Hydrogen Dryer 4q272a

LQS-IICSA REFRIGERATING HYDROGEN DRYER

OPERATION MANUAL

JIANGSU P. R. of CHINA JIANGSU XINZHONG TECHNOLOGY LNC.

LQS-IICSA REFRIGERATING HYDROGEN DRYER OPERATION MANUAL

CONTENTS CLAUSE NO.

DESCRIPTION

PAGE NO.

1.

FOREWORD ....................................................................................................................2

2.

TECHNICAL DATA ...........................................................................................................3

3.

SPECIFICATIONS............................................................................................................4

4.

INSTALLATION AND ADJUSTMENT ...............................................................................5

5.

GAS DRYER OPERATION / SHUT DOWN .....................................................................7

6.

ATTENTION POINTS DURING OPERATION AND DAILY MAINTENANCE....................7

7.

INPUT METHODS OF PROGRAMM FOR PROGRAMMABLE CONTORLLER..............8

8.

OIL REPLACING (DRAIN) METHOD FOR REFRIGERATING COMPRESSOR............10

9.

VACUUM PUMPING METHODS AND STEPS OF THE REFRIGERATING SYSTEM...10

10.

METHODS AND STEPS FOR CHARGING OR COMPLEMENTING FREON ...............12

11.

FAULT ANALYSIS AND MAINTENANCE OF REFRIGERATING SYSTEM ...................13

12.

MARK CHART (See Fig.11) ...........................................................................................13

13.

MATTERS NEEDING ATTENTION ................................................................................13

APPENDIX 1: RUN PROGRAM OF LQS-IICSA PROGRAMMABLE ...........................................14 APPENDIX 2: LIST OF ELECTRIC COMPONENTS AND PARTS...............................................16 APPENDIX 3：TABLE OF R12 TEMPERATURE VS SATURATION VAPOR PRESSURE...........17 APPENDIX 4: Brief Introduction to SE-11R-EX Programmable Logic Controller (PLC) ...............19 APPENDIX 5: Attached Drawing List............................................................................................22

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1.

FOREWORD

LQS-IIC Series Refrigerating Hydrogen Dryer (hereinafter referred as to Dryer) is a Kind of main equipment designed for decreasing the hydrogen humidity inside of the hydrogen-inner cooled generator by means of refrigerating, which is one of the main measures to improve the efficiency of the hydrogen inner cooled generator and ensure power plants to be running safely and smoothly. The product is mainly used for drying hydrogen from 200 to 600MW hydrogen inner cooled generator and in the hydrogen generation station. Adopted the programmable controller, LQS-IICSA Programmable Electrical Control System can control the operation of the Dryer by means of the programmer procedure according to the operation conditions. As the AC or is replaced by the solid-state relay (SSR), the Dryer has such characteristics as high sensitivity, excellent reliability simple composition and structure and convenient maintenance. Because of SSR applied, there is no point in the control section; the device's features are of good explosion-proof with safety and reliability. Since the hot-air defrosting technique with high effect has been adopted in the refrigerating system so that the defrosting is fast and of good effects. The temperature inside of the chiller can be displayed automatically because the chiller has such a function to display its temperature. The thin-film buttons are used on the control and the controlling is displayed by means of LEDS. The Dryer is characterized by small in volume, light in weight and compact in structure. This product was ed the appraisal by the Ministry in 1994, and it was examined and approved by the National Scientific and Technological Committee in 1995, chosen as “State New Product” and appointed as an accented product in electric machinery in the Ministry of Electric Power Industry. Thank you very much for your selection of our LQS-IIC Series Refrigerating Hydrogen Dryers.

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2.

TECHNICAL DATA PROGRAMMABLE DESCRIPTION LQS-IICSA Compressor Type

NJ2B4-s

Condensing Mode

water cooled (m3/h)

Refrigerating System

Raw Cooling Water Flow Refrigerating Oil Type

Hydrogen system

SUNISO 3GS

Refrigerating Oil Injection Volume Per One

(L)

Refrigerant Type

1.1 R12

Refrigerant Injection Quantity Per One

(kg)

6.5

Refrigeration Compressor Capacity

(kW)

3.72

Operation Pressure

Electric Control System

≥1.7

High Pressure

(MPa)

0.4~1.2

Low Pressure

(MPa)

0~0.2

Motor Power

(kW)

3.0

Max Hydrogen Pressure

(MPa)

1.0

Hydrogen Treatment Capacity Max

(Nm3/h)

100

Dew Point

(℃)

20

H2 Outlet Dew Point

(℃)

≤-5

Defrosting (Regeneration ) Time

(min)

3~5 415VAC 50 Hz 3φ

Power Supply Input Power

(kW)

Operation Mode

Single Device Operation Ⅱ CT1

Explosion-proof Grade

Dimension ( L×W×H )

4.0

(mm×mm×mm)

Weight

(kg)

Use for Generator Capacity

(MW)

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1450×850×1450 800 200~600


3.

