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Installation,
Operation, and
Service Information
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Installation
and Operation Manual
Aircel
HP Series Non-Cycling Refrigerated Air Dryer
Models: HP-45, 65, 80, 125, 200, 260, 415, 570, 860, 1000, 1400
This manual is property of the owner, and should be left with the unit when
start-up is complete. Aircel LLC. reserves the right to change design and
specifications without prior notice.
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Table of Contents
Troubleshooting
Related Manuals for Aircel HP Series
Summary of Contents for Aircel HP Series
- Page 1 Notice: - used to address practices not related to personal injury. This manual is property of the owner, and should be left with the unit when start-up is complete. Aircel LLC. reserves the right to change design and specifications without prior notice.
- Page 2 Aircel HP Series WARNING! General Safety Procedures • Improper installation, operation, or maintenance may contribute to conditions in the work area or facility that could result in personal injury and product or property damage. Check that all equipment is properly selected and sized for the intended use. • Consult and comply with national and local codes relating to fire or explosion and all other appropriate codes when determining the location and operation of this equipment. • Safe and efficient operation of the unit depends on proper installation. • Authorities with jurisdiction should be consulted before installing to verify local codes and installation procedures. In the absence of such codes, install unit according to the National...
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Page 3: Table Of Contents
Non-Cycling Refrigerated Air Dryer Contents Safety Statements ..........2 Shut-Down Procedures ........16 Data Sheet ............. 4 Shut-Down Emergency ....... 16 Refrigerant Safety Precautions ......5 Short-Term Shut-Down ......16 Design Parameters ..........6 Service Information ..........17 Description............6 Maintenance..........17 System ............6 Troubleshooting ..........19 Refrigeration Circuit ........7 Electrical ........... 19 Compressed Air Circuit ........ -
Page 4: Data Sheet
Aircel HP Series Data Sheet Model Number _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Serial Number _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _... -
Page 5: Refrigerant Safety Precautions
Non-Cycling Refrigerated Air Dryer Refrigerant Safety Precautions Refrigerant First Aid Recommendations Inhalation CAUTION! If high concentrations are inhaled, immediately remove individual from affected area to an area with a fresh air supply. Keep individual calm. Inhalation, Skin, & Eye Irritant If not breathing, give artificial respiration or if having difficulty breathing, give oxygen and call for • Use proper safety and protective emergency services. equipment, including chemical safety goggles or face shield and Skin Contact impervious gloves when handling... -
Page 6: Design Parameters
Aircel HP Series Design Parameters Type of dryer: Refrigerated and improved heat transfer properties allow for smaller condensers, which leads to air dryers with smaller Power supply: 115, 230, 460 Volt / single or three footprints. phase / 60Hz Refrigerant.type: R-134A... -
Page 7: Refrigeration Circuit
Non-Cycling Refrigerated Air Dryer Refrigeration Circuit Refrigerant is compressed by the compressor to a exchanger. This energy saving heat exchanger gas with high temperature and high pressure, which provides several advantages, such as a reduction then travels to the condenser (air or water cooled) of the heat load imposed on the refrigerant to condense the gas into a liquid. -
Page 8: Purpose And Intended Use
Non-Cycling Refrigerated Air Dryer Purpose and Intended Use Inspection on Arrival Non-cycling refrigerated air dryers are designed All non-cycling refrigerated air dryers are tested to remove moisture from compressed air by use of and operated before shipment. However, shipping mechanical refrigeration. They can provide pressure stresses have the potential to cause damage to dew points as low as (38° F- 42° F). Referigerated the unit. -
Page 9: Lifting Information
Aircel HP Series Lifting Information Installation Codes and Procedures 1. Use all lifting points provided. Special care must be used when lifting the dryer to prevent tip- over. WARNING! 2. Use clevis connectors, not hooks, on lifting slings. • Follow proper lock out/tag out procedures before performing 3. Only lift unit under support frame/base by using service or maintenance work. -
Page 10: Installation
Non-Cycling Refrigerated Air Dryer all applicable national and local codes. Our Installation company is not liable for any code violations, component damage, downtime or consequential 1. Locate unit on a level foundation. Dryer should damage related to customer supplied electrical be mounted on a suitably structured flat and components and connections. level floor or base that is free from vibration. -
Page 11: Typical Installation
Aircel HP Series Typical Installation Typical Installation 1. Check that the inlet and outlet connections Preliminary Start-Up Checklist are the correct size and pressure rating, and tightened securely. Notice: For scfm rated models 45 - 260, wait at least 6 hours after transporting or 2. Check that the correct power supply is moving of dryer system before starting connected to the non-cycling refrigerated air the dryers. - Page 12 Non-Cycling Refrigerated Air Dryer 5. With the customer-supplied compressed air d. The refrigeration gauge readings should be as to the system, OPEN the inlet valve slowly to follows: gradually pressurize the system. Do not open • Refrigerant suction pressure: valve too quickly. Opening valve and suddenly R-134A =28-40 psig pressurizing the system can cause damage to the R-404A = 75-90 psig dryer heat exchanger and other components. • Refrigerant.dischargepressure: 6.
