Aircel CDP Series User manual

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.
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.
Installation,
Operation, and
Service Information
Aircel
&DP-Series Regenerative Air Dryer
Models &DP-70, 100, 150, 200, 250, 300, 350,
450, 500
Installation
and Operation Manual

2
WARNING!
General Safety Procedures
• Improperinstallation,operation,ormaintenancemaycontributetoconditionsinthework
areaorfacilitythatcouldresultinpersonalinjuryandproductorpropertydamage.Check
that all equipment is properly selected and sized for the intended use.
• Consultandcomplywithnationalandlocalcodesrelatingtofireorexplosionandall
other appropriate codes when determining the location and operation of this equipment.
• Safeandefficientoperationoftheunitdependsonproperinstallation.
• Authoritieswithjurisdictionshouldbeconsultedbeforeinstallingtoverifylocalcodesand
installationprocedures.Intheabsenceofsuchcodes,installunitaccordingtotheNational
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.
 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.
  •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.
 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.
Aircel CDP-Series Models 70 - 500

Heatless Regenerative Air Dryer
3
Introduction
ThankyouforpurchasingAircel’s CDP-Series Regenerative Air Dryer System. You are now the proud owner of
one of the finest air dryers on the market. Aircel CDP-Series regenerative air dryers are engineered and
manufactured to provide you with many years of trouble free service.
To ensure that you get the get first class service from this equipment, we recommend you take some time and
read the contents of this manual.
Thismanualcontainsalltheinformationrequiredforinstallingandmaintainingyournewequipment.It
also includes the safety procedures and corresponding drawings. We strongly suggest that all personnel
involved with the machine, read the entire contents of the manual before proceeding with the installation or
maintenance activities.
Themanufacturerreservestherighttomakechangeswithoutanypriornotificationandisnotobligatedin
anymanner.InformationinthismanualisdeemedcurrentatthetimeofpublicationandAirceldisclaimsall
liability for any errors resulting in any loss or damage.
IfyouhavequestionsorneedadditionalcopiesorwouldliketoscheduleaAircel'sservicemanvisit,contact
your distributor.
Aircel
323 Crisp Circle
Maryville,TN37801
Toll-Free:(800)767-4599
Tel:(865)681-7066
Fax:(865)681-7069
Sales Information:
[email protected]
Order Entry:
[email protected]
www.AircelDryers.com
Contents
SafetyStatements .................................................. 2
Introduction.......................................................... 3
DataSheet............................................................. 4
SafetySymbols ...................................................... 5
GeneralSafetyInstructions ................................... 6
Description............................................................ 7
 Purpose&IntendedUse .............................. 7
 Features&Options ..................................... 8
InspectiononArrival ............................................ 9
TechnicalSpecifications ...................................... 10
HowitWorksDiagram ...................................... 11
Installation.......................................................... 12
TypicalInstallation ............................................. 12
InstallationChecklist .......................................... 13
Start-UpProcedure.............................................. 14
Shut-DownProcedure ......................................... 15
SequenceofOperation........................................ 15
ServiceInformation............................................. 17
 Maintenance&Checklists ......................... 17
Troubleshooting.................................................. 19
Troubleshooting Table........................................ 20
DesiccantMaterialSafetyDataSheet.................. 22
AircelProgrammableController ......................... 27
ElectricalDrawings ............................................. 36
 MainPower&PLCInput.......................... 36
 PLCOutput&Sensors .............................. 38
 BackPanel.................................................. 40
Enclosure Layout ....................................... 41
ServiceNotes ...................................................... 42
Warranty............................................................. 44

