Wilkerson WRA-0010, WRA-0015, WRA-0025, WRA-0035 Owner's/operator's Manual

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READ ALL INFORMATION IN THIS MANUAL BEFORE BEGINNING INSTALLATION OR OPERATION OF THE DRYER. BEFORE STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES, TURN OFF THE MAIN POWER TO THE DRYER AND COMPLETELY DEPRESSURIZE THE UNIT TO PREVENT PERSONAL INJURY.
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS UNDER PRESSURE.
NEVER OPERATE THIS DRYER ABOVE THE RATED OPERATING CONDITIONS. OPERATION ABOVE SPECIFIED CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO THE UNIT AND/OR PERSONAL INJURY.
®
WARNING
For further assistance contact:
P.O. Box 1237
1201 W. Mansfield Ave.
Englewood, CO 80150 Phone (303) 761-7601
FAX (303) 783-2300
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WILKERSON CORPORATION
REGISTERED TO ISO 9001
CERTIFICATE NO. A2192
FM21121
83-267-000-FL, REV. C • 08/02 • Printed in the U.S.A.
OWNER/OPERATOR MANUAL
COMPONENTS, INSTALLATION, OPERATION
AND SERVICE INSTRUCTIONS
REFRIGERATED COMPRESSED AIR DRYER
WRA-0010 — WRA-0035
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Table of Contents
Why you need a Wilkerson Dryer And Recommended Typical Installation ................Page 2
Dryer Dimensions And Recommended Wilkerson Accessories...................................Page 3
Installation Instructions....................................................................................................Page 4
System Panel And Parts List............................................................................................Page 5
Cabinet Components ........................................................................................................Page 6
Refrigeration Components...............................................................................................Page 7
Electrical Components......................................................................................................Page 8
Wiring Diagrams...........................................................................................................Page 9-11
Trouble Shooting Guide..................................................................................................Page 14
Warranty...........................................................................................................................Page 15
Return Policy ...................................................................................................................Page 16
Service Information.........................................................................................................Page 17
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WILKERSON Page 1
WHY YOU NEED A WILKERSON REFRIGERATED AIR DRYER
Untreated compressed air will contain contaminants such as water, compressor oil, rust, chemical conta­minants, and bacterial growth.
All of these contaminants will cause corrosion and product contamination.
With proper filtration and a Wilkerson refrigerated air dryer, in used contaminants will be reduced to a harm­less level.
The end result will be that the equipment which comes in contact with dry, treated, compressed air will stay cleaner, will not corrode, and will last longer.
FIGURE 1: TYPICAL COMPRESSOR ROOM LAYOUT:
COMPRESSOR
*COALESCING FILTERS RECOMMENDED FOR OIL FREE AND ODOR FREE AIR
RECOMMENDED INSTALLATION SHOULD INCLUDE AFTERCOOLER, SEPARATOR AND FILTRATION FOR GOOD
QUALITY COMPRESSED AIR.
AFTERCOOLER
SEPARATOR
REFRIGERATED
AIR DRYER
PRE-
FILTER
OPTIONAL
COALESCING*
FILTERS
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WILKERSON Page 3
Dryer Full Prefilter Recommended Recommended Model Inlet/Outlet Flow Type A Prefilter Type B Afterfilter Type C Weights Number Connections (
SCFM) 5.0 Micron 0.5-1.0 Micron 0.01 Micron lbs
WRA-0010
1
/4" NPT 10 F18-02-SG00 M18-02-BG00 M18-02-CG00 53
WRA-0015
1
/4" NPT 15 F18-02-SG00 M18-02-BG00 M18-02-CG00 75
WRA-0025
1
/2" NPT 25 F18-04-SG00 M18-04-BG00 M18-04-CG00 75
WRA-0035
1
/2" NPT 35 F18-04-SG00 M18-04-BG00 M18-04-CG00 75
DIMENSIONS
NOTE: Recommended filters were selected on the basis of flow capacity—not pipe size.