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Page 13: Automatic Drain Valve Adjustments
Aircel HP Series Air Cooled Condenser Requirements Automatic Drain Valve Adjustments Cooling air must be drawn from a clean source to The automatic drain valve supplied is standard on the reduce dust and dirt accumulation on the condenser separator and should open regularly and discharge coils. Air temperature should not exceed 100°F... -
Page 14: Cooling Water Requirements
Non-Cycling Refrigerated Air Dryer Cooling Water Requirements (water cooled condensing units) Cooling water is required for water-cooled water pressure, and dryer air load. The table below refrigerant condensers. The user is responsible for indicates the amount of cooling water required piping the water to and from the condenser. The in gallons per minute (gpm) at given incoming required water flow rate depends on the water temperatures for the condenser Hp size in each... -
Page 15: Shut-Down Procedures
Aircel HP Series Shut-Down Procedures WARNING! • To avoid possible hazard or injury, the operator should be fully familiar with the refrigerated air dryer system and its operation. • When the system is shutdown and power removed, lock out power supply and depressurize system before performing maintenance or service work to avoid injury to personnel or property damage. Shut-Down Emergency... -
Page 16: Service Information
Non-Cycling Refrigerated Air Dryer Service Information To reach a field service technician or for technical support, please call the number on the manual back Daily cover. With the dryer on-line: Maintenance • Verify the operating pressure, temperature, and Refrigerated air dryers require very little flow rate are correct and conform to those listed maintenance for satisfactory operation. Optimum in the Design Parameters section. Adjust system performance can be expected if the following if required. routine maintenance steps are taken. - Page 17 Aircel HP Series Filter Element Replacement 1. Depressurize the air system to release the compressed air from the air dryer. Notice: Shutting down the air compressor will not depressurize the air dryer unit. Close air line valves before and after dryer and then depressurize unit. Depressurize dryer by pushing the test button on the dryer system drain until there is no more pressure in the dryer system.
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Page 18: Troubleshooting
Non-Cycling Refrigerated Air Dryer Troubleshooting Electrical WARNING! WARNING! • Before any service or maintenance work is performed on the • Follow proper lock out/tag out refrigerated air dryer system, procedures before performing disconnect power supply and lock service or maintenance work. out power supply and depressurize • Electrical installation or maintence system. must be performed by a qualified • Follow proper lock out/tag out electrician and comply with all procedures before performing applicable national and local codes. -
Page 19: Condensate Removal
Aircel HP Series 1. High refrigerant readings generally indicate: • If the unit is equipped with y-strainer, disassemble and clean. • Dirty condenser - Clean immediately! • If oil is downstream from the dryer: • Dryer not turned on. - Oil coalescer element is saturated. • Overloading - Airflow or conditions in excess of dryer capacity. - Dryer not turned on during air usage. • High ambient temperature (> 100°F) Provide adequate ventilation for proper cooling, or reduce ambient temperature. WARNING! • Condenser fan(s) not running - Call Technical Support. Before any service or maintenance •... -
Page 20: Troubleshooting Table
Non-Cycling Refrigerated Air Dryer Troubleshooting Table Problem Probable Cause Remedy Water downstream Failed or short circuited Replace timer drain. of dryer system or no timer on drain. discharge from separator/ filter. Failed drain solenoid. Replace timer drain. Bulk liquid entering the Check drains on after cooler or air compressor. dryer from upstream. Inlet compressed air Check inlet air temperature and adjust as temperature to dryer required to meet specifications. exceeds dryer capacity air. Inlet compressed air CFM Check in inlet air cfm flow rate and adjust as flow rate exceeds dryer... - Page 21 Aircel HP Series Troubleshooting Table, continued Problem Probable Cause Remedy Water downstream and Refrigeration compressor Check airflow (cfm) and dryer capacity. Reduce dryer system not working cycles on/off and cannot airflow through dryer or replace with a larger properly or not working maintain suction pressure, rated cfm dryer. (Cont). dryer undersized. Shorted fan motor Check fan motor with ohmmeter and refer to winding.
