HANKISON H Series User manual

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REFRIGERATED
TYPE
COMPRESSED
AIR DRYERS
H Series
7610.719.3B73/06
Contents
GENERAL SAFETY INFORMATION ............................... 2
RECEIVING, STORING, MOVING, UNPACKING
1.0 DESCRIPTION........................................................... 3
2.0 INSTALLATION ......................................................... 4
2.1 Location .............................................................. 4
2.2 Position in the compressed air system ............... 4
2.3 Mounting ............................................................. 4
2.4 Piping .................................................................. 4
2.5 Electrical ............................................................. 4
2.6 Air-Cooled Models .............................................. 5
2.7 Compressor tiedown nuts -
7 1/2 and 10 horsepower units only .................... 5
3.0 OPERATION ............................................................... 6
3.1 Start-up and Shut down Procedures................... 6
3.2 Operational Sequence ........................................ 8
3.3 Fault Conditions .................................................. 10
3.4 Lights and Gauges.............................................. 10
3.5 Operational Check Points ................................... 10
4.0 MAINTENANCE.......................................................... 11
4.1 Separator/Filter Sleeve Replacement ................. 11
4.2 Air-Cooled Condenser - Special Instructions ...... 12
4.3 Water-Cooled Condenser - Special Instructions 12
Cooling Water Requirements ..................................... 15
4.4 Condensate Drains - Pneumatically Operated.... 16
4.5 Condensate Drains - Electrically Operated......... 17
TROUBLE SHOOTING ..................................................... 18
WARRANTY ..................................................................... 20
SERVICE DEPARTMENT: [phone]
INSTRUCTION MANUAL
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GENERAL SAFETY INFORMATION
1. PRESSURIZED DEVICES:
This equipment is a pressure containing device
• Do not exceed maximum operating pressure as shown on equipment serial number tag.
• Make sure equipment is depressurized before working on or disassembling it for servicing.
• A pressure relief device must be added to this equipment.
2. ELECTRICAL:
This equipment requires electricity to operate.
• Install equipment in compliance with national and local electrical codes.
• Equipment supplied as standard is not intended for installation in hazardous environments.
• Disconnect power supply to equipment when performing any electrical service work.
3. BREATHING AIR:
• Air treated by this equipment may not be suitable for breathing without further purification.
• Refer to OSHA standard 1910.134 for the requirements of breathing quality air.
RECEIVING, STORING, MOVING, AND UNPACKING
A. RECEIVING
This shipment has been thoroughly checked, packed and inspected before leaving our plant.
It was received in good condition by the carrier and was so acknowledged.
Upon receipt:
1. Check for visible Loss or Damage
If this shipment shows evidence of loss or damage at the time of delivery to you, insist that a notation of
this loss or damage be made on the delivery receipt by the carrier’s agent.
2. Check for Concealed Loss or Damage
When a shipment has been delivered to you in apparent good order, but concealed damage is found upon
unpacking, notify the carrier immediately and insist on his agent inspecting the shipment. Fifteen days from
receipt of shipment is normally the maximum time limit for requesting such inspection. Reporting damages
to the freight forwarder is the responsibility of the consignee.
B. STORING/SHUT DOWN
Dryer should not be stored outside (either crated or uncrated) or exposed to the weather. Damage
to electrical and control components may result.
IMPORTANT - WATER-COOLED UNITS
If unit is shut down in below freezing temperatures, the water-cooled condenser may freeze and cause perma-
nent damage. Condenser must be drained using drain cock located on the interconnecting water piping.
IMPORTANT - Do not store dryer in temperatures above 130°F, 54.4°C.
C. MOVING
Dryer is shipped on wooden pads to accommodate a fork lift truck. Move the dryer with a fork lift or rollers so as
to support it by the bottom of the frame or lift using lifting rings on frame.
Never lift dryer by attaching hooks or slings to the air inlet and outlet connections or to any part
within the dryer frame except lifting holes. Severe structural damage could result.
D. UNPACKING
Packaging material should be left in place until unit is in position.
Care should be taken during unpacking so that sharp objects do not come in contact with refrig-
eration lines, condenser tubing, etc., as a refrigeration leak could result.

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Air Side
A. Air inlet
B. Air-to-air heat exchanger
C. Air-to-refrigerant heat exchanger
(refrigeration evaporator)
D. Moisture separator
E. Automatic condensate drains
F. Drain service valve
G. Air outlet
H. Pressure Gauge
Refrigeration System
1. Refrigeration compressor
2. Water-cooled condenser with built in
receiver
3. Liquid line shut-off valve
4. Filter/dryer
5. Sight glass/liquid moisture indicator
6. Thermostatic expansion valve
7. Refrigeration evaporator
(air-to-refrigerant heat exchanger)
8. Accumulator
9. Suction line filter
10. By-pass system manual valve
11. By-pass system strainer
12. Hot gas by-pass valve
13. Desuperheating valve
14. Solenoid valves for pump-down system
15. Water regulating valve
16. Water strainer
FLOW SCHEMATIC
1.0 DESCRIPTION
A. Function
Refrigerated type compressed air dryers reduce the
moisture content in compressed air by lowering the
air temperature causing water vapor to condense
into a liquid. The liquid is then separated from the air
stream and discharged to drain. As long as the
temperature of the compressed air, as it travels
through a plant’s air system, does not fall below the
temperature to which it was chilled in the dryer
(referred to as dewpoint temperature), no more
water vapor will condense into troublesome liquid. In
addition, the air is filtered of all solid particles three
microns and larger. Clean, dry compressed air leaving
the dryer minimizes maintenance and repair of
pneumatic distribution, instrument and control, and
actuation devices, reduces product contamination,
and increases productivity.
B. Operation
Compressed air, saturated with water vapor, enters
the dryer and is precooled by the outgoinq refriger-
ated air in an air-to-air heat exchanger. Precooling
removes some of the heat load from the incoming
air allowing the use of a more efficient refrigeration
condensing section. The precooled air then enters
an air-to-refrigerant heat exchanger (refrigeration
evaporator) where it is cooled to a preset level by
giving up heat to the refrigeration system. As the air
cools, water vapor condenses into liquid droplets
which are separated out of the air stream by a
separator. Liquid condensate is discharged to drain
by three automatic condensate drains.
The cold air then exits after it has passed through
the other side of the air-to-air heat exchanger
where it is warmed by the incoming hot air. This
reheating increases the air's effective volume
(enabling it to do more work) and prevents pipe
sweating downstream.
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EFD
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COOLING
WATER (OUT)
COOLING
WATER (IN)
CRANKCASE HEATER
EF

