Aircel HP 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
HP Series Non-Cycling Refrigerated Air Dryer
Models: HP-45, 65, 80, 125, 200, 260, 415, 570, 860, 1000, 1400
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.
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 HP Series

Non-CyclingRefrigeratedAirDryer
3
Contents
SafetyStatements .................................................. 2
DataSheet............................................................. 4
RefrigerantSafetyPrecautions .............................. 5
DesignParameters................................................. 6
Description............................................................ 6
System.......................................................... 6
RefrigerationCircuit .................................... 7
Compressed Air Circuit................................ 7
PurposeandIntendedUse..................................... 9
InspectiononArrival ............................................ 9
LiftingInformation ............................................. 10
InstallationCodesandProcedures ...................... 10
Installation.......................................................... 11
TypicalInstallation ............................................. 12
PreliminaryStart-UpChecklist............................ 12
AutomaticDrainValveAdjustments................... 14
OperatingProcedure ........................................... 14
AirCooledCondenserRequirements .................. 14
CoolingWaterRequirements.............................. 15
Water Cooled Condenser Table ................. 15
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.
Shut-DownProcedures........................................ 16
Shut-DownEmergency............................... 16
Short-TermShut-Down.............................. 16
ServiceInformation............................................. 17
Maintenance............................................... 17
Troubleshooting.................................................. 19
Electrical ................................................... 19
Refrigeration .............................................. 19
CondensateRemoval.................................. 20
Other.......................................................... 20
Troubleshooting Table........................................ 21
Appendix ............................................................ 26
R-134ARefrigerantMSDS......................... 26
R-404ARefrigerantMSDS......................... 31
WiringDiagram ......................................... 38
ServiceNotes ...................................................... 45
Warranty............................................................. 48

4
Data Sheet
ModelNumber_____________________________________ SerialNumber________________________________________
DateofManufacture ________________________________
ShipDate __________________________________________ InstallationDate______________________________________
CustomerName
Address __________________________________________________________________________________________
__________________________________________________________________________________________
A c c e s s o r i e s ___________________________________________________________________________________________________________________
O t h e r __________________________________________________________________________________________________________________________
Aircel HP Series

Non-CyclingRefrigeratedAirDryer
5
Refrigerant Safety Precautions
Refrigerant First Aid Recommendations
Inhalation
Ifhighconcentrationsareinhaled,immediately
remove individual from affected area to an area
with a fresh air supply. Keep individual calm.
Ifnotbreathing,giveartificialrespirationorif
havingdifficultybreathing,giveoxygenandcallfor
emergency services.
Skin Contact
Incaseofcontactwiththeskin,immediatelyflush
skinwithcleanwaterforatleast15minutes.Treat
for frostbite if necessary by gently warming affected
areasandcallforemergencyservices.Removeany
contaminated clothing or shoes.
Eye Contact
Incaseofcontactwiththeeyes,immediatelyflush
eye(s)withcleanwaterforatleast15minutesand
call for emergency services.
CAUTION!
Inhalation, Skin, & Eye Irritant
• Usepropersafetyandprotective
equipment, including chemical
safety goggles or face shield and
impervious gloves when handling
refrigerants.
• Exercisecaretoensurethatliquid
refrigerant does not come in contact
withyourskinoreyes.
• DONOTSMOKE.
• Ventilationinworkareamustbe
adequatetokeeptheconcentration
ofrefrigerantbelow1,000ppm.
• Systemmustbefreeofallrefrigerant
before any welding or brazing can be
performed and must be done in a
well ventilated area.
• Decompositionofrefrigerantsis
hazardous! This material can be
decomposed by high temperatures
caused by an open flame.
Hydrofluoric acid and possibly
carbonyl fluoride can form in a
liquid or gaseous state. Avoid
exposuretothesetoxicfumesand
irritating materials.
• Leavetheworkareaimmediatelyif
youexperienceanyofthefollowing:
smell something unusual, feel light-
 headed,experienceshortnessof
breath, feel a tingling sensation in
your fingers or toes, suddenly feel
warm or a rapid heartbeat.

