Aircel AHLD E-Series User manual

Front Page
Desiccant Air Dryers
AHLD E-Series
Heatless Regenerative
Models 70, 100, 150, 200, 250, 300, 350,
450, 500, 600, 750, 1000, 1250, 1500,
2000, 2500, 3000, 3500, 4500, 5000 scfm
Installation
& Operations
Manual
Eective October 2017

AHLD Series | Heatless Regenerative Desiccant Air Dryer
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DRYER DATA SHEET
INTRODUCTION
Model Number: Serial Number:
Dryer Type: Date of Manufacture:
Ship Date: Installation Date:
Customer Name:
Customer Address:
Customer City: State/Zip:
Accessories:
Other:
Thank you for purchasing Aircel’s AHLD E-Series Heatless Regenerative Desiccant Air Dryer with integrated Energy Management
Purge Reduction System. You are now the proud owner of one of the nest desiccant dryers on the market. Aircel AHLD E-Series
dryers are engineered and manufactured to provide you with many years of trouble-free service and provides energy ecient
operation by reducing the overall dry purge air required for regeneration, saving energy and money. To ensure that you get rst
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 notication and is not obligated in any manner.
Infomration 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, need additional copies, or would like to schedule an Aircel service technician viist, contact your distributor.

Heatless Regenerative Desiccant Air Dryer | AHLD Series
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DRYER DATA SHEET
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 Total for System:
Dryer Outlet Dew Point:
Dryer Control Time Cycle:
Dryer EMS Dew Point Sensor Setting (for sensor outlet dew point):
High Dew Point Setting:
Demand Cycle Setting:
Outlet Dew Point Readout on Display:
Electrical Drawing Number:
Mechanical Drawing Number:
PLC Software Program Number:
Control Air Filter Element Number:
Inlet Pre-Filter Element Number (option):
Outlet After-Filter Element Number (option):
Inlet Valve:
Purge Exhaust Valve:
Vessel National Board Number (Left and Right Vessels):
Dryer System Weight:

AHLD Series | Heatless Regenerative Desiccant Air Dryer
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TABLE OF CONTENTS
Dryer Data Sheet 2
Introduction 2
Dryer Data Sheet 3
Safety Precautions 5
Safety Symbols 6
General Safety Instructions 7
Desiccant Safety Precautions 8
Why We Need Compressed Air Dryers 9
Purpose and Intended Use 9
Inspection on Arrival 9
Features & Options 10
Design Parameters 11
Dryer Description 11
How It Works 11
Flow Diagram 12
Installation 13
Pre-requisites for Installation 13
Location 13
Typical Installation Diagram 13
Installation Steps 14
Start-Up and Shut Down Procedures 15
Sequence of Operation 16
Maintenance 17
Weekly Checklist 17
Semi-Annual Checklist 17
Annual Checklist 17
Normal Operation Setup 18
Aircel Programmable Controller (APC) 19
System Navigation 19
Dryer Operations 20
Main Screen Navigation 24
Control Menu Navigation 24
Control Menu Operation 25
Settings Screen Operation 25
Time Control Main Navigation 26
Time Control Menu Operation 26
Analog Screen Navigation 27
Hours of Operation Screen Navigation 27
Alarm Screen Navigation 28
Alarm Pop-Up Screens 29
Troubleshooting Table 30
Appendix 32
Desiccant Material Data Safety Sheet 32
Drawings 37
Service Notes 43
Warranty 47

Heatless Regenerative Desiccant Air Dryer | AHLD Series
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Notice: For optimum performance, use only Aircel replacement parts.
Notice: For information and notes specific to custom designed and built dryers, reference the drawing package
provided with the unit. See warranty on manual back cover for custom engineered products.
NOTICE
Throughout this manual, signal words are present to advise of safety
precautions and/or standard practices. Obey these signal words as dened
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.
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.

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SAFETY INSTRUCTIONS
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 electrical 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.
!
X

Heatless Regenerative Desiccant Air Dryer | AHLD Series
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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.
Safe Operating Procedures
1. Pressurize and depressurize compressed air SLOWLY! Always open air valves slowly when pressurizing the airline
system or equipment. Repair air slowly when depressurizing your air system or equipment.
2. Circuit breakers, fusable 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 oils, 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 (CO) and are 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 whatsoever for loss, injury, or damage.
What You Must Not Do
1. Do not make any 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.
X
!
!