SPECIFICATIONS

3.1 Device Composition (See Fig. 01) The Dryer is mainly composed three parts: refrigerating system, hydrogen moisture removal system and electrical control system. The refrigerating system consists of a refrigerating compressor unit, a thermal expansion valve and an evaporator. The hydrogen moisture removal system is made up of a heat recovered, two coolers and a water tank. And the electrical control system consists of an electric control box, a defrosting solenoid valve, a temperature controller, a water level controller. 3.2 System Configuration and Operating Principle (See Fig. 02) 3.2.1 Refrigerating System The refrigerating compressor sucks in the low pressure gas of the refrigerant from the evaporator. After compressed, it turns into a high heat and high pressure gas, then comes into the condenser, and makes heat exchanging with air (or water). And then releases the heat refrigerant absorbed in the evaporator and the heat produced by the work done of the compressor. Now the high temperature and high pressure gas has been condensed into liquid refrigerant with high pressure. The high pressure liquid refrigerant, then through the receiver and dry filler after throttling and pressure reducing by a thermal expansion valve, it comes into the evaporator and absorbs the heat of hydrogen in the cooling unit, and makes refrigerant be boiling and evaporate it into gas, which comes into the compressor via the suction pipe and will be compressed by the compressor again. Repeating the process again and again, the heat in hydrogen is absorbed constantly. The temperature of moisture in hydrogen decreases under that of the dew point. The moisture will be separated out, achieving the result of freezing and removing the moisture. 3.2.2 Hydrogen Moisture Removal System 3.2.2.1 Heat Recovered The heat hydrogen gas with moisture from the generator comes into one of operation dryer, first it is with cold hydrogen gas (return gas) to make heat exchanging in heat recovered so as rising return gas temperature and make inlet gas temperature down. It is the first step of temperature decreasing to remove moisture. 3.2.2.2 Cooler The heat hydrogen gas with moisture ed through the heat recovered comes into the cooler via the connection pipe, making heat exchanging on the surface of the evaporator of the refrigerating system. The temperature of the hydrogen decreases under that of the dew point so that the moisture will be separate out from hydrogen with frost form. And the drying hydrogen is returned to the generator through the heat recovered again. 3.2.2.3 Water Tank The condensed water discharged from the cooler drains into the water tank via the drain pipe. When the water in the tank reaches a certain volume the water level switch will send out an alarm signal at local and remote. Then the drain valve should be opened to drain the water out. 3.2.3 Electrical Control System (See Fig. 06) 3.2.3.1 Single device operation

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If only Dryer MKG50 works as an operating device, the main power switch (-Q01) of Dryer MKG51 should be putted it turns off and the valve located at inlet of Dryer MKG51 should be turned to close. The Dryer MKG51 is out of service. Press down the buttons of "S.D." and “Defrost” and then press Button “Start”, Dryer MKG50 starts to work as a single device self-cycling operation to remove moisture from hydrogen gas. The protection system of refrigerating module is set a pressure protection, a phase- open protection and an over load protection. The reliable diaphragm solenoid valve should be adopted for defrosting. The water tank is equipped with a water level switch, which the capacity is 14L. When the water volume in the tank reaches to 10L, the level switch is actuated a light signal alarm at local and sent it to remote (dry ). 4.

INSTALLATION AND ADJUSTMENT

4.1 Installation (See Fig. 03, Fig. 04 and Fig. 05) Before installation, check carefully the moisture device to see if there is any damage caused by the transportation, which could make some influence upon the product performance, if any, solve it in time. Before installation please read this Operation Manual carefully. 4.1.1 The installation ambient conditions should meet the following requirements: 4.1.1.1 Location with good ventilation, clean air with less dust, having neither corrosive gas nor the direct sunlight. 4.1.1.2 The environment temperature should be lower than 50 deg C, the relative humidity should be less than 95%. 4.1.1.3 Enough space should be left in the installation place for the purpose of easy operation, repairing and maintenance. 4.1.1.4 Normally the dryer should be installed indoor, if it is necessary to install it outdoor, the water-proof and antifreezing measures are needed. 4.1.1.5 The foundation of the dryer should bear the weight of the device and prevent from sharp vibration. 4.1.1.6 The dryer should be placed on 6m-floor or 0 m-floor of the lower part of the generator. In order to reduce the fluid resistance in the pipe, the shorter of the hydrogen pipe, the better and the less number of the bend, the better. 4.1.2 The flow direction of hydrogen should be identical with the mark on the inlet/outlet of the dryer. Reverse connecting is forbidden. 4.1.3 If the condenser of the compressor is of a water- cooled type, the water flow direction should be identical with the mark on the inlet/outlet of the dryer. Reverse connecting is strictly forbidden. 4.1.4 The diameter of the inlet/outlet pipe of the water-cooled condenser should be 3/4 inch. The cooling water must use the pure water, Discharge of water ≥1.7m3/h, the enters and the exportation differential pressure of the cooling water ≥0.2MPa. 4.1.5 The gas purging in the dryer should be done at the same time of the generator purging period. When replacing, turn on the hydrogen inlet and outlet valves. Valves AA501 and AA502 are as for drain in replacing period. 5/34


