General Air Products Dry Air Pac DAP500 User manual

Dry Air Pac™
ENGINEERED COMPRESSED AIR DRYING SYSTEMS
FOR DRY PIPE SPRINKLER SYSTEM CORROSION MITIGATION
AND COLD STORAGE / FREEZER ROOM APPLICATIONS
Installation, Operation and
Maintenance Manual
MODELS DAP500, DAP1000 & DAP2000
Model Number System Capacity* Compressor HP Dryer Rating SCFM Approximate Shipping
Weight
DAP500 500 Gallon 210 375lbs
DAP1000 1000 Gallon 520 500lbs
DAP2000 2000 Gallon 527 550lbs
* System capacity is +/- 10% due to site location and conditions.
revision 070820PLC
Call 1-800-345-8207
or visit our web site for our complete product listing
www.GeneralAirProducts.com

IMPORTANT: ALL INFORMATION SUBJECT TO CHANGE WITHOUT NOTICE.
Consult factory for the most up to date version of this manual - 1-800-345-8207.
Table of Contents
Safety Guidelines
Section 1 - Installation Instructions
1.1 Location
1.2 Changing the Oil
1.3 Electrical Connection
1.4 Prior Run Time
1.5 Filter
1.6 Dew Point Monitor
1.7 DAP Outlet
1.8 DAP Air Maintenance Device
1.9 Electronic Drain Valve
Section 2 - Start-Up Instructions
Section 3 - Operation
3.1 - Description of Operation
3.2 - Setting Purge Pressure
3.3 - Coalescing Filter Operation
3.4 - Dryer Operating Sequence
Section 4 - Additional Specifications
Section 5 - Desiccant Replacement
Section 6 - Setting Pump Head Bolt Torque
Section 7 - Trouble Shooting Guide
Section 8 - Dry Air Pac General Arrangement
8.1 - General Arrangement for Models DAP 1000 & DAP 2000
8.2 - General Arrangement for Models DAP 500
Section 9 - Dry Air Pac Electrical Schematics
Section 10 - P&ID Diagram
Section 11 - Warranty Policy
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Safety Guidelines
This manual contains information that is very important to know and understand. This information is provided for SAFETY
and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols.
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 indicates important information, that if not followed may cause damage to
equipment.
Section 1 - Installation Instructions
1.1 Location
Install DRY AIR PAC in a clean, dry location, with ambient temperatures above 50° F at all times, adjacent to the
sprinkler system piping outside the cold room.
It is recommended that no more than three systems be connected to a single Dry Air
Pac; capacity of each system should not exceed the rated capacity of the Dry Air Pac.
The unit must be accessible on all sides for air flow and servicing all major components. The unit must be leveled
and anchored to the floor (the vibration isolators supplied with the unit MUST be utilized). If the location is below freezing
at any time the unit must be enclosed in a separate, heated enclosure to keep the temperature above 50° F.
Do not install the Dry Air Pac in an area where ammonia vapors or similar contaminants
exist. The equipment and desiccant can be damaged by ammonia and other vapors.
Locate the Dry Air Pac to ensure no ammonia or other vapors are drawn into the intake.
1.2 Changing the Oil
The Dry Air Pac has been filled with oil for test purposes. Check oil level when installing the unit. It is recommended
to change oil annually or every 500 hours of run time, whichever comes first. 2 Quarts of oil are shipped with each Dry Air
Pac. When adding or replacing oil only use General Part Number ACPO1Q Specially Formulated Compressor Oil.
Oil requirements are as follows:
DAP500 Approximately 8.5ounces
(middle of oillevel window)
DAP1000
Approximately 1 1/2 quarts
(middle of oil level window)
DAP2000
Approximately 1 1/2 quarts
(middle of oil level window)
Oil must be the non-detergent type. Lightweight lubricants and heavy gear oils should
not be used.
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DANGER
WARNING
CAUTION
NOTICE
NOTICE
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CAUTION