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INSTALLATION
Air-Cooled Condenser (Standard)
The dryer should be installed in a well-ventilated area. Ambient air should flow freely into the condenser opening (right side of dryer). Do not block or restrict this opening. There should be at least 12" (305 mm) clearance at the back and both sides of the dryer. The condenser fins and surfaces should be regularly cleaned with an air blow gun. The grill can easily be re­moved to access the condenser coil.
Ambient temperature should never be above 110°F (43°C) or below 40°F (4.4°C).
Compressed Air Piping
Pipe air “in” and “out” as indicated on dryer. Compressor induced vibration (or any other vibration) should be dampened by installing flexible piping between the dryer and compressor, or vibration dampeners on dryer floor legs. Prolonged vibration will damage dryer and void warranty. If piping incorporates a bypass circuit (recommended), make sure “in” and “out” shut-off valves are normally wide open and bypass valve completely closed. Do not undersize these valves.
Care Of Outside Of Dryer
This dryer is protected and decorated with the highest quality paint for lasting attractive appearance. To clean these surfaces, use a sponge, mild soap and warm water. Dry with a clean cloth. Do not use any abra-
sives or solvents. System Monitor
1. Dryer “Power on” on/off light illuminates to indicate power is on to the dryer.
2. Optional Refrigerant Suction Gauge displays dryer suction pressure.
3. High temperature warning light indicates the compressor is not running.
Before Start-Up
The gauge readings
BEFORE START UP will be:
1.
REFRIGERANT SUCTION PRESSURE: Indicates the
refrigerant pressure and during shut down corresponds with the ambient temperature (see page 5 for temperature-pressure chart and convert ambient temperature to pressure reading for R-22).
Example: 70° F ambient, R-22 pressure is approxi­mately 121.4 psig.
Start-Up
DO NOT START WITH A LOAD ON THE DRYER
Bypass the flow of air around the dryer before pushing the start button.
1. After pushing the start button, the power indicating
light will illuminate. Dryer is designed to run contin­uously and must not be cycled with the air compressor. The fan on air-cooled units will cycle in accordance with head pressure.
2. The refrigerant suction pressure gauge readings
AFTER START UP AND WHILE OPERATING UNDER RATED LOAD will be: R-22 (57-65 PSIG).
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WILKERSON Page 5
Control Panel and Components Voltage Part #
1 ON/OFF Switch 115 V 87-379-000
230 V 87-379-001
2 High Temperature Light 115 V 87-382-000
230 V 87-382-001
3 Refrigerant Gauge 49-082-000
RUNNING OPERATION
1. The non-cycling operation of the refrigerated dryer is
controlled by an automatic expansion valve (AXV). The fan control is used in conjunction to maintain head pressure during light or no load running condition.
2. The automatic expansion valve is preset at the factory. The suction pressure gauge should indicate 65
PSIG for
R-22. If adjustment is necessary refer to Figure 1.
AXV USED AS EITHER AN EXPANSION VALVE OR
AS A HOT GAS BY-PASS.
INCREASING THE SUCTION PRESSURE WILL RAISE THE EVAPORATOR TEMPERATURE. DECREASING THE SUCTION PRESSURE WILL LOWER THE EVAPORATOR TEMPERATURE.
Temperature-Pressure Chart (R-22)
TEMPERATURE PRESSURE
F PSIG
28 52.4 30 54.9 32 57.5 34 60.1 36 62.8 38 65.6
40 68.5 45 76.0
adjusting screw
Use a 3/8" wrench or socket to turn the adjusting screw. Turn clockwise to increase the suction pressure. Turn counterclockwise to decrease the suction pressure to the normal range.
