Refrigerated Air Dryer

User manual

GRD 1600 – GRD 2600

Compressed Air Solutions

GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

INDEX

Safety warnings ......................................................................... 1 Safety warnings

1. Introduction .................................................................................... 2
Important:
1.1 Foreword ............................................................................. 2
l Keep this manual with the machine throughout its service life.
1.2 Packaging ........................................................................... 2
l Carefully read this manual before carrying out any operation on the
1.3 Transport ............................................................................. 2
machine.
1.4 Storage ................................................................................ 2
l This machine is designed for PROFESSIONAL USE only. Only use the
1.5 Inspection ............................................................................ 2
machine for the purpose for which it is intended. Improper use of the
2. Installation (see Fig.1).................................................................... 2
machine absolves the manufacturer from all liability.
2.1 Electrical connection (See electric diagrams) ..................... 4
This manual has been compiled to help the final user perform just those
2.2 Condensate drain connection ............................................. 4
operations which do not require removal of the panels.
3. Start-up and operation ................................................................... 4
All other operations which involve the removal of covers from instruments or
3.1 Preliminary checks .............................................................. 4
electrical circuit-breakers using special tools must only be carried out by
3.2 Starting the dryer ................................................................. 4
trained personnel due to the danger of rotating parts or live components.
3.3 Stopping the dryer ............................................................... 5
Unauthorized changing and replacing of any components will be exempt
3.4 Operation............................................................................. 5
from warranty responsibility.
4. Maintenance................................................................................... 6
Each machine is equipped with an electric disconnect device which allows
4.1 Preventive maintenance ..................................................... 6
the operator to work on the machine in absolute safety. This device must
4.2 Disassembling the unit ........................................................ 6
always be used to disconnect the mains supply to avoid any risk of danger
4.3 Refrigerant leaks in the refrigeration circuit ........................ 7
during maintenance work (electric shocks, scalding, automatic start-up,
4.4 Refrigerant charging ........................................................... 7
moving parts and remote control).
5. Calibration (see Fig.2).................................................................... 7
Before servicing the dryer, you should always make sure the compressed air
6. Trouble shooting ............................................................................ 8
circuit is depressurized.
Fig. 1 Installation ................................................................................... 9
The key provided to remove the panels must be kept by the head of
Fig. 2 Calibration ................................................................................. 10
maintenance. When requesting technical assistance or ordering spare parts,
Fig. 3 Electrical Diagram ..................................................................... 11
always quote the model and serial number on the identification plate
7. Warranty Terms and Condition. ................................................... 15
mounted externally on the unit.
8. Contact Information ...................................................................... 19

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GRD Godrej & Boyce Mfg. Co. Ltd.
IMPORTANT: This manual is subject to modification. For the most
comprehensive and up-to-date information, the user is therefore required to
consult the manual supplied with the machine.
All figures to which the see Fig. references in this text can be found at
the end of this manual.
1. Introduction
1.1 Foreword
The dryers are designed to guarantee high quality compressed air and
minimum maintenance.
Please carefully read this manual to obtain maximum performance from your
dryer and ensure its correct installation and start-up in compliance with
manufacturer instructions.
1.2 Packaging
The dryer is packaged with plywood case strapped to a wooden pallet.
Instruction symbols (UNI ISO 780) for the movement, transport and storing
of the product are printed on the two sides of the packing.
User Manual
1.3 Transport
l Keep the unit in an upright position and do not leave it outdoors.
l Only move this machine using a forklift truck with a fork which is able to
handle the weight to be lifted.
l Care should be taken to avoid damaging internal components through
poor handling during movement, installation or use.
l Unpack the machine as close as possible to the installation site.
l Make sure the ambient temperature never exceeds 50℃.
l The manufacturer assumes no liability for damages which may be
caused by decayed or modified packaging.
1.4 Storage
If stored the packaged units must be kept inside, protected from humidity,
direct sunlight and rain, and at a temperature not exceeding 50℃.
Moreover, although stacking is permitted, the maximum weight must not be
more than the value shown on the packaging.
1.5 Inspection
ON receipt of the machine, make sure it has incurred no damage during
transit.
If any damage is detected promptly contact the haulage company.
2. Installation (see Fig.1)
a) Dryer should be installed indoors; where this is not possible it must
however be installed in a clean dry area, with a temperature between
5-50℃, and sheltered from the effects of direct weather (including
direct sunlight).
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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