4
Data Sheet
ModelNumber_____________________________________ SerialNumber ________________________________________
DryerType ________________________________________ DateofManufacture__________________________________
ShipDate __________________________________________ InstallationDate ______________________________________
CustomerName ____________________________________ Address ______________________________________________
AddressCont’d __________________________________________________________________________________________
A c c e s s o r i e s ___________________________________________________________________________________________________________________
O t h e r __________________________________________________________________________________________________________________________
DryerInletAirFlowRate ________________________________________________________________________________________
DryerInletTemperature __________________________________________________________________________________________
DryerAmbientTemperature____________________________________________________________________________________
DryerVoltage______________________________________________________________________________________________________
DryerMCAMinimumCircuitAmpacity_____________________________________________________________________
DryerMOPMaximumOvercurrentProtection______________________________________________________________
DryerOperatingPressure________________________________________________________________________________________
DryerMaximumOperatingPressure__________________________________________________________________________
DryerVesselPressureReliefValveSetting____________________________________________________________________
DryerDesiccantType_____________________________________________________________________________________________
DryerDesiccantWeightperVessel_____________________________________________________________________________
DryerDesiccantWeightTotalforSystem_____________________________________________________________________
DryerOutletDewpoint___________________________________________________________________________________________
DryerControlTimeCycle_______________________________________________________________________________________
DryerEMSRHSensorSetting(forsensingmid-bedmoisture)___________________________________________
HighDewpointSetting(option)________________________________________________________________________________
DemandCycleSetting(option)_________________________________________________________________________________
OutletDewpointReadoutonDisplay(option)______________________________________________________________
ElectricalDrawingNo.___________________________________________________________________________________________
MechanicalDrawingNo.________________________________________________________________________________________
PLCSoftwareProgramNo._____________________________________________________________________________________
ControlAirFilterElementNo._________________________________________________________________________________
InletPre-FilterElementNo.(option)___________________________________________________________________________
OutletAfter-FilterElementNo.(option)_______________________________________________________________________
InletValve__________________________________________________________________________________________________________
PurgeExhaustValve______________________________________________________________________________________________
VesselNationalBoardNo.(leftandrightvessels)__________________________________________________________
DryerSystemWeight_____________________________________________________________________________________________
Aircel CDP-Series Models 70 - 500

Heatless Regenerative Air Dryer
5
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.
High Noise Area: All personnel are required to wear ear protectors before
approaching the vicinity of the equipment.
Hazardous Fumes & Gases: Personnelmustwearprotectivegeartopreventinhaling
of the gases and fumes.
Suspension Points:Lookforthesesymbolsbeforemakinganyattempttomoveor
relocate your equipment.
Tips & Suggestions:Followingthesetipscanmakeyourworkeasier.
Extreme Caution: Thisindicatesthattheremightbepossibleriskofmaterialdamage
andpersonnelareadvisedtoexerciseextracaution.
Safety Instructions

6
General Safety Instructions
What You Must Do
1. Certified/authorizedelectriciansmustperformelectricalwork
2. ElectricalworkmustconformtothespecificationsindicatedbyAircelandanylocalorstatelawsthat
may apply.
3. Personnelmustwearappropriatesafetygearbeforeworkingonanyelectricalormechanicalaspectsof
the machine.
4. Appropriatetoolshavetobeusedforallinstallationandmaintenancework.Ifspecialtoolsarerequired
and are not available to the installation crew, contact the factory or your Aircel representative.
5. AcopyoftheOperationManualmustbemadeavailabletoallpersonnelinvolvedwiththeinstallation,
operation and maintenance of the equipment.
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
priorapprovalcanperformanyconstructionalworkonthemachine.
2. Donotuseforeignparts.
3. Compressedairfromthedryersisnottobeusedforbreathingpurposes–installabreathingairpackage
toensureconformancewithOSHAregulations
4. Donotdisableordisengageanyprotectiveequipmentusedonthemachine.
Safe Operating Procedures
1. PressurizeanddepressurizecompressedairSLOWLY!Alwaysopenairvalvesslowlywhenpressurizing
the airline system or equipment. Replace air slowly when depressurizing your air system or equipment.
2. Circuitbreakers,fusibledisconnect,andwiringshouldconformtonationaland/orlocalelectricalcodes.
Makecertainthatqualifiedelectricalpersonnelperformtheelectricalinstallationforthisunit.
3. Only use original fuses for the rated voltage and current.
4. Shutdowntheunitinthecorrectrecommendedprocedure.
5. BeforeanyworkonsystemalwaysDepressurizetheunitandremoveallelectricalpower.
6. Aftershutdown,putupwarningnoticetopreventtheunitfrombeingswitched“ON”accidentally.
7. Inspectallpiping,hosesandconnections.Makesurethatallhosesareingoodconditionandarerated
forthecorrectworkingpressure.Donotallowhosestocomeintocontactwithoil,chemicals,orsharp
objects.
8. Securecondensatedrainlines.Unsecuredflexibledrainlinesmaywhipviolentlyunderpressureandmay
cause bodily harm.
Aircelairdryersdonotremovecarbonmonoxideandisnotsafeforhumanrespiration(breathing).
BreathingairmustbeatleastgradeDqualityasdescribedincompressedairandgasassociation(CAGI)
commodityspecifications67.1-1966.UsermayrefertoOSHA29CFI1910.134forspecialprecautions
and equipment suitable for breathing air applications. Aircel disclaims any liability what so ever for loss,
injury or damage.
Aircel CDP-Series Models 70 - 500

