How it Works
Wilkerson
Loading...
WRA-0300-2

Wilkerson WRA-0250-2, WRA-0250-3, WRA-0250-4, WRA-0300-2, WRA-0300-3 Owner's/operator's Manual

...
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.
®
OWNER/OPERATOR MANUAL
COMPONENTS, INSTALLATION, OPERATION
AND SERVICE INSTRUCTIONS
REFRIGERATED COMPRESSED AIR DRYER
WRA 0250-WRA 0500
WRW 0250-WRW 0500
WARNING
83-030-000-FL • Rev. A • 9/95
Printed in the U.S.A.
REFRIGERATED AIR DRYER
SYSTEM MONITOR
POWER ON
HIGH TEMP
OUTLET ORESSYRE
OUTLET ORESSYRE
®
OPERATIONS
For further assistance contact:
P.O. Box 1237
1201 W. Mansfield Ave.
Englewood, CO 80150 Phone (269) 629-2550
FAX (269) 629-2475
Certificate No
BSI
R
E
G
I
S
T
E
R
E
D
F
I
R
M
NATIONAL
ACCREDITATION
OF CERTIFICATION
BODIES
®
R
E
G
I
S
T
E
R
E
D
F
I
R
M
WILKERSON OPERATIONS
REGISTERED TO ISO 9001
CERTIFICATE NO. A2192
FM21121
WILKERSON OPERATIONS Page 1
Table of Contents
Why you need a Wilkerson Dryer and recommended Typical Installation..................Page 2
Components of a Refrigerated Dryer Compressed Air System....................................Page 3
Dryer Performance Specifications...................................................................................Page 4
Installation Instructions and Start-up Procedure...........................................................Page 5
Preventive Maintenance, Dryer Dimensions and
Recommended Wilkerson Air Accessories ....................................................................Page 6
Compressed Air Circuit ....................................................................................................Page 7
Refrigeration Circuit..........................................................................................................Page 8
Control Panel Components..............................................................................................Page 9
Electrical Box Components ...........................................................................................Page 10
Refrigeration Components ............................................................................................Page 11
Cabinet Components ......................................................................................................Page 12
Wiring Diagrams.........................................................................................................Page 13-14
Trouble Shooting Guide..................................................................................................Page 15
Dryer Warranty ................................................................................................................Page 16
Service Information.........................................................................................................Page 17
Page 2 WILKERSON OPERATIONS
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 use, 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.
Rejection rates of your end products will drastically reduce when using dry, treated air in your plant manufacturing operation.
FIGURE 1: TYPICAL COMPRESSOR ROOM LAYOUT:
1 Air Compressor 2 Shut-off Valve 3 Flex Connector 4 Compressed Air Aftercooler 5 Flex Connector 6 Liquid Separator with
Electric Drain 7 Storage Tank 8 Prefilter 9 Electric Drain Valve
10 Flex Connector 11 Shut-off Valve 12 By-pass Valve 13 Flex Connector 14 Shut-off Valve 15 Afterfilter 16 Refrigerated Air Dryer
1
2
3
4
7
13
11
14
15
16
12
5
6
9
9
9
8
10
WILKERSON OPERATIONS Page 3
The Air Compressor 1
Although there are many types of compressors, all have some type of inlet filtration. If this filtration is not maintained or is not properly designed for ambient conditions (ie. large amounts of coal dust, road dust, fly ash, etc.) the result will be increased compressor maintenance and an additional contamination load on downstream equipment.
Shut-Off Valve 2, 11, 14
Sized in accordance with air flow capacities, to provide the minimum pressure drop.
Flexible Connections 3, 5, 10, 13
Flexible piping between a compressed air system and the air dryer or aftercooler is recommended to eliminate any possible vibration induced damage.
The Aftercooler 4
As the name implies, the aftercooler cools the hot air after compression. This not only reduces the temperature of the air to within acceptable values for downstream equipment, but also condenses out a very large amount of water. This is very important because for approximately every 20°F (11°C) reduction in compressed air temperature, one half of the water is condensed. A separator must be used to actually remove the water from the system.
The Separator 6
The separator removes the large droplets of oil and water from the compressed air stream which condense in the aftercooler, subsequently improving the dryer capacity. Though one of the least expensive components of the compressed air system, the separator is one of the most critical. A difference of only a few percent efficiency in a separator can allow substantial amounts of additional water to pass downstream, both overloading a dryer and causing potential maintenance problems. A properly sized electronic drain should be installed to drain away accumulated liquids.
Storage Tank 7
This acts as a storage vessel which will also remove liquids. Therefore, an electric drain valve should be installed. (Note:
Where possible the receiver should be installed with the inlet near the bottom and the outlet near the top.)