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B. Holes are provided in the dryer base to permanently
mount it to a level solid floor. Ensure the dryer is level
by grouting, if necessary. The structural steel base is of
an open design to facilitate cleaning and washing
under the unit.
2.4 Piping
Utility connections should be made
without equipment forces or moments at any connec-
tion point.
A. Air Inlet & Outlet
1. Connect compressed air lines to connections
marked “Air Inlet” and “Air Outlet” on dryer. Inlet
and outlet should be connected to air lines of
equal or larger diameter than piping sizes fur-
nished on the dryer. Check drawing for Inlet and
Outlet location and size.
2. Use of a 1/16" thick flat ring compressed synthetic
gasket (Garlock or equal) is recommended. At the
time of installation, the gaskets should be coated
with a high grade lubricant to facilitate making a
tight joint. Crane thread lubricant (or equal) is
recommended.
A pressure relief valve must be
installed to protect the dryer pressure vessels from
over pressurization. No valves may be located
between the dryer and the pressure relief device.
Check local codes for other requirements.
B. Automatic Condensate Drains
Automatic condensate drains are piped to a common
fitting on the base plate. Condensate should be
piped from this fitting to an open, vented floor drain
or sump.
Liquid discharge is at system pressure
and may require that drain line be anchored.
Do not put a valve in the drain line or
obstruct the discharge of the condensate in any way
(such as with severe bending of drain line).
C. Water-Cooled Models - Water Supply and Drain Lines
Connect cooling water inlet and outlet. Unit is
supplied with water strainer and water regulating
valve. See Technical Data Section for cooling water
requirements.
NOTE: It is preferable to install inlet and outlet water
pressure and temperature gauges in water system.
2.5 Electrical
If a disconnect switch is utilized, only time
delay, dual-element fuses (Fusetron, or equal) should be
used.
The dryer is designed to run continuously
and must not be wired to cycle on and off with the air
compressor. Dryer compressor can be placed in Standby
Mode during shutdown periods.
2.0 Installation
2.1 Location
A. A moderately heated, well ventilated area is the best
location for the installation of the dryer.
B. Ambient Temperatures:
Water-Cooled - Standard: 35 to 130°F, 2 to 54°C
Optional: -20 to 130°F, -29 to 54°C
Air-Cooled with integral condenser -
Standard: 35 to 110°F, 2 to 43°C
Optional: -20 to 110°F, -29 to 43°C
Air-Cooled with remote mounted condenser -
Dryer only - Standard: 35 to 110°F, 2 to 43°C
Optional: -20 to 110°F, -29 to 43°C
Condenser - Standard: -20 to 110°F, -29 to 43°C
C. Avoid locations immediately adjacent to cold exterior
windows or walls or adjacent to high temperature
ovens or boilers.
D. Dryers should be installed in a location which will
allow ease of servicing, cleaning and good visibility of
furnished instrumentation. A three (3) foot wide
access area should be provided on all sides of dryer.
AIR-COOLED MODELS
A . Air-cooled condensers are furnished
with legs which provide free air movement. DO NOT
obstruct the entering or exiting air across the con-
denser. The outlet vertical air discharge should have
no obstruction within a distance equal to ten times
the diameter of any fan.
B. Avoid installing condenser where air being drawn
across the condenser has been run through and
heated by devices such as air-cooled aftercoolers or
compressor intercoolers. In some cases cooler air can
be diverted into the condenser intake by erecting a
baffle between the condenser and other equipment.
It is also possible to duct cooler air from an external
source to the condenser intake. Care must be taken
that the duct work is large enough so as not to restrict
air flow or that a blower is installed in the duct work to
provide required air flow.
2.2 Position in the compressed air system
This type of dryer is normally located downstream of the
compressor receiver tank and before the main plant air
distribution line(s). A three valve bypass should always be
installed to permit the continued use of the plant com-
pressed air system during any dryer maintenance or
servicing operations. No prefilter upstream of the dryer is
required unless an excessive amount of scale and/or oil is
present in the compressed air system.
2.3 Mounting
A. At the permanent dryer location, remove the dryer
from its shipping pads.

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Cooling Water
Outlet
SIDE VIEW
Cooling Water
Inlet
FRONT VIEW
Air Inlet
Air Outlet
Electrical
Enclosure
Condensate
Drain
Connection
Control Panel
MOUNTING NUT
LOWER
1/16" SPACE
MOUNTING STUD
RUBBER SPACER
LOCKWASHER
MOUNTING BASE
MOUNTING NUT
LOWER
SHIPPING
SPACER
MOUNTING
SPRING
MOUNTING NUT
UPPER
Compressor Tie-Down Nuts
7 1/2 & 10 HP Units Only
2. After condenser is in place, run refrigeration lines
between dryer and condenser; cut off brazed ends of
refrigeration lines and braze new lines to cut off ends
using appropriate couplings.
Interconnecting refrigerant lines must
be adequately sized and designed to ensure proper oil
return, including traps, check valves, and separators
where necessary.
3. Using access ports on hot gas and liquid lines, evacu-
ate lines with vacuum pump to remove air and mois-
ture. Add refrigerant only if necessary.
2.7 Compressor shipping spacers - 7 1/2 and 10
horsepower units only
The following procedure must be followed
to prevent compressor damage.
A. Remove the upper mounting nuts and shipping
spacers from the four (4) mounting studs.
B. Place one (1) rubber spacer on each stud, and replace
mounting nut, leaving 1/16" space between the
mounting nut and upper spacer.
A. Electrical entry is through electrical connection entry
hole in electrical enclosure. If optional disconnect
supplied use entry hole in disconnect enclosure.
B. Connect power to proper terminals.
C. Recommended branch circuit and unit fuse protection
can be found in the Technical Data Section.
D. Be sure that voltage to unit is as marked on unit
nameplate and on condensing unit baseplate.
E. Air-Cooled models - remote condensers - wire
condenser to terminals in dryer electrical enclosure
identified on electrical schematic.
F. Remote Alarm Connection
Connection for external alarm is made on the terminal
strip found in the main electrical enclosure. See
electrical drawings supplied with the unit for connec-
tions. If provisions for multiple alarms are provided
(optional) see schematic.
NOTE: Two (2) amps is the maximum current draw
through the alarm contacts.
G. Optional Remote Standby/Run - See Electrical Wiring
Schematic on page 9.
2.6 Air-Cooled Models
A. Integrally mounted condenser: Condensers mounted
on the dryer are shipped prepiped, charged with
refrigerant, and ready to operate.
B. Remote mounted: Installation of remote
mounted condenser should be preformed by a
qualified refrigeration mechanic.
1. Both the dryer and condenser are supplied with
isolation valves in the off position and are shipped fully
charged with refrigerant. Refrigerant lines have been
brazed shut to prevent leakage of refrigerant.
Air-Cooled Models with
Integral Condenser
(Optional)