b) The compressed air inlet temperature must never exceed 60℃. For parameters values parameters values
different temperatures to those indicated above, please consult the Minimum inlet 10℃ Iron content ＜0.2ppm
manufacturer. temperature
c) Allow for a 1.5-meter gap around the unit to facilitate maintenance and Langelier index 0-1 Oxygen content ＜0.1ppm
ensure unimpeded air discharge from the condenser. PH value 7.5-9 NO3- ＜2ppm
d) You should install the dryer at least 50m3 space room. Electrical HCO1- 70-300ppm
e) The Maximum working pressure is 15 bar(g). Don’t install/use in the 10-500μS/cm
conductivity
system which exceed this pressure value. Dissociated CO2 ＜5ppm
f) For most compressed air applications, we recommend the following NH3 <1ppm
installation plan (see Fig.1). This layout ensures optimum compressor, Al3- ＜0.2ppm
filter and dryer performance and also guarantees excellent air quality Cl- <50ppm
whilst minimizing operating costs. Total hardness Pressure of 0.3-1.0MPa
g) Do not obstruct the dryer air grilles. 70-150ppmCa
cooling water
h) Avoid recirculation of hot condenser air back into the condenser air
inlet. CO3
i) If the system is prone to instantaneous pressure surges which exceed Cooling waters for different model dries (see annex)
the dryer rated capacity, mount a suitably sized receiver near the m) Always install a bypass line with shut-off valves (supplied as option) to
overpressure source. permit maintenance or calibration without interrupting the compressed
For more precise information, contact the manufacturer or distributor. air flow to the user.
j) It is necessary to install a pre-filter (max.3 micron) on the dryer intake n) The dryer pneumatic circuit must be protected by one or more safety
to prevent rust, scale or other pollutants from entering the system and valves to prevent the design pressure (16 BARG) from being exceeded at
clogging the condensate drain and heat exchangers, thereby causing all times.
severe pressure drops. This filter must be close to the dryer inlet. o) These valves must be fitted in such a way that there is no risk of any
k) Water cooling dryer: It is necessary to install a filter (max. 16 micron) on expelled fluid coming into contact with operators.
the condensate intake to prevent clogging the cooling passages, hereby p) Correctly connect the dryer to the air inlet and outlet connections.
causing bad cooling effect. If the compressed air circuits are subject to vibration, use hoses to
connect the dryer to compensate for this. If the circuits are subject to
l) Cooling water of water cooling dryer
pulsations, eliminate them by connecting the dryer to an air chamber to
The quality and pressure of the cooling water should be compliance equalize the pressure.
with the followings:

