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© 2016 Johnson Controls, Inc.
Part No. 64-378-14, Rev. D
Code No. LIT-718050T
A-4400 Series Refrigerated Air Dryers
Installation and Maintenance
64- 378- 14, Rev. D
Technical Bulletin A-4400
Issue Date 0316
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Table of Contents
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Summary of Contents for Johnson Controls A-4400 Series
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Page 1: Table Of Contents
64- 378- 14, Rev. D Technical Bulletin A-4400 Issue Date 0316 A-4400 Series Refrigerated Air Dryers Installation and Maintenance INTRODUCTION Product Overview INSTALLATION PROCEDURES Location Unpacking the Unit Conventional Wall Mounting Arrangement Air Connections Base Mounting Arrangement Activated Carbon Filter Installation... - Page 2 Replacement Coalescing Oil Removal Filter Element Kit Activated Carbon Oil Vapor Removal Filter Pressure Reducing Valve Power On/Fail Lamp Refrigeration Service Condenser Fan Motor Replacement Condenser Air Dryer Compressor Motor Wiring Circuit Excessive Vibration SPECIFICATIONS REPAIR INFORMATION 2 Air Dryers—A-4400 Series Technical Bulletin...
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Page 3: Introduction
Introduction The A-4400 Series Refrigerated Air Dryers are designed for continuous Product operation to supply dry air to pneumatic control systems. All components Overview are selected and assembled to provide dependable service over a long period of time with a minimum amount of maintenance. -
Page 4: Installation Procedures
Installation Procedures The A-4400 Series Refrigerated Air Dryer must be located in an open area Location that will permit free circulation of air through the ends of the unit. The A-4400 requires 12 in. (305 mm) top clearance (as measured from the top of the cabinet) and 12 in. -
Page 5: Air Connections
Capped High Pressure Connection for High Pressure Riser (Models with a Factory Mounted Air Purification System) Figure 1: A-4400 Series Refrigerated Air Dryer Shown with Optional Factory Mounted Air Purification System Dimensions The high pressure side of the compressed air line, after the compressor tank, must be connected to the 3/8 in. -
Page 6: Base Mounting Arrangement
(All Field Furnished) 5-1/2 7-1/2 9-11/32 13-11/16 Figure 2: DryFlow A-4400 Series Refrigerated Air Dryer Base Mounting Hole Patterns (Plan View) Dimensions On models with an optional factory mounted Air Purification System, the Activated activated carbon oil vapor removal filter is packaged separately within the... -
Page 7: Drain Connections
This will cause the bowl to drain. When the bowl has been drained, replace the connections and tubing. Air Dryers—A-4400 Series Technical Bulletin... -
Page 8: Permanent Wiring Using Conduit
Permanent All A-4400 Series Refrigerated Air Dryers are furnished with a Wiring Using cord and plug to fit a standard 115 volt receptacle. If permanent Conduit wiring is required using conduit, proceed as follows: 1. Cut the line cord to a sufficient length so that it will reach from the compressor terminal box through Hole 1 as illustrated in Figure 3;... -
Page 9: Wiring To Air Compressor
Note: The air dryer motor voltage must match the air compressor motor voltage in order to wire the unit as illustrated in Figure 4. Dryer 115 VAC 60 Hz Pressure Air Compressor Air Compressor Switch Disconnect Figure 4: Single-Phase Air Compressor Motor Air Dryers—A-4400 Series Technical Bulletin... -
Page 10: Commissioning
Readings are recorded on a label inside the dryer cabinet base. Apply this Correction correction to the evaporator gauge to obtain a precise reading. The A-4400 Series Refrigerated Air Dryers are factory set to protect Evaporator against air side freeze-up down to ambient temperatures of 40°F (4°C) and Pressure altitudes up to 1500 ft. -
Page 11: Low Ambient Temperature Compensation
Also, if the pressures were changed from the normal settings, indicate the changes on the air dryer to facilitate future service. Air Dryers—A-4400 Series Technical Bulletin... -
Page 12: Servicing Procedures
Servicing Procedures The A-4400 Series Refrigerated Air Dryer is equipped with an automatic Particle Filter condensate drain trap assembly with a particle filter. The particle filter should be replaced annually or whenever the filter element appears dirty. To replace the particle filter element and/or automatic drain valve, refer to Figure 6 and proceed as follows: 1. -
Page 13: Coalescing Oil Removal Filter
