AIR DRYER SUPPLIER CATR-1600-200 User manual

Model CATR
Heatless Air Dryer
Instruction
Manual
Please have the following
information available, when
contacting ADS regarding this
dryer:
Model No. CATR-1600-200
Serial No. 101901
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.

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
Page 2 of 40 03/22/2019
TABLE OF CONTENTS
SECTION 1: INTRODUCTION
1.1 General Information
1.2 Safety Instructions
1.2.1 Identification of Signs and Symbols in this Manual
1.2.2 Safety Tips for Maintenance, Inspection and Assembly Work
1.3 Product Information
1.3.1 Installation
1.3.2 Storage
SECTION 2: START UP & OPERATION
2.1 Dryer Location & Mounting Specifications
2.2 Preventive Maintenance Prior to Start-up
2.3 Air Supply
2.4 Air Discharge Piping
2.5 Drain Piping (on mounted prefilter)
2.6 Start Up
2.6.1 Purge Rate
2.7 Operation
2.7.1 Standard Inlet Conditions
2.7.2 Description
2.7.3 Theory of Operation
2.7.4 Sequence of Operation
2.7.5 Pressure Vessel Regulations
2.7.6 Airtightness Test
SECTION 3: COOLER ASSEMBLY
3.1 Dryer Inlet Cooler Assembly
3.1.1 The Cooling Core
3.2 The Pneumatic Motor and Cooling Fan Blade
3.3 The Pneumatic Regulator
3.4 Data Table for Cooler Assembly (for dryer w/air motors only)
3.5 The Mist Lubricator
3.6 The Separator

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
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TABLE OF CONTENTS
SECTION 4: MAINTENANCE
4.1 Maintenance
4.1.1 Suggested Preventive Maintenance Schedule
4.2 Fill-Up / Replacement of Desiccant
4.2.1 For First Time Fill-Up
4.2.2 To Replace Used Desiccant
4.3 Filter Maintenance
4.3.1 General Comments and Use
4.3.2 Function
4.3.3 Assembly and Installation
4.3.4 Maintenance
4.3.5 Instructions for Changing Filter Elements
4.4 Solenoid Valves
4.5 Pilot Operated Valves
SECTION 5: DOCUMENTATION
5.1 Spare Parts List
5.2 Data Reports (as applicable)
SECTION 6: TROUBLESHOOTING & CUSTOMER SERVICE
6.1 Troubleshooting
6.1.1 Short-Term Shut-Down
6.1.2 Shut-Down in Case of a Fault or for Maintenance
6.2 Customer Service
6.2.1 Corporate Office
6.2.2 Inquiry Information
SECTION 7: MSDS
7.1 Desiccant MSDS
SECTION 8: WARRANTY
8.1 Warranty
SECTION 9: ENGINEERING DRAWINGS & DOCUMENTS
9.1 Engineering Drawings & Documents

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
Page 4 of 40 03/22/2019
SECTION 1: INTRODUCTION
1.1 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.
The information in this instruction manual can help the user take full advantage of
the air dryer’s many features and ensure years of safe, reliable operation. This
instruction manual must always be kept within reach of the air dryer at the site of
installation/operation.
All maintenance, inspection, and assembly work is to be carried out by personnel
who are authorized and qualified, who are adequately informed, and who have
read the instruction manual in its entirety with a complete understanding of the
contents and the air dryer's operation. Should personnel not possess the
necessary knowledge, they must be trained and instructed by qualified personnel.
This training may be carried out by the manufacturer at the request of the user.
1.2 Safety Instructions
1.2.1 Identification of Signs and Symbols in this Manual
This instruction manual contains important information for safe, proper, and
economic operation. The safety tips and advice contained in this instruction
manual, as well as all safety labels printed directly on, or attached to the air dryer,
must be followed at all times and must be kept completely legible.
Symbols of important note in this instruction manual, whose disregard could
endanger people and/or equipment, are indicated by the following symbols:
Danger against electrical voltage!
This symbol indicates that dangerous voltage constituting a
risk of electric shock is present.
Attention / Warning!
This symbol indicates that there are important operating
and maintenance instructions which any and all
operators should read closely to avoid danger and
prevent problems. The instructions must be followed to
avoid serious injury and/or damage to components.
Advice
This symbol indicates an instruction or procedure of
particular interest or importance that must be followed to
avoid damage to components and/or to ensure proper use
of the air dryer.