7
Heatless Regenerative Air Dryer
Why We Need Compressed Air Dryers
Untreated compressed air contains many contaminants such as water, compressor oil, pipe scale and
contaminationfromambientair.Allthesecontaminantscauseexcessivecorrosion,erosion,freezingand
product contamination to all components that come in contact with the untreated compressed air. A
regenerative type dryer system with all recommended filtration will remove these contaminants to harmless
levels. The end result is that instruments that come in contact with the dry compressed air stay clean and do
notcorrode,thereforelastingmuchlonger.Productsthatmaycomeincontactwithcleandrycompressed
air are virtually unaffected. Therefore rejection rates are reduced.
:K\:H1HHG&RPSUHVVHG$LU'U\HUV

Aircel Regenerative Desiccant Air Dryers can dry compressed air to -100°F PDP (Pressure Dew Point), Standard
Regensrative 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 regenerating either based on the Energy Management System (EMS) control
or a fixed time cycle. Aircel manufactures various types of desiccant air/gas dryers. These dryers offer fail-safe
design in the event of power interruption. Air will continue to flow through the dryer without deadheading; also
purge exhaust valves will close preventing loss of air pressure. The tower operating status lights and the highest
quality non-lubricated air/gas inlet valves will ensure reliable operation for many years to come.

Product Description

•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 -100°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 min. cycle = -40°F PDP, 5 min. cycle = -100°F PDP 
• 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.
• Control pilot air filter provides clean air to air control system for long trouble-free reliable operation.
• Desiccant towers are designed, fabricated and stamped according to ASME code.(CDP-70 and up).
• Desiccant fill and drain ports for ease of desiccant replacement.
• Structural steel frame.
• Highly reliable non-lubricated air inlet and outlet valves (APV) Automatic Piston Valve.(CDP-70 —
CDP-500)
• Highly reliable angle seat design purge exhaust valves.(CDP-70 - CDP-500 ).
• Common alarm indicator and common alarm dry relay contact for remote indication.
• Tower Operating L.E.D. status lights (Left/Right Tower Drying, Left/Right Tower Regenerating)
• ON/OFF switch and power ON light.
• NEMA 4 weather resistant electrical system construction.

8
Standard Features
Additional Options
• Tower pressure display and Failure to shift alarm utilizing pressure transducers
• Outlet dew point sensor with dew point readout on system display
• Mounted, piped and wired filtration packages
• Outlet dew point 4-20 mA signal
• High humidity alarm
Aircel CDP-Series Models 70 - 500

Heatless Regenerative Air Dryer
9
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/
packagesthatareindicatedinthepackingslip.
2. Removethecrateandpackaging.Inspectthe
unit for any visible damage.
3. Report any damage to the delivery carrier.
4. Requestawritteninspectionreportfromthe
ClaimsInspectortosubstantiatetheclaim.
5. Fileclaimswiththedeliverycarrier.
6. Compareunitreceivedwithdescriptionof
productordered.Checktheserialplatelabel
andmakesurethatitisthecorrectModelwas
ordered.NotetheequipmentCapacityand
PowerSupplyrequirementsandensurethatthey
are in accordance with your specifications. The
rated conditions of the dryer are indicated on
theserialplatelabel.Ifthereisanydiscrepancy,
contact your representative listed on the manual
backcover.
7. Shippingstressescanloosenconnections.
All pipe and tubing connections should be
inspected.
8. Reportincompleteshipmentstothe
delivery carrier and your Aircel service
representative.
CAUTION!
• Donotmisuseormodifyunderany
conditions.Misuseormodification
of this equipment may result in
personal injury.