4.1.6 The steel pipe connecting between the generator and the dryer .The U-form bend in the pipe is forbidden, if any, a blow-down valve should be supplied at the lowest point of the bend. 4.1.7 The grounding of the dryer should be reliable when the electric mounting is carried out. 4.2. Adjustment 4.2.1 Preparations before adjustment 4.2.1.1 Check all the connecting nuts of each pipe in the refrigerating system, to see if there is any looseness and check the leakage at all the connectors by means of a halogen leak detector or by suds (Refrigerant R12 has been filled into the condenser before delivery). 4.2.1.2 Check the oil-level through the oil level gauge of the refrigerating compressor. The oil level shouldn't be lower than the “lowest level line” (Refrigerating Oil SUNISO 3GS has been filled into the compressor before delivery). 4.2.1.3 Adjusting the pressure of the pressure controller in the compressor module to 1.5MPa at high pressure and 0-0.02MPa at low pressure (The pressure has been adjusted before delivery). 4.2.1.4 Turn on the inlet/outlet valve of the hydrogen pipe connecting between the dryer and the generator. 4.2.1.5 Anti-clockwise turn fully to open suction valve AA001, discharge valve AA002 and liquid valve AA003 of the refrigerating condenser. The discharge valve AA002 should be returned to close 1/4 to 1/2 circles after fully open. 4.2.1.6 Check the three-phase power supply, the voltage should be 415V± 10%, otherwise it cannot be started. After the above-said items have been fulfilled, the device could be started for adjusting or calibration. 4.2.2 Adjustment and calibration. 4.2.2.1 Electric calibration (See Fig.6) Calibration for the single device operation (a) Insert the programmable processor into the programmable controller, (Attention the power supply should be turned off first), then turn on the power supply, check the run program and check the working, defrosting and interval time. (Before delivery, the run program has been input. For the checking and alteration methods, please see Section 7). (b) Time adjusting Range adjusted for working time:

0.5～2 h

Range adjusted for defrosting time:

3～5 min

Range adjusted for time intervals:

15～60 min

(All the above are the time range adjusted, and the actual value should be fixed according to the real working conditions) (c) After then, the power supply should be turned off, and the processor should be taken out. (d) Turn on the power supply.

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(e) Press down “S.D.” and “Defrost” buttons. (f) Press down “Start” button, the dryer will carry out both refrigerating and moisture removing. 4.2.2.2 Refrigerating adjustment After running of the device, adjust finally the thermal expansion valve DP101, making sure that the pressure valve of the low pressure gauge of the compressor should be within 0.02-0.1MPa. (After the device running for a space, some frost may appear on the surface of the air intake duct in the front of the snifter valve of the refrigerating compressor). If there is no abnormal event, the device comes into the automatically alternative running status. As 3 UA Thermal Overload Relay (-K03) has a good reliability of differential open-phase protection. If such open-phase takes place, the fault should be removed, and reset manually –K03, the dryer can start again. 5.

GAS DRYER OPERATION / SHUT DOWN

5.1 Starting Up After calibration, the dryer withdraws from running because of other reasons, if it is needed for it to run, the starting up methods and steps are as following. Single device running 5.1.1 First checking all the valves and the power supply according to 4.2.1.4 to 4.2.1.6 of Section 4. 5.1.2 Turn on the power supply of the dryer (“Power" indicator will be lit up) 5.1.3 Press down Buttons “S.D.” and “Defrost” (both the two indicators are lit up but “Defrost” Indicator is green) 5.1.4 Press down Button “Start”. (“Refrigerating” Indicator is lit up). The dryer is put into the self-cycling operation, (When defrosting is taken place, its indicator will be turned red from green). 5.1.5 Check all the parts of the dryer to see if its operation is normal. 5.2. Shut Down 5.2.1 Press down Button "Stop" ("Refrigerating" Indicator is lit up) 5.2.2 Switching OFF the power supply -Q01 of the dryer. (“Power” Indicator will go out). 6.

ATTENTION POINTS DURING OPERATION AND DAILY MAINTENANCE

6.1. Points for Attention during Operation 6.1.1 Check the oil level of the compressor through the oil gauge frequently and make sure that the height of the oil be neither lower than the lowest oil level line nor higher than 2/3 of the oil tank, otherwise, oil charging or discharging will be necessary. 6.1.2 Check frequently the pressure gauge of the compressor to see if the high and the low pressures are within the specified ranges. 6.1.3 Pay attention to the compressor to see if it works normally, or if there is any abnormal sound can be heard. 6.1.4 Pay attention to all the connecting points to see if there is any leakage of oil, normally the oil

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leak position is in the same place of the leakage position, if any, stop the device and solve it in time, but the open fire is strictly forbidden at that time. 6.1.5 Check frequently the water level through the water level gauge. The volume of the water left cannot be over 2/3 of the height of the water level gauge. The water left should be discharged once a day(Within a few days after the dryer is put into service, or after hydrogen is complemented, there may be much water left, so in creasing the draining times is needed). 6.2 Routine Maintenance for the Refrigerating Compressor CHECKING ITEM

DAILY MONTHLY

YEARLY

REMARKS

Checking the oil volume of the compressor

#

See Para4.2.1.2

Checking High/Low Pressure

#

See Section 2

Abnormal sound by the compressor during operation

#

Hearing

Perfection of the grounding wire Damage of the electric wirings Looseness of the terminals