INCREASE
DECREASE
FIGURE 1
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Part
Item Description Model Number Number
1 Intake Grille WRA-0010 63-044-000
WRA-0015 - WRA-0035 63-049-000
2 Exhaust Grille WRA-0010 63-047-000
WRA-0015 - WRA-0035 63-053-000
3 Base WRA-0010 63-763-000
WRA-0015 - WRA-0035 63-901-000
4 Base Plate WRA-0010 63-755-000
WRA-0015 - WRA-0035 63-900-000
5 Lid WRA-0010 63-762-000
WRA-0015 - WRA-0035 63-902-000
CABINET COMPONENTS
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REFRIGERATION COMPONENTS
WILKERSON Page 7
Item Description Voltage Model # Part #
1 Compressor 115-60-1 WRA-0010 51-120-113
208/230-50-1 WRA-0010 51-120-114
115-60-1 WRA-0015 51-120-117
208/230-50-1 WRA-0015 51-120-118
115-60-1 WRA-0025 51-120-117
208/230-50-1 WRA-0025 51-120-118
115-60-1 WRA-0035 51-120-119
208/230-50-1 WRA-0035 51-120-120
2 Separator WRA-0010/0015 WSA-02-F00
WRA-0025/0035 WSA-04-F00
3 Filter Dryer ALL 54-071-000
Item Description Voltage Model # Part #
4 Expansion Valve ALL 52-000-000
ALL 52-000-000
5 Evaporator Coil WRA-0010 ARP-96-951
WRA-0015 ARP-96-952
WRA-0025/35 ARP-96-953
6 Condenser WRA-0010 50-121-104
WRA-0015 50-121-103
WRA-0025/35 50-121-105
7 Fan Blade ALL 51-137-104
8 Fan Motor 115-60-1 ALL 51-130-108
208/230-50-1 ALL 51-130-109
9 Fan Control ALL 87-092-000 10 Refrigerant Service Valve — ALL 52-090-000
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ELECTRICAL COMPONENTS
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Item Description Voltage Model # Part #
1 Terminal Strip 115v/230v ALL 87-115-000 2 Run Capacitor 115v/230v WRA-0035 87-613-100 3 Start Relay 115v/230v WRA-0035 87-600-100 4 Start Capacitor 115v WRA-0035 87-610-100
230v WRA-0035 87-610-102
5 Relay 115v WRA-0010 51-026-000
115v WRA-0015/25 51-025-001 230v WRA-0010 51-025-002
230v WRA-0015/25 51-025-003
6 Overload 115v WRA-0010 51-025-004
115v WRA-0015/25 51-025-005 115v WRA-0035 51-025-010
230v WRA-0010 51-025-006 230v WRA-0025/35 51-025-007 230v WRA-0035 51-025-011
7 Start Capacitor 115v WRA-0010 N/A
115v WRA-0015/25 51-025-008 230v WRA-0010 N/A 230v WRA-0015/25 87-610-102
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WIRING DIAGRAM
WILKERSON Page 9
10 SCFM (RSIR)
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WIRING DIAGRAM
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15 and 25 SCFM (CSIR)
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WIRING DIAGRAM
WILKERSON Page 11
35 SCFM (CSR)
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Model WSA-02-F00 Separator
For WRA-0010 and WRA-0015
Model WSA-04-F00 Separator
For WRA-0025 and WRA-0035
BODY
NNR
BOWL
O-RING
DEFLECTOR VANE
FILTER
ELEMENT
ELEMENT
RETAINER
NNR
AUTOMATIC MECHANICAL DRAIN
BODY
NNR
ELEMENT
FILTER
ELEMENT
RETAINER
NNR
BOWL O-RING
DEFLECTOR VANE
O-RING
TRANSPARENT
PLASTIC
BOWL
METAL
BOWL
GUARD
NUT
O-RING
AUTOMATIC MECHANICAL DRAIN
TRANSPARENT PLASTIC BOWL
METAL BOWL GUARD
NUT
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WILKERSON Page 13
Model WSA-04-F00 Separator
For WRA-0025 and WRA-0035 cont.
WARNING
DO NOT PLACE PLASTIC BOWL UNIT IN SERVICE
WITHOUT METAL BOWL GUARD INSTALLED
Plastic bowl units are sold only with metal bowl guards. To minimize the danger of flying fragments in the event of plastic bowl failure, the metal bowl guards should not be removed. If the unit is in service without the metal bowl guard installed, manufacturer's warranties are void, and the manufacturer assumes no responsibility for any resulting loss.
IF UNIT HAS BEEN IN SERVICE AND DOES NOT HAVE A METAL BOWL GUARD, ORDER ONE AND INSTALL BEFORE PLACING BACK IN SERVICE..