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
Page 5 of 40 03/22/2019
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 Portions of the dryer and related piping will reach temperatures which could cause
serious burns, if not insulated or shielded. Personnel working on or near the dryer
should be cautioned to this particular danger.
If the equipment is installed in a high traffic area, protective barriers may be required
to prevent possible damage of equipment and to prevent contact with hot surfaces.
1.2.2.2 Unplug the dryer before attempting to work or perform maintenance on the dryer.
1.2.2.3 Do not attempt to remove any dryer parts while the dryer is pressurized. First, isolate
the dryer (if bypass valving has been installed) or shut off the compressor. Then,
slowly depressurize the dryer through the afterfilter bleed.
1.2.2.4 Do not allow tools or other obstructions to interfere with the shaft of the switching
valves. Keep all body parts away from the switching valve shafts while the dryer is
operating. The actuation is sudden and can cause bodily injury.
1.2.2.5 Caution!
All pipes and wire connections must be tightened!
Furthermore, before start-up:
The pipes must be checked for the presence of scale, abraded material from the
threading, or other similar impurities.
All shut off valves on the pre-filter, adsorption dryer, after-filter and on the bypass
line should be closed.
Unless proper heat tracing is provided, the ambient temperature must not be less
than 33°F (1°C).
Breakdowns resulting from faulty installation do not fall under warranty obligation.

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
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SECTION 1: INTRODUCTION
1.2.2.6 Danger!
Wear protective goggles when working with the desiccant!
Note:
If desiccant comes into contact with the eyes, rinse eyes immediately with a large
amount of clear water.
If the desiccant is spilled, clean up without causing swirls of dust.
In case of fire, there is no restriction on the use of fire extinguishing material; the
reaction with water and foam is defined as strong.
A mask must be worn to avoid inhalation of the desiccant dust.
1.2.2.7 Slowly open the inlet valve and gradually increase the pressure by reading the
chamber pressure gauge. Do not open the valve abruptly as the sudden pressure
change may damage the dryer.
1.3 Product Information
The CATR heatless dryer is used for the purpose of drying compressed air and other
gases according to its respective design. The standard model CATR heatless dryer
is equipped with two desiccant vessels and provides pure, dry, compressed air or
gases when used under the design conditions as specified upon purchase.
Attention / Warning!
Use of the dryer can endanger personnel and can lead to considerable damage
to the dryer and other material assets if:
it is operated by personnel not trained or instructed in its use
it is improperly used
it is improperly maintained or serviced
This can result in the loss of all damage claims.
This dryer is designed for neutral media (gas) free of aggressive water, oil, and
solid elements. Air Dryer Supplier, Inc., accepts no liability for corrosion
damage and malfunctions caused by aggressive media.
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.

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
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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. Shipping damage is not covered by
warranty.
Use the appropriate, load-rated lifting equipment and observe safe lifting
procedures during all operations of installation. The equipment should be
unloaded as close as possible to the installation site to minimize any chances
of equipment damage.
After the adsorption dryer has been delivered, it must be checked for damage that
may have occurred during transport. Any damages should be reported immediately
to the transport company to begin the claim process.
Note:
For lifting and transportation, only the skid or frame lifting points of the dryer
may be used. Do NOT support the dryer by the interconnecting piping any
other attached component.
1.3.2 Storage
Unless proper heat tracing is provided, dryer must be stored in a dry place,
preferably indoors; protected from the elements, including freezing or
extremely warm temperatures.
If the adsorption dryer is to be stored for a long period of time, its place of storage
must be dry and free of dust. There has to be a minimum ambient temperature of
33°F (+1°C).