#

Visual check

#

Visual check

Safety device

#

Visual & instrumental check

Electric loop

#

Visual & instrumental check

Oil pollution of the compressor

#

Visual and sampling check

Attention: When Dryer normal operation, The high and the low pressure manometer indicated value of the refrigeration compression should conform to the pressure scope which "Technical Parameter" center stipulated, the snifter pipe of the refrigerates compressor surface should be rime, Dryer disposition the number to reveal the temperature to demonstrate the meter demonstrated temperature assumes the drop tendency. When the dew point meter ( provides) reports to the police, should inspect the wet installment refrigeration system the working condition: If the high and the low pressure instructed value of the refrigeration compression is not normal (Dryer disposition number to reveal temperature to demonstrate meter demonstrated temperature stays at a high level, snifter pipe surface also does not have rime), this time, must move Dryer withdrawal movement, cuts spare to Dryer investment movement, before the Dryer movement to have to confirm already purified processing, then according to " Dryer Starting Up " to carry on the operation. Dryer according to "Refrigeration System trouble analysis And Processing" to the breakdown to carry on the inspection, the adjustment or the service. If Dryer movement to be normal, should inspect other systems (for example to connect wet installment hydrogen pipeline valve whether does turn on, hydrogen pipeline whether stops up). 7.

INPUT METHODS OF PROGRAMM FOR PROGRAMMABLE CONTORLLER

7.1 Programmer Installation

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Turn off the power supply of the electric control box first, insert the programmer into the programmable logic controller, then turn on the power supply. 7.2 Program Input Methods First put the toggle switches to the position of PRG.. Program text Input melted 0000 STR 1 Press down STR SHF 1 ENT 0001 OUT 20 Press down OUT SHF 20 ENT 0002 STR 1 Press down SHF 1 ENT 7.3 Program Checking Method Taking the above-said programs as examples, put the toggle switch to position “RUN”, the window will display “0000”. 7.3.1 Press down “NXT”, it will display “0001”, the value of “0000”, now Indicator “STR” is lit up. 7.3.2 Press down “NXT”, it will display “0020”，the value of “0001”, now Indicator “OUT” is lit up. 7.3.3 Press down “NXT”, it will display "0001", the value of “0002”, now Indicator “STR” is lit up. If Button “PRV” is pressed again, it will display “0020”, the value of last “0001”, now Indicator “OUT” is lit up. If the content of “0001” is needed to be seen again, press down “SHF” 、“1” (or “0001”) and “NXT”, it will display "0001". Press "NXT" once more again, it will display “0020”, the value of this statement. Now, Indicator "OUT" is lit up. 7.4 Time Value Changing LQS-IICSA Refrigerating time 0067, 0071 Defrosting time 0076, 0080 Interval time 0085, 0089 Among the above said statements, Statements 0067, 0076, 0085 of LQS-IICSA are value adjusted by a counter, the range of which is 0~9999, while 0071,0080,0089 of LQS-IICSA are values adjusted by a timer, the range of which is 0~999.9 seconds. The time values of refrigerating, defrosting and interval time are the product of the values adjusted by the counter times those adjusted by the timer. It is needed to pay attention that in order to ensure the timing accuracy, the value adjusted by the counter should be taken as small as possible, and that of the timer, as big as possible. Example: Changing value 4 of 0067 into value 3 Steps: 7.4.1 First put the toggle switch to Position “PRG” (displaying “0000”) 7.4.2 Press down “SHF”, “0067”, “NXT” (displaying “0067”) and “NXT” (displaying value of “0004”) 7.4.3 Press down “SHF”, “3” (displaying value of “0003”) and “ENT” (displaying “0068”) 7.4.4 Put the toggle switch to Position “RUN”, turns off the power supply, take out the programmer. 9/34


Now the changing is completed. 7.5 Clearing All the Memory Contents Press down CLR, SHF, 348, DEL, and NXT. 7.6 Clearing Method to Cancel the Mal-operation (when “E01” is displayed) Press down CLR.

8.

OIL REPLACING (DRAIN) METHOD FOR REFRIGERATING COMPRESSOR

First of all adjust the pressure controller to make the low pressure be -0.1MPa, then start the compressor and turn the valve rod clockwise to turn off Snifter Valve AA001 of the compressor. When the pointer of the low pressure gauge goes down to the specified limit, the pressure controller comes into operation, the compressor stops working automatically. When the low pressure goes up again, the compressor comes into operation again. In this way, the compressor works intermittently for several times, the low pressure does not go up any move. Then the power supply should be cut off and Discharge Valve AA002 of the compressor should be turned off by means of turning clockwise its valve rod. Screw off the plug of the oil filler hole (or screw off the plug of the discharging hole), charging (or discharging) Oil 3GS to the specified height. (Any other lubricating oil than refrigeration oil is forbidden to be filled in), then tighten the plug wrapped with new adhesive tape to block up the oiling hole. Loosen a little the connector of the piping connecting the high pressure gauge and start the compressor. Put your hand over the loosened connector of the piping of the high pressure gauge, some air drained off should be felt. Once there is no air drained off, fasten the pipe connector of the high pressure gauge and turn off the compressor immediately. Now the whole process of oil charging (or discharging) is totally finished. Before operating, Snifter Valve AA001 and Discharging Valve AA002 should be turned on at first, and then the dryer could be started for operation and come into service. The leakage should be tested at the loosened positions of oil charging (or discharging) by means of a halogen leak detector or soap suds. 9.

