AIR DRYER SUPPLIER CATR-1600-200 Instruction Manual
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AIR DRYER SUPPLIER CATR-1600-200 Instruction Manual

Heatless air dryer
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Model CATR
Heatless Air Dryer
Instruction
Manual
Prior to installation and
start-up of this dryer,
please read and
implement the
"Installation & Start-up"
section of this manual.
Prior to operating this
dryer, it is advised that
this entire manual be
studied and clearly
understood.
Please have the following
information available, when
contacting ADS regarding this
dryer:
Model No. CATR-1600-200
Serial No. 101901

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Summary of Contents for AIR DRYER SUPPLIER CATR-1600-200

  • Page 1 "Installation & Start-up" section of this manual. Prior to operating this dryer, it is advised that this entire manual be studied and clearly understood. Please have the following information available, when contacting ADS regarding this dryer: Model No. CATR-1600-200 Serial No. 101901...

  • Page 2: Table Of Contents

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR TABLE OF CONTENTS SECTION 1: INTRODUCTION General Information Safety Instructions 1.2.1 Identification of Signs and Symbols in this Manual 1.2.2 Safety Tips for Maintenance, Inspection and Assembly Work Product Information 1.3.1...
  • Page 3 AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR TABLE OF CONTENTS SECTION 4: MAINTENANCE Maintenance 4.1.1 Suggested Preventive Maintenance Schedule Fill-Up / Replacement of Desiccant 4.2.1 For First Time Fill-Up 4.2.2 To Replace Used Desiccant Filter Maintenance 4.3.1 General Comments and Use 4.3.2...

  • Page 4: Section 1: Introduction

    SECTION 1: INTRODUCTION General Information Read this Instruction Manual Carefully This instruction manual from Air Dryer Supplier, Inc., is an aid in becoming familiar with the air dryer, its operation, and application in accordance with its intended use as described herein.

  • Page 5: Safety Tips For Maintenance, Inspection And Assembly Work

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 1: INTRODUCTION 1.2.2 Safety Tips for Maintenance, Inspection and Assembly Work Attention / Warning! As with any piece of industrial machinery, common sense and safety precautions should be observed. Please adhere to the following: 1.2.2.1...

  • Page 6: Product Information

    Applications other than those mentioned in this manual must be agreed to by Air Dryer Supplier, Inc., and confirmed in writing. In the interest of further development, Air Dryer Supplier, Inc., reserves the right to make changes at any time which, in keeping with the essential characteristics of the air dryer described here, may be necessary for increasing efficiency or for reasons relating to safety or to normal business practice.

  • Page 7: Storage

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 1: INTRODUCTION 1.3.1 Installation Attention / Warning! Upon delivery of the air dryer, it must be checked for damage that may have occurred during transport. If there is any evidence of damage due to shipping, immediately enter a claim with the carrier.

  • Page 8: Section 2: Start Up & Operation

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION Prior to installation and start-up of this dryer, please read and implement this section. Dryer Location & Mounting Specifications 2.1.1 The standard electrical components are designed specifically for NEMA 4.
  • Page 9 7/8" 12" 7/8"  Based on 1/16" gasket material.  If other than 150# flange rating, consult Air Dryer Supplier, Inc. Maximum torque for aluminum filter flanges is 75 ft. lbs. Reference ADS-316 Rev 0 Page 9 of 40 03/22/2019...

  • Page 10: Air Supply

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION Air Supply 2.3.1 The air supply for a standard CATR heatless dryer should be between 80-100F / 26.67°C-37.78°C and 100-175 PSIG / 6.90-12.07 Bar(G) compressed air.

  • Page 11: Start Up

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION Start-up Attention / Warning! Prior to start-up: It is recommended that the operational program of the dryer and the wiring schematic be studied before operating the dryer.

  • Page 12: Purge Rate

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION 2.6.1 Purge Rate In order to maintain the proper dew point, the dryer must receive the proper amount of purge gas. If there is excessive back pressure in the tower being regenerated (1 or 2 PSIG), check the purge piping and muffler for cleanliness.