Prefiltration 8
Wilkerson refrigerated air dryers will operate efficiently and reliably without filtration. But if your system also requires dirt and oil free air, then appropriate particulate or coalescing filtration is required.
Electric Drains 9
Proper drainage of accumulated liquids is essential to proper system operation. Should liquids be allowed to build up in receivers and filters, liquid “slugging” can occur causing loss of performance to downstream components.
Automatic electric drain valves provided on the dryers automatically drain liquid water from the dryer evaporator and separator. They feature full adjustment of drain cycles from 1 to 45 minutes, and valve opening durations from 1 to 15 seconds. Two indicator lights for indicating “power on” and “valve open” status allow for easy visual inspection. Electric drains are also recommended for all other drain points in the compressed air system including separators, filters, receivers, and drip legs.
By-pass Valve System 12
It is strongly recommended that a by-pass valve system be utilized to provide for convenient maintenance and service. Applications which require a continuous supply of dry air should consider installing two dryer systems. This will assure a steady supply of dry air under any conditions.
Afterfiltration 15
For critical applications, to obtain a maximum downstream oil content of .01 ppm/wt and .003 ppm/wt respectively. See the chart below for recommended afterfilters.
The Refrigerated Air Dryer 16
The Wilkerson Refrigerated Air Dryer is the result of unprecedented research and testing. It is subjected to simulated no load, partial load and full load performance examinations to meet our quality standards. As such, it will provide years of reliable service if properly installed and operated within its design specifications. The dryer should be installed in a well ventilated area.
Components Of A Refrigerated Dryer Compressed Air System
Recommended Filtration
Recommended Coalescing Prefilters/Afterfilters
Dryer Dryer/Filter Model Pipe Type A Type B1 Type C Number Size 5.0 Micron 1.0 Micron (.01 ppm downstream
Inlet/Outlet Particulate Coalescing remaining oil content)
WR( )-0250 2" NPT F35-0
C-0
00 M35-0C-S00 M35-0C-000
WR( )-0300 2" NPT F35-0
C-0
00 M35-0C-S00 M35-0C-000
WR( )-0400 2" NPT F35-0
C
-000 M36-0C-S00 M36-0C-000
WR( )-0500 2" NPT F35-0
C
-000 M36-0C-S00 M36-0C-000
NOTE: Recommended filters were selected on the basis of flow capacity—not pipe size.
Page 4 WILKERSON OPERATIONS
Water-Cooled Performance Specifications (60 Hz)
Performance Specifications: Flow Capacity (dm
3
/s) (50Hz)
Air-Cooled Performance Specifications (60 Hz)
Flows* at 37.7° C Comp Full Model Inlet Air Temperature Rating Load Shipping Number 2-4°C Dew Point** Voltage (HP) Amps Weight
(dm3/s/hr)
WRA-0250-4 99 380/50/3 2.0 4.4 660 WRA-0300-4 118 380/50/3 2.5 5.2 675 WRA-0400-4 158 380/50/3 3.2 6.4 690 WRA-0500-4 197 380/50/3 3.8 7.7 700
All inlet and outlet air connections are: 2" NPT. Specifications apply to air-cooled, water-cooled and 50 hertz.
Air flow rates are based on 100 psig (7 bar) inlet pressure and 100°F inlet air temperature.
System
COMPRESSOR DATA Full Model SCFM Load Fan Number Flow Voltage HP Full Load Amps LRA Amps CFM Shipping
WRA-0250-2 250 230/60/1 2.0 9.9 53 12.1 1700 660 WRA-0250-3 250 230/60/3 2.0 6.6 49 8.8 1700 660 WRA-0250-4 250 460/60/3 2.0 3.3 24 4.4 1700 660
WRA-0300-2 300 230/60/1 2.5 12.7 64 14.9 1700 675 WRA-0300-3 300 230/60/3 2.5 7.7 49 9.9 1700 675 WRA-0300-4 300 460/60/3 2.5 3.9 24 5.0 1700 675
WRA-0400-2 400 230/60/1 3.2 17.2 95 19.4 1870 690 WRA-0400-3 400 440/60/3 3.2 10.8 65 13.0 1870 690 WRA-0400-4 400 460/60/3 3.2 5.3 27 6.4 1870 690
WRA-0500-2 500 230/60/1 3.8 21.5 46 23.7 1870 700 WRA-0500-3 500 230/60/3 3.8 13.3 92 15.5 1870 700 WRA-0500-4 500 460/60/3 3.8 6.6 116 7.7 1870 700
System
COMPRESSOR DATA Full Model SCFM Load Number Flow Voltage HP Full Load Amps LRA Amps Shipping
WRA-0250-2 250 230/60/1 2.0 9.9 53 9.9 660 WRA-0250-3 250 230/60/3 2.0 6.6 49 6.6 660 WRA-0250-4 250 460/60/3 2.0 3.3 24 3.3 660
WRA-0300-2 300 230/60/1 2.5 12.7 64 12.7 675 WRA-0300-3 300 230/60/3 2.5 7.7 49 7.7 675 WRA-0300-4 300 460/60/3 2.5 3.9 24 3.9 675
WRA-0400-2 400 230/60/1 3.2 17.2 95 17.2 690 WRA-0400-3 400 440/60/3 3.2 10.8 65 10.8 690 WRA-0400-4 400 460/60/3 3.2 5.3 27 5.3 690
WRA-0500-2 500 230/60/1 3.8 21.5 46 21.5 700 WRA-0500-3 500 230/60/3 3.8 13.3 92 13.3 700 WRA-0500-4 500 460/60/3 3.8 6.6 116 6.6 700
Installation Instructions
NOTE: ALL ELECTRICAL AND MECHANICAL CONNECTIONS MUST BE MADE BY A QUALIFIED PERSON.