- Page 22 Non-Cycling Refrigerated Air Dryer Problem Probable Cause Remedy Low air pressure Failed or short circuited Replace timer drain. downstream due to timer on drain. continuous air flow through the moisture drain line. Failed drain solenoid. Replace timer drain. Solenoid valve stuck open. If power is off and the air stops leaking, replace the timer drain. If power is off and air continues leaking, clean the timer drain. Noise or vibration Shipping damage has caused Check all mounting bolts on compressor and coming from refrigerated compressor mounting to tighten. air dryer system.
- Page 23 Aircel HP Series Troubleshooting Table, continued Problem Probable Cause Remedy High Refrigeration Circuit Refrigeration condenser Clean / blow off condensing coil of dirt or Head Pressure coil fouled or dirty or air debris from the inside out. Clear area in front of (compressor is overloaded flow blocked.
- Page 24 Non-Cycling Refrigerated Air Dryer Problem Probable Cause Remedy High refrigerant suction Refrigeration circuit Contact technical support for assistance. pressure, suction gauge hot gas bypass valve out of reading out of range and adjustment or defective. water downstream of refrigeration dryer. Refrigeration expansion Contact technical support for assistance. valve or TXV adjustment fitting out of adjustment.
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Page 25: Appendix
Aircel HP Series Appendix Refrigerant Material Safety Data Sheet - R-134A (HP-20 – HP-500) MATERIAL SAFETY DATA SHEET Prepared to U.S. OSHA, CMA, ANSI and Canadian WHMIS Standards 1. PRODUCT IDENTIFICATION CHEMICAL NAME; CLASS: NON-FLAMMABLE GAS MIXTURE Containing One of the Following Components in a Nitrogen or Air Balance Gas: Dichlorodifluoromethane, 0.0005-2.0%;... - Page 26 Non-Cycling Refrigerated Air Dryer 3. HAZARD IDENTIFICATION EMERGENCY OVERVIEW: This gas mixture is a colorless, odorless gas. Releases of this gas mixture for which Nitrogen is the balance gas may produce oxygen-deficient atmospheres (especially in confined spaces or other poorly-ventilated environments); individuals in such atmospheres may be asphyxiated.
- Page 27 Aircel HP Series R134-A Refrigerant Material Safety Data Sheet, continued 8. EXPOSURE CONTROLS - PERSONAL PROTECTION VENTILATION AND ENGINEERING CONTROLS: No special ventilation systems or engineering controls are needed under normal circumstances of use. As with all chemicals, use this gas mixture in well-ventilated areas. If this gas mixture is used in a poorly-ventilated area, install automatic monitoring equipment to detect the levels of Phosphine and Oxygen.
- Page 28 Non-Cycling Refrigerated Air Dryer 11. TOXICOLOGICAL INFORMATION 1,1,2-TRICHLORO-1,1,2- Bladder: other changes urine Biochemical: Enzyme inhibition, TRIFLUOROETHANE (continued): composition; Nutritional Gross induction, or change in blood or tissue Metabolic: weight loss or decreased levels: phosphatases (Inhalation-Mouse) 260 gm/m /2 hours: weight gain TCLo (Inhalation-Rabbit) 20 ppm: female 8- Behavioral: somnolence (general...
- Page 29 Aircel HP Series R134-A Refrigerant Material Safety Data Sheet, continued 15. REGULATORY INFORMATION ADDITIONAL U.S. REGULATIONS: U.S. SARA REPORTING REQUIREMENTS : This gas mixture is subject to the reporting requirements of Sections 302, 304, and 313 of Title III of the Superfund Amendments and Reauthorization Act, as follows:...
- Page 30 Non-Cycling Refrigerated Air Dryer Appendix Refrigerant Material Safety Data Sheet - R-404A (HP-700 ) Material Safety Data Sheet R-404A CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME: R-404A DISTRIBUTOR: National Refrigerants, Inc. 661 Kenyon Avenue Bridgeton, New Jersey 08302 FOR MORE INFORMATION CALL: IN CASE OF EMERGENCY CALL: (Monday-Friday, 8:00am-5:00pm) CHEMTREC: 1-800-424-9300 1-800-262-0012...
- Page 31 Aircel HP Series R-404A Refrigerant Material Safety Data Sheet, continued R-404A INGESTION: Ingestion is unlikely because of the low boiling point of the material. Should it occur, discomfort in the gastrointestinal tract from rapid evaporation of the material and consequent evolution of gas would result.