Design Parameters
Type of dryer: Refrigerated
Power supply: 115, 230, 460 Volt / single or three
phase / 60Hz
Refrigerant.type: R-134A
R-404A
ChemicalComposition:HFC
Parameter
Description
Optimum Maximum Minimum
AirPressure(psig) 100-125 *See Data
Label 225
AirInlet
Temperature(°F) 80-100 140 40
Ambient
Temperature(°F) 75 120 35
Evaporation
Temperature(°F) 35-42 60 33
SuctionGauge
Reading(psig) 28-40 60 28
DischargeGauge
Reading(psig) 160-230 260 80
SuctionGauge
Reading(psig) 75-90 130 75
DischargeGauge
Reading(psig) 290-400 450 160
Description
System
The non-cycling refrigerated air dryer product covers
the flow range listed on the manual front cover and
provides reliable dew point performance in most flow
conditions. Through optimization
of critical dryer components – heat exchanger,
separator, and condensate removal – the system
ensures the highest performance at full- and partial-
load conditions. R-134a refrigerant is used in dryer
models AR-45 through AR-1000 while R-404A is used in
the AR-1400 and higher models. R-134a is a pure
refrigerant providing consistent performance (zero
temperature glide) and easy service (no mixture of
different refrigerants). R-404A is a blend of three pure
refrigerants: 52% R-143A, 44% R-125, and 4% R134A
(by mass). This blend is nearly azeotropic meaning it
has a negligible temperature glide. R404A is well suited
to larger equipment as the higher operating pressures
and improved heat transfer properties allow for smaller
condensers, which leads to air dryers with smaller
footprints.
Hot saturated air enters the air-to-air heat
exchanger of the Non-Cycling Refrigerated Air Dryer
and is precooled by the outgoing dry air.
Precooling saves energy by reducing the heat load
on the dryer’s compressor. The cool saturated air
enters the air-to-refrigerant heat exchanger where
air temperature is lowered to the 38 to 42°F range.
This dramatic temperature drop condenses water
and oil.
The mixture of cold air and condensation then
flows into the two-stage separator filter where
liquids and contaminants are removed by
centrifugal action, directional flow change, and
velocity reduction. Once bulk liquids have been
removed, the compressed air goes through a
stainless steel mist eliminating filter that coalesces
oil aerosols and oil vapors within the 100-micron
range, and then separates and removes them. At
this point, the compressed air is dry and virtually
oil-free.
Cold, dry air exits through the precooler heat
exchanger and is reheated by incoming hot air.
Reheating restores energy and also prevents
condensation from forming on the outside of air
distribution piping. In the refrigeration unit, the
compressor pumps hot, high-pressure gaseous
refrigerant to the condenser where it is cooled
and liquefied by ambient air. From the condenser,
liquid refrigerant first flowsthrough the receiver,
then through a filter/dryer, and finally through the
expansion valve where pressure and temperature
are reduced. This reduction in pressure causesthe
liquid refrigerant to boil until it reaches the s
aturation temperature that corresponds to its
pressure. As the low-pressure refrigerant passes
through the evaporator, heat flows from the
compressed air to the refrigerant, causing the
boiling to continue until all refrigerant is vaporized.
Refrigerant gas is returned to the compressor and
the cycle is repeated. A hot gas by-pass valve is used
to control temperature in the evaporator.
6
Aircel HP Series
All Models
R-134AR-404A

Refrigeration Circuit
Refrigerant is compressed by the compressor to a
gas with high temperature and high pressure, which
then travels to the condenser (air or water cooled)
to condense the gas into a liquid. Liquid travels to
the evaporator (refrigerant-to-air part of the heat
exchanger) and back to the compressor suction
side. The process then repeats. A thermal expansion
hot gas by-pass valve is used on the non-cycling
dryers as a freeze protector in low load conditions
([1-1/4 HP] and up).
Compressed Air Circuit
exchanger. This energy saving heat exchanger
provides several advantages, such as a reduction
of the heat load imposed on the refrigerant
compressor and condenser, providing more
energy to the outlet air, and preventing
condensation of moisture on the outside of the
plant distribution air line piping. From the
air-to-air heat exchanger, air will enter into the
evaporator further reducing its temperature
to a desired pressure dew point. As the air is
cooled, moisture is condensed, separated, and
discharged through the condensate drain. The
cooled air then reenters the air-to-air heat
exchanger, in a direction opposite to the flow
of the warm, saturated incoming air. This
counter flow action assures high temperature
differential throughout the heat exchanger,
resulting in a more effective heat transfer.
7
Non-CyclingRefrigeratedAirDryer
compressor liquid
receiver
refrigerant
outlet
air out refrigerant
inlet
air in
suction air cooled
accumulator condensor
Air to Refrigerant Heat Exchanger
Refrigerant Circuit
Typical Schematic Flow Diagram
The compressed air dryer circuit uses a patented
air-to-air heat exchanger, which acts as a precooler/
reheater. Hot, saturated, compressed air first enters
the air-to-air heat exchanger, where it is pre-cooled
by outgoing air from the air-to-refrigerant heat
air to water
separator
air from water
separator