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
Page 8 of 40 03/22/2019
SECTION 2: START UP & OPERATION
Prior to installation and start-up of this dryer,
please read and implement this section.
2.1 Dryer Location & Mounting Specifications
2.1.1 The standard electrical components are designed specifically for NEMA 4.
2.1.2 Remove all protective shipping crates, flange covers, etc.
Should vibrations occur on the installation location, the dryer is to be placed
onto vibration dampeners.
2.1.3 Because of vibration during shipping and installation, some lines, fittings, bolts, and
connections may have loosened; therefore, inspect all and, if required, tighten.
2.1.4 Locate and install any items that may have shipped loose from the dryer, such as
exhaust mufflers, auxiliary filters, etc.
2.2 Preventive Maintenance Prior to Start-up
2.2.1 All air dryers are tested at the factory for leak-tight joints and tightness of bolts;
however, during shipment, some bolts may vibrate loose. We have no control over
the handling our compressed air systems receive after leaving our factory. To
prevent costly problems at start-up and operation, all bolts should be checked for
tightness prior to system pressurization. This will assure gasket life, as well as
prevent possible gasket blowout. Gasket joints should be bubble tested after four or
five complete cycles of the dryer, to ensure gaskets are sealed. Any loose joints will
need to be re-tightened and re-tested for leaks.
If the dryer includes manual butterfly valves, valves must be totally closed before re-
torquing bolts.
Following is a comprehensive procedure for tightening all pressurized gasketed
joints:
2.2.2 TIGHTEN BOLTS IN SEQUENTIAL ORDER (i.e. 0- 180, 90- 270,
45- 225, and 135- 315) until final torque is reached.
2.2.3 Use ROTATIONAL TIGHTENING until all bolts are stable at final torque level (two
complete rotations are usually required).
Reference the next page for continuation of the flange bolt torque procedure.

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
Page 9 of 40 03/22/2019
SECTION 2: START UP & OPERATION
2.2 Preventative Maintenance Prior to Start-up (continued)
Illustration: Flange bolt torque sequence
FLANGE BOLT TIGHTENING TORQUES
150# FLANGE RATING
SIZE BOLT
QTY. BOLT
SIZE
RECOMMENDED
TORQUE / BOLT
(FT. LBS.)
MAXIMUM TORQUE
(FT. LBS.)
1" 4 ½" 16 64
1 ½" 4 ½" 32 64
2" 4 5/8" 64 128
3" 4 5/8" 110 128
4" 8 5/8" 78 128
6" 8 ¾" 148 230
8" 8 ¾" 201 230
10" 12 7/8" 191 372
12" 12 7/8" 254 372
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.
FLANGE BOLT
TORQUE PROCEDURE
8 BOLTS
SEQUENTIAL
ORDER ROTATIONAL
ORDER
1-2 1
3-4 5
5-6 3
7-8 7
2
6
4
8

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
Page 10 of 40 03/22/2019
SECTION 2: START UP & OPERATION
2.3 Air Supply
2.3.1 The air supply for a standard CATR heatless dryer should be between 80-100F /
26.67°C-37.78°C and 100-175 PSIG / 6.90-12.07 Bar(G) compressed air.
2.3.2 Caution!
In piping the air to the dryer, use a pipe size equal to, or larger than, the dryer line
size.
2.3.3 The compressed air generated by a reciprocating compressor contains some
pulsation; the amplitude and frequency being related to the number of stages,
speed, etc. Normally, the pulsation associated with a multi-stage compressor will not
affect the operation of the dryer; however, it is recommended that a PULSATION
DAMPENER be installed between a reciprocating compressor and the dryer to
prevent excessive desiccant breakup and component fatigue.
A pulsation dampener should be used in any installation where the pulsation
seems excessive.
2.3.4 If the compressed air system cannot be shut down during dryer maintenance
periods, a three-valve block and bypass valving arrangement should be installed
prior to start-up to allow for isolating and depressurizing the dryer, while still
maintaining compressed air delivery. Reference the "Engineering Drawings &
Documents" section of this manual for the Flow Schematic which will indicate the
factory supplied arrangement. Note that the bypassed air will not be dried.
Reference the “Maintenance” section of this manual for the suggested preventive
maintenance schedule.
2.4 Air Discharge Piping
2.4.1 If an air receiver is required in the compressed air system for air storage, it should
be installed after the dryer. Here it will store dry air.This will eliminate the possibility
of overloading the dryer with stored air in wet receivers.
2.5 Drain Piping (on moisture separator/prefilter assembly)
2.5.1 All the moisture removed from the prefilter is drained away through the drain valves
under the prefilter. The prefilter drain port should be connected to a suitable drain
through piping of sufficient size for its length, to avoid pressure drop or blockage due
to contaminants in the draining water.
It is recommended that at some convenient point in the drain piping, the water
flow should be visible, so proper drain operation can be visually verified.

