HIROSS ZANDER division.

Wrong installation, use and handling.

PoleStar Smart refrigeration dryers.

2

Evaporator leaks.

Evaporator leaks are almost always caused by

localized freezing which shows up as swelling.

3

Evaporator construction. Why are compact exchangers more likely to clog

compared to older designs?

Remember the cell telephones from the 1970’s? Like cell telephones, heat exchanger technology has moved on to new, compact technologies.

4

Evaporator construction. High efficiency mini and micro channels offer

multiple advantages. But, they have to be kept clean to remain highly efficient.

Reduced size of heat exchanger and lower air pressure drop; a key energy saving!

Reduced charge of refrigerant; a key ecological impact also for future service issues.

Smaller compressor needed and lower absorbed power.

Smaller product package and footprint; reducing the package price, transit and storage costs.

Increased cooling capacity of exchangers permits downsizing of large systems to be more competitive.

5

Evaporator construction. We can provide shell-and-tube solutions (Large

Capacity Dryers) and finned tube coil versions (Quasar) which are not available in the PST or SPL dryer ranges.

6

Evaporator leaks. Localized freezing is almost always due to solid

particle blockage of scale or typically rust. But be aware that swarf, plastic and other materials left over from the piping installation can also block the unit.

7

Evaporator leaks. If mixed with oil this can often be a sort of sludge.

8

Evaporator leaks. A classic example is to find the inlet stinking of oil

and the outlet perfectly clean!

9

Evaporator leaks.

These solid particles, which are not always rust,

are able to penetrate deep down through the core of the evaporator even to the outlet!

10

Evaporator leaks.

Multi-cooler dryers have more evaporator surfaces

to clog with solid particles so pay extra attention to protect them!

11

Evaporator leaks. So, we have rendered the air section of the dryer

as non-ferrous as possible and rust is coming from elsewhere!

12

Evaporator leaks. Rust is coming from up-stream of the dryer which

is usually plain carbon steel piping exposed to the saturated conditions after the air compressor.

13

Evaporator leaks. This is rust removed

from the inlet of a large capacity dryer in a platinum mill with 30m of piping and no pre-filter.

14

Evaporator leaks. This is why we insist on the need for a pre-filter. In

this site there is no pre-filter and the piping is standard carbon steel which rusts in the saturated conditions upstream of the dryer.

15

Evaporator leaks. But if the pre-filter is also made of un-treated carbon

steel then that can rust too; so try to use Aluminium housings, stainless steel or at least internally paint treated filters.

16

Evaporator leaks. If the inter-connecting piping between the pre-filter

and the dryer inlet is made of carbon steel then that will rust and block the exchanger over time.

17

Evaporator leaks. Here there is a pre-filter but there is an air manifold

and piping between it and the dryers and the risk here is of carbon steel that piping rusting; causing contamination of the heat exchangers over time.

18

Evaporator leaks. This is why we always request a pre-filter very close

to the dryer and recommend non rusting inter-connecting piping. You need to prevent rust entering the dryer!

19

Parker Transair non ferrous piping. Remember that Parker’s Transair division offers you

a complete range of non ferrous very low air pressure drop compressed air piping solutions to help protect downstream equipment!

20

Evaporator leaks. Protect the dryers with rust free Parker filters.

Remember that elements deteriorate over time even

if not used. Max. 18 months. Filters performance deteriorates as the elements become more dirty and bypasses may occur.

Increased air pressure drop also adds running costs.

We advise annual filter element replacement.

21

Parker service reminder tools.

22

Parker service reminder tools. The Parker service reminder has been changed

into a new format which uses a key ring and holder.

23

Parker service reminder tools. The servicereminder.com web site is also very

useful for special client applications such as rail where it is not suitable to use a hanging indicator.

24

Parker service reminder tools. Filters and other

products needing annual service can often be located in inconvenient places.

Place the Parker service reminder at convenient locations for greater visibility to help jog memories for service interventions.

25

Parker service reminder tools. Annual indicator to remind

end users to do service.

Small, easy to use key ring format.

Economical and uses no batteries.

Temperature controlled with food safe ink.

Do not attach to hot or cold surfaces; leave in ambient.

The QR code takes you to the Parker home page.

26

Parker service reminder. A key box is available for

plant maintenance managers to have a single, visual display on their office wall of the Parker service reminders to represent their product status around their factory.

Helps maintain accuracy through constant temperature.

One visual display.

27

Parker service reminder tools.

Supplied ready to use in a

plastic bag.

28

Parker service reminder tools. Remove safety pin and push in slider to activate.

1.

3. 4.

2.

29

Parker service reminder tools. A cable tie can be used utilizing the free slot on the

fob body.

Can be used as a key chain for transport applications.

30

Parker service reminder tools. A 3 month version has been created for the water

fountain product.

31

Compressor failures.

Lack of lubrication

and no oil return.

Excessive cycling.

Lack of refrigerant flow.

