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