Section 1 - Installation Instructions (cont’d)
1.3 Connecting Voltage
Connect supply voltage to separate line terminals L1, L2 and L3 on terminal block. All wiring must conform to the
National Electrical Code (NEC) and any local or building codes.
Wire size must be capable of carrying the unit load without dropping the voltage at the
terminals below normal operating levels. Check incoming wire size; if there are
any questions please contact us.Check all wire connections in control cabinet, since
they may loosen during shipment.
Be sure the control power transformer has its primary side jumpers connected to match the incoming supply
voltage. Each unit is run at the factory. Motor rotation will always need to be checked. After connecting the power, use the
on/off switch on the front of the unit to turn on the compressor briefly to check rotation. An indicating arrow is on the
compressor flywheel. If rotation is not correct on three phase units, reverse any two leads.
On single phase units refer to the motor nameplate, however it should not require changing as it has been run at
the factory. If you feel this is required please consult with factory personnel as there may have been changes made to the
unit, which should be discussed with the factory PRIOR TO starting the unit. Please ensure sufficient power is available at
the unit. Long feed line runs can cause voltage drops, which can affect the performance of the unit and damage the motor.
Only qualified electrical personnel should connect the unit.
1.4 Prior Run Time
Each Dry Air Pac is shipped with desiccant installed. Run the unit for a 1/2 hour before connecting to the sprinkler
system. This will allow the desiccant to become conditioned to the proper dew point. Throttle outlet valve to maintain air
drying tower pressure between 70 psig and 100 psig during this period.
The Dry Air Pac should not run for more than 40 minutes in any given hour.
If you are connecting to an old piping system there may be existing leaks in the system
which cause the compressor to cycle more frequently than 4 times per hour. If this is
the case there are three suggestions: 1. Fix the leaks. 2. Add a second Dry Air Pac to
provide enough air to bring the cycle times back to less than 4 times per hour. 3. Add
a receiver, which can act as a storage buffer to supply more air to the system. This should be discussed with factory personnel,
as it will only work in cases where minor leaks are involved.
1.5 Filter
The Dry Air Pac is supplied with a removable, threaded inlet air filter so that if the AHJ requires air to be drawn from
the cold room this can be done.
These units have been FM Approved with air not being drawn from the freezer room.
Therefore we do not recommend they be connected to the freezer room.
The Dry Air Pac is designed so that performance will not be adversely affected with the filter left in place directly
on the compressor. If connected in the cold room, the piping back to the compressor must be 1 1/2" minimum pipe size for
this run, bushed down directly at the compressor inlet. This pipe must be heat traced and insulated. The inlet filter should
be mounted on the inlet end of this pipe directly in the cold room. The interconnecting piping must be clean of any foreign
matter, which may be drawn into the compressor and cause damage.
1.6 Dew Point Monitor
There is a 1/2" pipe plug installed in the outlet tee. This is provided as a point to install a dew point monitoring
device, should you require one. This is after the regulator and gives you the pressure dew point of the system. Be careful
to follow the dew point monitor manufacturer's recommendations regarding installation.
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CAUTION
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Section 1 - Installation Instructions (cont’d)
1.7 DAP Outlet
The Dry Air Pac outlet is from the combination particulate filter with pressure regulator, mounted on the lower right
side of the unit facing the control panel. Connect this outlet to the sprinkler system air inlet.
1.8 DAP Air Maintenance Device
The Dry Air Pac has a UL Listed/FM approved Air Maintenance Device built into the unit. It must be adjusted to
system requirements. It replaces the final regulator, which should be left fully open once the Air Maintenance Device has
been adjusted and valved into the line. If connecting more than one system to the unit, the Air Maintenance Device should
be in the fill position and the individual AMD's used to control each system should be utilized.
Leaks in the piping system will affect the pump up time of the system. The Dry Air Pac
has been factory tested to produce the published capacity, for systems without leaks.
1.9 Electronic Drain Valve
An electronic drain valve is installed on each unit. The drain is pre-set when the unit leaves the factory. If
necessary you can adjust the time between openings and the length of time the valve is open using the control knobs
located on the front of the control panel. Under normal circumstances the maximum time between openings should be suf-
ficient. If more frequent openings are required due to excessive compressor operation simply decrease the duration
between openings. The Automatic-Off-Manual Test switch can be used to check operation. Leave this switch in “Automatic”
during normal operation.
Section 2 - Start-Up Instructions
As noted previously, the unit must run for a minimum of a 1/2 hour before air is taken from the Dry Air Pac into the
sprinkler system. Follow instructions in section 1.4
With all the connections made as described in “Installation Instructions”, the unit is ready to start. With the valve
ahead of the coalescing filter closed, turn the unit on. The compressor will start to fill the receiver tank and the tank pressure
gauge on the front of the control panel will indicate the pressure. The unit will pressurize the receiver to approximately 100
psig and then shut off the compressor.
Do not adjust the pressure switch on the unit. It is factory set for correct operation of
the unit. Warranty may be void if the pressure switch is reset.
When the compressor stops, the unloader line will operate to bleed off the pressure in the line from the compressor to the
receiver inlet, so that the compressor does not start loaded. Air exhausts from the small valve at the side of the switch
immediately after the compressor is shut off. This should not occur when the compressor is running or for long periods of
time after the compressor shuts off. If this occurs, contact the factory.
Slowly open the valve ahead of the coalescing filter and pressurize the rest of the Dry Air Pac. The Air Maintenance
Device should be in fill mode, with the 3/4" valve open.
Slowly open the outlet valve to pressurize the sprinkler system. The final regulator is factory set to 40 psig. The
outlet valve should always be set to maintain pressure on the drying tower between 70 to 100 psig.
At no time should the outlet valve be opened to bleed all pressure off the drying system,
as this adversely affects drying quality.
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NOTICE
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