Table of Contents
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Installation,
Operation, and
Service Information
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injury.
Installation
and Operation Manual
Aircel
AHLD E-Series Heatless Regenerative
Desiccant Air Dryer
Models AHLD-70 E, 100 E, 150 E, 200 E, 250 E, 300 E, 350 E,
450 E, 500 E, 600 E, 750 E
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
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Summary of Contents for Aircel AHLD E-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.
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Page 2: Safety Statements
Electric Code, NFPA No. 70-latest edition. • A qualified installation and service agent must complete installation and service of this equipment. • DO NOT weld on / to pressure vessel or modify it in any way. • DO NOT remove, modify, or adjust protective or safety devices. • Lock out power supply and depressurize system before performing maintenance or service work. • DO NOT operate the equipment with the control panel door open. Notice: For optimum performance, use only Aircel replacement parts. Notice: For optimum performance, use only original equipment replacement parts. Notice: For information and notes specific to a custom designed and built dryer, reference the drawing package provided with the unit. See warranty on manual back cover for custom engineered products. This manual contains specific precautionary statements relative to worker safety. Read thoroughly and comply as directed. Discuss the use and application of this equipment with a representative. Instruct all personnel on safe use and maintenance procedures. Understand and obey the following signal words used in this manual. • DANGER! - indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. -
Page 3: Table Of Contents
Data Sheet ............. 4 Safety Symbols ............5 Troubleshooting ..........19 General Safety Instructions ........6 Troubleshooting Table ........20 Description............7 Desiccant Material Safety Data Sheet ....22 Aircel Programmable Controller ......27 Purpose & Intended Use ......7 Electrical Drawings ..........36 Features & Options ........8 Inspection on Arrival ..........9 Main Power & PLC Input......36 Technical Specifications ........10 PLC Output & Sensors ...... -
Page 4: Data Sheet
Aircel AHLD E-Series - Models 70 - 750 Data Sheet Model Number _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Serial Number _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _... -
Page 5: Safety Symbols
Heatless Regenerative Desiccant Air Dryer Safety Instructions Safety Symbols Used in Manual Important Information: Readers of the manual must pay extra attention to instructions and information succeeding this symbol. Warning: This indicates that it is dangerous and could result in physical injury and death if the instructions are not followed correctly. Electrical Danger High Voltage: This means that there is a risk of electric shock and only authorized personnel with proper gear must approach it. -
Page 6: General Safety Instructions
6. Before performing any maintenance operations on the equipment, the unit must be shut down, isolated, electrical power removed, and completely depressurized. 7. To ensure compatibility and continued trouble free operation, only genuine Aircel parts must be used. What You Must Not Do 1. Do not make constructional changes to the unit. Only Aircel or its authorized representatives with the... -
Page 7: Description
Therefore rejection rates are reduced. Purpose & Intended Use Aircel Regenerative Desiccant Air Dryers can dry compressed air to -100°F PDP (Pressure Dew Point), Standard Regenerative Desiccant Air Dryers dry compressed air down to -40°F PDP. The compressed air stream is passed through a desiccant bed, which removes the moisture through the process of adsorption. Twin towers filled with desiccant alternate between drying and regeneration either based on the Energy Management System (EMS) control or a fixed time cycle. Aircel manufactures various types of desiccant air/... -
Page 8: Features & Options