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3.0 Operation
3.1 Start-up and Shut down Procedures
A. Pre-start-up Procedure
After making sure Master switch is OFF (Pushed in),
energize dryer. Power on light will illuminate.
Do not turn Master switch to ON at
this time. Dryer must be energized twenty-four (24)
hours before refrigerant compressor is started.
Verify crankcase heater is energized or getting hot.
NOTE: Start-up should be done only under the
supervision of a qualified refrigeration mechanic who
is familiar with accepted operational practices for
refrigeration systems. Compressor crankcase should
be warm.
1. Water-Cooled models - Open main water supply
valve and allow water to flow through the condenser.
Check for water leaks. Water will not flow through
water valve unless unit is operating.
2. Open refrigeration valves
a. Backseat hot gas by-pass line manual shut-off valve
(by turning counterclockwise as far as possible).
b. Open compressor high side (discharge) service
valve by first back seating (turning counterclock-
wise as far as possible) then (water-cooled models
only) turning clockwise two (2) complete turns.
c. Back seat liquid line shut-off valve (by turning
counterclockwise as far as possible), then turn
clockwise two (2) complete turns.
d. Back seat compressor suction service valve (by
turning counterclockwise as far as possible).
e. Refrigerant leak test all refrigerant connections
and refrigeration system components using a
halogen leak detector. Pay particular attention to
control lines which may have loosened during
shipment or handling. Refrigerant leaks are nor-
mally evidenced by the presence of oil at the leak.
3. Check compressor for correct oil level. (Oil should be
visible in sight glass).
4. Check electrical voltage to be sure it is within the limits
shown in Technical Data Section or 10% of nameplate
voltage.
5. Check that automatic condensate drain valve isolation
valves are open.
6. Air-Cooled models - Check that any isolation valves
between dryer and condenser are open.
B. Start-Up Procedure - (Dryer energized; master switch
OFF)
DRYER MUST BE ENERGIZED (POWER ON
LIGHT ILLUMINATED) TWENTY-FOUR (24) HOURS BEFORE
START-UP OF THE REFRIGERATION COMPRESSOR.
1. After dryer has been energized at least twenty-four
(24) hours pull Master switch to ON position. Dryer
display will indicate either STANDBY or SYSTEM EN-
ABLED on operator interface.
2. Turn Stand-by/Auto Selector Switch to AUTO position.
a. If SYSTEM ENABLED is displayed, dryer will automati-
cally pump down before valves open and PREPAR-
ING TO RUN followed by DRYER RUNNING or COMP
LOADING is displayed.
b. If STANDBY is displayed, valves will open and
PREPARING TO RUN followed by DRYER RUNNING or
COMP LOADING is displayed.
3. While keeping the air by-pass valve open and air outlet
valve closed, SLOWLY open the dryer inlet valve to
pressurize the dryer.
4. Leak test all air piping, flanges, and drains for possible
air leaks.
5. Air-Cooled Models - Fan(s) in compressor section
should start up after unit has been running for several
minutes. Fan(s) may not start up immediately upon
introducing power to the condensing unit since they
are controlled by means of a refrigerant pressure
switch. This switch may cycle fan(s) off and on in order
to adjust to varying load conditions in refrigerant
system.
IMPORTANT: Air-Cooled Models - Check for proper
fan rotation. Air should be pulled up through con-
denser.
NOTE: After 10 minutes HI EVAP AIR TEMP will also be
displayed. After air load has been put on unit and
switch resets, clear messge.
6. After dryer has operated about fifteen (15) minutes,
SLOWLY open the dryer air outlet valve.
7. Close the dryer air by-pass valve.
8. Make a general inspection of the dryer. Tighten all
bolts, nuts, and fittings.
9. Remove all service gauges and test instruments.
Replace all seal caps on valves. Retest connections for
leaks with leak detector.
10. Allow the dryer to operate normally for at least three
(3) hours. Recheck operation of all controls, safety
switches, instrumentation and condensate drains.
11. Review Operational Check Points as listed in
Section 3.5.
C. Standard Shut-Down Procedure
Turn Stand-by/Auto Selector Switch to STAND-BY position.
Allow dryer to operate in this mode during shutdown
period. (Master switch remains in ON position).
D. Maintenance Shut-Down Procedure
This procedure is used to shut unit down for extended
maintenance periods.
1. Turn Stand-by/Auto Selector Switch to STAND-BY
position. Allow unit to cycle several times.
2. Push the Master switch to the OFF position.
NOTE: Except for maintenance reasons, leave dryer
energized. This allows the crankcase heater to func-
tion.
De-energize dryer at disconnect if
working on electrical or rotating components.