  • Page 13: Operation

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION Prior to operating this dryer, it is advised that this entire manual be studied and clearly understood. Operation Carry out maintenance work only when the dryer is switched off, depressurized (even though gauges may read 0, there may still be air in the dryer), and disconnected from the electric power supply.

  • Page 14: Description

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION 2.7.2 Description The CATR heatless air dryer is a complete system consisting of the following major components: 2.7.2.1 Drying Vessels Two ASME Code stamped vessels containing activated alumina desiccant (reference the "Documentation"...
  • Page 15 AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION 2.7.2 Description (continued) 2.7.2.4 Particulate Afterfilter After the compressed air leaves the second drying vessel, it may contain small particles of desiccant dust. This material is inert, harmless, and presents no health or safety problems;...

  • Page 16: Theory Of Operation

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION 2.7.3 Theory of Operation Wet compressed air enters the dryer at the bottom and is directed by non-lubricated switching valves into the drying tower. The wet air encounters dry desiccant and moisture is transferred from the air to the desiccant.
  • Page 17 AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION 2.7.4 Sequence of Operation (continued) STEP TIME DESCRIPTION OF ACTION 270 SEC. DE-ENERGIZE SV4 OPENS V5 DE-ENERGIZE CR1 DE-ENERGIZE TR2 DE-ENERGIZE SV2 CLOSES V3 (RE-PRESSURIZE LEFT TOWER) 300 SEC.

  • Page 18: Pressure Vessel Regulations

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 2: START UP & OPERATION 2.7.4 Sequence of Operation (continued) NOTES: 1. At Tower Shift if PS1 or PS2, each with its respective REGEN TOWER, does not reach SETPOINT of 10 PSI, panel indicator light of RED will energize indicating a “FAIL TO DEPRESSURIZE”.

  • Page 19: Section 3: Cooler Assembly

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 3: COOLER ASSEMBLY Dryer Inlet Cooler Assembly This section will outline the operation of the dryer inlet cooler assembly for the CATR dryers. There are five main elements of the cooler assembly on the CATR series dryer.

  • Page 20: The Pneumatic Motor And Cooling Fan Blade

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 3: COOLER ASSEMBLY The Pneumatic Motor And Cooling Fan Blade The pneumatic motor and cooling fan blade provided is relatively maintenance free and there are only a few points that should be followed to assure satisfactory performance.

  • Page 21: The Pneumatic Regulator

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 3: COOLER ASSEMBLY The Pneumatic Motor And Cooling Fan Blade (continued)  A service valve has been provided to shut the supply air off to the motor if required.

  • Page 22: Data Table For Cooler Assembly (For Dryer W/Air Motors Only)

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 3: COOLER ASSEMBLY The Pneumatic Regulator (continued)  The pressure regulator has a locking handle. To adjust the regulator, lift the setting knob and turn clockwise (to increase pressure-fan RPM) or anti-clock wise (to decrease pressure-fan RPM) as required.

  • Page 23: The Mist Lubricator

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 3: COOLER ASSEMBLY The Mist Lubricator The mist lubricator mechanism will provide an aerosol mist stream to the pneumatic cooler motor. Review the data table in Section 3.4 to set the oil delivery rate for the appropriate dryer-cooler motor model.

  • Page 24: Section 4: Maintenance

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE Maintenance 4.1.1 Suggested Preventive Maintenance Schedule The CATR dryer requires a minimum of maintenance as most components are maintenance-free; however, a certain amount of preventive maintenance is recommended to assure years of trouble-free, high performance service.
  • Page 25 DO NOT REPRESSURIZE DRYER OR RECONNECT POWER TO THE DRYER YET! 2. Test desiccant for dynamic capacity. Contact Air Dryer Supplier, Inc., for instructions which will include the issue of a Return Merchandise Authorization (RMA) to send in desiccant samples for testing.
  • Page 26 AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE 4.1.1.4 EVERY 32,000 HOURS OR 48 MONTHS Attention / Warning! DO NOT REPRESSURIZE DRYER OR RECONNECT POWER TO THE DRYER YET! 1. Drain all the desiccant from both vessels through the drain at the bottom of each vessel.