For information for materials harmful to plastic bowls, contact a Mobay Chemical or General Electric office for information regarding materials that will attack polycarbonate plastic.
CAUTION
Certain compressor oils, chemicals, household cleaners, solvents, paints and fumes will attack plastic bowls and can cause bowl failure. Do not use near these materials. When bowl becomes dirty replace bowl or wipe only with clean, dry cloth. Reinstall metal bowl guard or buy and install a metal bowl guard. Immediately replace any crazed, cracked, damaged or deteriorated plastic bowl with a metal bowl or a new plastic bowl and metal bowl guard.
EXCEPT as otherwise specified by the manufacturer, this product is specifically designed for compressed air service, and use with any other fluid (liquid or gas) is a misapplication. For example, use with or injection of certain hazardous liquids or gases in the system (such as alcohol or liquid petroleum gas) could be harmful to the unit or result in a combustible condition or hazardous external leakage. Manufacturer's warranties are void in the event of misapplication, and manufacturer assumes no responsibility for any resulting loss. Before using with fluids other than air, or for non-industrial applications, consult manufacturer for written approval.
REPAIR KITS AND REPLACEMENT PARTS
Bowl O-ring kit...........................................................................GRP-95-900
Transparent plastic bowl assemblies:
Plastic bowl only.....................................................................GRP-95-929
Metal bowl kits:
with petcock............................................................................GRP-95-930
with petcock, sight gauge.......................................................GRP-95-931
with Automatic Mechanical Drain (Viton seals) ......................GRP-95-960
Drains kits:
Automatic Mechanical Drain .....................................................GRP-95-973
Automatic Mechanical Drain with Viton seals.........................GRP-95-981
ACCESSORIES
Sight gauge (for metal bowl).....................................................GRP-95-079
REPAIR KITS AND REPLACEMENT PARTS
Bowl O-Ring Kit........................................................................GRP-95-009
Transparent Plastic Bowl Kits:
with Bowl Guard, Auto Mech. Drain.......................................FRP-95-015
Bowl Guard ..............................................................................GRP-95-013
Metal Bowl Kits:
with Automatic Mechanical Drain and Viton seals.................FRP-95-950
with petcock and sight gauge ................................................GRP-95-133
Sight gauge (for metal bowl)....................................................GRP-95-079
Drain Kits:
Automatic Mechanical Drain with Viton Seals..........................GRP-95-981
Automatic Mechanical Drain ....................................................GRP-95-973
MAINTENANCE
1. TO CLEAN BOWL OR REPLACE FILTER ELEMENT: a. Depressurize unit. b. Inspect and replace crazed, cracked, damaged or deteriorated
seals and bowls with original manufacturer's approved seals and bowls.
c. IF BOWL BECOMES DIRTY, replace it or clean it by wiping it with a
soft dry cloth.
2. IF UNIT HAS RIGID (FELT) FILTER ELEMENT, replace or clean it periodically. Remove element and tap it on a hard surface. Use an air gun to blow out residual dirt.
3. IF UNIT HAS A OIL REMOVING CLOTH FILTER ELEMENT, replace it with a new one every six months, or sooner if it becomes dirty or causes pressure drop of 10 psi (0,7 bar) or more at rated flow.
4. IF METAL BOWL HAS A MANUAL PETCOCK, drain bowl at least once per work shift.
5. IF BOWL HAS AN AUTOMATIC MECHANICAL DRAIN, clean screen around drain seat whenever elements is cleaned or changed. Remove adapter nut. Remove drain assembly. Use an air gun to blow dirt out of screen and valve assembly.
6. BEFORE PLACING UNIT IN SERVICE, reinstall bowl and bowl guard and lock them securely in place.
Model WSA-02-F00 Separator
For WRA-0010 and WRA-0015 cont.
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TROUBLE SHOOTING GUIDE
Symptom Cause
Dryer not running a. Low voltage to the dryer “Power
ON
light is ON b. Compressor over-load open
c. Defective compressor start components d. Compressor windings open
Dryer not running a. Switch not turned on “Power
ON” light is
OFF b. No power
c. Circuit breaker fuse d. Improperly wired e.
