SPX Refrigerated Dryer Training

1. SPX Refrigerated Dryer Training

2. Refrigeration Theory Vapor Compression Refrigeration Cycle - Components Evaporator Metering Device Compressor Condenser

3. Refrigerant Flow Refrigerant Flow Refrigerant Flow Refrigerant Flow Refrigeration Theory Vapor Compression Refrigeration Cycle – Refrigerant Flow Evaporator Refrigerant Flow Refrigerant Flow Refrigerant Flow Metering Device Compressor Condenser Refrigerant Flow Refrigerant Flow Refrigerant Flow Condenser

4. Refrigeration Theory Vapor Compression Refrigeration Cycle – Heat Flow Evaporator Evaporator Heat flows IN to evaporate the refrigerant Metering Device Compressor Condenser Condenser Heat is drawn OUT to condense the refrigerant

5. Suction Side (Low Pressure) Discharge Side (High Pressure) Refrigeration Theory Vapor Compression Refrigeration Cycle – Pressure Regions Evaporator Metering Device Compressor Condenser

6. Vapor Side Liquid Side Refrigeration Theory Vapor Compression Refrigeration Cycle – Phase Regions Evaporator Metering Device Compressor Condenser

7. Hot Compressed Air In Cool Compressed Air Out Refrigerated Dryers Basic Refrigerated Compressed Air Dryer Evaporator

8. Hot Compressed Air In Cool Compressed Air Out Hot Gas Bypass Valve Refrigerant Refrigerant Refrigerated Dryers The Hot Gas Bypass Valve in HV series Dryers

9. Hot Compressed Air In Hot Compressed Air In Cool Compressed Air Out Cool Compressed Air Out Refrigerant Hot Gas Bypass Valve Refrigerant Refrigerated Dryers The Hot Gas Bypass Valve in HPRP series Dryers

10. Hot Compressed Air In Hot Compressed Air In Cool Compressed Air Out Cool Compressed Air Out Refrigerant De-Superheating Valve Refrigerant Refrigerant Hot Gas Bypass Valve Refrigerant Refrigerant Refrigerant Refrigerated Dryers The De-Superheating Valve

11. Refrigerated Dryers Accumulator / Receiver

12. Refrigerated Dryers Refrigerated Dryer Temperature Testing 1 Compressor inlet 2 Compressor outlet 8 3 Condenser outlet 4 Filter/Dryer 1 6 7 5 5 TXV 6 De-superheating valve 2 7 HGBV 4 8 Bypass tie-in 3

13. Refrigerated Dryers Flo-Con Hot Gas Bypass Valve • Used on 200 cfm through 3000 cfm dryers • R134A and R404a refrigerants • Internally and externally equalized

14. Refrigerated Dryers Operating Pressures

15. The Evaporator Brazed Plate Heat Exchangers 100 thru 3000 scfm AISI 316L stainless steel plates, stamped with unique herringbone geometry 99.9% pure copper brazing material Brazed (sweat) connections Seal plate Channels are formed when the plates are brazed together

16. HPRP Refrigerated Dryers 1000 to 3000 SCFM HPRP 800 to 3000 SCFM HES Air Cooled Water Cooled 230/430/575 Volt No Loss Demand Drain Optional: Cold Coalescer Gauges

17. How It Works Hot Gas Bypass Valve Refrigeration Control

18. HPRP Refrigerated Dryers Large Flow Refrigerated Dryer Design • Features • Stainless steel plate heat exchangers • Non-ferrous piping • Carbon steel separator housing • Separator / filter • R-404a refrigerant • Wired to CE standards • Top-mounted inlet / outlet connections • Flush-to-wall placement • Demand drains

19. HPRP Refrigerated Dryers Filter/Separator Condenser Evaporator/ Heat Exchanger TXV No Loss Demand Drain HGBP Valve

20. HES Refrigerated Dryers HES Dryer Advanced compressed air treatmentThe Concept: • Sensors in the Digital Evaporator communicate temperatures to the Digital Controller • The Digital Controller loads/unloads the Digital Scroll • The Digital Scroll sends the exact amount of cooling energy (No More… • No Less) to the Evaporator

21. HES Refrigerated Dryers Filter / Sight Glass Receiver Digital Scroll Compressor Fixed Scroll Compressor Oil Equalization Tube and Oil Sight Glass

