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Aircel VF-10 Installation And Operation Manual

Vf series non-cycling refrigerated air dryer
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Installation,
Operation, and
Service Information
Throughout this manual,
signal words are present to
advise of safety precautions
and/or standard practices.
Obey these signal words as defined
below:
DANGER! - indicates an
imminently hazardous situation
which, if not avoided, will result
in death or serious injury.
WARNING! - indicates a
potentially hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION! - indicates a
potentially hazardous situation
which, if not avoided, may
result in
minor or moderate
injury.
Notice: - used to address
practices not related to personal
injury.
Installation
and Operation Manual
Aircel
VF Series Non-Cycling Refrigerated Air Dryer
Models VF-10, 15, 25, 40, 50, 60, 75, 100, 125, 150, 200, 250,
300, 400, 500 600, 800, 1000, and 1200
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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Summary of Contents for Aircel VF-10

  • Page 1 Aircel Operation, and VF Series Non-Cycling Refrigerated Air Dryer Service Information Models VF-10, 15, 25, 40, 50, 60, 75, 100, 125, 150, 200, 250, 300, 400, 500 600, 800, 1000, and 1200 Throughout this manual, signal words are present to advise of safety precautions and/or standard practices.

  • Page 2: Safety Statements

    • 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 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.

  • Page 3: Table Of Contents

    Non-Cycling Refrigerated Air Dryer Contents Safety Statements ..........2 Cooling Water Requirements ......15 Data Sheet ............. 3 Water Cooled Condenser Table ....15 Refrigerated Air Dryer Serial Plate Label ....4 Shut-Down Procedures ........16 Refrigerant Safety Precautions ......5 Shut-Down Emergency ....... 16 Design Parameters ..........6 Short-Term Shut-Down ......16 Description............6 Service Information ..........17 System ............

  • Page 4: Data Sheet

    Aircel VF Series - Models 10 - 1200 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 VF Series - Models 10 - 1200 Design Parameters Hot saturated air enters the air-to-air heat Type of dryer: Refrigerated exchanger of the Non-Cycling Refrigerated Air Dryer and is precooled by the outgoing dry air. Power supply: 115, 230, 460 Volt / single or three Precooling saves energy by reducing the heat load phase / 60Hz on the dryer’s compressor. The cool saturated air Refrigerant type: R-134A & R-404A enters the air-to-refrigerant heat exchanger where air temperature is lowered to the 38 to 42°F range. Chemical Composition: HFC This dramatic temperature drop condenses water and oil. Parameter Optimum Maximum Minimum...

  • Page 7: Refrigeration Circuit

    Non-Cycling Refrigerated Air Dryer This energy saving heat exchanger provides Refrigeration Circuit several advantages, such as a reduction of the heat load imposed on the refrigerant compressor and Refrigerant is compressed by the compressor to a condenser, providing more energy to the outlet gas with high temperature and high pressure, which air, and preventing condensation of moisture then travels to the condenser (air or water cooled) on the outside of the plant distribution air line to condense the gas into a liquid.
  • Page 8 Aircel VF Series - Models 10 - 1200 air inlet air outlet separation cell stainless steel mist eliminator air to refrigerant incoming air heat exchanger pre-cooler / heater exiting air refrigerant refrigerant inlet refrigerant outlet Typical Schematic Flow Diagram (75 - 1200 scfm rated models)

  • Page 9: 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 10: Lifting Information

    Aircel VF Series - Models 10 - 1200 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. the fork lift openings provided. Do not lift by • Electrical installation must be piping.

  • Page 11: 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 12: Typical Installation

    Aircel VF Series - Models 10 - 1200 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 10 - 250, 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 13 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 R-134a valve too quickly. Opening valve and suddenly = 28-40 psig pressurizing the system can cause damage to the • Refrigerant discharge pressure R-134a dryer heat exchanger and other components. = 160-250 psig 6. Check the air system piping connections and dryer system connections for leaks at this time. • Refrigerant suction pressure R-404a Repair and retest any leaks. = 28-40 psig 7. Verify that all instrumentation (pressure • Refrigerant discharge pressure R-404a gauge/s) and drain air tubing fittings are tight.

  • Page 14: Automatic Drain Valve Adjustments

    Aircel VF Series - Models 10 - 1200 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 15: Cooling Water Requirements

    Non-Cycling Refrigerated Air Dryer Cooling Water Requirements (water cooled condensing units) Cooling water is required for water-cooled and dryer air load. The table below indicates the refrigerant condensers (scfm rated model 100 and amount of cooling water required in gallons per up). The user is responsible for piping the water minute (gpm) at given incoming temperatures to and from the condenser.