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AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
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SECTION 2: START UP & OPERATION
2.6 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.
Desiccant level must be checked. Wear protective goggles and mask when
working with desiccant. Fill desiccant standpipe before pressurizing the dryer
system. If the desiccant was shipped separately, reference the "Maintenance"
section in this manual for the desiccant first-time fill-up instructions. The
MSDS can be referenced in the "Desiccant MSDS" section of this manual.
Recheck desiccant level one month after start-up and refill as necessary;
desiccant should be filled through the standpipe.
All pipes and wire connections must be tightened. Reference the
"Maintenance" section of this manual for preventative maintenance prior to
start-up.
Pipes must be checked for presence of scale, abraded material from the
threading, or other similar impurities.
All shut-off valves on the dryer, prefilter, afterfilter, and on the bypass line
should be closed.
The ambient temperature must not be less than 33F / 0.56°C.
Adjust the purge adjustment valve in accordance with the parameters listed in
Section 2.6.1 of this manual. The (2) purge isolation valves must be left fully
open at all times during operation.
CATR Models with Aftercoolers – set the regulator and oil mist lubricator in
accordance with the table in Section 3.4 of this manual.
Turn the switch to the “POWER ON” position.
The adsorption dryer should be operated for approximately 3 to 4 hours with the
outlet valve closed. This is to fully regenerate the desiccant which will likely have
been saturated during transportation and installation.
After the regeneration phase, slowly open the shut off valve behind the after-
filter slowly while observing the chamber pressure gauge. Do not open the
valve abruptly as a sudden pressure change may damage the dryer.
The adsorption dryer is now ready for operation and will function continuously
and fully automatically.

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AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
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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. The purge piping
must be kept clean at all times to maintain the proper purge rate. The "left/right
tower failed to depressurize" alarm will alarm when the back pressure exceeds 5
psig. At this time, the mufflers MUST be cleaned or replaced to assure satisfactory
dryer performance.
ALTERNATE FLOW PURGE SETTINGS
Capacity
(SCFM) Purge (PSIG)
@100 Purge (PSIG)
@125 Purge (PSIG)
@150 Purge (PSIG)
@175
1600 65 51 41 33
1400 55 43 34 31
1200 45 35 31 21
1000 35 26 20 16
800 25 18 14 11
Aftercooler Setting: 60 PSIG

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AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
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SECTION 2: START UP & OPERATION
Prior to operating this dryer,
it is advised that this entire manual be
studied and clearly understood.
2.7 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.
Never make any changes to the dryer that are not specifically authorized by
Air Dryer Supplier, Inc.
Only use original spare and accessory parts.
2.7.1 Standard Inlet Conditions
At standard inlet conditions of 100ºF, 100 psig, and providing a –40ºF pressure dew
point according to DIN ISO 7183.
Note:
All values given above assume a standard dryer with a standard scope of
supply and standard operating conditions as explained above. Dryers that
have been specifically modified for a particular application may have different
values than those shown.

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AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
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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" section of this manual for the Specification Sheet
and Spare Parts List which will indicate the desiccant quantity) are firmly mounted
on a structural steel base. Each vessel is provided with stainless steel desiccant
retaining screens at both inlet and outlet. Separate desiccant fill and drain
connections allow for fast and easy desiccant replacement without disturbing
process piping (reference the "Maintenance" section of this manual for desiccant fill-
up/replacement instructions). A safety relief valve is installed on each vessel.
2.7.2.2 Switching Valves
Main compressed air flow through the CATR heatless dryer is controlled by
reinforced teflon-seated high performance butterfly valves (3" and larger) or 2-way
ball valves (2" and smaller). This improved 2-way valve design provides for lower
overall system pressure drop and it eliminates undesirable wet air transfer between
compressed air streams simultaneously flowing through the same valve internal
plug, rotor, or ball.
The valves are opened and closed by over-sized actuators. These actuators are
driven by well filtered, cool, dry air supplied by the control air filter. The coalescing
quality filter element contained therein removes all particulates above 0.3 micron in
size; thereby assuring long pneumatic actuator life. Control air lines need no
lubricators as the pneumatic actuators have been permanently pre-lubricated.
2.7.2.3 Moisture Separator / Rough Coalescing Prefilter / Coalescing Prefilter
After the compressed air leaves the compressor, it will contain liquid water and oil.
This will cause a problem for the dryer as it will not remove liquid water from the air
stream. It is essential that the dryer be fitted with a water separation system located
directly before the dryer inlet. This water separation system will include a moisture
separator, a rough coalescing prefilter, a coalescing prefilter, and equipped with float
style, zero air loss drains.