10
Technical Specifications
How Does it Work? (seediagram1)
Moisturesaturatedcompressedairentersthe
coalescingprefilter(F1)whereaerosolsare
coalesced then drained via an automatic drain
system. The moist water vapor-laden inlet air
free of liquid water flows to the inlet of the dryer
throughtheAPV(AutomaticPistonValve)(V1)
which diverts the inlet air to one of the towers, in
thisexampletower(T1).Airflowsupwardthrough
the adsorbent bed removing the moisture vapor,
thedriedairflowexitsthetowerthroughtheoutlet
APVvalve(V2)flowingtotheoutletparticulate
afterfilter(F2)whichremovesparticulatesfrom
the air stream. Clean and dry air now flows to the
process air distribution system.
As one tower is drying air, the other tower will be
regenerating(purging)theadsorbentbed.Inthis
example,tower(T2)willberegenerating.Prior
toregeneration,theexhaustvalve(V4)isopened
and the tower is depressurized to near atmospheric
pressure, the tower will now be regenerating.
Duringtheregeneratingprocessasmallportionof
dryoutletcompressedairisused,15%onaverage
basedonstandarddesigncapacityof100psig,
100°Finletair,100°FambientairandPDPof
-100°F.Thedryregenerationairflowischanneled
throughtheoutletAPVvalvetotheregenerating
tower(T2)removingmoisturefromtheadsorbent
bedandexitstheregeneratingtower(T2)through
exhaustvalve(V4)andexhaustmufflertoambient.
Afterregenerationcycleiscomplete,valve(V4)
closescausingtower(T2)torepressurizetoline
pressure.
Next,thetowerswillswitchwhenexhaustvalve
(V3)openscausingtower(T1)todepressurizeand
regenerate,simultaneouslytheinletandoutletAPV
valves(V1)and(V2)willshiftthepistonstothe
lowpressuretower(T1)causingtheinletairflow
tobedivertedtotower(T2)whichwillnowbethe
drying tower. This switching process will continue
repeatedly.
The dryer control system is completely automatic
and cycles the system through the drying and
regeneration cycles. The standard cycle drying time
is2.5minutes,regenerationcycleis1.5minutes,and
repressurizingcycleis1minute.
The Aircel CDP-Series Heatless Dryer
incorporates a unique energy saving control system
to reduce purge air loss with its integrated Energy
Management Purge Reduction System which utilizes
a moisture sensor sampling the air from the outlet of
the dryer, after the fixed purge time is complete the
regenerating/purging tower will repressurize.
If the moisture sensor senses a low moisture condition
or low load in the drying tower, the drying tower will
remain in the drying mode after the fixed drying time
cycle for an extended period of time. The end result is
an overall purge reduction and significant energy savings.
CAUTION!
• Donotmisuseormodifyunderany
conditions.Misuseormodification
of this equipment may result in
personal injury.
Aircel CDP-Series Models 70 - 500

11
Heatless Regenerative Air Dryer
Diagram1:HowitWorks
Drying
Tower
Regenerating
Tower
Air Saturated with Moisture
Dry Air
F1 F2
T2
T1
V1
V2
F1 - Mounted Pre-Filter
F2 - Mounted After-Filter
V1 - Automatic Piston Valve
V2 - Automatic Piston Valve
V3 - Purge Exhaust Valve
V4 - Purge Exhaust Valve
T1 - Desiccant Tower 1
T2 - Desiccant Tower 2
V4
V3
Regeneration Air