  • Page 27: Fill-Up / Replacement Of Desiccant

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE Fill-Up / Replacement of Desiccant The air dryer is filled from the top and can be emptied by either vacuuming from the top (recommended) or emptying from the bottom. Reference the "Engineering Drawings &...

  • Page 28: To Replace Used Desiccant

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE Fill-Up / Replacement of Desiccant (continued) 4.2.2 To replace used desiccant:  To replace used desiccant, do not attempt any maintenance while dryer is pressurized.  First, isolate the dryer (IF BYPASS VALVING HAS BEEN INSTALLED), or shut off compressor, turn off dryer, then slowly depressurize the dryer.
  • Page 29 AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE Fill-Up / Replacement of Desiccant (continued) 4.2.2 To replace used desiccant (continued):  The amount of desiccant per tower will be specific; reference the "Documentation" section of this manual for the Specification Sheet and Spare Parts List which indicate the required desiccant quantity or contact Air Dryer Supplier, Inc.

  • Page 30: Filter Maintenance

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE Filter Maintenance 4.3.1 General comments and use The prefilters eliminate liquid water and oil carryover into the desiccant dryer. The desiccant dryer cannot remove liquid water or oil from the air stream, so it is important for the dryer to have a prefilter.

  • Page 31: Instructions For Changing Filter Elements

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE Filter Maintenance (continued) 4.3.5 Instructions for changing filter elements  Disconnect power to the dryer and depressurize before attempting any type of maintenance.  Using a ½” drive ratchet handle, unscrew and remove the top cover from the filter housing.

  • Page 32: Solenoid Valves

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 4: MAINTENANCE Solenoid Valves 4.4.1 Periodically clean the solenoid block. If a solenoid fails to operate, check the following:  Control Circuit – Check the terminal strip on the controller for the proper voltage.

  • Page 33: Section 5: Documentation

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 5: DOCUMENTATION Spare Parts List The Spare Parts List which is included on the following pages in this section is specific to the air dryer identified on this instruction manual's cover (reference Model No.
  • Page 34 Air Dryer Spare Parts List with Stock Recommendations Model No: CATR-1600-200 Serial No: 101901 April 2019 The following is a complete spare parts list. Items with quantities in the "Recommended Spare Qty." column are the minimum we advise that you place in your stock to have on hand in case of an emergency. We cannot guarantee that specific parts you may need will be available immediately from our stock.
  • Page 35 Air Dryer Spare Parts List Model No.: CATR-1600-200 Serial No.: 101901 Rec. Qty. Description Part # Spare Qty. 1" air motor lubricator (ML1) ADS-480-101898-00 Filter silencer, 1" female thd (FS1) ADS-490-101898-00 Muffler, 2” MNPT, air dryer, 200 PSI (M1-6) ADS-490-101898-01 Muffler, ¼”...
  • Page 36 Air Dryer Spare Parts List Model No.: CATR-1600-200 Serial No.: 101901 Rec. Qty. Description Part # Spare Qty. 4-way single coil solenoid (SV4) ADS-823-115-600 4-way dual coil solenoid (SV1) ADS-827-115-600 1 ¼" x 1 ½" 200# bronze relief valve (PRV1,2)
  • Page 37 101901 Air Dryer Supplier, Inc., 1626 Wind Chase Drive, Talbott, TN 37877 Air Dryer Supplier, Inc., 1626 Wind Chase Drive, Talbott, TN 37877...

  • Page 39: Section 6: Troubleshooting & Customer Service

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 6: TROUBLESHOOTING & CUSTOMER SERVICE Troubleshooting Following proper preventive maintenance procedures will go far toward assuring trouble-free dryer performance; however, failures may still occur. This section will help to identify the source of the problem and to affect a remedy.

