Wilkerson WRA-0250-2 Manual del propietario
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.
THIS DRYER USES REFRIGERANT R-22. COMPLY WITH ALL LOCAL,
STATE, AND FEDERAL REGULATIONS CONCERNING REFRIGERANT
WHEN PERFORMING ANY MAINTENANCE OR SERVICE ON THE
REFRIGERATION SYSTEM. ALL REFRIGERATION SYSTEM REPAIRS
OR MAINTENANCE NOT DETAILED IN THIS MANUAL SHOULD BE
DONE BY A QUALIFIED REPAIR PERSON.
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
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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 conta-
minants, 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 harm-
less 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
12
34
7
13
11
14 15
16
12
56
999
810
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 M35-0
C
-000
WR( )-0300 2" NPT F35-0
C
-
0
00 M35-0C-S00 M35-0
C
-000
WR( )-0400 2" NPT F35-0
C
-000 M36-0C-S00 M36-0
C
-000
WR( )-0500 2" NPT F35-0
C
-000 M36-0C-S00 M36-0
C
-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 (dm3/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 shut-
off 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
Page 6 WILKERSON OPERATIONS
Preventive Maintenance Cont.
A. Weekly Checklist
1. Check Air-Cooled condenser coil for contaminants and
clean as required. Check Water-Cooled condenser coil for
proper water flow.
2. Inspect all electrical drains for operation. Turn off the shut-
off valve and depress the manual override switch on the
electrical valve, this will depressurize the discharge line,
and clean the “Y” strainers.
3. Assure dryer inlet temperature does not exceed 120°F
(48°C).
4. Assure dryer ambient temperature does not exceed
110°F (43°C) and there are no ventilation obstructions
around the dryer. Ventilate the area and remove
obstructions as required.
5. Check separator, receiver, filter drains and strainers.
Check filter high differential pressure indicators, and
replace fouled elements as needed.
B. Semi-Annual Checklist
1. Remove and inspect all air system filters for excessive
particulate loading and physical damage. Replace the
filters that show any sign of damage, or if pressure drop
exceeds 7 psid (0,5 bar).
2. Shut off drain shut-off valves and clean “Y” strainers.
Disassemble solenoid valves if necessary and check for
contaminants. Clean as required.
10.38 9.36 7.88 6.50
.50
67.8860.7554.75
35.42
6.75
5.06
1/4" NPT DRAIN
LOCATIONS
POWER CORD
ACCESS
AIR INLET
AIR OUTLET
7.56
10.25
12.87
25.25
29.62
1/2 NPT (FEMALE)
WATER OUTLET
1/2 NPT (FEMALE)
WATER INLET
(WATER
CONNECTIONS
FOR WRW ONLY)
Air-Cooled and Water-Cooled Dryers
Dimensions
WILKERSON OPERATIONS Page 7
The Compressed Air Circuit
Hot, saturated, compressed air first enters the air-to-air heat
exchanger “A”, where it is precooled by the exiting dry outlet
air. By precooling the incoming air, energy is saved by
reducing the heat load imposed on the refrigeration system.
As soon as the incoming air comes in contact with the cooler
air, condensation begins.
The saturated air then enters the evaporator (section “B”)
where the air temperature is reduced to 35°F to 39°F
(1.6° to 3.8°C). The water vapor is condensed and drained
off. The cold air then flows through the separator “C” where,
by gravity and vortex action the condensed water and
contaminants are collected in a “quiet zone” at the bottom of
the separator and are discharged through an automatic drain
valve. Our unique and highly efficient separator design
combines centrifugal action, directional flow change,
impingement, and velocity reduction to achieve superior
performance.
The dry chilled air then reenters the air-to-air exchanger
where it precools the incoming air and in turn is reheated.
Reheating of the air does not affect its dew point. The chilled
air flows in a counter flow thereby assuring high temperature
differential throughout the heat exchanger. The reheating
of the air prevents moisture condensation on the air
system piping.
AIR TO AIR AND EVAPORATOR
FLOW SCHEMATIC
REFRIGERANT IN
REFRIGERANT OUT
X17 Drain
Air Outlet
Air Inlet
EVAPORATOR
“B”
AIR TO AIR HEAT EXCHANGER
“A”
WATER
SEPARATOR
“C”
REFRIGERATION
EVAPORATOR
COIL
Page 8 WILKERSON OPERATIONS
The refrigerant compressor (“A”) increases the pressure and
the temperature of the returning suction vapor containing the
latent heat removed from the air by the evaporator (“B”). This
high pressure vapor is then condensed by being cooled in the
condenser (“C”). The condenser surrenders the heat to the
surrounding ambient.
The liquid refrigerant flows from the receiver through a liquid
line heat exchanger located in the suction line (“H”), through
the filter/dryer (“E”), and the the thermostatic expansion valve
(“F”), which regulate the flow of refrigerant into the evaporator
(“B”). The liquid refrigerant removes the heat from the
compressed air by evaporation. The hot-gas bypass valve
(“G”) controls the temperature of the evaporator by sensing
low evaporator pressure and injecting hot discharge gas to be
mixed with the liquid refrigerant entering the evaporator,
creating an artificial load during low load operation to prevent
ice from forming in the evaporator.
The refrigerant now flows to the suction accumulator (“D”),
where any liquid refrigerant is intercepted allowing only vapor
to return to the compressor completing the refrigeration cycle.
Refrigeration Circuit
SUCTION
ACCUMULATOR
(D)
EXPANSION
VALVE
(F)
HOT GAS
BY-PASS VALVE
(G)
TXV
BULB EXTERNAL
EQUALIZER
LINE
FILTER
DRYER
(E)
EVAPORATOR
(B)
LIQUID
LINE HEAT
EXCHANGER
(H)
COMPRESSOR
(A)
CONDENSER
(C)
AIR FLOW
DISCHARGE SUCTION
WILKERSON OPERATIONS Page 9
CONTROL PANEL COMPONENTS
Item Description Part Number
1 On/Off Switch 87-379-000
2 High Temperature Light 87-382-000
3 Air Pressure Gauge 49-111-000
4 Refrigerant Pressure Gauge 49-093-000
5 Digital Display 87-508-000
6 Selector Knob 87-470-000
Check air compressor aftercooler system. Clogged or fouled heat exchanger surfaces in the aftercooler (water or air cooled) are
the principal cause of high inlet air temperatures to dryer.
Check air compressor as well. Lack of lubrication, excessive wear, compressor undersized (i.e. substantial increase in air
consumption without adding to compressor capacity: oil cooler malfunction, etc.)
If high ambient temperature is the problem, immediately begin to cool dryer area with ventilating fans, open windows, louvers,
etc. Sustained high temperatures will damage dryer.
Dryer Indicates “High Inlet Temperature”
Este manual sirve para los siguientes modelos
11
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