Non-CyclingRefrigeratedAirDryer
9
Purpose and Intended Use
Non-cyclingrefrigeratedairdryersaredesigned
to remove moisture from compressed air by use of
mechanical refrigeration. They can provide pressure
dewpointsaslowas(38°F-42°F).Referigerated
dryers are used to protect industrial compressed air
systems,machinery,andtools.Toensuremaximum
performance and safe operation of this dryer,
everyone associated with its installation, operation,
and maintenance must read, understand, and follow
the instructions of this manual.
CAUTION!
• Donotmisuseormodifyunderany
conditions.Misuseormodification
of this equipment may result in
personal injury.
Inspection on Arrival
All non-cycling refrigerated air 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. Reportanydamagetothedeliverycarrier.
2. Requestawritteninspectionreportfromthe
ClaimsInspectortosubstantiatetheclaim.
3. Fileclaimswiththedeliverycarrier.
4. 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.
5. Shippingstressescanloosenconnections.
All pipe and tubing connections should be
inspected.
6. Observe pressure of refrigerant suctions gauge
todetermineifrefrigeranthasleakedduring
transit.Ifthegaugereadingdoesnotmatchthat
mentioned on the serial plate label, immediately
contactTechnicalSupportlistedonthemanual
backcover.
7. Reportincompleteshipmentstothedelivery
carrier and your service representative.

Lifting Information
1. Useallliftingpointsprovided.Specialcaremust
be used when lifting the dryer to prevent tip-
over.
2. Useclevisconnectors,nothooks,onlifting
slings.
3. Only lift unit under support frame/base by using
theforkliftopeningsprovided.Donotliftby
piping.
4. Checktheapproximateweightprovidedon
the specification control drawing to ensure
adequatelifttruckcapacity.
5. Allow only qualified operators to lift the
equipment.
6. RefertoapplicableOSHAregulationsandlocal
codeswhenusingcranes,forklifts,andother
lifting equipment.
WARNING!
• Failuretolifttheunitcorrectlycan
result in severe personal injury or
property damage.
• Useappropriateliftingequipment
and adopt all safety precautions
needed for moving and handling the
equipment.
• Ahandcart,forkliftorcraneis
recommended for unloading and
installation.
• Liftunitbyliftinglugsandframe
only.Donotliftbypiping.
Installation Codes and Procedures
WARNING!
• Followproperlockout/tagout
procedures before performing
serviceormaintenancework.
• Electricalinstallationmustbe
performed by a qualified electrician
and comply with all applicable
national and local codes.
1. Safeandefficientoperationoftheunitdepends
on proper installation.
2. 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andNFPANo.70-latest
edition.
3. A qualified installation and service agent
versed in all regulatory codes must complete
installation of this unit.
CAUTION!
• AcopyoftheOperationManual
must be made available to all
personnel involved with the
installation, operation and
maintenance of the equipment,
to avoid injury to personnel or
property damage.
• Appropriatetoolsmustbeusedfor
all installation and maintenance
work,toavoidinjurytopersonnel
or property damage.
10
Aircel HP Series