Aircel AHLD E-Series - Models 70 - 750 Standard Features • Integrated Energy Management Purge Reduction System for efficient energy savings and reduced cost of operation. • Optimal tower size for low velocities reducing desiccant fluidization, and high contact time for efficient low dewpoint performance. • Tower pressure relief valves. • Standard design capacity based on 100 psig, 100°F inlet air, 100°F ambient air and PDP of -40°F. • Purge exhaust mufflers for quiet operation. • Tower pressure gauges for additional visual operation of dryer operation. • Stainless steel desiccant supports and air diffusers to prevent channeling. • Counter-current reactivation for efficient desiccant regeneration. • PLC Controlled Electrical System • Adjustable (5 min., 10 min.) Cycle times: 10 minute cycle for the standard -40°F PDP outlet dewpoint systems, 5 minute cycle used in the optional -100°F PDP outlet dewpoint systems. • Controlled repressurization to slowly repressurize the regenerated vessel to line pressure prior to switch over preventing desiccant bed movement and attrition. • Fail safe design: failure of power and/or pilot air causes the purge exhaust valves to close eliminating loss of air pressure. The System also provides uninterrupted drying air flow preventing a deadheading affect. -
Page 9: Inspection On Arrival
Heatless Regenerative Desiccant Air Dryer Inspection on Arrival All Aircel dryers are tested and operated before shipment. However, shipping stresses have the potential to cause damage to the unit. To ensure smooth installation, it is recommended that immediately upon receipt of the unit, the system is checked for the following: 1. Make sure you have received all the crates/... -
Page 10: Technical Specifications
Aircel AHLD E-Series - Models 70 - 750 Technical Specifications Next, the towers will switch when exhaust valve How Does it Work? (see diagram 1) (V3) opens causing tower (T1) to depressurize and regenerate, simultaneously the inlet and outlet APV Moisture saturated compressed air enters the valves (V1) and (V2) will shift the pistons to the coalescing pre filter (F1) where aerosols are low pressure tower (T1) causing the inlet airflow coalesced then drained via an automatic drain to be diverted to tower (T2) which will now be the system. The moist water vapor-laden inlet air drying tower. This switching process will continue free of liquid water flows to the inlet of the dryer repeatedly. -
Page 11: How It Works Diagram
Heatless Regenerative Desiccant Air Dryer Air Saturated with Moisture Regeneration Air Dry Air F1 - Mounted Pre-Filter Regenerating Drying F2 - Mounted After-Filter Tower Tower V1 - Automatic Piston Valve V2 - Automatic Piston Valve V3 - Purge Exhaust Valve V4 - Purge Exhaust Valve T1 - Desiccant Tower 1 T2 - Desiccant Tower 2 Diagram 1: How it Works... -
Page 12: Installation
To ensure a safe and smooth installation, we recommend you go through the steps indicated below: • Make sure that all personnel involved have read this Operation Manual thoroughly. If you have any questions, feel free to contact your Aircel representative or the factory and we will be glad to assist you. If you need help with the commissioning, we will be glad to schedule a factory serviceman to visit your site and commission the dryer for a nominal fee. -
Page 13: Installation Checklist
A fused disconnect is not supplied with this equipment therefore one must be supplied by customer. All electrical fuses, breakers, etc. should be properly sized. Aircel is not liable for any code violations; component damage, downtime or consequential damage related to customer supplied electrical components and connections. -
Page 14: Start-Up Procedure
Aircel AHLD E-Series - Models 70 - 750 Start-Up Procedure At any point during the process of startup or shutdown, you notice anything unusual; we recommend you refer to the operation manual immediately. If you cannot find the answer in the troubleshooting section, contact your Aircel representative or the factory at once. 11. Check the drain valve for proper operation 1. Ensure that the dryer is connected to a and discharge of liquid (filters and suitable compressed air supply. Make sure separators, etc.). that the pressure of the supply is equal to 12. Near the dryer outlet (APV) valve, check... -
Page 15: Shut-Down Procedure
Heatless Regenerative Desiccant Air Dryer Shut-Down Procedure At any point during the process of startup or shutdown, you notice anything unusual; we recommend you refer to the operation manual immediately. If you cannot find the answer in the troubleshooting section, contact your Aircel representative or the factory at once. 1. Slowly OPEN the by-pass valve. 2. Slowly CLOSE the Inlet and outlet “shut-off” valves. 3. To depressurize the dryer after the Dryer is isolated. Turn Power ON … a purge exhaust valve will open and the dryer system starts to depressurize, also the manual vent valve on the outlet afterfilter can be opened to depressurize the Dryer until the tower pressure gauges read ‘0’ psig. - Page 16 Aircel AHLD E-Series - Models 70 - 750 Sequence of Operation (cont’d) Step 4: Extended Drying Vessel 1 A few seconds before the end of repressurization the AHLD E-SERIES Controller’s integrated Energy Management Purge Reduction System looks at the moisture sensor, if the moisture load is low enough, vessel 1 (T1) will continue to dry for an extended drying period until the moisture load has reached a set high level, the controller will then advance to step 5 and the vessels will switch. This feature reduces the overall purge consumption saving energy and money. Step 5: Vessel 1 Depressurizing (0-5 secs)