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F5
F1 F6 F2 F7 F3
SHIFT ESC
ENTER
F8
F4
OPERATOR INTERFACE
I
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O
STANDBY
• Modo de
Espera
• Attente Standby
Mode
AUTO
• Modo
Automático
• Auto Mode
WARNING: Disconnect the electric power before
servicing
ATTENTION: Déconnecter du circuit d'alimentation
eléctrique avant l'entretien
PRECAUCION: Desconecte la energía eléctrica
antes de realizar cualquier
mantenimiento
557.1
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F5
F1 F6 F2 F7 F3
SHIFT ESC
ENTER
F8
F4
OPERATOR INTERFACE
Control Panel
Master Switch
Stand-by/Auto Selector
Switch
(momentary switch - turn
to desired operating mode
and release - verify status
on Operator Interface
Display
Operator
Interface
General Alarm
(fault) Light
(Red)
Power on
Light (White)
Operator Interface
Functions
F1 - Return to status display
F2 - System pressures display
F3 - System temperatures display
F4 - Electric drain - push-to-test (for use with models supplied with electric drains)
F5 - (shift + F1) - Sensor calibration; low pressure cutout setting (password required)
F6 - (shift + F2) - English or metric unit selection
F7 - (shift + F3) - Refrigerant low pressure cutout override
F8 - (shift + F4) - Electric drain - time between discharge setting; for use with models
supplied with electric drains)
1. Use Up and Down arrows to put cursor over DRAIN DELAY ad press ENTER.
2. Use Up and Down arrows to set time between discharges and press ENTER.
Up and Down Arrows - Use to scroll through multiple messages
To reset head and oil pressure faults press F1. To clear use arrow keys to place
cursor on alarm message and press ENTER.
To clear all other faults from display select message with the arrow keys and press
ENTER.
Note: Do not use ESC key; if inadvertently pressed, press again to clear.
Display
Function
Buttons
E. Start-Up Procedure - (Master switch on; dryer in Stand-
by mode.)
POWER TO THE DRYER MUST BE ENER-
GIZED (POWER ON LIGHT ILLUMINATED) TWENTY-FOUR
(24) HOURS BEFORE START-UP OF THE REFRIGERATION
COMPRESSOR
1. Turn Stand-by/Auto selector switch to AUTO.
2. Allow at least 15 minutes of dryer operation before
flowing compressed air through dryer.
3. Review Operational Check Points, section 3.5.

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3.2 Operating Sequence
1. With master switch OFF (pushed in), turn disconnect
switch "DISC" to on. Control transformer "IT", and
crankcase heater "HTR", are energized. Power on light
(white) illuminates. "DRYER ENERGIZED" is indicated on
display. Disconnect switch "DISC" must be left on
except for maintenance reasons. Crankcase heater
"HTR" must be energized twenty-four (24) hours prior
to start up.
2. Pull master switch on. Display indicates STANDBY or
SYSTEM ENABLED.
3. To "START" turn momentary Stand-by/Auto selector
switch to AUTO and release.
a. If STANDBY is displayed and no fault condition
exists, motor starter "M" coil, liquid valve solenoid
"1SOL", and hot gas by-pass valve solenoid "2SOL",
are energized. Display indicates "PREPARING TO
RUN" followed by "DRYER RUNNING" or "COMP
LOADING". If "SYSTEM ENABLED" is displayed dryer
will pumpdown prior to valves energizing.
Condition Display Message
Dryer energized; Master Switch Off DRYER ENERGIZED
Dryer energized; Master Switch On STANDBY or SYSTEM ENABLED
Status Stand-by Selected Dryer will pump down if suction pressure is high
(indicated by "DRYER PUMPING DOWN") followed by
"STAND-BY"
Auto Selected PREPARING TO RUN followed by
COMPRESSOR LOADING and 33%, 50%, 66%, 75%
83%, or 100%
Refrigerant (low-side) Suction SUCTION PRESSURE
Pressures Refrigerant (high-side) Head HEAD PRESSURE
Compressed air at inlet to dryer INLET AIR PRESSURE
Optional - Differential pressure across dryer AIR PRESSURE DROP
Temperatures Optional - Compressed air at inlet to dryer INLET AIR TEMP
Optional - Lowest air temperature LOWEST AIR TEMP
Compressor Solid State Motor Protector Open SSMP-1MTR
Compressor Solid State Motor SSMP-2MTR
Protector Open (2nd Compressor)*
Motor Starter Protector Open MTR STARTER - 1MTR
Motor Starter Protector Open (2nd Compressor)* MTR STARTER - 2MTR
Low oil pressure OIL PRESSURE -1 MTR
Low oil pressure (2nd Compressor)* OIL PRESSURE - 2MTR
Low (low or suction) side refrigerant pressure LOW REFRIG PRESS
Faults High (high or head) side refrigerant pressure HIGH REFRIG PRESS
High evaporator air temperature HI EVAP AIR TEMP
Optional - Low water pressure LOW WATER PRESS
(water-cooled models)
Optional - High differential pressure CHECK SEPARATOR
Optional - Low evaporator air temperature LOW EVAP AIR TEMP
Optional - High condensate level (air-to-air drain) DRAIN 1 HIGH LEVEL
Optional - High condensate level (air-to- DRAIN 2 HIGH LEVEL
refrigerant drain
Optional - High condensate level (separator drain) DRAIN 3 HIGH LEVEL
Optional - High inlet compressed air temperature INLET AIR TEMP
* 50 HP and larger
b. As low side system pressure drops to unloader set
point(s), PLC output(s) energize solenoids(s) 3SOL
and 4SOL (35 HP and larger) which unload com-
pressor cylinder(s). As pressure rises above the
unloader set point(s), compressor will load in
reverse sequence. Percentage following "Com-
pressor Loading" indicates percentage of cylinders
loaded.
c. Compressor runs automatically unless a SSMP,
motor starter, low oil pressure, high head pressure,
or low suction pressure fault occurs.
4. To put in STANDBY turn momentary Stand-by/Auto
selector switch to STANDBY and release.
a. Display indicates "DRYER PUMPING DOWN".
b. Compressor motor "MTR" continues the pump
down cycle until low side system pressure reaches
the low pressure cutout point. At cutout point,
the PLC de-energizes motor starter "M" coil.
Display indicates STANDBY.
c. If low side system pressure rises to low pressure
set point, compressor starts and pumpdown
repeats automatically.
Operator Interface Display

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Consult Factory For
Wiring Schematic