VACUUM PUMPING METHODS AND STEPS OF THE REFRIGERATING SYSTEM

The purpose of vacuum pumping is to remove and clean up the residual gas and moisture and to ensure the tightness under vacuum conditions. There are two vacuum pumping methods, one is used by the compressor of the dryer of its own, the other is used by means of a vacuum pump. 9.1 Vacuum Pumping by Means of the Compressor of the Dryer of its Own. 9.1.1 Vacuum pumping method when there is no refrigerant in the refrigerating system After repairing, the components and/or parts repaired in the refrigerating system, it is used for carrying out vacuum pumping when there is no refrigerant in the refrigerating system, this kind of method can be applied. The detail methods and steps are as following: 9.1.1.1 Turn on Discharge Valve AA002, loosen the multipurpose channel cover of Discharge Valve AA002 in order to discharge the air, and meanwhile turn on all the other valves in the system. 9.1.1.2 Starting the compressor for air exhausting until the sound of air exhausted from Discharge Valve AA002 cannot be heard, then connect a piece of flexible pipe to the multipurpose channel temporarily, the other end of the flexible pipe will be inserted into a container filled with refrigerant in

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order to observe if there is any air bubbles in the container. It will be OK if there is no air bubble within 5 minutes. 9.1.1.3 After vacuum pumping, screw in tightly the multipurpose channel cover of Discharge Valve AA002, then the device may be stopped. 9.1.2 Vacuum pumping method when there is some refrigerant in the refrigerating system When there is some refrigerant in the refrigerant storage tank in the compressor module, Charging Valve AA003 and Discharge Vive AA002 should be turned off, the vacuum pumping at low pressure and steps are as following: 9.1.2.1 First of all, screw off the cover connecting the high pressure gauge to the multipurpose channel of Discharge Valve AA002, turn on Snifter Valve AA001. Starting the refrigerating compressor module to carry out vacuum pumping at low-pressure section. 9.1.2.2 When the sound of air exhausted cannot be heard in Discharge Valve AA002, connect a piece of flexible pipe to the multipurpose channel temporarily, the other end of the flexible pipe will be inserted into a container filled with refrigerant in order to observe if there is any air bubbles in the container. It will be OK if there is no air bubbles within 5 minutes. 9.1.2.3 After vacuum pumping, screw in tightly the multipurpose channel cover of Discharge Valve AA002, then the device may be stopped. 9.1.3 Air Exhausting Methods of the Refrigerating System When a small amount of air is entered into the refrigerating system, the refrigerating efficiency could be affected, so, it should be removed out. First the leakage point(s) at low pressure should be checked and remedied. Then remove the air in the system. The methods and steps are as following: 9.1.3.1 First of all turn off Valve AA003, and then turn on Valves 101 and 102. 9.1.3.2 Starting the refrigerating compressor module. 9.1.3.3 When the negative pressure after pumping appears and does not drop down on the low pressure gauge, stop the system. 9.1.3.4 Loosen the multipurpose channel cover of Valve AA002 (Note: The cover should not be disconnected), air in the system will go out of the multipurpose channel of Valve AA002. At that time, touch the air exhausted by your hand, when you feel cold (normally it does not excess 10 seconds). The multipurpose channel cover of Valve AA002 should be screwed in tightly: 9.2. Vacuum Pumping by Means of a Vacuum Pump This method applies to vacuum pumping any component and/or parts repaired in the refrigerating system. The methods and steps are as following: 9.2.1 Apply a copper pipe (or a Nylon pipe) to connect the multipurpose hole of Valve AA001 of the device compressor and the vacuum pump. 9.2.2 Turn on Valve AA001, Valve AA002 and Valve AA003 of the refrigerating system in the dryer (Note: turning anti-clockwise the valve rod, the valve will be turned on, when Valve AA001 is fully turned on, then it is necessary to turn them clockwise for 1-2 turns.) 9.2.3 Cut off the system power supply of Solenoid Valve AA004 and then connect it to an external

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power of 415VAC, and make the valve be turned on. 9.2.4 Start the vacuum pump for pumping the whole system and when the pressure value on the vacuum meter is less than 0.095MPa, turn the valve rod anticlockwise of Valve AA001 so as to close the multipurpose hole. 9.2.5 Disconnect the vacuum pump and the connecting pipe. Put the nut with washer on the multipurpose hole of Valve AA001 of the compressor then screw it in tightly. 9.2.6 Disconnect the external power of Solenoid Valve AA004 and reset it to the system power supply. When the above-said work is finished, the vacuum pumping is also completed. 10. METHODS AND STEPS FOR CHARGING OR COMPLEMENTING FREON 10.1 Methods and Steps for Charging Freon Freon charging is under such conditions that the vacuum status exists inside of the refrigerating system. The method for Freon charging is as following: 10.1.1 Turn anti-clockwise fully the valve rod of Valve AA001 of the compressor and shut off the multipurpose through hole of Valve AA001. Use the copper pipe mounted with a silica-gel dryer to connect the multipurpose through hole and the nozzle of the Freon cylinder by its both ends respectively. 10.1.2 The Freon cylinder should be put in positive direction on a platform balance so as to weight Front filled. 10.1.3 Turn on slightly the Freon cylinder and then turn it off immediately, and loosen the nut of the multipurpose through hole of Valve AA001 in the compressor. The air will be rid from the pipe by the refrigerant, and then tighten the nut. 10.1.4 Turn on the valve of the Freon cylinder. (If the cylinder is fully filled with Fron, the valve should be turned on slightly in order to prevent from damaging the cylinder) then weight and record the weight of the cylinder. 10.1.5 Turn on Valve AA002, then press down Button "S. D." and Button "Start", now the dryer is working. 10.1.6 Turn on clockwise the valve rod of Valve AA001 of the compressor by 1-2 turns; the refrigerant vapor will be sucked slowly by the compressor. 10.1.7 When Freon in the system is filled up to the required quantity, the nozzle of Fron cylinder should be turned off immediately, then turn anti-clockwise the valve rod of Valve AA001 to the end position, shut off the multipurpose through hole, disconnect the connecting pipe and Freon cylinder. The nut with washer should be put on the multipurpose through hole and screw in it tightly. 10.2 Freon Complementary Methods When the refrigerant in the refrigerating system of the dryer is not enough because of leaking, and after the leaking point(s) is remedied, appropriate amount of refrigerant should be supplemented. If some air has been entered the refrigerating system, it should be discharged first according to the methods in 8.1.3, then the refrigerant could be supplemented. The detail methods and steps are as following: 12/34