12
Installation
Pre-requisites for 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.
• HaveextracopiesoftheOperationManuals.
• Specialcaremustbetakenwhiletransportingtheunittotheinstallationsite.
• Dryermustnotbemovedorliftedbytheattachedpiping.
Location
• Carefulconsiderationshouldbegiventothelocationofthedryerinordertoassureoptimum
results. Ensure that the load bearing weight of the floor is adequate for the weight of the dryer.
• Thedryershouldbelocatedinanopenareaandalevelground.Dryershouldbeboltedtothefloor
to eliminate vibrations.
• Theambienttemperatureshouldbebetween40°Fand100°F.Lowtemperaturecouldaffectthe
dryer process and result in high outlet dew point.
• Inconditionswheretheambientdropsbelowfreezing,Aircelrecommendstheuseofheattraceon
any coalescing filter sumps and drain lines and the use of heated type drains.
• Dryerandaccompanyingfiltersshouldbeinstalledwithatleast2-5feetclearancefromthe
adjoining walls to provide easy access for routine maintenance.
TypicalInstallation
Aircel CDP-Series Models 70 - 500

13
Heatless Regenerative Air Dryer
Onlyqualifiedpersonnelshouldmakeelectricalandmechanicalconnections.
Equipment for Installation: This dryer does not need any special tools for installation
Foundation:Dryershouldbemountedonasuitablystructuredflatandlevelfloororbasethatisfree
fromvibration.Specialcaremustbeusedwhenliftingthedryertopreventtip-over
Mounting: Bolt dryer to the foundation using the boltholes provided in the frame.
Piping:Connecttheinletofthedryertothemoistgasfromthecompressor/receiver/inletfilter.Install
theInletpipingandtheinletshutoffvalve,InstalltheOutletpipingandtheoutletshutoffvalve(aunion
with a valve by-pass can be installed at the inlet and outlet valves to accommodate isolation of the dryer
formaintenance).Compressedairpipinghastobeatleastthesamesizeasthatoftheinletandoutlet
connections of the dryer. Larger pipe sizes can be used with reducers.
Back Pressure Regulator:Installbackpressureregulatortopreventanypossibilityoffluidizationofthe
desiccant bed. When there is a sudden increase in the demand for compressed air downstream of the
dryer, a huge pressure drop develops and can affect the performance of the dryer and the drying material
(desiccant).
Desiccant:Makesurethatthedryertowersarefilledwithdesiccant.Largerdryersmayhavedesiccant
shipped separately – in which case, the media has to be filled into the pressure vessels from the desiccant
fillports.Caremustbetakenwhenfillingthemediaanditmustbedonegraduallytopreventpowdering.
Muffler:Iftheeventthatmufflershavebeenshippedloose,theymustbeinstalledandsecured
By-pass:Ifthedryerisnotsuppliedwithoptionalby-passvalveitishighlyrecommendedthatby-pass
valve be installed around the dryer and filters. These by-pass shut-off valves will permit the dryer and
filters to be removed from the compressed air system for servicing without shutting down the entire
compressed air system.
Electrical:Makeallelectricalconnectionstothedryerasshownonthewiringdiagram.Specialcaremust
betakeninconnectingthepropervoltageasindicatedonthespecificationsheetandwiringschematic.
Additional Valving/Piping:Wheninstallingequipmentorcomponentskeepinmindtheserviceabilityof
the equipment and provide additional valves to isolate, bypass, and to depressurize as needed.
Exhaust:Ifyouintendtoventyourexhaustwithadditionalpiping,thedischargepipingfromtheexhaust
shouldnotbepipedupwardwithoutanarrangementforremovingtrappedcondensate.Makesurethat
youdonotapplyabackpressureonthisexhaustsystem.Ifexhaustpipingistobeextended,trytostay
within15to20feetandusethenextlargerpipesize.
Note: Itismandatorythatdryerbegrounded.Useofyourplantsframeasagroundmaycauseproblems
with the control. 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.
Installation