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AIR DRYER INSTRUCTION MANUAL
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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; however, to provide absolute top quality compressed air, a
particle removal filter is recommended.
2.7.2.5 Control Group
The complete operation of the CATR heatless dryer is fully automatic and pre-
programmed to shift drying vessels continuously before the design water load can
be reached (breakthrough). The standard control is done with a PLC which operates
the pilot air solenoids, which in turn actuate the switching valves; all without operator
attention.
2.7.2.6 Instrument Panel
The standard instrument panel assures that operating personnel are always
informed of all phases of the CATR heatless dryer operation. Alarms are displayed
here.
Panel mounted pressure gauges are included as standard.
The standard gauge panel includes right and left vessel gauges and purge gauge for
purge setting.

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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. The direction of air flow during
drying is upflow; design of the towers prevents fluidization of the desiccant.
At the top of the dryer, the dry process air is directed to the outlet of the dryer
through check valves. Approximately 15% of the dry air is directed into the
regenerating tower, where it is depressurized to atmospheric pressure and is used to
regenerate the desiccant. After removing moisture from the desiccant, the purge air
exits the dryer through a muffler and is blown out to the atmosphere.
After a preset time, the dryer will shift towers. At tower shift, the regenerating tower
is gradually repressurized; the switching valves shift and the offstream tower is
depressurized.
The Flow Schematic can be referenced in the "Engineering Drawings &
Documents" section of this manual.
2.7.4 Sequence of Operation
STEP TIME DESCRIPTION OF ACTION
1. 0 SEC. ENERGIZE SV4
CLOSES V5
DE-ENERGIZE SV1-1
ENERGIZE CR1
2 SEC. ENERGIZE SV1-2
CLOSES V1
OPENS V2
“RIGHT TOWER ONSTREAM”
ENERGIZE TR2
START 5 SECOND TIME DELAY
2. 7 SEC. ENERGIZE SV2
OPENS V3
(DEPRESSURIZE LEFT TOWER)
“LEFT TOWER REGENERATING”
START TIME DELAY OF 30 SECONDS
IF PS1 DOES NOT REACH THE SET POINT
OF 10 PSI, THEN;
“LEFT TOWER FAIL TO DEPRESSURIZE”

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SECTION 2: START UP & OPERATION
2.7.4 Sequence of Operation (continued)
STEP TIME DESCRIPTION OF ACTION
3. 270 SEC. DE-ENERGIZE SV4
OPENS V5
DE-ENERGIZE CR1
DE-ENERGIZE TR2
DE-ENERGIZE SV2
CLOSES V3
(RE-PRESSURIZE LEFT TOWER)
4. 300 SEC. ENERGIZE SV4
CLOSES V5
DE-ENERGIZE SV1-2
ENERGIZE CR1
302 SEC. ENERGIZE SV1-1
OPENS V1
CLOSES V2
“LEFT TOWER ONSTREAM”
ENERGIZE TR1
START 5 SECOND TIME DELAY
5. 357 SEC. ENERGIZE SV3
OPENS V4
(DEPRESSURIZE RIGHT TOWER)
“RIGHT TOWER REGENERATING”
START TIME DELAY OF 30 SECONDS
IF PS2 DOES NOT REACH THE SET POINT
OF 10 PSI, THEN;
“RIGHT TOWER FAIL TO DEPRESSURIZE”
6. 570 SEC. DE-ENERGIZE SV4
OPENS V5
DE-ENERGIZE CR1
DE-ENERGIZE TR1
DE-ENERGIZE SV3
CLOSES V4
(RE-PRESSURIZE RIGHT TOWER)
7. 600 SEC. GO TO STEP 1