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Page 17: Service Information
Heatless Regenerative Desiccant Air Dryer Maintenance Prior to performing any maintenance on the dryer, all personnel are strongly advised to familiarize themselves with the equipment by reading the entire contents of this operation manual. Aircel strongly recommends the strict adherence of all the safety procedures prior to any performing any maintenance activity on the dryer. A. The pressure differential indicator referred to as the “Delta-P” is a very good indicator of the state of the filter elements. Maintenance personnel must pay attention to these to keep the dryer running with full efficiency Change filter elements on a regular basis, once a year maximum for a 1-shift operation. Change more frequently if operating 2 or 3 shifts such as every 6 months. - Page 18 Aircel AHLD E-Series - Models 70 - 750 Maintenance (cont’d) Semi-Annual Checklist 1. Remove and inspect all filters for excessive particulate loading and physical damage – if required replace prefilters, afterfilters, pilot air filter and mufflers (filter elements should still be changed on regular basis once a year maximum for a 1 shift operation. Change more frequently if operating 2 or 3 shifts such as every 6 months.). 2. Check pressure differential indicator and if it turns red, replace the element. 3. Remove exhaust mufflers. Knock out excess particulate and back flow with dry compressed air. If particulate cannot be removed completely change the exhaust mufflers. Check backpressure in regenerating tower, if more than a few psig on the pressure gauge, clean or replace exhaust mufflers. (Change mufflers on a regular basis typically every 2-3 months for optimum performance) 4. Check desiccant condition. Powder in the mufflers is a indication of the status of the desiccant. 5. Check all solenoid valves - coil condition and control circuit. 6. Check dryer operation. 7. Inspect and clean inlet and outlet APV (Automatic Piston Valves). Annual Checklist 1. Replace elements in prefilters, afterfilters, and pilot air filter. 2. Replace mufflers. 3. Recalibrate dewpoint analyzer probe (if used) send back to factory for recalibration. 4. Replace inlet and outlet APV valve seals. 5. Check dryer for proper operation. WARNING! • Before any service or maintenance...
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Page 19: Troubleshooting
Troubleshooting The following section briefly discusses the various faults that can occur in the dryer, the reason of the fault and how it can be rectified. If you do not find the solution to your problem, contact your Aircel representative or the factory. All necessary safety and precautionary steps must be followed before attempting to perform any of the recommended measures to resolve any faults in the air dryer. -
Page 20: Troubleshooting Table
Aircel AHLD E-Series - Models 70 - 750 Troubleshooting (cont’d) Problem Probable Cause Remedy High Dewpoint High inlet air flow Reduce inlet air flow Inlet air temperature above Reduce inlet air temperature to design spec design spec Poor pre-filtration Check pre-filter element, replace if needed Inlet air pressure below Increase pressure to the dryer design spec Desiccant contaminated Replace desiccant Purge flow orifice in the Dismantle outlet APV valve, and clean out the outlet APV valve may be orifice... - Page 21 Heatless Regenerative Desiccant Air Dryer Troubleshooting (cont’d) Problem Probable Cause Remedy Check pilot valve and pilot air supply, dismantle and clean exhaust valve check flow control valve Exhaust valves(s) not attached to purge exhaust valve actuator may Dryer Fails to not be adjusted properly (should be adjusted so Shift Towers functioning exhaust valve opens within a 8-12 second time period) No input power Check that dryer is on with correct voltage. Check, replace if needed Controller failure Pilot air supply restricted Check pilot filter, and pilot tubing restriction. Purge flow orifice in the Dismantle outlet APV valve, and clean out the outlet APV valve may be orifice clogged Inlet APV valve malfunction Dismantle, clean, and reinstall Outlet APV valve Dismantle, clean, and reinstall malfunction Purge muffler clogged Purge Failure Remove and clean, replace if needed Purge flow orifice in the Dismantle outlet APV valve, and clean out the...