10.2.1 Turn on Valve AA001, Valve AA002 and Valve AA003 (Turning anti- clockwise the valve rod, the valve will be turned on). 10.2.2 Screw off the nut of the multipurpose through hole of Valve AA001. Use the copper pipe (or Nylon pipe) mounted a silica gel dryer to connect the multipurpose through hole of Valve AA001 and the nozzle of the Freon cylinder by its both ends respectively (The brand and the type of Freon must be identical with that specified in Operation Manual. The cylinder should be put in positive direction in order to fill the refrigerant vapor in the refrigerating system. The liquid of the refrigerant is absolutely not allowed to be filled in). 10.2.3 Turn on slightly the Freon cylinder and then turn it off immediately and loosen the nut of the multipurpose through hole of Valve AA001 in the compressor, the air will be rid from the pipe by the refrigerant and then tighten the nut. 10.2.4 Turn on the valve of the Freon cylinder (If the cylinder is fully filled with Fron, the valve should be turned on slightly in order to prevent from damaging the cylinder). 10.2.5 Press down Button "S.D." and Button "Start", now the dryer is working. 10.2.6 Turn on clockwise the valve rod of Valve AA001 of the compressor by 1-2 turns; Refrigerant vapor will be sucked slowly by the compressor. 10.2.7 Observe carefully the air intake duct of the compressor, to see if the frost appears on Valve AA001. The Freon cylinder nozzle should be turned off immediately, then turn anti-clockwise the valve rod of Valve AA001 to the end position, shut off the multipurpose through hole, disconnect the connecting pipe and Freon cylinder. The nut with washer should be put on the multipurpose through hole and screw in it tightly. When the above-said operations are over, that means the complementary of Freon is fulfilled and the device can be put in service. 11. FAULT ANALYSIS AND MAINTENANCE OF REFRIGERATING SYSTEM (See the attached Table) 12. MARK CHART (See Fig.11) 13. MATTERS NEEDING ATTENTION 13.1 Before the use, please carefully reads this instruction booklet, and will preserve well prepares consults in the future. 13.2 Not es through specialized training or does not have the specialist please do not at will disassemble this equipment in the field. 13.3 Must not change, the increase without this factory agreement or demolish this equipment and the part, otherwise creates consequence this unit is not responsible. 13.4 To this instruction booklet content, if discovers unclear place, please s with this factory.

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APPENDIX 1: RUN PROGRAM OF LQS-IICSA PROGRAMMABLE 0000 STR 1 0001 OUT 20 0002 STR 1 0003 OUT 17 0004 STR 151 0005 STR 152 0006 STR 142 0007 OR 22 0008 AND STR 0009 OR STR 0010 MCS 0011 STR 5 0012 OR 142 0013 OR CNT 603 0014 OR 22 0015 OUT 155 0016 MCS 0017 STR CNT NOT 602 0018 AND 2 0019 AND 3 0020 OUT 22 0021 STR CNT 601 0022 OUT 156 0023 STR CNT 601 0024 OUT 143 0025 STR 153 0026 AND 143 0027 OUT 23 0028 MCR 0029 STR NOT 24 0030 AND NOT 22 0031 OUT 157 0032 MCR 0033 STR 152 0034 MCS 0035 STR 143 0036 OR NOT 22 0037 OUT 21 0038 STR 12 0039 AND NOT 23 0040 OUT 142 0041 MCR 0042 STR 4 0043 OR 151 0044 AND NOT 0 0045 AND NOT 7 0046 OUT 151 0047 STR 7 0048 OR 152 0049 AND NOT 0 0050 AND NOT 4 0051 OUT 152 0052 STR 6 0053 OR 153 0054 AND NOT 13 0055 OUT 153

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0056 STR 151 0057 OUT 25 0058 STR 152 0059 OUT 26 0060 STR 153 0061 AND NOT 23 0062 OUT 27 0063 STR TMR 611 0064 STR NOT 155 0065 OR 374 0066 CNT 601 0067 4※ 0068 STR TMR NOT 611 0069 AND 155 0070 TMR 611 0071 900※ 0072 STR TMR 613 0073 STR NOT 156 0074 OR 374 0075 CNT 602 0076 1※ 0077 STR TMR NOT 613 0078 AND 156 0079 TMR 613 0080 120※ 0081 STR TMR 615 0082 STR NOT 157 0083 OR 374 0084 CNT 603 0085 1※ 0086 STR TMR NOT 615 0087 AND 157 0088 TMR 615 0089 900※ 0090 END Note:※Time Statement