  • Page 40: Short-Term Shut-Down

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 6: TROUBLESHOOTING & CUSTOMER SERVICE 6.1.1 Short-Term Shut-down Attention! After the following step, dryer will remain pressurized! The following sequence is to be heeded when switching off the dryer: ...

  • Page 41: Customer Service

    Allan@airdryersuppliers.com 6.2.2 Inquiry Information When contacting Air Dryer Supplier, Inc., please have the following information available:  Serial Number, which can be found on the front cover of this manual, on the ASME code nameplate on the dryer towers, or in the electrical enclosure.

  • Page 42: Section 7: Msds

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 7: MSDS & CUT SHEETS Desiccant MSDS The Desiccant MSDS (Material Safety Data Sheet) which is included on the following pages in this section is specific to the air dryer identified on this instruction manual's cover (reference Model No.
  • Page 43 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 1 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) 1. Identification Product identifier used on the label 3/16" Activated Alumina Desiccant Recommended use of the chemical and restriction on use Recommended use*: Industrial catalyst * The “Recommended use”...
  • Page 44 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 2 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) 3. Composition / Information on Ingredients According to Regulation 1994 OSHA Hazard Communication Standard; 29 CFR Part 1910.1200 The product contains: CAS Number Content (W/W) Chemical name...
  • Page 45 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 3 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) 6. Accidental release measures Personal precautions, protective equipment and emergency procedures Avoid dust formation. Avoid contact with the skin, eyes and clothing. Use personal protective clothing. Information regarding personal protective measures see, section 8.
  • Page 46 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 4 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) Body protection: Body protection must be chosen depending on activity and possible exposure, e.g. apron, protecting boots, chemical-protection suit (according to EN 14605 in case of splashes or EN ISO 13982 in case of dust). General safety and hygiene measures: No eating, drinking, smoking or tobacco use at the place of work.
  • Page 47 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 5 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) Incompatible materials water, reducing agents Hazardous decomposition products Decomposition products: Hazardous decomposition products: No hazardous decomposition products known. Thermal decomposition: No decomposition if used correctly. 11.
  • Page 48 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 6 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) Chronic Toxicity/Effects Other Information The product has not been tested. The statements on toxicology have been derived from the properties of the individual components.
  • Page 49 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 7 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) Persistence and degradability Assessment biodegradation and elimination (H2O) Not applicable for inorganic substances. Additional information Other ecotoxicological advice: The product has not been tested. The statements on ecotoxicology have been derived from the properties of the individual components.
  • Page 50 Material Safety Data Sheet 3/16" Activated Alumina Desiccant Revision date : 2014/06/19 Page 8 of 8 Version: 6.0 (53732394/SDS_GEN_US/EN) 16. Other Information MSDS Prepared on: 2014/06/19 We support worldwide Responsible Care® initiatives. We value the health and safety of our employees, customers, suppliers and neighbors, and the protection of the environment.

  • Page 51: Section 8: Warranty

    Air Dryer Supplier, Inc., in writing of its intention to do so. Any such use of equipment will be at Purchaser’s sole risk and liability.
  • Page 52 SECTION 8: WARRANTY Warranty (continued) Correction by Air Dryer Supplier, Inc., of nonconformities whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of Air Dryer Supplier, Inc., for such nonconformities whether based on contract, warranty negligence, indemnity, strict liability, or otherwise with respect to or arising out of such equipment.

  • Page 53: Section 9: Engineering Drawings & Documents

    AIR DRYER SUPPLIER, INC. AIR DRYER INSTRUCTION MANUAL Model CATR SECTION 9: ENGINEERING DRAWINGS & DOCUMENTS Engineering Drawings & Documents The drawings which are included on the following pages in this section are specific to the air dryer identified on this instruction manual's cover (reference Model No. and Serial No.).

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