  • Page 16: Shut-Down Procedures

    Aircel VF Series - Models 10 - 1200 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 The non-cycling refrigerated air dryer system can...

  • Page 17: 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 18 Aircel VF Series - Models 10 - 1200 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.

  • Page 19: 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 20: Condensate Removal

    Aircel VF Series - Models 10 - 1200 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 • Refrigerant control too high - Contact...

  • Page 21: 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 22 Aircel VF Series - Models 10 - 1200 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. motor specifications for correct value. Check wiring schematic to ensure proper wiring of fan motor. Replace motor if required.
  • Page 23 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 24 Aircel VF Series - Models 10 - 1200 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 25 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.

  • Page 26: Appendix

    Aircel VF Series - Models 10 - 1200 Appendix Refrigerant Material Safety Data Sheet: R-134a Models 10 to 800 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 27 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-134a Models 10 to 800, continued 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 28 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-134a Models 10 to 800, 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 29 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-134a Models 10 to 800, continued 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:...
  • Page 30 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-134a Models 10 to 800, 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 31: R-404A Material Safety Data Sheet

    Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200 SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 This SDS adheres to the standards and regulatory requirements of Great Britain and may not meet the regulatory requirements in other countries.
  • Page 32 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 Vapours are heavier than air and can cause suffocation by reducing oxygen available for breathing.
  • Page 33 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 necessary. Call a physician. Skin contact Flush area with lukewarm water.
  • Page 34 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 fire. Further information : Cool containers / tanks with water spray.
  • Page 35 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 7.3. Specific end use(s) no data available SECTION 8: Exposure controls/personal protection 8.1.
  • Page 36 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 Predicted No Effect Concentration (PNEC) ●...
  • Page 37 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 The choice of an appropriate glove does not only depend on its material but also on other quality features and is different from one producer to the other.
  • Page 38 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 SECTION 10: Stability and reactivity : Decomposes on heating.
  • Page 39 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 LC50 / 4 h rat :567000 ppm Low Observed Adverse Effect Concentration (LOAEC) / dog :75000 ppm Cardiac sensitization No Observed Adverse Effect Concentration (NOAEC) / dog :50000 ppm...
  • Page 40 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 • 1,1,1,2-Tetrafluoroethane rabbit Classification: Not classified as irritant Result: slight irritation Not expected to cause eye irritation based on expert review of the properties of the substance.
  • Page 41 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 Animal testing did not show any mutagenic effects. Tests on bacterial or mammalian cell cultures did not show mutagenic effects.
  • Page 42 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 • Pentafluoroethane LC50 / 96 h / Danio rerio (zebra fish): > 200 mg/l Information given is based on data obtained from similar substances.
  • Page 43 Non-Cycling Refrigerated Air Dryer Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 no data available 12.5. Results of PBT and vPvB assessment no data available 12.6.
  • Page 44 Aircel VF Series - Models 10 - 1200 Refrigerant Material Safety Data Sheet: R-404a Models 1000 to 1200, continued SAFETY DATA SHEET according to Regulation (EC) No 1907/2006 and 453/2010 ™ ® DuPont SUVA 404A refrigerant Version 4.0 Revision Date 21.11.2012 Ref. 130000000494 14.4. Packing group: not applicable 14.5.

  • Page 45: Wiring Diagram

    Non-Cycling Refrigerated Air Dryer Wiring Diagram, SCFM Rated Models 10 to 75: 1 Phase, 120 Volt, 60 Hz...
  • Page 46 Aircel VF Series - Models 10 - 1200 Wiring Diagram, SCFM Rated Models 100, 125, and 150: 1 Phase, 120 Volt, 60 Hz...
  • Page 47 Non-Cycling Refrigerated Air Dryer Wiring Diagram, SCFM Rated Model 200: 1 Phase, 208/230 Volt, 60 Hz...
  • Page 48 Aircel VF Series - Models 10 - 1200 Wiring Diagram, SCFM Rated Model 250 and 300: 3 Phase, 460 Volt, 60 Hz...
  • Page 49 Non-Cycling Refrigerated Air Dryer Wiring Diagram, SCFM Rated Models 400 to 1200: 3 Phase, 460 Volt, 60 Hz...

  • Page 50: Service Notes

    Aircel VF Series - Models 10 - 1200 Service Notes Date Service Performed Notes...
  • Page 51 Non-Cycling Refrigerated Air Dryer Service Notes, continued Date Service Performed Notes...

  • Page 52: 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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