Installation
1. Locateunitonalevelfoundation.Dryershould
be mounted on a suitably structured flat and
level floor or base that is free from vibration.
2. Installunittoprovideadequateclearancefor
maintenanceservices.Dryerandaccompanying
filters should be installed with at least 2 to
5 feet clearance from the adjoining walls to
provide easy access for routine maintenance and
adequate air flow across the condensing coil.
3. The frame or cabinet must be securely bolted
to the foundation to prevent movement
resulting from earth tremors and induced piping
vibration.
4. Installunitusingthecorrectpipesizeand
pressurerating.Seedrawingpackageprovided
with the unit. Connect the inlet of the dryer to
themoistgasfromthe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 appropriately rated reducers.
Operation at elevated pressure or temperature
may cause damage to the dryer or serious injury
topersonnel.Eachdryerischeckedatthe
factory for proper operation at the conditions
noted on the serial plate label.
5. Provideadequatepowersupply.SeeDesign
Parameterssection.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.
Itismandatorythatthedryerbegrounded.
Useofyourplant’sframeasagroundmay
cause problems with the controls. A fused
disconnect is not supplied with this equipment;
therefore, one must be supplied by customer.
Allelectricalfuses,breakers,etc.shouldbe
sized by a qualified electrician and comply with
all applicable national and local codes. Our
company is not liable for any code violations,
component damage, downtime or consequential
damage related to customer supplied electrical
components and connections.
6. The ambient temperature should be between
45°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, it is recommended that a heat
trace be used for the equipment. This will
ensure trouble-free operation during the winter
months (the dew point of the outlet air will be
consistent).*Insomecases,aheadpressure
control valve may be needed. (optional)
7. Donotplacethesysteminserviceuntilthe
above steps have been completed and that all
ratings and specifications have been verified to
matchtherequirementsinthedrawingpackage
supplied with the unit.
8. Ifthereareanychangesintheoperating
conditions of the system from those published
inthismanual,contactTechnicalSupport.
11
Non-CyclingRefrigeratedAirDryer

Preliminary Start-Up Checklist
Notice:Forscfmratedmodels45-260,wait
at least 6 hours after transporting or
moving of dryer system before starting
the dryers. Turn the main power switch
to the dryer on, but do not turn the
dryer on/off switch to the on position
until 6 hours have passed.
Forscfmratedmodels415andlarger,
ensure that the power switch is in
the“off” position, but the electrical
service to the dryer is energized. This
dryer must be in this mode for at
leasttwelve(12)hourstoallowthe
compressorcrankcaseheatertoenergize
and evaporate any liquid refrigerant
fromthecompressor.Aftertwelve(12)
hours,turnONthepowerswitchof
the dryer. The power indicating light
shouldturnON.
TypicalInstallation
Typical Installation
12
1. Checkthattheinletandoutletconnections
are the correct size and pressure rating, and
tightened securely.
2. Checkthatthecorrectpowersupplyis
connected to the non-cycling refrigerated air
dryer system with an adequate disconnect
switch.
3. Checkthatallcompressedairlineservicevalves
are open and that compressed air is available to
be supplied to the non-cycling refrigerated air
dryer system.
4. Checkthatallliquiddrainservicevalvesare
open.Thisistoensurethatanyresidualbulk
condensate that may have accumulated in the
compressed air lines is discharged immediately
upon start up. These drains must be closed
once system is brought on line for use. The
drain valve on the refrigerated air dryer can be
opened by pushing the test button located on
the drain body.
Aircel HP Series

5. With the customer-supplied compressed air
tothesystem,OPENtheinletvalveslowlyto
graduallypressurizethesystem.Donotopen
valvetooquickly.Openingvalveandsuddenly
pressurizing the system can cause damage to the
dryerheatexchangerandothercomponents.
6. Checktheairsystempipingconnectionsand
dryersystemconnectionsforleaksatthistime.
Repairandretestanyleaks.
7. Verifythatallinstrumentation(pressure
gauge/s) and drain air tubing fittings are tight.
8. Ensure that the air system has come up to
full pressure and has filled the dryer with
compressed air. Before opening the outlet valve
on the system and after the dryer has been
started under no load, let the dryer run for at
leastfifteen(15)minutestoallowstabilization
of the system. Verify the following:
a. The dryer is designed to run continually
and should not be cycling on and off with
the air compressor. The non-cycling
operation of the dryer is controlled by an
automaticexpansionvalveorathermostatic
expansionvalve/hotgasby-passvalve.The
valves will open and close automatically
depending on the of heat load to the
evaporator, thus maintaining the desired
pressure dew point.
b. Checktheinletcompressedairtemperature
and pressure to the dryer and verify that it
meets the specified requirements.
c. Fanrotation,fordryerswithanair-cooled
condenser, rotation should be in accordance
with the fan rotation shown on the details
locatedontopandbackofthecondenser.
Cooling air is drawn through the condenser
coils.Ifthemotorrotationisnotcorrect,
turn off the power switch and put the main
power supply disconnect in the “off”
position;lockandtag;checkthewiring;
correctthewireleadlocations;recheckfor
correct rotation.
13
Non-CyclingRefrigeratedAirDryer
d. The refrigeration gauge readings should be as
follows:
• Refrigerant suction pressure:
R-134A =28-40 psig
R-404A = 75-90 psig
•Refrigerant.dischargepressure:
R-134A = 160-230 psig
R-404A = 290-400 psig
Notice:Theabovedischargepressuresdepend
upon ambient temperature and can
vary slightly according to temperature
fluctuations.
9. Afterthepreliminarystartupchecklisthasbeen
completed, the compressed air outlet valve on
the dryer system can now be slowly opened to
supply clean dry compressed air to the facility.
10. Afterstart-upandapproximatelyonemonth
ofservice,checkthatallpipingandfittingsare
tightandfreeofleaks.
Notices:
• Modelswiththehotgasby-passvalvesand
expansionvalvesarepresetatthefactory
for the desired dew point. Donotadjust
without consulting with the factory.*
• Thedryersarefullyautomaticanddonot
requireanyauxiliarycontrols.
*Adjustments not authorized by the
factory may void the warranty.