1. The dryer needs to be installed in a well ventilated area. There needs to be 12" (30 cm) clearance for the condenser air inlet of the dryer.
2. In the location the dryer is installed the ambient temperature should not exceed 110°F (43°C) or fall below 40°F (4.4°C).
3. The inlet compressed air should not exceed 120°F (49°C). NOTE: EXCESSIVE AMBIENT OR INLET AIR
TEMPERATURE WILL RESULT IN UNSATISFACTORY PERFORMANCE AND IF NOT REMEDIED CAN RESULT IN PERMANENT DAMAGE TO THE DRYER.
4. The dryer must be mounted on a suitable structure, on an elevated, or flat and level floor.
5. It is recommended, that the air system be installed similar to the layout shown in Fig.1 Page 2. Using shut­off valves and by-pass valves will allow for servicing of the filters, drain valves, and dryer removal without shutting down the compressed air system.
6. Electric drain connections must be made in manner that it
will not interfere with the flow. The discharge needs to be treated in accordance with local and national EPA code/regulations.
7. Verify that the “service voltage” is correct and that the
dryer is not wired to cycle with the air compressor, the power to the dryer must be continuous.
8. Pressurize the air system, check for leaks and correct.
9. For “water cooled condensers” the water flow rate must
not be lower than what is specified on page 4, and the incoming water temperature must not exceed 80°F.
WARNING: NEVER REMOVE THE ELECTRICAL
CONTROL PANEL WITHOUT TURNING OFF
ELECTRICAL SERVICE DISCONNECT TO THE DRYER
Start-up Procedure
NOTE: THE DRYER HAS A REFRIGERANT CRANKCASE HEATER. PRIOR TO INITIAL START-UP THE CRANKCASE HEATER SHOULD BE ENERGIZED FOR 24 HOURS BEFORE TURNING ON THE DRYER.
POWER TO THE CRANKCASE HEATER IS SUPPLIED WHEN THE MAIN ELECTRICAL SERVICE DISCONNECT IS TURNED ON. THE POWER ON/OFF SWITCH OF THE DRYER HAS NO CONTROL OF THE CRANKCASE HEATER.
LEAVE THE POWER ON/OFF SWITCH OFF
FOR THE FIRST 24 HOURS.
Do not start the dryer with an air load, bypass the airflow before turning on the dryer. By pushing the power switch to the on position the green light will illuminate, the red high temperature light will come on briefly and then go off. If the red light remains on for over 3 minutes thru the dryer off and refer to the trouble-shooting guide. The fan will not come on immediately, it will cycle in accordance with the head pressure. Without any air load through the dryer, the fan may stay off up to 5 minutes before coming on; this is normal. If the dryer is equipped with a refrigerant suction pressure gauge, it should be indicating between 57-65 psig without any air load. Open the air by-pass valve and allow full air flow thru the dryer. Various dryer functions and conditions can be monitored. Temperature at the probe locations will be displayed on digital display (optional) by rotating the selector knob. Simultaneously, pressure, air and refrigerant, can be monitored on the analog gauges.
MAXIMUM INLET AIR TEMPERATURE: 120° F MAXIMUM INLET AIR PRESSURES: 200 PSIG MAXIMUM AMBIENT AIR TEMPERATURE: 110° F MAXIMUM INLET WATER COOLED CONDENSER TEMPERATURE: 80° F
Water Flow Requirements at Various Water
Temperatures
Gallons per hour at the following temperatures
60°F 70°F 80°F
WRW-0250 80 100 132 WRW-0300 100 125 165 WRW-0400 120 150 198 WRW-0500 140 175 231
WILKERSON OPERATIONS Page 5
Loading...
+ 12 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use