Page 25 of 25