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GRD Godrej & Boyce Mfg. Co. Ltd.
q) Do not connect condensate drains common to other pressurized drain
lines in a closed circuit. Make sure the outflow from the condensate
drains is unimpeded.
Connect the condensate piping in such a way to ensure that sound
levels are kept to a minimum during drainage.
Ensure that all condensate is disposed in a responsible manner, in
accordance with local norms concerning environmental protection.
r) The ambient air around the dryer and compressor must not contain
solid or gaseous contaminants. All compressed and condensed gases
can generate acids or chemical products which may damage the
compressor components inside the dryer.
Take particular care with sulphur, ammonia, chlorine and installations in
marine environments. For further advice or assistance please consult
the manufacturer.
s) If the dryer is installed in seismic zone, suitable protection against
seismic stress should be fitted.
t) In setting where there is an average or high risk of fire, provide an
adequate firefighting system or fit CE safety valve on the dryer
refrigeration circuit positioned directly (without any shut-off valve) on
the low pressure side, set to a pressure of 19 bar(g), with a discharge
capacity of at least 0.2 kg/sec. This operation must be carried out by a
trained and certified technician.
The valve must be positioned in such a way that it does not discharge in
the operator’s direction.
2.1 Electrical connection (See electric diagrams)
a) The connection cable should be compliance with the local laws and
regulations. The minimum size of power cable shouldn't be smaller than that
of main power line of electrical diagram. When wiring, for single phase
User Manual
power, connect the single phase line to the L-N blocks, for three phase power,
connect the three phase line to L1-L2-L3 blocks separately, and connect the
earth wire to yellow/green blocks.
b) Install a residual current circuit breaker IΔ n=0.3A upstream of the
plant, and a TT-type power supply system with earthed electric control
panel terminal.
2.2 Condensate drain connection
The dryer is supplied with the timed drain. Refer to Chapter 8 of drain
installation.
a) Condensate drain has been installed on the unit and connected to the
controller board.
b) Place the condensate drain in the discharge system.
c) All the maintenance shall be done by specialist.
3. Start-up and operation
3.1 Preliminary checks (for model GRD - 1600 ≈ GRD - 2600)
Before starting up the dryer, make sure that:
a) The air inlet valves are closed and there is no air flow through the dryer.
b) The mains power supply is commensurate with the dryer voltage.
c) The dryer is installed in compliance with the installation instructions
given in Chapter 2.
3.2 Starting the dryer
a) Use the ‘START’ button to start the dryer.
b) Always start up the dryer before activating the air compressor.
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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

c) Set the main disconnect switch (QS) to ON so that the green line lamp 3.4 Operation
illuminates.
d) Wait about 5 minutes before activating the air compressor. Do not exceed the machine’s design limits, bypass excess air flow and check
e) Slowly open the air inlet valve to pressurize the dryer. the unit model and/or installation.
f) Open the outlet valve. The dryer is now operating (drying). For maximum performance from your dryer, follow the maintenance
g) Always leave the dryer running while the air compressor is operating. schedule descried in Chapter 4.

h) For models GRD - 1600 ≈ GRD – 2600 only: After stopping the

dryer, wait at least 20 minutes before starting it again.

i) For models GRD - 1600 ≈ GRD – 2600 only: each unit is fitted

with a three-phase scroll compressor, it is highly important to check

the direction of rotation of the compressors. If supplied with the
wrong phase sequence, they will turn in the opposite direction. In this
case they are very noisy and risk getting damaged. SWAP OVER THE
PHASES IMMEDIATELY.
Check that the (HP) gauge pressure on the front of the panel
decreases.

3.3 Stopping the dryer

a) Use the ‘STOP’ button to stop the dryer.

b) Stop the dryer 2 minutes after shutting down the air compressor or
interrupting the air flow to the dryer.

Compressed air must never enter the dryer when the dryer is switched

off or when it is in an alarm situation which stops the refrigeration

compressor.

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

WEEKLY CONDENSATE DRAIN

4. Maintenance Based on the degree of dirtiness of the condenser water, the
screen should be cleaned.
The user is responsible for recording all maintenance in a machine log, which
COMPRESSOR
is to be accessible to maintenance personnel.
MONTHLY Make sure the compressor head temperature is between 15℃
This log is to contain at least the following information:
a) Details of all repairs and maintenance; and 120℃ when running. If this is not the case consult Chapter 7.

b) The quantity and type of refrigerant loaded or discharged on each

occasion; CONDENSER
c) The results of any analysis of recycled refrigerant; Remove any dust from the fins of condenser.
d) The origin of any recycled refrigerant; EVERY 4 COMPRESSOR
e) Operation to the components of dryer; MONTHS Make sure compressor power consumption complies with data
f) The results of routine inspections; plate specifications.