14
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.
1. Ensurethatthedryerisconnectedtoa
suitablecompressedairsupply.Makesure
that the pressure of the supply is equal to
the normal operating pressure of the dryer.
2. Checktomakesurethe“shut-off’valves
are closed and that by-pass valve is open.
3. Close all manual drain/vent valves.
4. Slowlypressurizethedryerbygradually
(slowly)openingtheinletshut-offvalveto
theOPENposition.
5. Whenbothtowersofthedryerare
completelypressurized,checkthecomplete
systemforpossibleairleaks.Usesoap
and water to test all joints and fittings.
Ifanyleaksaredetected,immediately
depressurizetheunitandcorrecttheleaks.
6. Makecertainthatanyautomatic
condensate drain isolation valves are in
the open position so proper condensate
draining can occur.
7. Whennormaloperatingpressureis
reached,switchonelectricalpower(Turn
switchtoONposition)
8. Withby-passvalveclosed,opentheoutlet
valve slowly to allow air downstream.
9. Whenenergizedoneofthetowersshould
depressurize.
10.Checktheoperationofseveralcycles
completely by following the control panel
display screen operation, the panel lights
ontheelectricalbox,andthetower
pressuregaugestomakecertainthedryer
system is operating as displayed. Also
refertothehowitworkssection,flow
diagram, electrical drawing, dryer control
display screen descriptions, and sequence of
operation in this manual for reference.
11.Checkthedrainvalveforproperoperation
anddischargeofliquid(filtersand
separators,etc.).
12.Nearthedryeroutlet(APV)valve,check
the control air/ pilot air regulator secondary
pressure, the regulator gauge should read
100psig.Increaseordecreaseregulator
knobtoachievea100psigcontrolair
secondary pressure reading.
13.Makecertainthepurgeexhaustvalves
slowlyopenwithinan8to12secondtime
period, some adjustment of the flow control
valve attached to the actuator may be
required, after adjustment tighten down the
lockingcollar.
14.Make certain a slight amount of air flow is felt
at the end of the Dew Point Sensor (if aplicable).
Adjust the needle valve, as needed, for more or
less flow. Typical flow is +/- .1 SCFM.
15.Reviewthedryersystemdisplayscreen
shots(inthismanual)tomakecertain
the parameters are set as needed in the
customer dryer.
16.Purgeairflowispresetandnotadjustable.
After the initial startup, the dryer operation is completely automatic. To understand the details of the
operation,werecommendyouusethehowitworkssection,flowdiagram,electricaldrawing,dryercontrol
display screen descriptions, and sequence of operation in this manual for reference.
Aircel CDP-Series Models 70 - 500

15
Heatless Regenerative 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.
4.Switchoffelectricalpowerafterbothtowershavebeendepressurized.
Sequence of Operation
Step 1: Vessel 2 Depressurizing
  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
 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-100°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.
Step 3: Vessel 2 Repressurizing
  Vessel2(T2)purgeexhaustpilotsolenoidvalvewillde-energize
 causingvessel2(T2)purgeexhaustvalve(V4)toclose,thisallows
 vessel2(T2)torepressurizetolinepressure,sinceaircontinues
 flowingthoughthesmallorificeintheoutletAPVvalve(V2)
 pressurizingvessel2(T2).

16
Step 4: Extended Drying Vessel 1
 AfewsecondsbeforetheendofrepressurizationtheCDP
  -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
 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
 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-100°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
 Vessel1(T1)purgeexhaustpilotsolenoidvalvewillde-energize
 causingvessel1purgeexhaustvalve(V3)toclose,thisallows
  vessel1(T1)torepressurizetolinepressure,sinceaircontinues
 flowingthoughthesmallorificeintheoutletAPVvalve(V2)
 pressurizingvessel1(T1).
Step 8: Extended Drying Vessel 2
 AfewsecondsbeforetheendofrepressurizationtheCDP
 -SERIESController’sintegratedEnergyManagementPurge
 ReductionSystemlooksatthemoisturesensor,ifthemoisture
 loadislowenough,vessel2(T2)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1and
the vessels will switch. This feature reduces the overall purge
consumption saving energy and money.
Sequence of Operation (cont’d)
Aircel CDP-Series Models 70 - 500