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APPENDIX 2: LIST OF ELECTRIC COMPONENTS AND PARTS ITEM

Description

FLAG

Specs & Type

Qt'y

Remarks

1

D.D.Temperature Display

FT001

XMT-102

1

2

Temperature Sensor

FT002

Cu100

1

3

Programmable controller

-U10

SE-11R-EX

1

4

Programmer

-U20

R-21P-EX

1

5

Automatic Circuit Breaker

-Q01

DZ20Y-100/330 30A

1

6

Automatic Circuit Breaker Operating Mechanism

-Q10

7

SSR(Solid State Relay)

-K01

~380/40A

3

8

SSR

-K02

~380/20A

2

9

Cmtroling Transformer

-T01

380V/220V

1

10

Overload Relay

-K03

3UA59/00-1H

1

11

Fuse

-F01~05

RT14-20

5

12

Thin Film ON/OFF Plate

-S41~45

LQS-IIC

1

13

Over Travel Switch

-K10

LX3-11H

1

14

LED(Monocular)

-B01~03 -B05

φ5mm

4

15

LED(Tow-color)

-B04

φ5mm

1

For defrosting

16

Terminal Array

-X01

A21-2015

1

19ts

17

Solenoid Valve

AA004

FDF8MB/380v

1

18

Solenoid Valve

AA005

FDF10MB/380v

1

19

Cooling Fan

AN002-M02 AN003-M03

250F2L-01

2

20

Pressure Controller

-K20

P830HM

1

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1


APPENDIX 3：TABLE OF R12 TEMPERATURE VS SATURATION VAPOR PRESSURE Temperature （℃）

Absolute pressure （MPa）

Temperature （℃）




-70

0. 0123

-29

0.1047

-3

0. 2791

-68

0. 014

-28

0. 1093

-2

0. 2885

-66

0. 0159

-27

0. 1139

-1

0. 2984

-64

0. 0179

-26

0. 1187

0

0. 3084

-62

0. 0202

-25

0. 1236

+1

0. 3186

-60

0. 0227

-24

0. 1288

+2

0. 3291

-58

0. 0254

-23

0. 1340

+3

0. 3398

-56

0. 0284

-22

0. 1394

+4

0. 3509

-54

0. 0317

-21

0. 1451

+5

0. 3622

-52

0. 0353

-20

0. 1509

+6

0. 3737

-50

0. 0392

-19

0. 1568

+7

0. 3856

-48

0. 0434

-18

0. 1629

+8

0. 3977

-46

0. 0480

-17

0. 1693

+9

0. 4103

-44

0. 0530

-16

0. 1758

+10

0. 4227

-42

0. 0584

-15

0. 1825

+11

0.4358

-40

0. 0642

-14

0. 1893

+12

0.4491

-39

0. 0673

-13

0. 1965

+13

0.4626

-38

0. 0705

-12

0. 2038

+14

0.4765

-37

0. 0737

-11

0. 2112

+15

0.4907

-36

0. 0772

-10

0. 2191

+16

0. 5

-35

0. 0807

-9

0. 2269

+17

0.5201

-34

0. 0844

-8

0. 2350

+18

0. 5351

-33

0.0882

-7

0. 2434

+19

0. 5505

-32

0.0921

-6

0. 25208

+20

0. 5663

-31

0.0962

-5

0. 2607

+21

0. 5824

-30

0.100

-4

0. 2698

+22

0. 5889

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(cont.） Absolute pressure （MPa）