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3.3 Fault Conditions
NOTE: Clear fault messages by selecting fault message
with up down arrow keys and pressing ENTER on the
operator interface. Messages will not clear until fault
condition is corrected.
A. Faults; Compressor Protection
1. Manual Reset
NOTE: Dryer will pumpdown and display STANDBY after
fault condition is corrected and reset.
a. OIL PRESSURE: Low oil pressure - Oil protection
switch "OPS" ensures sufficient oil pressure to
prevent burnout of compressor. Switch opens
after time delay on low oil pressure differential.
After ten (10) minutes or fault correction, manu-
ally reset the unit by pressing F1 on the operator
interface.
SWITCH MUST NOT BE RESET MORE
THAN THREE (3) TIMES WITHIN A THIRTY (30) MINUTE
PERIOD. If the problem persists, contact
manufactureØ s service department.
NOTE: Dryer will pumpdown and display "STAND-
BY" after reset.
b. HIGH REFRIG PRESS: High (high or head) side
refrigerant pressure - The PLC opens the compres-
sor control circuit if the high side pressure ex-
ceeds set point. For settings, refer to Technical
Data Sheet. Manually reset the unit by pressing F1
on the operator interface.
DO NOT RESET UNTIL HEAD PRES-
SURE IS 250 PSIG, 17.6 KGF/CM2OR LESS.
c. MTR STARTER: Motor starter protector - Motor
starter thermal overload protectors "MSP" open
on excessive motor current. Reset is manual at
motor starter.
2. Automatic Reset
NOTE: Dryer will pumpdown and display "STAND-BY"
after fault condition corrects.
a. LOW REFRIG PRESS: Low (low or suction) side
refrigerant pressure - The PLC opens the compres-
sor control circuit if the low side refrigerant
pressure drops below set point. For settings refer
to Technical Data Sheet. Reset is automatic.
b. SSMP: Solid state motor protection - Solid state
motor protection "SSMP" provides three (3) leg
protection with three separate sensors. Reset is
automatic after two minute delay.
Use OHM meter only (6 volt max.)
to check (SSMP) module. Measure resistance only
between each sensor terminal and common
terminal. Make no attempt to apply external
voltage or current to sensor terminals or damage
will result requiring compressor replacement.
B. Faults, Informational
1. HI EVAP AIR TEMP: High evaporator air temperature
indicates when process gas temperatures exceeds
"HTS" set point.
2. LOW WATER PRESS: Optional - Indicates that water
supply pressure is below set point.
3. CHECK SEPARATOR: Optional - Indicates pressure drop
across dryer exceeds set point.
4. HI INLET AIR TEMP: Optional - Indicates inlet air tem-
perature is greater than 120°F, 4 9 °C.
5. LOW EVAP AIR TEMP: Optional - Indicates air tempera-
ture in evaporator is below the set point.
6. DRAIN LEVEL HIGH: Optional - Indicates condensate
level in automatic drain(s) is above the set point.
3.4 Light and Gauges
A. Power-on indicator (white) illuminates when unit is
energized.
B. General alarm (fault) indicator (red) illuminates if a fault
condition occurs.
NOTE: The HI EVAP AIR TEMP does not energize the fault
light.
C. Air inlet pressure gauge indicates pressure of com-
pressed air at inlet nozzle of air-to-air precooler/
reheater. This is a local mount gauge on the inlet pipe.
3.5 Operational Check Points
1. Check to see that power-on light is illuminated.
2. After sufficient running time with load on unit (ap-
proximately 15 minutes) check to see that General
Alarm light is out and there are no fault messages
displayed.
3. Check air inlet pressure gauge to ensure correct
pressure is being supplied to dryer. Lower than design
pressure may result in dryer being overloaded.
4. Check for proper oil level on compressor crankcase
sight glass. Oil level should be visible.
5. Check refrigerant sight glass. Presence of bubbles
after five (5) minutes of operation may indicate that
more refrigerant is required.
Leak test refrigeration system for
refrigerant leak and repair any leaks before adding
refrigerant. Do not add refrigerant unless other
symptoms suggest low refrigerant charge.
6. Check liquid moisture indicator which is incorporated
in the liquid refrigerant sight glass. The moisture
indicator should show a “Dry” system.
NOTE: On initial start-up if indicator shows “Caution” or
“Wet” proceed with start-up and recheck after twenty-
four (24) hours. If indicator shows “Wet,” refrigerant
filter/dryer core may need to be replaced.
7. Check refrigerant suction pressure display for proper
reading. See Technical Data Section.
8. Check head pressure display for proper reading. See
Technical Data Section. Refer to Section 4.2.B for
possible causes of high pressure readings if present.
9. Water-cooled units - Check to ensure that water flow
to condenser is sufficient and at the proper tempera-
ture and pressure. See Technical Data Section. Insuffi-
cient flow may indicate that strainer is plugged
10. Check condensate drains. Check that manual shut off
valves ahead of drains are open. After sufficient
running time check for visible signs that drains are
discharging.

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4.0 Maintenance
4.1 Separator/Filter Sleeve Replacement
A. When to replace Filter Sleeves
At rated flow conditions, when removing liquids,
pressure drop will normally be 1 psi (0.07 bar) or less
across the separator or 5 psi (0.35 bar) or less across
the entire dryer. An increase in pressure drop will
occur only as the filter sleeve becomes loaded with
solid particles. It is recommended that, for maximum
filtration efficiency, the filter sleeves be replaced when
pressure drop across the separator exceeds 10 psi (0.7
bar) or total pressure drop across the dryer exceeds 15
psi (1.05 bar).
B. Procedure for changing separator/filter sleeves
NOTE: Refer to Technical Data Section for correct
replacement sleeve set.
1. Bypass the unit to permit servicing.
Depressurize the dryer assembly before
servicing.
2. Remove screws and lift off insulation cap from top of
separator vessel.
3. Models with grooved pipe coupling - loosen bolts and
remove coupling, gasket, and pipe cap.
Models with hand hole - loosen nut and remove yoke,
gasket, and seal plate.
4. Starting in the center unscrew the separator/ filter
cartridge(s) (1) by turning end cap. (Do not remove
nut at this point.)
5. Clean face of inlet manifold (2) with a mild detergent
using a long-handled brush or a clean rag attached to
a rod. Manifold face must be free of dirt and grease
to ensure proper O-ring seal between top cap and
manifold.
6. Remove nut (3) and cap (4).
7. Slide disposable filter sleeve (5) over separator core (6).
8. If necessary, clean separator core with soap and water.
It can be disassembled if necessary.
9. Slide new filter sleeve (5) over separator core (6) and
replace cap (4) and nut (3).
10. Install new O-ring(s) (7) into groove in cap(s).
Coat O-rings with grease (Dow Corning
O-ring lube or equivalent) before inserting in groove
in cap in order to keep the O-ring in position during
installation.
a. Coat exposed threads of thru-bolt with an anti-
seize compound to prevent corrosion of the
manifold threads.
b. Starting from outside (cartridges closest to vessel
wall) screw separator/filter cartridge(s) (1) into inlet
manifold connection(s). A cone in the manifold will
guide the cartridge bolt into the female threads. It
is only necessary to finger tighten the cartridge to
ensure the seal.
DO NOT WRENCH TIGHTEN
c. Reinstall grooved pipe coupling or hand hole cover
after inspecting gasket to ensure its integrity.
d. Reinstall insulation cap.
GROOVED PIPE COUPLING
HAND HOLE
1
4
6
3
2
7
5
SEAL PLATE
VESSEL
YOKE
NUT
GASKET
TILT THE SEAL PLATE
AND GASKET TO FIT IN OPENING
HAND HOLE
Gasket
Coupling
Half
Grooved Pipe
on Housing
Grooved
Pipe Cap
Bolts