Automatic Drain Valve Adjustments
The automatic drain valve supplied is standard on the
separator and should open regularly and discharge
any accumulated water into the drain line. The
period between openings varies with the dryer and
operating conditions (electronic type). To minimize
air losses, the timer should be adjusted to open
the drain solenoid just long enough to discharge
the accumulated condensate. The factory sets the
automaticdrainstoopenfor7secondsaboutevery7
minutes.Ifmorethantwosecondsofdryaircomes
out at the end of every discharge cycle, reduce the
open time (seconds) or increase the interval of the
discharge(minutes)tominimizeairloss.Ifliquid
is still being discharged when the discharge cycle
stops, increase the open time (seconds) or shorten the
interval of discharges (minutes) so it discharges more
often.
Operating Procedure
After the initial startup, the dryer operation is
completely automatic. To understand the details of
theoperation,seetheflowdiagramonpages7and8.
Model by
SCFM Rating
Refrigeration
Hp
Cooling air
flow (cfm)
45 1/5 275
65 1/4 300
80 1/3 300
125 1/2 350
200 3/4
260 1 1/4 750
415 1 1/2 1250
570 3000
860 3 1/2 3000
1000 55000
1400 55000
14
Air Cooled Condenser Requirements
Cooling air must be drawn from a clean source to
reduce dust and dirt accumulation on the condenser
coils.Airtemperatureshouldnotexceed100°F
(38°C).
Aircel HP Series
2
525

Cooling Water Requirements (water cooled
condensing units)
Cooling water is required for water-cooled
refrigerant condensers. The user is responsible for
piping the water to and from the condenser. The
required water flow rate depends on the water
temperature. A water-regulating valve (supplied
with the dryer) automatically adjusts the flow to
compensate for variation in water temperature,
(CF)-ConsultFactory
Notices:
• Watercooledcondensersarepre-setatthefactoryforcitywaterusage.
• Waterregulatingvalvemayneedtobeadjustedtootherwatersupplyconditions.Contacttechnical
support for assistance.
• Minimumwaterpressureis25psigforcitywaterand35psigfortowerwater.Coolingwater
pressures less than these minimums may reduce dryer drying capacity.
• Maximumwaterpressureis125–150psig.
water pressure, and dryer air load. The table below
indicates the amount of cooling water required
in gallons per minute (gpm) at given incoming
temperatures for the condenser Hp size in each
model. The refrigerant discharge pressure control
will shut down the refrigerant compressor if cooling
is inadequate.
Incoming Water Flow Rate Requirements
(in gpm at different inlet water temperatures)
Model by
SCFM Rating Condenser Hp 70°F 80°F 85°F 90°F
1 1.25 1.5 CF
1.5 1.9 2.25 CF
2 2.5 3 CF
33.75 4.5 CF
456CF
7 8.75 10.5 CF
10 12.5 15 CF
12 15 18 CF
14 17 20 CF
15 19 24 CF
Water Cooled Condenser Requirements Table
15
Non-CyclingRefrigeratedAirDryer
1/4
1/3
1/2
3/4
1 1/2
2
5
5
65
80
125
200
260
415
570
860
1000
1400
3 1/2
1 1/4