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DESICCANT SAFETY PRECAUTIONS
Desiccant First Aid
Recommendations
INHALATION
Use a contoured dust mask during loading and
unloading operations. If high concentrations are inhaled,
immediately move to fresh air. Keep person calm. If
not breathing, give articial respiration. If breathing is
dicult, give oxygen. Call a physician.
SKIN CONTACT
In case of contact, immediately flush skin with plenty of
soap and water for at least 15 minutes.
EYE CONTACT
In case of contact, immediately flush eyes with plenty of
water for at least 15 minutes. Call a physician.
SPILLS
Clean accidental spills by vacuuming, sweeping, or
flushing to a sewer treated for suspended solids. Avoid
creating excess dust.
WARNING!
INHALATION, SKIN, & EYE IRRITANT:
The desiccant used in this equipment is not considered
hazardous. Contact with and disposal of desiccant
must be in accordance with the relevant MSDS and
all local codes and regulations. The following lists the
more common safety measures to be observed during
loading and unloading operations. Reference the MSDS
in the appendix for complete safety measures.
!

Heatless Regenerative Desiccant Air Dryer | AHLD Series
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WARNING!
• Failure to lift the unit correctly can result
in sever personal injury or property
damage.
• Use appropriate lifting equipment and
adopt all safety precautions needed for
moving and handling the equipment.
• A hand cart, fork lift, or crane is
recommended for unloading and
installation.
• Lift unit by lifting lugs and frame only. Do
not lift by piping.
!
WARNING!
• Follow proper lock out/tag out
procedures before performing service or
maintenance work.
• Electrical installation must be performed
by a qualied electrician and comply with
all applicable national and local codes.
!
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.
!
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 regenerative type dryer system with all
recommended ltration 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
unaected. Therefore, rejection rates are reduced.
Purpose and Intended Use
Misuse or modication of this equipment may result in personal
injury. Do not misuse or modify. The high eciency heated
regenerative desiccant dryer is used exclusively for purifying
compressed air in non-hazardous locations.
The state-of-the-art system is designed and constructed
in accordance with the rules and regulations regarding
adsorption technology and industrial safety. There are hazards
accompanying this type of product if not operated for the
intended purpose by trained and specialized personnel.
Inspection on Arrival
All heated regenerative desiccant dryers are tested and
operated before shipment. However, shipping vibration may
cause damage such as loosening of certain parts. To ensure
smooth installation, it is recommended that immediately upon
receipt of the unit, the system is checked for the following:
1. Inspect unity on delivery.
2. Report any damage to the delivery carrier.
3. Request a written inspection report from the Claims
Inspector to substantiate the claim.
4. File claims with the delivery carrier.
5. 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.
6. Vibration during shipping can loosen the connections.
Inspect all pipe and tubing and make sure they are all
tightened and secured.
7. Report incomplete shipments to the delivery carrier and
your service representative.

AHLD Series | Heatless Regenerative Desiccant Air Dryer
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FEATURES & OPTIONS
Standard Features
• Integrated Energy Management Purge Reduction System for ecient energy savings and reduced cost of operation.
• Optimal tower size for low velocities reducing desiccant uidization, and high contact time for ecient low dew point
performance.
• Tower pressure relief valves.
• Standard design capacity based on 100 psig, 100°F inlet air, 100°F ambient air, and Pressure dew point of -40°F.
• Purge exhaust muers for quiet operation.
• Tower pressure gauges for additional visual operation of dryer operation.
• Stainless steel desiccant supports and air diusers to prevent channeling.
• Counter-current reactivation for ecient desiccant regeneration.
• PLC Controlled Electrical System
• Adjustable (5 min., 10 min.) cycle times: 10 minute cycle for the standard -40°F Pressure dew point outlett dew point
systems, 5 minute cycle used in the optional -100°F Pressure dew point outlet dew point systems.
• 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 ow, preventing a deadheading aect.
• Control pilot air lter provides clean air to air control system for long trouble-free reliable operation.
• Desiccant towers are designed, fabricated, and stamped according to ASME code.
• Desiccant ll and drain ports for ease of desiccant replacement.
• Structural steel frame.
• Highly reliable non-lubricated air inlet and outlet valves (APV) Automatic Piston Valve (AHLD 70 E - AHLD 750 E) and high
performance, non-lubricated buttery valves (AHLD-1000 E - AHLD-1500 E).
• Highly reliable angle seat design purge exhaust valves.
• Tower operating LED status lights (left and right tower dryer, left and right tower regenerating).
• On/O switch and power On light.
• NEMA 4 weather resistant electrical system construction.
Additional Options
• -100°F outlet pressure dew point.
• Failure-to-shift alarm with pressure transducers.
• Outlet dew point sensor with dew point readout on system display.
• High humidity alarm.
• Outlet dew point 4-20 ma signal.
• Mounted, piped, and wired ltration packages.