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4.3 Water-Cooled Refrigerant Condenser - Special
Instructions (Cleanable shell and tube type)
A. Water tubes should normally be mechanically cleaned
periodically to assure optimum condenser efficiency.
How often should they need cleaning depends on so
many variables that it is impossible to recommend a
schedule. Some will never need cleaning, others
perhaps need cleaning once a year. In rare cases,
cleaning is required several times a year.
Frequency of cleaning will depend on individual water
conditions, so a suitable cleaning schedule should be
worked out based on experience. An inspection of the
water tubes is recommended after the first six (6)
months of operation to aid in establishing a cleaning
schedule.
Proper operation of cooling towers will increase the
interval between cleaning considerably. The tower
overflow (bleed-off) rate should be checked fre-
quently. Most cooling tower manufacturers recom-
mend an overflow of about ten percent (10%) of the
water circulated. If a tower is operated with insuffi-
cient overflow, the resulting mineral concentration in
the water can cause rapid and heavy fouling inside the
condenser tubes. This will necessitate excessively
frequent cleaning and may lead to severe corrosion.
See CLEANING INSTRUCTIONS (Section 4.3.C) for de-
tailed cleaning instructions, methods and procedures.
B. Operational Deficiencies
1. High head pressures- particularly high (head) pressure
indicates (but does not always mean) a fouled con-
denser. It is advisable to double check the refrigeration
system to make sure that fouling is actually causing
the trouble.
The following possibilities should always be checked
before cleaning is undertaken.
a. Refrigerant overcharge: Feel side of condenser for
high liquid level
b. Clogged water strainer: Check and clean if neces-
sary.
c. Air in Refrigeration System: Check system pressure
after unit has been “OFF” for one (1) hour. Com-
pare this pressure with the refrigeration pressure
at ambient temperature. They should be the same.
If system pressure is high, purge air from the
refrigeration system.
d. Defective or stuck water regulating valve: Check its
operation.
e. High water temperature entering condenser:
Check cooling tower fan for broken belt(s) and
cooling tower for fouling.
f. Insufficient water flow: Check water supply pres-
sure and flow. Check circulating pump and system
for obstructions, fouling or leaks.
g. Incorrectly set water regulating valve: Check its
setting. Return to factory specifications.
4.2 Air-Cooled Refrigerant Condensers - Special
Instructions
A. The coil of the condensing section must be kept clean
to maintain refrigeration capacity. Monthly, or as
required, blow out condenser coil with compressed air.
If heavily contaminated, coils can be cleaned with mild
detergent and water. In exceptionally dirty locations a
furnace type filter can be installed in front of the
condenser intake to prevent rapid fouling of coil. If a
filter is used it must be changed regularly to prevent a
restriction of the cooling air flow.
B. Operational Deficiencies
1. Condenser Cooling System - High head pressure can
be caused by insufficient cooling air flow across the
condenser, too high an ambient air temperature or a
dirty condenser. Check to determine if condenser
fan(s) are running (see fan control note below) and
that no obstructions are too near the face of the
condenser. Ambient air temperature should be
checked at local heat sources or recirculating air might
raise the actual air temperature above the average
room temperature. The condenser should be checked
and cleaned, if dirty.
2. Fan Control - In order to assure satisfactory operation
of the air-cooled unit at low ambient temperatures, a
fan control switch has been provided to automatically
stop and start fan(s). This switch is actuated by the
unit head pressure and operates fan(s) individually to
maintain a minimum head pressure.

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c. Algae or slime can usually be controlled by means
of an intermittent or batch treatment to shock the
organisms. Chemicals used for this treatment are
chlorine, bromine, pentachlorphenate, copper-
sulphate, or potassium permangenate. Some of
these, however, may promote corrosion if used in
excessive quantities or if not properly controlled.
d. Conductivity Galvanic Corrosion
Water treatment should be under-
taken only by those who are qualified and compe-
tent to prescribe what is required for each indi-
vidual problem. Beware of secret compounds and
guarantee’s that claim (to render) obviously
improbable results.
NOTE: In consideration of the above, it should be
apparent to the user that the manufacturer cannot
accept responsibility for inefficient operation or
corrosion of the condenser when caused by
foreign materials or failure to use adequate water
treatment. Again, necessary water treatment
should be initiated at, or before, the time of
installation since deterioration, when once started,
is extremely difficult to stop.
C. Water-cooled Refrigerant Condenser Cleaning
1. The following procedures and precautions should be
observed when cleaning is undertaken. The warranty
on the condenser is void if it is damaged by improper
methods or tools.
The condenser heads (end plates) are removable on all
models. For reference, the “water head” is the end
plate to which all condenser water piping is connected
and the “return head” is the end plate on the oppo-
site end of the condenser.
2. Chemical Cleaning - the condenser manufacturer
does not recommend any particular chemical prepara-
tion. The same treatment is not applicable to all
installations. See MAINTENANCE WATER COOLED
REFRIGERANT CONDENSER (Section 4.3.B.3) for general
information on water treatment.
In any case:
(a) Use only preparations from an established, reliable
source.
(b) Follow directions exactly- particularly regarding
amounts to use, and flushing or neutralizing
procedure after cleaning.
3. Mechanical Cleaning
a. Before disassembly of the condenser for mechani-
cal cleaning, the following must be performed:
(1) Stop operation of the refrigeration system. The
refrigerant does not need to be pumped out of
the condenser.
(2) Stop operation of the water circulating pump
and the cooling tower, if applicable.
h. Fully opened compressor discharge service valve:
Check to see that it is closed two (2) complete
turns. See 3.0 Operation, Section 3.1.A.2.C "Open-
ing Refrigeration Valves" for more information.
2. Low or high water temperatures at the condenser
outlet-The condenser is regulated by a pressure
actuated water regulating valve supplied by the
factory. In normal operation, the temperature differ-
ence between the water temperature leaving the
condenser and the refrigerant condensing tempera-
ture [saturation temperature, from refrigerant table,
corresponding to discharge (head) pressure] will be
between 5°F/9°C and 12°F/22°C. This normal tempera-
ture difference occurs regardless of the water tem-
perature entering the condenser.
If a low water temperature (more than 12°F/22°C
below the refrigerant saturated condensing tempera-
ture) is experienced, cleaning is indicated. Good heat
exchange is not being accomplished because of water
tube fouling.
If a high water temperature at the outlet is experi-
enced, something other than a fouled condenser may
be causing improper system operation and/or high
discharge (head) pressures. Restricted water flow, or a
low water supply pressure, is indicated. A restriction
can occur with foreign matter in the condenser, but it
is also likely to be somewhere in the water system.
3. Water Treatment
The long range performance of the refrigerant
condenser will be adversely affected by poor water
conditions. Therefore, it is recommended that an
analysis of the condenser water be made and treat-
ment, if required, commenced prior to operating the
refrigeration system.
Chemical additives, including those to stop algae and
related growths, should be obtained only from a
reputable, established supplier, and used specifically
according to directions. Excessive or incorrect treat-
ment of the water can cause more harm than none at
all; the pump, piping and cooling tower may be
damaged as well as the condenser.
For general information, the three major problems
which the water treatment must cope with are: (1)
scaling of the condenser surfaces, (2) corrosion and (3)
algae or slime.
a. Scale control is usually undertaken with phosphate
compounds. Scale is most often encountered
when the ph of the water is high or on the alkaline
side.
b. Corrosion is generally the result of low ph, or on
the acidic side. Among the chemicals used for
corrosion control are glassy phosphates,
chromates, and nitrates. Chromates are poisonous
and must be handled carefully.
If the ph of the water is maintained between six
and eight, there will be the minimum tendency
toward scale on the high (above 8.0 ph) side and
corrosion on the low (below 6.0) side.