Shut-Down Procedures
Shut-Down Emergency
The non-cycling refrigerated air dryer system can
be shut down under any conditions and at any time
by turning the unit off at the dryer or at the main
disconnect switch. Once power is removed from
the dryer system, the dryer must be isolated from
the compressed air stream to avoid a refrigeration
circuit over pressure situation.
Short-Term Shut-Down (over night or weekends)
The refrigerated air dryer system can be shut down
at any time by turning the unit off at the dryer by
using the on/off switch or at the main disconnect
switch.
WARNING!
• Toavoidpossiblehazardorinjury,
the operator should be fully familiar
with the refrigerated air dryer
system and its operation.
• Whenthesystemisshutdownand
powerremoved,lockoutpower
supply and depressurize system
before performing maintenance
orserviceworktoavoidinjuryto
personnel or property damage.
16
Aircel HP Series

Service Information
To reach a field service technician or for technical
support,pleasecallthenumberonthemanualback
cover.
Maintenance
Refrigeratedairdryersrequireverylittle
maintenance for satisfactory operation. Optimum
performancecanbeexpectedifthefollowing
routinemaintenancestepsaretaken.
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 before performing
maintenanceorservicework.
• Followproperlockout/tagout
procedures before performing
serviceormaintenancework.
• 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.
Followallsafetyprocedurespriorto
performing any maintenance activity
on the dryer.
Daily
With the dryer on-line:
• Verifytheoperatingpressure,temperature,and
flow rate are correct and conform to those listed
intheDesignParameterssection.Adjustsystem
if required.
• Alwayscheckrefrigerantgaugestoinsure
refrigerationsystemisworkingproperly.
• Checkcondensatedrainseparatorforproper
condensatedischarge.Ifnodischargeisevident
then depressurize the unit, dismantle and clean
separatorand/ordrainline.Properdraintrap
maintenanceistheowner’sresponsibility.Itis
not covered by warranty.
• Makecertainairflowisdirectedthroughdryer
only. Observe by-pass valves proper positions.
Weekly
• Repeatalldailyinspectionsandrecorddatain
the maintenance log.
• Cleanthecondensercoilsofaccumulated
dust and dirt with a soft brush and/or with
air pressure from a compressed air nozzle
(maximum100psig).
• Checkthegaugereadingsforoptimumsystem
operation.
• Checkoilremovalfilter(coalescer)indicator(if
applicable); if it is red, replace the filter.
17
Non-CyclingRefrigeratedAirDryer

Filter Element Replacement
1. Depressurizetheairsystemtorelease
the compressed air from the air dryer.
Notice:Shuttingdowntheaircompressorwill
not depressurize the air dryer unit.
Close air line valves before and after
dryer and then depressurize unit.
Depressurizedryerbypushingthetest
button on the dryer system drain until
there is no more pressure in the dryer
system.
2. Removethefilterbowlbyturningthebowl
1/4turncounterclockwise,besuretheO-ring
is in place on the top half of the oil filter
housing and that the O-ring seats properly. Air
leaksmayoccuriftheO-ringisnotsecured
(important).
3. The same procedure applies when removing
the filter separator for changing the element (if
applicable).
18
Aircel HP Series

Troubleshooting
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.
• 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.
• Followallsafetyprocedurespriorto
performing any maintenance activity
on the dryer.
Ifthereisaproblemwiththerefrigeratedairdryer
or contamination down stream is present, the
problem may be identified from one or more of the
following sources:
• Electrical
• Refrigeration
• Condensateremoval(drains)
• Other
• Makecertainthatthedryerisconnected
to proper power supply in accordance with
electrical diagram provided.
• Checkelectricalbreaker,fuse,ordisconnectto
determine if there is electrical power to the unit.
• Aquickcheckshoulddetermineifthepower
switch is turned on and the unit is running.
• Afterdeterminingthatpowerissuppliedtothe
unit,gotothenextstep.
Refrigeration
WARNING!
• Followproperlockout/tagout
procedures before performing
serviceormaintenancework.
• Electricalinstallationormaintence
must be performed by a qualified
electrician and comply with all
applicable national and local codes.
19
Non-CyclingRefrigeratedAirDryer
Electrical
WARNING!
Refrigeranthandlingmustbeperformed
by a qualified technician and all
applicable national and local codes
must be followed.
Notice: Alwaysobserverefrigerantpressure
gauge(s) to determine if and how
refrigeration circuit is operating.
Non-cyclingrefrigeratedairdryerswithR-134a
refrigerant should have a suction gauge pressure
readingof28-40psigandadischargegauge
pressurereadingof160-230psigwiththeunitinthe
onpositionunderfullorpartialload.Ifthe
refrigerant gauge(s) reads more or less than the
above specified pressures, troubleshoot items on the
following page.