Oil contamination.

Inverted phases.

Voltage dips, peaks and imbalance.

32

Compressor failures. Lack of oil lubrication of the

compressor will result in scoring and failure of bearings and the shaft.

33

Compressor failures. Lack of oil lubrication can also cause the orbiting

scroll bearing to seize.

34

Compressor failures.

Poor or no oil return can occur

if the internal orifice of the separator or the filter is blocked. It is important to change the filter during service interventions to the circuit.

35

Compressor failures.

A leaking evaporator will almost

certainly cause compressor failure due to humidity contamination of the oil, which is highly hygroscopic, and becomes acidic. If this acidity is not completely cleaned then repeat compressor failure can occur even just a few weeks after the original replacement.

It is advisable to replace also liquid separators to eliminate accumulated contaminated oil.

Burnt compressors can also be wrongly diagnosed as being caused by an evaporator leak!

36

Compressor failures.

We can provide an acidity test kit 398H271637.

We can also provide acid neutralizer

398H271638 for service interventions.

37

Compressor failures. Remember in case of service visits to add oil

when re-charging. You can assume to lose about 10% of the oil charge from the refrigerant circuit when you pull the charge.

38

Compressor failures. Inverted phases of

the compressor will result in a high dew point warning, scoring and failure.

In reverse operation the orbiting scroll will create a vacuum against the fixed scroll and score metal-to-metal; resulting in failure.

39

Compressor failures. Inverting the power supply phases of three phase

units is easy but fatal for the compressor and difficult to diagnose after the event!

Care is always needed to verify the correct cooling airflow, dew point, pump flow and pressure.

Phase inversion typically occurs on commissioning through the installer paying no attention to this issue.

Phase inversion can occur at any time through temporary disconnections of the power cabling during electrical interventions made on the user’s main board, after a power outage, or even transfer of the product itself.

Remember that the products have an automatic re-start on return of power after an outage.

40

Compressor failures. We have added a three phase monitor to block the

unit in case the user inverts the power supply phases (this protects also the fans).

41

Compressor failures. The phase monitor has both LED’s lit when the

phases are correct and only the green LED lit when the phases are inverted. In that case there is a flashing CP alarm on the dryer’s controller.

42

Compressor failures. Voltage dips outside of +/-10% can cause multiple

component failures.

43

Additional compressor protection. We can provide an optional multi-functional

protection which blocks the unit in case of excessive voltage surge and dips (+/-10%), inverted phases and loss of a phase.

44

Additional compressor protection. This relay has a green LED lit to show power is on, a

yellow LED when the relay is active, and a flashing red LED for an alarm condition.

This is standard on our three phase ATT dryers.

45

Electrical failures. Loose wiring is the common theme with

miscellaneous electrical component failures.

We tighten terminals and connectors in final test and we recommend that you do so too before commissioning.

46

First Aid kits.

Fuses can burn due to

excess current – which is their function of course – but we suspect board replacement can originate from this instead of replacing fuses!

This is why we offer First Aid kits of small electrical parts, including fuses, to be sold with every unit!

47

First Aid service car kit.

We have also created a single service car First Aid

kit for the complete PST120-1800 range.

48

First Aid kit flyers. A flyer is added to each of the dryers, chillers and

aftercoolers to promote the sale of First Aid kits of small electrical parts with every unit!

49

Fan switch upgrade kit.

A KP5 upgrade kit is available for the PST dryers.

50

Structural and packaging. Natural condensation

can also occur on top of the insulation if it has not been correctly sized for the ambient conditions.

Our standard insulation is 10mm thick to cope with the majority of installations but if there are special conditions then special insulation can be quoted as was done for this PSH460W for a tropical ambient.

51

Structural and packaging. The dryers are only for internal installations but we

often receive requests for special painting or galvanized panels. Be aware that we can quote an all AISI304 or 316L option on request which is much better and easier than special painting.

One of six PSH460W

specials with AISI316L

base, panels, top and

compressed air piping, base,

stand, nuts and bolts; multi-

function phase monitor,

electrical panel ventilation

and thicker insulation for a

tropical environment.

52

Structural and packaging. ShockWatch transit

sensors are fitted deter bad handling and to capture dropped and wrongly handled units to the end user.

The sensor has been lowered to improve sensibility.

53

Structural and packaging. Optional wooden cases are available for the full

range and special marking versions can be fulfilled.

54

Structural and packaging. Bad handling is nothing to do with the packaging and

must be registered on the carrier’s delivery note.

Repeat: you can buy a wooden case package option!

55

Customer obligations. To provide correct and complete sizing and

selection data of the product for the application.

Ensure correct installation of the product: structural, electrical, hydraulic and pneumatic.

Not to modify the product.

Correct operation of the product.

Do required service.

Local country obligations, e.g. leak tests or pressure vessel thickness tests.

HIROSS ZANDER division.

Thank you!

Wrong installation, use and handling.