22. HES Refrigerated Dryers Digital Scroll Refrigeration Compressor • The Controller sends a signal to the solenoid valve of the Digital Scroll to load or unload in ten second cycles • The Digital Scrollwill be unloaded for 4 seconds and loaded for 6 seconds under 60% load conditions on the dryer • This is how tight dew point control and maximized energy savings are achieved Disengaging Solenoid Discharge Connection Suction Connection

23. Refrigerated Dryer Troubleshooting Common Problems … Operator Error • Hot Starting • Overload • Insufficient Water Supply • Bypass Valve Open • Common Drain Lines

24. Refrigerated Dryer Troubleshooting Common Problems … Dryer Failures • Refrigerant Leaks • Compressor Failure • Loose Electrical Connections (Overheated) • Board Failure • Pressure Control Failure • Temperature Probe

25. Refrigerated Dryer Troubleshooting • A refrigeration leak will cause refrigeration compressor to overheat and cycle on the internal compressor overload. • A shorted fan switch can cause an evaporator to freeze up. • Refrigerant sight glasses should be 1/2 to full. The level of refrigerant may modulate at no load or low load conditions.

26. Refrigerated Dryer Troubleshooting Refrigerant leak in evaporator: An internal leak can result in compressed air in the refrigeration system Symptoms • Loss of cooling • High head pressure • Wet sight glass (TXV systems) • Loss of refrigerant. No leak to atmosphere found

27. Refrigerated Dryer Troubleshooting Airflow Problems • Dirty Filters • Evaporator Freezing • Malfunctioning Drain • Closed • Open • Liquid Water Entering the Dryer • Overloading

28. = Certain Failure 275°F = Danger Level = Danger Level 250°F 250°F = Maximum desirable = Maximum desirable 225°F 225°F Refrigerated Dryer Troubleshooting Compressor Discharge Temperatures

29. Refrigerated Dryer Troubleshooting Refrigerant Compressor Lubricants 310ºF to 320ºF - Oil begins to vaporize Results: Increased bearing and cylinder wear 350°F and above - Oil breaks down Results: Produces contaminants in the system and accelerates wear of the internal components

30. HPRP and HES Refrigerated Dryers 4 2 3 1 5 10 8 7 9 6 9 9 • Temperature Indicator • Operator Interface Display • Current time/Total Operating Hours/Hours to service/Active faults • Power-on Light • Compressor-on Light • Alarm/Service Light Reset Button Drain Push-to Test Button On/Off Programming Keys Set/Run Button emm™ controller

31. HES Refrigerated Dryers HES Dryers Display • Controller Automatically Scrolls Through Five LCD Screens that Display: • Date/Time/Operating Status • Hours-to-Service • Total Compressor Operating Hours • Instantaneous Load 1 • Cumulative Energy Savings 2 • 1 “Instantaneous Load” is displayed in “real time” as a percentage of design capacity. • 2 “Cumulative Energy Savings” accept a cost/KwH value and projects the savings while using US Dollars or Euros for display symbols.

32. Failed Scroll Compressor

34. HES High Capacity Refrigerated Air Dryers Flow models 3750 to 12500 scfm

35. Modular Construction Modules are coupled together to form larger combinations

36. Modular Construction Stainless Steel Outlet Header Stainless Steel Inlet Header Module Electrical Box Stainless Steel Interconnecting Piping and sanitary Fittings Module Isolation Valves Filter/Separator with Grade 9 Elements Stainless Steel Brazed Plate Heat Exchangers Optional Coalescing Filters with Grade HF Elements Digital Scroll Refrigerant Compressor Electric Demand Drains Stainless Steel Water-Cooled Condenser Base Pan with Forklift Channels HES5000

37. Master Energy Monitor Intuitive Controls • Measured energy savings performance: • Instantaneous load (as a %) • Cumulative energy savings (currency in $/ €) • Projected annual savings (currency in $/ €) • Average monthly load (last 30 days as a %) • Average daily load (last 24 hours as a %) • Individual modules operation and real-time status: • Module status (on/off, scheduled on/off, standby) • Refrigerant suction temperature (°F/C) • Refrigerant suction pressure (psi/bar) • Coldest air temperature (°F/ °C) • Refrigerant discharge temperature (°F/°C) • Refrigerant discharge pressure (psi/bar) • Optional: Enhanced Instrumentation Package • mem™ plus text display and warnings for: inlet air temperature; cooling water temperature and outlet air pressure Operator Interface