When the pressure drop reaches 7.5 psig (52.5 kPa), the indicator becomes entirely red, indicating that the filter element needs to be replaced. Even if the indicator is not entirely red, it is recommended that the filter element be replaced annually. Air Dryers—A-4400 Series Technical Bulletin... -
Page 14: Replacement Coalescing Oil Removal Filter Element Kit
2. Disconnect the drain tubing. 3. Depress the lever on the filter bowl clamp, and turn it 1/8 revolution in either direction. Drop the metal bowl guard and bowl to expose the filter element. 14 Air Dryers—A-4400 Series Technical Bulletin... -
Page 15: Activated Carbon Oil Vapor Removal Filter
OFF, the lamp will need to be replaced as follows: Disconnect the power supply to the air dryer. Cut the two leads leaving behind a convenient length of wire for use with the replacement bulb. Air Dryers—A-4400 Series Technical Bulletin... -
Page 16: Refrigeration Service
1. Switch the service bypass valve in order to bypass the dryer. Allow the unit to run unloaded a minimum of 10 minutes prior to adjusting the expansion valve. 2. Remove the cover from the dryer. 16 Air Dryers—A-4400 Series Technical Bulletin... - Page 17 To use the valve, unscrew the cap to expose the Schrader valve pin. Use a vacuum pump to evacuate the unit of all refrigerant into an approved refrigerant receptacle before repairing leaks. Repair any external leaks found using hard solder and flux. Air Dryers—A-4400 Series Technical Bulletin...
- Page 18 8. If the evaporator pressure (gauge reading plus correction) does not return to normal as illustrated in Figure 5, adjust the expansion valve as described in the Refrigeration Service section. Figure 8: Service Valve Detail for Access to Evaporator 18 Air Dryers—A-4400 Series Technical Bulletin...
- Page 19 Figure 9: A-4400 Series Refrigerated Air Dryer with Cover Removed Air Dryers—A-4400 Series Technical Bulletin...
- Page 20 Filter With Drain Trap Removal Automatic Filter Drain Figure 10: Schematic of A-4400 Series Refrigerated Air Dryer with Service Bypass Valve Positioned for Normal Operation (Shown with Optional Factory Mounted Air Purification System) Inlet From Safety Relief Air Compressor Valve...
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Page 21: Condenser Fan Motor Replacement
14. Slide the fan motor assembly into the cabinet, over its base mounting location. 15. Secure the fan motor assembly to the cabinet base using a 3/8 in. wrench and the mounting screws retained in Step 4. Air Dryers—A-4400 Series Technical Bulletin... - Page 22 Excessive Vibration section in this bulletin. 19. Reinstall the cabinet cover, and using a 1/4 in. hex-head wrench blade screwdriver, secure it in place using the cover mounting screws retained in Step 2. Figure 12: Condenser Fan Motor Assembly 22 Air Dryers—A-4400 Series Technical Bulletin...
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Page 23: Condenser
(such as improper pickup or dropout), which cannot be determined by any of the above tests. If the new relay fails to correct the problem, either replace the compressor or the entire air dryer. Air Dryers—A-4400 Series Technical Bulletin... -
Page 24: Excessive Vibration
1/4 in. (6 mm). 5. Reconnect the power supply to the air dryer and check that the excessive vibration has been eliminated. Repeat the above procedure as necessary. 24 Air Dryers—A-4400 Series Technical Bulletin... -
Page 25: Specifications
The performance specifications are nominal and conform to acceptable industry standards. For application at conditions beyond these specifications, consult the local Johnson Controls office. Johnson Controls, Inc. shall not be liable for damages resulting from misapplication or misuse of its products. -
Page 26: Repair Information
Repair Information Figure 14: Repair Parts (See Table 3) Figure 15: Repair Parts (See Table 3) 26 Air Dryers—A-4400 Series Technical Bulletin... - Page 27 An F-400-20 Coupling (1/8 in. external NPT x 1/8 in. internal NPT) is included with the replacement drain valve. **** The A-4000-6010 auto drain and A-4000-1054 manual override assemblies are only compatible with each other and do not work with the A-4000-610 auto drain and A-4000-154 manual override assemblies. Air Dryers—A-4400 Series Technical Bulletin...
- Page 28 507 E. Michigan Street, Milwaukee, WI 53202 Metasys® and Johnson Controls® are registered trademarks of Johnson Controls, Inc. All other marks herein are the marks of their respective owners. © 2016 Johnson Controls, Inc 28 Air Dryers—A-4400 Series Technical Bulletin...
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