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Page 22: Desiccant Material Safety Data Sheet
Aircel AHLD E-Series - Models 70 - 750 Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2009/12/04 Page: 1/5 (30286124/MDS_GEN_US/EN) Version: 3.0 1. Substance/preparation and company identification Company 24 Hour Emergency Response Information BASF CORPORATION CHEMTREC: 1-800-424-9300 100 Campus Drive BASF HOTLINE: 1-800-832-HELP Florham Park, NJ 07932, USA 2. - Page 23 Heatless Regenerative Desiccant Air Dryer Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Page: 2/5 Version: 3.0 (30286124/MDS_GEN_US/EN) If on skin: After contact with skin, wash immediately with plenty of water and soap. Consult a doctor if skin irritation persists.
- Page 24 Aircel AHLD E-Series - Models 70 - 750 Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Page: 3/5 Version: 3.0 (30286124/MDS_GEN_US/EN) Advice on system design: Provide local exhaust ventilation to control dust. Provide local exhaust ventilation to maintain recommended P.E.L. Personal protective equipment Respiratory protection: Wear a NIOSH-certified (or equivalent) particulate respirator.
- Page 25 Heatless Regenerative Desiccant Air Dryer Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Page: 4/5 Version: 3.0 (30286124/MDS_GEN_US/EN) Skin irritation: Information on: Aluminum oxide rabbit: non-irritant (OECD Guideline 404) ---------------------------------- 12. Ecological information Information on: Aluminum oxide Acute and prolonged toxicity to fish: DIN 38412 Part 15 static golden orfe/LC50 (96 h): >...
- Page 26 Aircel AHLD E-Series - Models 70 - 750 Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Page: 5/5 Version: 3.0 (30286124/MDS_GEN_US/EN) Registration status: released / listed TSCA, US OSHA hazard category: ACGIH TLV established SARA hazard categories (EPCRA 311/312): Acute SARA 313:...
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Page 27: Aircel Programmable Controller
Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller System display shows the dryer operations and provides the user the ability to change certain dryer settings. Red LED: Common alarm light Text Display Standard alarms: EMS Humidity Probe failure and Drain fault Optional alarms: High Humidity, Dew Point probe failure and Failure to Shift Red LED: Energy Savings DEL Key Active Light... - Page 28 Aircel AHLD E-Series - Models 70 - 750 Aircel Programmable Controller Step 1: Vessel 2 Depressurizing (0-5 secs) Vessel 2 (T2) purge exhaust pilot solenoid valve is energized which supplies control air to the purge exhaust valve (V4) which opens slowly, depressurizing vessel 2 (T2). Simultaneously the inlet and outlet APV (Automatic Piston Valve V1 & V2) shift positions directing the inlet air to vessel 1 (T1) to be drying the air. The air flows up through the desiccant bed and exits to the outlet APV valve (V2) to the outlet particulate filter then to the customer dry process air system. Step 2: Vessel 2 Regenerating (6-240 secs) Step 2 is a continuation of step 1 except vessel 2 (T2) will be regenerating, vessel 2 (T2) purge exhaust valve (V4) is still open, vessel 1 (T1) is drying the inlet air. A small portion of dry outlet air from vessel 1 (T1) (15% average based on standard design capacity of 100 psig, 100°F inlet air, 100°F ambient air and PDP of -40°F) is taken through a small orifice in the outlet APV valve (V2) and used to regenerate the desiccant bed in vessel 2 (T2) until 240 seconds has been reached. The screen also shows the relative humidity reading as well as the (optional) dew point when applicable. The timer on this step counts to 240 seconds (4-minutes). There is a warning sign that will flash in the upper right hand portion of the screen for any alarm. There is also a red LED alarm light that will flash on the PLC display for any...
- Page 29 Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Step 5: Vessel 1 Depressurizing (0-5 secs) Vessel 1 (T1) purge exhaust pilot solenoid valve is energized which supplies control air to the purge exhaust valve (V3) which opens slowly, depressurizing vessel 1 (T1). Simultaneously the inlet and outlet APV (Automatic Piston Valve V1 & V2) shift positions directing the inlet air to vessel 2 (T2) to be drying the air. The air flows up through the desiccant bed and exits to the outlet APV valve (V2) to the outlet particulate filter then to the customer dry process air system. Step 6: Vessel 1 Regenerating (6-240 secs) Step 6 is a continuation of step 5 except vessel 1 (T1) will be regenerating, vessel 1 (T1) purge exhaust valve (V3) is still open, vessel 2 (T2) is drying the inlet air. A small portion of dry outlet air from vessel 2 (15% average based on standard design capacity of 100 psig, 100°F inlet air, 100°F ambient air and PDP of -40°F) is taken through a small orifice in the outlet APV valve (V2) and used to regenerate the desiccant bed in vessel 1 (T1) until 240 seconds has been reached. Step 7: Vessel 1 Repressurizing (241-300 secs)
- Page 30 Aircel AHLD E-Series - Models 70 - 750 Aircel Programmable Controller Main Screen Navigation LEFT/RIGHT LEFT/RIGHT ALARM S CREEN CONTROL M ENU Control Menu Navigation LEFT/RIGHT LEFT/RIGHT MAIN S CREEN SETTINGS M ENU ...