g) Significant periods during which the machine is not used.
Before accessing live electrical parts, disconnect the power supply to the
dryer using disconnect switch “QS” or disconnect the cable connections.
SAFETY DEVICES
ST High temperature thermostat
HP High pressure switch
LP Low pressure switch
COMPRESSOR TYPE
PISTON compressor on models GRD - 0460 ≈ GRD - 0600 (single phase)
SCROLL compressor on models GRD - 0775 ≈ GRD - 2600 (three phase)
N.B.: Always use original spares supplied by the manufacturer.
Failure to do so renders the manufacturer not liable for incorrect unit
operation.
YEARLY CONDENSATE DRAIN
Fully disassembling the drain valve, and clean the spare parts.
(read the drain valve manuals)
WATER-COOLED MODELS
In applications with a very high fouling tendency (e.g. when using
extremely hard water) clean the exchanger by circulating a
cleaning liquid. Use a tank with a weak acid, 5% phosphoric acid,
or if the exchanger is frequently cleaned 5% oxalic acid. Pump the
cleaning solution at a flow rate of a minimum 1.5 times of the
normal flow rate, preferably in order to get rid of all the acid
before starting up the system again. Clean at regular intervals.
4.2 Disassembling the unit

4.1 Preventive maintenance The machine has been designed and constructed to guarantee continuous
operation. The long service life of some components such as the fan and
For optimum performance of your dryer, please follow the periodic compressor depends on good maintenance.
maintenance schedule described below. The unit must only be disassembled by a refrigerant specialist.

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

Refrigerant liquid and lubricating oil inside the refrigeration circuit must be 4.4 Refrigerant charging
recovered in compliance with current norms in the country where the
machine is installed. THIS OPERATION MUST ONLY BE PERFORMED BY A REFRIGERANT
SPECTALIST.
RECYCLING DISASSEMBLY WHEN REPAIRING THE REFRIGERATION CIRCUIT, COLLECT ALL THE
Frame and panels Steel / epoxy resin polyester REFRIGERANT IN A CONTAINER AND DISPOSE OF IT IN AN APPROPRIATE
Heat exchanger (cooler) Copper/ aluminum / carbon steel MANNER.
Pipes / collectors Copper / aluminum / carbon steel Characteristics of refrigerant R407C
Drainage system Brass / PC In normal temperature and pressure conditions the above refrigerant is a
Heat exchanger insulation EPS (polystyrene sintered) colorless, class A1 gas with TVL value of 1000ppm (ASHRAE classification).
Pipe insulation Gum synthetic If a refrigerant leak occurs, thoroughly air the room before commencing
Compressor Steel / copper / aluminum / oil work.
Characteristics of refrigerant R134a
Condenser Steel / copper/ aluminum
R134a is now being used as a replacement for R-12 CFC refrigerant in the
Refrigerant R407C / R134A
area of centrifugal, rotary screw, scroll and reciprocating compressors. It is
Valve Brass
safe for normal handling as it is non-toxic, non-flammable and non-corrosive.
Electrical cable Copper/ PVC

5. Calibration (see Fig.2)

4.3 Refrigerant leaks in the refrigeration circuit
The dryer is supplied with factory setting with values shown in Fig. 2 and
The unit is delivered in perfect working condition, already charged therefore
refrigerant as specified. No further calibration needed.
Refrigerant leaks may be identified by the compressor overload protector (SK)
or safety thermostat (ST). The pressure gauge points to "0".
IF A LEAK IS DETECTED IN THE REFRIGERANT CIRCUIT, PLEASE SEEK
TECHNICAL ASSISTANCE.

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

6. Trouble shooting

The following diagram lists the various problems which may occur during the dryer’s service life.
In the case of serious difficulties, please contact a refrigerant specialist. NOTE: Always bypass the dryer when it is out of service.