17
Heatless Regenerative 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.
B. Theusefullifeofafilterelementdependsonthequalityofair.Freeopenareasforinputand
exhaustwillensurelesserintakeofdirtandparticles.
C. Powdereddesiccantcanaccumulateinthemufflerandincreasethebackpressureintheregenerating
tower change mufflers on a regular basis typically every 2-3 months for optimum performance.
D. Oilandoilvaporcandrasticallyreducethelifeofthedesiccant.Takeprecautionstoeliminateall
traces of oil from the airflow
E. Fluctuatingdewpointindicatesunevendryingandregenerationbetweenthetowers,anexhaust
valvemaynotbeworkingproperlyormufflermaybecloggedordirty,alsovesseldiffuserscreen
may be clogged.
Weekly Checklist
1. Checkalldrainvalves,prefilter,afterfilterandseparators
2. Checkanypressuredifferentialindicators(Delta-P)onthepre-filterandafterfilter(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.).
3. Checkdryerforcorrectoperation.
4. Verifydryerispurgingatthepurgeexhaust,afterdryerdepressurizes.
5. Checkthedewpoint(ifavailable)toensurethedewpointisbeingachieved.
6. 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).

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.
18
Maintenance (cont’d)
WARNING!
• Beforeanyserviceormaintenance
workisperformedonthe
refrigerated air dryer system,
disconnectpowersupplyandlock
out power supply and depressurize
system.
• Followproperlockout/tagout
procedures before performing
serviceormaintenancework.
• Followallsafetyprocedurespriorto
performing any maintenance activity
on the dryer.
Aircel CDP-Series Models 70 - 500

19
Heatless Regenerative Air Dryer
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.
Beforeanyattemptismadetoundertakeanyaction,themachinemustbeshutdown,isolated,
depressurized,andpowereddown.Followtheshutdownprocedures.
Note: Sometroubleshootingwillhavetobedonewhilesystemispressurizedand
energizedsouseextremecaution.
1. Depressurizetheunit
2. Checktomakesureiftheunithasbeendamagedexternallyorifanypartismissing.
3. Checkifthereisproperpowersupplyandifitcorrespondstothatmentionedonthedataplate.
4. Checktoseeifthereispoweratalltheelectricalconnectionsinthemachineandthepropervoltage.
5. Checkifcontrolairisavailableandtheproperpressureatallpneumaticallyoperatedcomponents.
6. Makesureallshut-offvalvesareinthecorrectposition.
7. Checktheairflow,inlettemperatureandpressureandmakesureitfallswithintheoperatingrange.
Troubleshooting

20
Troubleshooting (cont’d)
Problem Probable Cause Remedy
High Dewpoint High inlet air flow Reduce inlet air flow
Inletairtemperatureabove
design spec Reduce inlet air temperature to design spec
Poorpre-filtration Checkpre-filterelement,replaceifneeded
Inletairpressurebelow
design spec Increasepressuretothedryer
Desiccantcontaminated Replace desiccant
Purgefloworificeinthe
outletAPVvalvemaybe
clogged
DismantleoutletAPVvalve,andcleanoutthe
orifice
Backpressurein
regenerating chambers Mufflersareclogged,installnewmufflers
Exhaustvalve(s)notfully
opening or closing
Checkpilotvalveandpilotairsupply,
dismantleandcleanexhaustvalve,checkflow
controlvalveattachedtopurgeexhaustvalve
actuatormaynotbeadjustedproperly(should
beadjustedsoexhaustvalveopenswithina
8-12secondtimeperiod)
APVvalveleaking Dismantleandclean,replacesealsandpistonif
needed
Noinputpower Checkthatdryerisonwithcorrectvoltage
Noinputpower Checkthatdryerisonwithcorrectvoltage
Controller failure Check,replaceifneeded
High-Pressure Drop Low inlet pressure Increaseinletpressuretodesignpressure
Desiccantdusting High inlet flow velocities due to high flow
Inletprefilterdirty Inspectandreplaceasneeded
High inlet flow rate Reduce inlet flow rate to meet dryer spec
Outlet filter dirty Inspectandreplaceasneeded
Desiccantdiffuserscreens
clogged Inspectedandcleanifneeded
High Back Pressure in
Regenerating Tower Purgemufflerclogged Clean and replace if needed
Desiccantdiffuserscreens
clogged Inspectedandcleanifneeded
Restrictivepurgeexhaust
piping Clean and replace with larger pipe if required
Aircel CDP-Series Models 70 - 500