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Model CATR
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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”.
2. Toggle switch in electrical enclosure is used to set the overall cycle length of
either 5 minutes (300 SEC) or 10 minutes (600 SECONDS). 10 minutes is
shown.
a. For 5 minutes STEP TIME alters to the following:
i. STEP 1: 0 sec & 2 sec
ii. STEP 2: 7 sec
iii. STEP 3: 120 sec
iv. STEP 4: 150 sec & 152 sec
v. STEP 5: 157 sec
vi. STEP 6: 270 sec
vii. STEP 7: 300 sec
2.7.5 Pressure Vessel Regulations
Never weld on, or alter, a pressure vessel in any way.
The pressure vessels are designed according to the standard technical
requirements. They fulfill the test and the certifying procedure, as required by ASME
Code and carry the “U”, “UM” ASME Symbol as required.
2.7.6 Airtightness Test
All CATR heatless dryers are subjected to a pneumatic air test prior to shipment
using compressed air and soap solution. System should be re-tested after
installation to ensure system integrity and joints are sealed.

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
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SECTION 3: COOLER ASSEMBLY
3.1 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. They are the cooling core, the pneumatic motor with cooling fan blade, the air
regulator, the mist lubricator and finally the cooler outlet separator. The cooler
assembly requires minimal maintenance. There are adjustments that can be made
to reduce air consumption of the cooler motor based on the flow and temperature of
the air entering the cooling core.
3.1.1 The Cooling Core
The cooling core provided is relatively maintenance free and there are only a few
points that should be followed to assure satisfactory performance. Review the
bullet points during installation and operation.
The cooler should be installed in such a manner where the skid is level to allow
liquids being condensed to drain towards the outlet connection of the assembly.
The cooler should be located in an area to permit free movement of the air
around it. The warm discharge air must be free to dissipate to avoid being
recycled into the cooler inlet.
The cooler assembly has an outlet temperature gauge and this temperature
should be monitored to assure the dryer inlet temperature does not exceed sizing
limitations or the dryer will no longer maintain an acceptable dew point and can
become saturated.
Verify the cooler core and finger guard for obstructions that can lead to elevated
cooler outlet temperatures.
Do not remove the finger guard from the cooler assembly unless cooler core
service is being performed. After service the guard must be re-installed to
provide protection and prevent debris from damaging the cooling fan blade and
cooler core.
Note:
Cleaning the exterior fin surface may be required when discharge
temperature increases beyond desired temperatures. Cleaning may be
accomplished by low pressure steam jet (with detergent if necessary).
Caution!
DO NOT use caustic based chemicals. Verify detergents ensuring compatibility
with aluminium. Cleaning of internal fin surfaces may be accomplished by
circulating a degreaser solvent that is compatible with aluminium. Alkaline
material should never be used.

AIR DRYER SUPPLIER, INC.
AIR DRYER INSTRUCTION MANUAL
Model CATR
Reference ADS-316 Rev 0
Page 20 of 40 03/22/2019
SECTION 3: COOLER ASSEMBLY
3.2 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. Review the bullet points during installation and operation.
Note:
The fan blade assembly should be inspected at time of installation and after
every 4 weeks of operation to ensure integrity of the fan blades. DO NOT
attempt to repair a damaged fan blade. A damaged fan assembly should only
be replaced with factory original part. The air supply line to the cooler motor-
fan assembly should be disconnected if fan service is to be performed. A
damaged pneumatic motor can affect the integrity of the fan blades. If the
cooler pneumatic motor fails the fan blade assembly should be inspected for
stress cracks by a qualified person, or have the fan blade assembly replaced.
The cooling fan may need replacement every 1-2 years depending on severe
duty found at site.
Caution!
The exhaust stream from the pneumatic motor may contain solid particles or
oil aerosol. Wear eye and skin protection at all times while in the proximity of
this equipment.
Ensure the oil mist delivery to the motor is properly adjusted. A data table of
adjustments has been provided at the end of this section.
Ensure pneumatic motor outlet muffler is clean and unobstructed of dirt particles
that will prevent normal operation of the motor.
Ensure the delivery pressure to the motor is set per the data table provided at the
end of this section.
For long term storage (several weeks) the motor should be properly lubricated at
time of start up to ensure trouble free and long term performance.
Important!
The pneumatic cooler motor provided requires oil lubrication. The type of oil
recommended is a non-detergent SAE#10 air tool oil. Flushing of the motor may be
required to remove excessive dirt, foreign particles moisture or oil. Use only air tool
flushing solvent. Do not use kerosene or any other type of combustible solvents to
flush motor.
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