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(3) Close the condenser water shut-off valves
adjacent to the unit.
(4) Drain the water from the condenser. Many
models have a drain plug in the return head.
b. Disassembly
Remove the bolts or nuts, as applicable, heads and
gaskets from both ends of the condenser. Note
gasket markings, if any. Some gaskets are marked
with ridges, notches or letters. If space is limited,
the tubes can be cleaned with only one end open,
although it is difficult to flush out the clogged end
passages.
If a head gasket does not lift off from the tube
sheet and the head, do not try to pry it off. A
surface may be cut, which would cause a leak. To
free a sticking gasket, replace the head and tap it
on the outer face with a mallet or a block of wood.
After a few taps, the gasket should spring free.
c. Cleaning Procedures
Gaskets need only be rinsed in running water as
rust, scale or dirt will not generally stick firmly to
the gasket material. A rag or a soft bristle brush is
all that should be required to remove any foreign
matter.
The inside of the heads, the outer tube sheet
surfaces and the studs should be cleaned with
clear water only and a rag or a soft bristle brush. A
worn paint brush is excellent. These surfaces have
been coated with a special plastic base material, on
some models which will give years of protection
against corrosion, unless damaged. Never use a
wire brush, or a strong caustic on these surfaces.
Condenser tubes should be flushed clear with air,
water or a piece of rag on a stick or wire. In many
cases this is all that is required. If the inside sur-
faces are smooth, even though discolored, further
cleaning is not necessary. It is useless to try to get
a bright copper surface on the inside of the tubes.
They will discolor almost immediately in service,
and the condenser has been designed with an
adequate reserve for moderate fouling on these
surfaces.
If, however, a rough coating remains inside the
tubes after flushing and wiping, further cleaning is
desirable. The color of this coating varies with
water conditions, but roughness indicates cleaning
tools should be used.
A set of recommended cleaning tools is available
from the condenser manufacturer. If any other
type tool is considered, it should first be tried on a
piece of copper tubing held in a vise or flare block.
If any flakes of copper appear, or if score marks are
made inside the tube, the tool should not be used.
Never use anything with sharp or rigid edges
which could cut into the copper tubing.
When using a cleaning tool, keep the inside of the
tube wet, and move the tool slowly from one end
to the other while rotating it at a moderate speed.
A hand drill brace is recommended. If an electric
drill is used, a low speed attachment on a 1/4" size
drill is preferred. Larger units are powerful enough
to damage a tube if for any reason the cleaning
tool should stick. After one or two passes in each
tube, it should be flushed and inspected. Often
this is enough, although some deposits may
require more cleaning. In any case, stop when a
few places begin to show a copper color in each
tube.
d. Reassembly
After cleaning, wipe all foreign matter from the
tube sheets and studs. Install each gasket exactly
as it was removed. Note the gasket markings, if
any.
Install each head exactly as it was removed.
Tighten all bolts or nuts, as applicable, evenly and
firmly.
If the gaskets seal surface or ridge is damaged, and
a replacement is not immediately available, water
leaks can be stopped by removing the gasket,
drying it, and applying a thin film of a non-harden-
ing gasket sealer, such as Peratex #2, around the
seal surface or ridge. This film should be quite thin
(no thicker than the height of the seal ridge itself,
if applicable) and about 3/ 16 inch wide. Then
reassemble.
If a new gasket is put on later, be sure to remove
any grit or particles that stick to the sealer film on
the tube sheet. It is not necessary to remove all
traces of the sealer before installing a new gasket,
as long as no particles that could cut into the new
gasket remain on the surface.

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Cooling Water Requirements
38°F P.D.P 50°F P.D.P
Max. Refrig. Cooling Cooling Max. Refrig. Cooling Cooling
Capacity Water Flow Water Capacity Water Flow Water
Nominal Water Valve (BTU/HR) Rate @ 85°F Pressure (BTU/HR) Rate @ 85°F Pressure Drop
Horsepower Size (GPM) Drop (PSID) (GPM) (PSID)
7.5 1" 78,800 14.6 6.0 96,660 17.2 9.2
10 1" 117,600 21.0 10.3 143,400 25.6 16.7
15 1 1/4" 155,600 23.5 9.3 195,200 34.8 15.1
20 1 1/4" 166,160 30.8 9.8 206,880 36.9 18.6
25 1 1/2" 213,440 39.5 11.4 278,620 49.7 20.0
30 1 1/2" 247,340 45.8 16.6 306,680 54.7 26.0
35 2 1/2" 315,820 58.4 11.9 395,460 70.5 15.2
40 2 1/2" 385,600 71.3 12.2 468,420 83.5 17.7
50 2 1/2" 426,880 79.0 13.9 557,240 99.4 22.3
60 3" 494,680 91.5 2.6 613,360 109.4 2.9
70 3" 631,640 116.9 3.8 790,920 141.0 6.2
80 3" 747,320 130.3 3.1 929,800 185.3 3.4
100 4" 937,800 173.6 < 5* 1,150,400 213 < 5 *
- Table valid for Copeland units only. * No other data available.
- Cooling water @85°F - for other conditions consult manufacturer.