+23

0. 6157

+37

0. 8891

+55

1. 3101

+24

0. 6326

+38

0.9108

+60

1. 5171

+25

0. 6507

+39

0. 9344

+65

1.68728

+26

0. 6681

+40

0. 9582

+70

1. 8714

+27

0. 6862

+41

0. 9814

+75

2.0703

+28

0. 7049

+42

1. 005

+80

2. 2792

+29

0. 7239

+43

1. 0301

+85

2. 5108

+30

0. 7249

+44

1. 0548

+90

2. 7545

+31

0. 7627

+45

1. 0803

+95

3. 0156

+32

0.7830

+46

1. 1057

+100

3. 2968

+33

0. 8036

+47

1. 1322

+105

3. 5921

+34

0. 8241

+48

1.1591

+110

3. 9077

+35

0. 8454

+49

1. 1866

+36

0. 8671

+50

1. 2138

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APPENDIX 4: Brief Introduction to SE-11R-EX Programmable Logic Controller (PLC) 1. System Configuration As a kind of industries control device, PLC consists of a U, an Input/output interface, system program and program storage unit. SE-11 series is made up of a PLC with an integrated I/O, the interior of which offers the above-said functions. Fig. 07 is the block diagram of PLC basic units. 2. General Configuration (see diagram as follow) 2.1 State Indicators On the left-up side of the front , there are 4 LED state indicators. They are "RUN" "BATT" "U" and PWR (power) to indicate the working status of SE-11. 2.1.1 RUN: Green indicator, monitor the working status of U. ON: U is in program running status OFF: U is in program not running status 2.1.2 BATT: Red indicator, monitoring the lithium (Li) battery which is used for protecting CMOS RAM to see it is O.K or not. ON: The voltage of Li battery is lower than the voltage that can not preserve the content of the storage. OFF: Li battery voltage is normal 2.1.3 U: Red indicator monitoring U status ON: U is abnormal OFF: U is normal 2.1.4 PWR: Green indicator, monitoring the power supply of internal DC power supply ON: Power Supplying of the internal +5V DC is normal OFF: Power Supplying of the internal +5V DC is abnormal or there is no power of +5V. Note: "ON" of green indicator means working normally while "ON" of red indicator means working abnormally. 2.2 Sockets on the Just under the above said indicators, on the , there is a socket of 26 pins which is used for connecting the programmer or data display unit and EPROM write-in. 2.3 I/O status display On the lower part in the right of the , there is a set of LED which are used for indicating respectively the real time ON/OFF status of 15 inputs (0-7,10-16) and 9 outputs (17,20-27). 2.4 PROM Socket Open the objective plate located in the lower right of the . There is a PROM socket, which can place EPROM or EEPROM there used as program storage.

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2.5 Socket on the side plate On the side plate there is a socket with 9 pins, which is used for connecting a communication adapter (E11DM) and it will be a standard RS- 232 or RS-422 communication port and then it can carry out the data communication with a super seat computer or a super seat PC. 2.6 Li (Lithium) Battery The Li (Lithium) battery, which is used as a spare power supply for CMOS RAM memory is mounted under a cover plate of snap-fastener type. During power cut, Li battery is used for maintaining CMOS RAM as follows: 2.6.1 program in RAM chip 2.6.2 Counting accumulated value of the counter 2.6.3 The status that is needed for power failure memory retention in the stage coils and the internal coils will be effective only when internal Coils 373& 761 are connected by programming. 2.6.4 The contents of Data R400-R577 PLC running mode 2.7 Li Battery Replacement The long service time of Li battery is used as a spare one in SE-11PLC. Normally it can be used for more than 5 years. But its life will become shorter when it is used under mal- conditions (such as at high temperature and/or high humidity). When the voltage of the battery is low, it should be replaced as soon as possible (Battery Type: RB-5). At that time the "BATT" indicator on the of SE11PLC or on the programmer will be lit up, and meanwhile the special inner coil 377 will be connected. 2.7.1 Battery replacing methods: 2.7.1.1 Cut off the power supply of PLC 2.7.1.2 Open the movable cover plate located on the left side of SE-11. Pull out carefully the battery and the connector. 2.7.1.3 Pull out the battery plug, replacing the battery with a new one, the system has enough capability to maintain the contents of CMOS for 10 minutes without power. Pull back the battery and the cover plate in position. Warning: Please pay attention to the used battery when it is handled. The used Li battery cannot be discarded randomly, do not try to recharge the used battery nor make it be short- circuit. Otherwise it may cause battery explosion, burning and releasing harmful substances. 2.7.1.5 Power on and check the battery indicator to see if it went out and check SP377 to see it is off, otherwise check the plugs again. 3. Performance parameter ITEM Control method Programming Scan rate

PERFORMANCE PARAMETER Cyclic operation and Timer operation Ladder diagram language、Stage language 3.5ms(500words sequence control command)

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ITEM Program capacity Program memory Number points for input and output Stage coils Internal coils Special coils Shift Timer and counter Drum controller (10000steps) High-speed counter Data Diagnosing feature

Monitor feature Protection mode Cassette interface

PERFORMANCE PARAMETER LK words CMOS RAM or EPROM、EEPROM Input: 15points(4 points may be used software filter) Output: 9points 72 points (32 points with power failure memory retention) 155 points (59 points with power failure memory retention) 18 points 155 points (59 points with power failure memory retention) 20 points counter: 1~9999 timer: 0.1~999.9sec 0.01~99.99sec 20 PCs 2 points, response: 2 KC’s Number of stage setting: 20 steps Total: 184 (include data and T/C accumulated value ) U abnormality, memory abnormality, battery abnormality, grammar error 24 points of I/O display, U abnormality, battery abnormality, monitoring by the programmer of multi-point operation, ON/OFF checking, timer/counter accumulated value, ’s data monitoring 4 bits Interface circuit built in the programmer

4. Commonly technical condition ITEM Power Operation temperature Existence temperature Ambient humidity Dielectric strength Insulation resistance Environmental air Weight Battery life

TECHNICAL PARAMETER AC 115/230V±15% 47~63Hz 25VA DC 24V±10% Supply to : DC24V±5%, max 100mA 0 to 60℃ -10℃ to 70℃ 5 to 95% (non-condensing) AC 1500V(50/60Hz, 1 min) between power source and external terminal More than 20 MΩ between power source and external terminal No corrosive gases permitted Approx. 2kg including programmer General 2 years, exist 8~10 years

21/34


APPENDIX 5: Attached Drawing List Fig. 01

FIG.1

LQS-II DRYER STRUCTURE (WATER COOLED)

Fig. 02 Fig. 03 Fig. 04 Fig. 05 Fig. 06 Fig. 07 Fig. 08 Fig. 09

SE-11R-EX INPUT CIRCUIT & WIRING DIAGRAM

Fig. 10 Fig. 11

PLC BASIC NUIT

FIG.12

PLC BASIC NUIT

22/34


FIG. 01

LQS-II DRYER STRUCTURE (WATER COOLED)

23/34


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