- Page 31 Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Control Menu Operation • Push OK to engage the menu • Scroll to the desired selection and Push OK CONTROL M ENU Settings Screen Operation For use with optional outlet dewpoint display and high humidity alarm. SETTINGS S CREEN • To engage, Push OK then scroll to the desired set point to be changed • Push OK on the set point to be changed and use...
- Page 32 Aircel AHLD E-Series - Models 70 - 750 Aircel Programmable Controller Time Control Menu Navigation This time cycle control menu allows the user to choose between a 10 minute standard time cycle and a shorter 5 minute cycle for lower dewpoint option. TIME C YCLE C ONTROL LEFT/RIGHT LEFT/RIGHT S ETTINGS M ENU ANALOG S CREEN Time Control Menu Operation ...
- Page 33 Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Analog Screen Navigation The analog screen simply displays the analog output signals ANALOG S CREEN LEFT/RIGHT LEFT/RIGHT TIME C ONTROL S CREEN HOURS O F O PERATION Hours of Operation Screen Navigation The hours of operation screen gives the user the amount of run time as well as the total amount of hours saved with the energy management system.
- Page 34 Aircel AHLD E-Series - Models 70 - 750 Aircel Programmable Controller Alarm Screen Navigation ALARM S CREEN LEFT/RIGHT LEFT/RIGHT TOTAL H OURS O F O PERATION MAIN M ENU Alarm Pop-Ups • No Alarm: alarm has been corrected • High Outlet Dew Point (option): dew point has reached set point (check desiccant, prefilters, control system) • Failure to Shift (option): tower did not properly repressurize...
- Page 35 Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Alarm Pop-Up Screens No Alarm is the normally closed state of the common alarm relay. The Drain Fault is an alarm that triggers when there is no air present on the drain or when the liquid level has reached a point that needs to Drain and cannot. The drain will also fault if there is...
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Page 36: Electrical Drawings
Aircel AHLD E-Series - Models 70 - 750 Electrical Drawings Main Power & PLC Input: All AHLD E Models... - Page 37 Heatless Regenerative Desiccant Air Dryer Electrical Drawings Main Power & PLC Input: All AHLD E Models...
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Page 38: Plc Output & Sensors
Aircel AHLD E-Series - Models 70 - 750 Electrical Drawings PLC Output & Sensors: All AHLD E Models... - Page 39 Heatless Regenerative Desiccant Air Dryer Electrical Drawings PLC Output & Sensors: All AHLD E Models...
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Page 40: Back Panel
Aircel AHLD E-Series - Models 70 - 750 Electrical Drawings Back Panel: All AHLD E Models... -
Page 41: Enclosure Layout
Heatless Regenerative Desiccant Air Dryer Electrical Drawings Enclosure Layout: All AHLD E Models... -
Page 42: Service Notes
Aircel AHLD E-Series - Models 70 - 750 Service Notes Date Service Performed Notes... - Page 43 Heatless Regenerative Desiccant Air Dryer Service Notes Date Service Performed Notes...
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Page 44: Warranty
Aircel warranty excludes damages due to corrosion, lack of proper maintenance, incorrect installation, modification, or misapplication of equipment. Routine maintenance or adjustment required under normal operation as outlined in the Aircel operation and maintenance manuals are not covered under warranty. Once Aircel has been given adequate opportunity to remedy any defects in material or workmanship in accordance with Aircel Warranty Policy and Procedures, Aircel retains the sole option to accept return of the goods, with freight paid by the purchaser, and to refund the purchase price for the goods after confirming the goods are returned undamaged and in usable condition. Such a refund will be the full...
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