Hight-limit Excessive High

High air Compressor Ice
High dew point or overload current refrigerant
FAULT outlet
protector noisy formation
discharge
temperature consumption
tripped pressure

Fan pressure
Condenser Ambient Condenser Low Calibrate switch
Compressed Reduce Clean
dirty(cooling air temperature dirty(cooling air evaporation or replace (kp5)incorrectly
air pressure No No temperature condenser
outlet too hot) over 38¡ æ Yes outlet too hot) pressure valve Yes calibrated
too low Yes
No No
Yes
No
Yes

Clean Condenser
CAUSE High Repair Fan does condenser
Yes dirty
Increase air fan not work
Clean refrigerant Yes
pressure No
condenser Yes discharge
pressure No
No Replace Fan does
fan not work
Yes
and Fan does No
not work No
Compressor Bypass air by keeping air
Yes components inlet open.Manually open
Excessive Reduce No perished condensate drain.Repair
thermal load compressed air before restarting
Repair (compressor heat quantity or air
fan Yes Yes
too hot) temperature
REMEDY No
Repair or Compressor
Lack of replace winding insulation
Low current Yes partially perished
refrigerant compressor
consumption
Yes Recharge
No No
Seek
external
assistance

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

Fig.1 Installation

A LT ER N A TIV E R EC E IVE R PO S ITIO N

R eceiver
B ypass
Filter(m ax.3¦ Ìm ) (recom m ended,and
A ir com pressor optionally available)
F ilter
To com pressed air
ring m ain

D ryer

O il / w ater s eparator

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

Fig. 2 Calibration
MODEL COMPONENT SETTING NOTES

R407C/R22

GRD - 0460
Calibr
Hot gas valve 4.8BAR/4.0bar

GRD - 2000～GRD - 2600

Calibr

Start:18BAR
GRD - 1600 ≈ GRD - 2600 Fan pressure switch(PV) Diff:4BAR
Stop:14BAR

Stop:28BAR Rest
GRD - 1600 ≈ GRD - 2600 High pressure switch(HP)
Start:21BAR

Start:4.0BAR
GRD - 1600 ≈ GRD - 2600 Low pressure switch(LP) Diff:1.5BAR
(Stop:2.5BAR)

Rest
GRD - 1600 ≈ GRD - 2600 High temperature protection Stop:120℃

Pressure controlled water Calibr

GRD - 1600 ≈ GRD - 2600 16bar(+0.1,-0)
valves

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

Fig. 3 Electrical Diagram GRD - 1600 ≈ GRD – 2600

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

7. Warranty Terms and Conditions

I. All material under the conditions of the Warranty must be promptly sent by the Purchaser to Godrej

1. The Purchaser shall return to Godrej’s head office in Mumbai the defective part or parts within 30 days from the date of first intimation with
transportation charges prepaid

2. If material is sent to Godrej after 30 days from the date of the first intimation Godrej will not entertain the claim. Following procedure should be
adopted for sending the material.

a. Parts should be properly packed to avoid damage. Any parts that show damage marks or other indications of being abused or mishandled, during
their removal shall not be considered under this warranty.

b. Each part should be tagged with complete information as per instruction no. II herein.

c. When a part of an assembly is defective only that part should be sent to Godrej and not the complete assembly of sub-assembly.

II. Any claim under the warranty shall not be entertained or considered unless the Purchaser submits in writing within one week of failure the reasons and full
particulars of the failure or defects including information in the warranty claim checklist

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GRD Godrej & Boyce Mfg. Co. Ltd. User Manual

Godrej Compressed Air Solutions (CAS) Products (i.e.) Compressors, Blowers, Compressed Air Flow Control Systems-Supply/Demand side & accessories (but
excluding spares and consumables) are guaranteed to the original purchasers, (who have paid full price, taxes and charges for the products) against defective
workmanship and material for a period of 12 months from the date of commissioning or 18 months from the date of invoice, whichever is earlier (hereinafter called
the warranty period). If within this period, the CAS product proves to be defective by reason only of faulty materials or bad workmanship of any part or component,
but not due to the abnormal or improper use or handling and/or lack of regular and proper servicing, the defective part or component will be replaced or repaired
free of charge at the option of Godrej, subject to following conditions:
1) Notice of defect must be communicated in writing to Godrej’s head office at Mumbai within one week of its being noticed.