ON/OFF switch defective
High discharge pressure a. Fan not operating (Above 335 psig) b. Dirty or blocked condenser
c. High ambient conditions d. Excessive air load exceeding
the capacity of the dryer
High suction pressure a. Excessive air load exceeding the capacity (57 to 65 normal) of the dryer
b. AXV setting too high c. High ambient temperature
Low suction pressure a. Low or no air load (57 to 65 normal) b. Fan not cycling at low load
c. AXV setting too low d. Refrigerant leak (low on refrigerant) e. Low ambient temperature and fan not cycling
Moisture in air system a. Dryer over loaded (air flow) downstream b. Separator drain not functioning
c. Air bypass valve open d. Refrigeration system not operating e. Improper air piping
High pressure drop a. Dryer over loaded (air flow) in dryer air circuit b. Heat exchanger clogged
c. Iced evaporator coil
High temperature light ON a. Air inlet temperature too high (Refrigerant compressor OFF) b. Refrigerant shortage
c. Blocked condenser
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Page 16
In an effort to maximize warranty support and minimize confusion concerning the Wilkerson Refrigerated Air Dryer warranty policy,
the following is presented as a supplement to the standard Wilkerson warranty policy.
First, please note that Wilkerson is not necessarily responsible for labor costs associated with a warranted part. It has been incorrectly assumed by many customers that Wilkerson would accept labor charges regardless of the claim submitted. This is not the case as indicated by the following clarifications.
Problems such as plugged drains, burned out light bulbs, simple electrical trouble shooting, and minor adjustments will not be covered under warranty. It is our intent to work with the customer over the phone to correct such minor problems.
For example: It is not uncommon for a hot-gas bypass valve to drift slightly out of calibration over a period of time. This simple adjustment can be performed by the customer under most circumstances. It requires no knowledge of refrigeration systems and will be supported by telephone and written documentation. This not only saves the customer time but also educates them on this common procedure so that it can be performed again when the dryer is not under warranty.
Naturally, customers will not be expected to perform major repairs such as replacing a compressor or installing a heat exchanger. These tasks must be performed by a qualified technician. Along these lines, a customer may be asked to take ohm or amp readings to determine if a compressor needs to be replaced. At this point, it is not necessary to write down every task a customer may be asked to perform. These issues are better addressed on a case-by-case basis.
Now that the written warranty policy has been reviewed and some examples given, the next step is to review the correct way to file a warranty claim. The following “Warranty Procedure” clearly outlines the obligations of Wilkerson Corporation and the procedure to be followed when processing a warranty claim.
WILKERSON REFRIGERATED AIR DRYER WARRANTY
Wilkerson products are warranted to be free from defects in material and workmanship, under proper use, installation, application and maintenance in accordance with Wilkerson's written recommendations and specification for a period of one year from the date of shipment from the factory (refrigerated dryers are warranted for 2 years). Wilkerson's obligation under this warrant is limited to, and the sole remedy for any such defect shall be, the repair or replacement (at Wilkerson's option) of unaltered products returned to Wilkerson and proven to have such defect, provided such defect is promptly reported to Wilkerson within said one-year period.
This is the only authorized Wilkerson warranty and is in lieu of all other express or implied warranties or representation, including any implied warranties of merchantability or fitness, or of any other obligations on the part of Wilkerson.
Warranty claims must be submitted and shall be processed in accordance with Wilkerson's established warranty claim procedure. In no event will Wilkerson be liable for business interruptions, loss of profits, personal injury, costs of delay or for any other special, indirect, incidental or consequential losses, cost or damages.
NOTE: Routine maintenance and minor adjustments to Wilkerson refrigerated compressed air dryers are not covered under this warranty. Prior to performing any possible warranty service or replacing a possible warranted part, Wilkerson must be notified at (303) 761-7601. Failure to comply with this procedure will result in denial of warranty claim. Please fill in the Service Information Sheet prior to calling Wilkerson.