- Page 32 Non-Cycling Refrigerated Air Dryer R-404A UNUSUAL FIRE AND EXPLOSION HAZARDS: R-404A is not flammable at ambient temperatures and atmospheric pressure. However, this material will become combustible when mixed with air under pressure and exposed to strong ignition sources. Contact with certain reactive metals may result in formation of explosive or exothermic reactions under specific conditions (e.g.
- Page 33 Aircel HP Series R-404A Refrigerant Material Safety Data Sheet, continued R-404A EYE PROTECTION: For normal conditions, wear safety glasses. Where there is reasonable probability of liquid contact, wear chemical safety goggles. RESPIRATORY PROTECTION: None generally required for adequately ventilated work situations. For accidental release or non-ventilated situations, or release into confined space, where the concentration may be above the PEL of 1,000 ppm, use a self-contained, NIOSH- approved breathing apparatus or supplied air respirator.
- Page 34 Non-Cycling Refrigerated Air Dryer R-404A 10. STABILITY AND REACTIVITY NORMALLY STABLE? (CONDITIONS TO AVOID): The product is stable. Do not mix with oxygen or air above atmospheric pressure. Any source of high temperature, such as lighted cigarettes, flames, hot spots or welding may yield toxic and/or corrosive decomposition products. INCOMPATIBILITIES: (Under specific conditions: e.g.
- Page 35 Aircel HP Series R-404A Refrigerant Material Safety Data Sheet, continued R-404A 13. DISPOSAL CONSIDERATIONS RCRA Is the unused product a RCRA hazardous waste if discarded? Not a hazardous waste. If yes, the RCRA ID number is: Not applicable. OTHER DISPOSAL CONSIDERATIONS: Disposal must comply with federal, state, and local disposal or discharge laws.
- Page 36 Non-Cycling Refrigerated Air Dryer R-404A STATE RIGHT-TO-KNOW In addition to the ingredients found in Section 2, the following are listed for state right-to-know purposes. INGREDIENT NAME WEIGHT % COMMENT No ingredients listed in this section ADDITIONAL REGULATORY INFORMATION: R-404A is subject to U.S. Environmental Protection Agency Clean Air Act Regulations at 40 CFR Part 82. WARNING: Contains Pentafluoroethane (HFC-125), 1,1,1-trifluoroethane, tetrafluoroethane, greenhouse gases which may contribute to global warming.
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Page 37: Wiring Diagram
Aircel HP Series Wiring Diagram, 1/5 - 1/3 HP Models: 1 Phase, 120 Volt, 60 Hz... - Page 38 Non-Cycling Refrigerated Air Dryer Wiring Diagram, 1/2 - 3/4 HP Models 1 Phase, 120 Volt, 60 Hz...
- Page 39 Aircel HP Series Wiring Diagram, 1-1/4 HP Models: 1 Phase, 208/230 Volt, 60 Hz...
- Page 40 Non-Cycling Refrigerated Air Dryer Wiring Diagram, 1-1/2 HP Models: 3 Phase, 230 Volt, 60 Hz...
- Page 41 Aircel HP Series Wiring Diagram, 1-1/2: 3 Phase, 460 Volt, 60 Hz...
- Page 42 Non-Cycling Refrigerated Air Dryer Wiring Diagram, 2-5 HP Models: 3 Phase, 460 Volt, 60 Hz...
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Page 43: Service Notes
Non-Cycling Refrigerated Air Dryer Service Notes Date Service Performed Notes... - Page 44 Aircel HP Series Service Notes, continued Date Service Performed Notes...
- Page 45 Non-Cycling Refrigerated Air Dryer Service Notes, continued Date Service Performed Notes...
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Page 46: Warranty
NO OTHER REPRESENTATIONS, WARRANTIES OR GUARNATEES EXCEPT AS STATED IN THIS PARAGRAPH AND ALL OTHER WARRANTIES INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, WHETHER EXPRESS OR IMPLIED ARE HEREBY EXPRESSLY EXCLUDED AND DISCLAIMED. Parts and Service For genuine Aircel replacement parts, call: 800-767-4599 www.airceldryers.com For faster service, have unit’s model and serial number, part number, description, and quantity available. Aircel LLC. is a leading designer and manufacturer of dryer systems and components. Aircel LLC. 323 Crisp Circle Maryville, TN 37801 sales@airceldryers.com © 2012 Aircel LLC. Printed in USA December 2012...