2) a) It shall be entirely at the discretion of Godrej to effect repair or replacement either at site of operation or their Works at Mumbai or at Branches or at any
other place of their choice.
b) The purchaser shall pay in advance, all incidental costs, handling, removal or refitting or transportation charges both ways (all such costs and charges
being determined by Godrej) before any work is undertaken by Godrej under warranty.

3) All costs, incidental to dismantling, reassembling and handling facilities in carrying out replacement or repair of any defective part by Godrej shall be borne by
the purchaser.

4) Godrej under the terms of warranty, are not bound to replace or give credit for a complete assembly where only a part is found to be defective.

5) The purchaser should strictly follow the instructions given in the company’s operation manual regarding the use and operation of the Products.

6) The purchaser is bound to properly maintain the Products periodically, as per Godrej’s user/maintenance manual, and /or recommendations employing
only qualified personnel for this purpose. Godrej’s representative shall have full and free right of access to the Products.

7) Godrej will make every effort to carry out repair or replacement when needed as soon as possible, but no claim will be entertained for any delay in carrying
out such repair or replacement.

8) No monetary claim of any kind for damage or loss resulting directly or indirectly from the use or non-use of the Products will be entertained by Godrej.

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9) The decision of Godrej on all matters relating to this warranty, compliance or non-compliance of any of its condition or as to the cause of defect or to the
replacement of or repair to any part of the Product shall be conclusive and binding on the purchaser.

10) The defective part, which may be replaced, shall become the property of Godrej and the purchaser shall have no claim in respect thereof.

11) At the expiration of the warranty period, all obligations of Godrej under this warranty period shall cease irrespective of the fact that during the warranty
period the Product was not in use for any reason whatsoever including breakdown or the time taken for repair or replacement or in transit. The warranty
shall not, in any case, be extended.

12) The following shall not be covered by this warranty:

a) Damage due to use of insufficient lubrication or oil, or use of lubrication or oil not approved by Godrej.
b) Any defect occurring due to improper storage or by not following Standard procedures of preservation when lying unused.
c) Wear and tear of the Product during normal use.
d) Any damage by misuse, neglect, bad and faulty maintenance, accidents, sabotage, fire, earthquake, flood or other acts of God or act of enemy or by civil
commotion.

13) The warranty shall immediately cease and become void and will be treated as cancelled if during the warranty period;

a) Any part or parts of the CAS Product are replaced with part or parts not supplied or approved of by Godrej or if the Product is handled or operated by
personnel not technically qualified to do so or the Product has been dismantled or repaired by any person other than Godrej’s service personnel and /or
b) It is observed that there was tampering with the Product including removal, obliteration or alteration of the name plate or any plate bearing specifications,
or hour meter reading or numbers or marks.

14) Except as provided by this Warranty all statutory or other warranty condition or description expressed or implied as to the state, quality or fitness of the
product are hereby expressly excluded

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15) Godrej reserves the right to make any changes, additions or improvement in their Products, accessories and components or thereof at any time without being
obliged to make such or similar changes, additions or improvement in the equipment previously sold under the warranty.

16) None of the Company’s employee or its authorized dealers or representatives (other than Godrej’s service Manager) or their superiors have any authority to
vary or alter the terms of this warranty.

17) All claims under this warranty are subject to the jurisdiction of the competent courts in Mumbai City alone not withstanding that the goods may have been
sold or delivered elsewhere.

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8. Contact Information

CONTACT DETAILS:

Godrej & Boyce Mfg. Co. Ltd

Electricals & Electronics Division
Compressed Air Solutions - AEM
Regd. Office : Pirojshanagar, Vikhroli,
Mumbai- 400 079, INDIA
Tel : 91-22-6796 2251 To 2259
Fax : 91-22-6796 1410 / 1525
E-mail : caservice@godrej.com; casene@godrej.com;
Website : www.godrej-airsolutions.com

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