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 before performing
maintenanceorservicework.
20
1. Highrefrigerantreadingsgenerallyindicate:
• Dirtycondenser-Cleanimmediately!
• Dryernotturnedon.
• Overloading-Airfloworconditionsin
excessofdryercapacity.
• Highambienttemperature(>100°F)
Provideadequateventilationforproper
cooling, or reduce ambient temperature.
• Condenserfan(s)notrunning-Call
TechnicalSupport.
• Refrigerantcontroltoohigh-Contact
technical support for assistance.
2. Low refrigerant readings generally indicate:
• Lowambienttemperature-Temperatures
below40°F.Increaseambienttemperatures
or install head pressure control valve.
Contact technical support for more
information.
• Refrigerantcontrolsettingtoolow-
Contact technical support for assistance.
• Lossofrefrigerant-CallTechnicalSupport
or qualified refrigeration service.
Condensate Removal
The non-cycling refrigerated air dryer uses a
refrigeration circuit to cool the compressed air
which causes moisture to condense. The condensed
moisture is separated from the dry air and purged
through an automatic drain.
1. Condensatedownstreamofdryer:
• Iftheunitisequippedwithautomaticdrain
override switch, push manual override
button to test drain flow.
• Ensureautomaticelectronictimer(if
applicable) is functioning properly.
• Ensuremoistureseparator(and
coalescer)drainlinesarefreefromblockage.
• Iftheunitisequippedwithy-strainer,
disassemble and clean.
• Ifoilisdownstreamfromthedryer:
- Oil coalescer element is saturated.
-Dryernotturnedonduringairusage.
Other
Sometimesawateroroilproblemdownstream
from the dryer can be identified by an inadvertent
action or inaction by the operator.
• Dryernotturnedonbeforeairusage.
• By-passvalvesinwrongposition.
• Airusageexceedingdryercapacity.
• Oilcoalescerelementdirty.
• Automaticdrainsnotmaintained.
Aircel HP Series

Troubleshooting Table
Non-CyclingRefrigeratedAirDryer
Problem Probable Cause Remedy
Water downstream
of dryer system or no
discharge from separator/
filter.
Failedorshortcircuited
timer on drain.
Replacetimerdrain.
Faileddrainsolenoid. Replacetimerdrain.
Bulkliquidenteringthe
dryer from upstream.
Checkdrainsonaftercooleroraircompressor.
Inletcompressedair
temperature to dryer
exceedsdryercapacityair.
Checkinletairtemperatureandadjustas
required to meet specifications.
InletcompressedairCFM
flowrateexceedsdryer
capacity.
Checkininletaircfmflowrateandadjustas
required to meet specifications.
Leakintheairtoair 
sideoftheheatexchanger.
Replaceheatexchanger.
Water downstream and
dryersystemnotworking
properly.
Refrigerationcompressor
stopped due to plugged or
dirty condenser coil.
(HighPressure)
Clean condensing coil and ensure adequate
ventilation of unit.
Refrigerationcompressor
cycles on/off and cannot
maintain suction pressure.
Checkcondensingcoilfordirtordebristhat
could prohibit adequate ventilation of the
refrigerantcircuit.Ifitisclean,checkrefrigerant
pressure gauge(s) to determine if the unit is low
on refrigerant.
Low refrigerant. Checkforleakinrefrigerationcircuit,repairand
recharge according to specifications.
Low refrigerant, possible
leakinairtorefrigerant
sideofheatexchanger.
Repairorreplaceheatexchangerandrecharge
according to specifications.
Refrigerationcompressor
is overheated.
Turnoffdryerandwait20-40minutes,restart
dryer.Refrigerantcontrolsettingsmayneed
adjustment, contact technical support.
Refrigerationcompressor
has burned out or
windings have gone
to ground.
Replacecompressor,checkforleakin
refrigeration circuit, repair and recharge
according to specifications, contact technical
support.
21