Service Information Sheet
1. Dryer Model No.
2. Dryer Serial No.
3. Date Installed and Started Up
4. Prefilter Model No(s). (if no prefilters are present, so indicate)
5. Nature Of Problem
WILKERSON Page 15
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Page 16 WILKERSON
There are two scenarios in which a warranty claim is processed - when a customer calls Wilkerson direct and when a customer
calls a distributor.
Customer Calls Wilkerson Direct
Wilkerson will ask the customer for the usual supporting information. This is:
1. Model Number
2. Serial Number
3. Ambient Air Temperature and Environmental Conditions (dusty, etc.)
4. Inlet Air Temperature, Pressure, and Flow
5. Inlet Air Quality, i.e. do they have prefiltration?
6. Condenser Condition - Clean/Dirty
7. Is Separator Drain Functional?, etc.
If these questions are satisfactorily answered and the service problem is not identified, this process will be continued until the
problem is determined or the customer can no longer provide needed information.
At that time a decision will be made as to whether or not to call in an outside service organization to look at the unit. Often, during the trouble shooting process, the probable cause of the problem will be identified as a part which is not immediately available locally. This part will usually be supplied to the service organization prior to the service organization making the actual service call. This will help avoid unnecessary calls.
The following policies, procedures and limitations apply to returned dryers:
1) Prior to being returned to the factory, all returned units will be assigned an ATR number by the Wilkerson Customer Service Department. All dryers which are returned to the factory without an ATR number will be returned to the sender, freight collect.
2) All dryers which have been authorized for return must be shipped to the factory freight prepaid. Wilkerson will not accept any freight collect dryers.
3) Repair and testing of returned dryers normally takes 1 to 2 working days after receipt.
4) Wilkerson will return a repaired dryer to the customer freight prepaid. This will include normal ground transportation only with­in the continental U.S. Special delivery or out-of-country transportation will be paid by the customer.
5) Wilkerson will not be liable for shipping damage. Insurance should be considered if the customer is concerned.
6) All dryers will be returned in the same package in which they arrive unless otherwise requested and paid for.
7) Repaired dryers are warranted for the remainder of the original warranty period.
8) All labor and parts determined not to be covered under warranty will be billed to the customer. Payment must be received *prior to return of the dryer.
For Dryers not being returned to Wilkerson:
If the customer has an established policy preventing trouble shooting of the dryer, or is uncooperative, Wilkerson will then have no choice but to send in a service organization. If the problem turns out to be a major one which could not have been handled by simple trouble shooting and adjustment, Wilkerson will accept the service charges for the repair. If, on the other hand, there was no problem, the problem required a minor adjustment, or the problem was caused by faulty installation, shipping damage, etc., Wilkerson will not cover the cost of service. Instead, the customer will be directly responsible for the cost of the service.
Customer Calls Distributor
When a customer calls the distributor with a possible warranty situation, Wilkerson must be contacted immediately by either the customer or distributor. Wilkerson will require the same basic supporting information, including the customer's name, contact name and telephone number.
If, for some reason, the customer or distributor does not wish to provide the information required, the possible warranty claim cannot be processed. It is the responsibility of the distributor to provide all information required or requested so that warranty claims can be processed quickly and efficiently.
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SERVICE INFORMATION FOR MANUFACTURER
WILKERSON Page 17
We will be glad to assist with any service problems you may have. However, before contacting us, please have the following information available.
1. MODEL NUMBER 2. SERIAL NUMBER
3. What is the nature of the problem?
4. What is the Refrigerant Suction Pressure Gauge reading?
OTHER INFORMATION NEEDED: A. AIR TEMPERATURES AND PRESSURES
Inlet air temperature ___________________°F (°C) Outlet air temperature _____________________°F (°C) Inlet air pressure___________________psig (bar) Outlet air pressure _____________________psig (bar)
B. AIR FLOW
What is H.P. of compressor? __________________ What is the air flow? _______________scfm (Nm3/h)
C. AMBIENT CONDITIONS AT DRYER INSTALLATION
What is the ambient air temperature? _____________°F (°C) Is ambient air at dryer installation dusty? ____________ Has condenser been cleaned recently? ___________
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