Aircel VF-10 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
VF Series Non-Cycling Refrigerated Air Dryer
Models VF-10, 15, 25, 40, 50, 60, 75, 100, 125, 150, 200, 250,
300, 400, 500 600, 800, 1000, and 1200
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VFSeries-Models10-1200

Non-CyclingRefrigeratedAirDryer
3
Contents
SafetyStatements .................................................. 2
DataSheet............................................................. 3
RefrigeratedAirDryerSerialPlateLabel .............. 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
 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.
CoolingWaterRequirements.............................. 15
Water Cooled Condenser Table ................. 15
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MaterialSafetyDataSheet ............ 26
 R-404aMaterialSafetyDataSheet ............ 31
 WiringDiagram ......................................... 45
ServiceNotes ...................................................... 50
Warranty............................................................. 52

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VFSeries-Models10-1200

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) 100-125 200 80
AirInlet
Temperature(°F) 80-100 100 40
Ambient
Temperature(°F) 75 100 32
SuctionGauge
Reading(psig) 28-40 60 28
DischargeGauge
Reading(psig) 160-250 350 80
Evaporator
Temperature(°F) 38-42 60 33
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. Environmentally refrigerant is
used in all refrigerated compressed air dryers. the
refrigerants used provide consistent performance
(zero temperature glide) and easy service.
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50-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 flows through the receiver,
then through a filter/dryer, and finally through the
expansionvalvewherepressureandtemperature
are reduced. This reduction in pressure causes
the liquid refrigerant to boil until it reaches the
saturation 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VFSeries-Models10-1200

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 hot gas by-pass valve is
used on the non-cycling dryers as a freeze protector
inlowloadconditions(100scfmratedmodels[1/2
Hp] and up).
Compressed Air Circuit
The compressed air dryer circuit uses a patented
air-to-airheatexchanger,whichactsasaprecooler/
reheater(scfmratedmodels50andup).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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.
compressor liquid
receiver
air out
air in
refrigerant
inlet
refrigerant
outlet
air cooled
condensor
suction
accumulator
Air to Refrigerant Heat Exchanger
Refrigerant Circuit
TypicalSchematicFlowDiagram(10-60scfmratedmodels)
7
Non-CyclingRefrigeratedAirDryer

8
air inlet air outlet
separation cell
air to refrigerant
heat exchanger
refrigerant
inlet
air
refrigerant refrigerant outlet
exiting air
incoming air
stainless steel mist eliminator
pre-cooler / heater
TypicalSchematicFlowDiagram(75-1200scfmratedmodels)
AircelVFSeries-Models10-1200

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VFSeries-Models10-1200