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17
1
16
4
3
20
15
18
36
5
2
7
9
11
19
13
38
14
10
8
DETAIL A
DETAIL B
6
37
DETAIL C
4.4 Condensate Drains - Pneumatically Operated
A. Monthly- Flush out accumulated sludge and dirt by
opening manual drain valves.
See Exploded View
B. Disassemble and service at least once a year. NOTE:
Before starting the servicing procedure, make sure you
have a repair parts kit on hand.
1. Close valve ahead of drain.
2. Depressurize drain by opening manual drain valve.
3. Disconnect drain lines.
4. Remove shell bolts (27, 28) and detach bottom shell
assembly (26). Remove seal ring retainer (24) and case
seal ring (29).
5. To rebuild drain mechanism:
a. Remove six screws (14) from piston cylinder (38) and
remove cylinder.
b. Remove nut (19), lock washer (11), piston discs (9 &
10), piston seal (8), and key washer (7) from bottom
of valve stem assembly.
c. Remove valve stem assembly (3) from valve body (2)
by lifting valve stem assembly upward.
d. Remove retainer clip (36) and pivot pin (17), and lift
float arm assembly (15) off of valve stem assembly
(3).
e. Remove pilot valve screw assembly (18) from float
arm assembly and replace with a new assembly from
the repair parts kit. Reassemble float arm assembly
to valve stem assembly using new pivot pin and
retainer clip from repair parts kit.
f. Remove valve sleeve (5) from valve stem assembly
and replace valve disc (4) with new disc from repair
parts kit.
g. Replace sleeve seal (“V” ring) (6) on valve sleeve
making sure “V” shape is in the same position as
shown on Detail A on drawing.
h. Reassemble valve sleeve to valve stem assembly as
shown on drawing. Lubricate sleeve seal with lubri-
cant supplied with repair parts kit or petroleum jelly.
i. Reassemble piston, and piston seal (“V” ring) (8) using
new parts from repair parts kit.
j. Reassemble key washer (7), piston assembly, lock
washer (11), and nut (19) to valve stem assembly.
Make sure “V” shape of piston seal is in the same
position as shown on Detail B and that the key on
the key washer is in the hole (37) directly opposite
drain connection on valve body.
k. Lubricate piston seal, and piston cylinder wall with
lubricant supplied in repair parts kit or petroleum
jelly.
l. Reassemble piston cylinder (13) to valve body with
six screws. Make sure bleed hole (38) in piston
cylinder is not plugged up. Raise and lower valve
assembly to make sure it operates freely.
20
29
31
24
27
28
26
Seal Ring Retainer
Rod

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4.5 Condensate drains - Electrically Operated
A. Monthly - Flush out accumulated sludge and dirt by
opening manual drain valve.
B. Periodically clean internal strainer in bottom of
reservoir.
m. Place seal ring retainer (24) into bottom shell
assembly (26) making sure that end of float arm
assembly with counterweight (20) is positioned in
open area of seal ring retainer. For 506 series
models, make sure rod on top of float assembly
fits into hole in seal ring retainer as shown in Detail
C.
n. Before reassembling shell, make sure float mecha-
nism moves freely up and down.
o. Position new case seal ring (29) ABOVE the small lip
on the seal ring retainer.
p. Reassemble bottom shell to top shell.
q. Reconnect drain lines and close manual drain valve.
6. Open valve ahead of drain.
Isolation Valve
Reservoir with
Internal Strainer
Manual Drain Valve

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1. Power off Check main switch, fuses and wiring.
2. Master off/on switch Pull master off/on switch out.
3. Loose electrical connections or faulty wiring Check wiring and tighten connections.
4. Hot gas or liquid line solenoid valve closed Check for burned out holding coil.
5. Unit in STANDBY mode Turn switch to auto.
6. Compressor motor burned out Replace, if defective.
1. Leaking liquid line solenoid Remove obstruction or replace valve.
2. Leaking hot gas valve Replace valve.
3. Leaking valves in compressor Replace valve plate assembly.
1. Water-cooled units - Excessive water flow Adjust water regulating valve or, on 3" and
through condenser 4" water valve clean power head.
2. Air-cooled units-Fan switch not cycling properly
. Check/replace fan switch.
3. Leaky compressor suction valve Examine valve discs & seats; replace if necessary.
4. Worn piston rings Replace if worn.
Compressor stopped because
of high head pressure
"HIGH REFRIG PRESS"
Compressor stopped because
low suction pressure
"LOW REFRIG PRESS"
Compressor stopped because
of low oil pressure
"LOW OIL PRESSURE"
Compressor stopped because
solid state motor protector
open
"SSMP"
Compressor stopped because
motor starter protector open
"MTR STARTER"
High air temperature leaving
the evaporator
"HIGH EVAP AIR TEMP"
Compressor will not start
Compressor cycles
intermittently in standby mode
Low refrigerant head pressure
1. Faulty high pressure transducer (PT200) Check pressure reading, calibrate/
replace. (Consult factory for calibration)
2. Refrigerant overcharge Reclaim excess refrigerant.
3. Air in refrigeration system Check for leaks and recharge unit.
Properly dispose of old refrigerant.
4. Air load on unit during start-up Take air load off unit during start-up.
5. Water-cooled units - Insufficient water flow
through condenser
(1) Water regulating valve not adjusted Adjust water regulating valve.
(2) Dirty water strainer Clean water strainer.
(3) Water lines too small Increase water main size to condenser.
(4) Discharge shutoff valve not fully open Open valve.
(5) Condenser water pump off Check and start.
(6) Plugged or scaled condenser tubes Clean tubes.
(7) Low water pressure differential Check. Should be a 40 psi differential.
(8) Inlet water temperature too high Use cooler water.
6. Air-cooled units
a) Condenser dirty Clean condenser.
b) Fans not operating Check for power. Check fan switch pressure
set point. Fan motor faulty repair or replace.
1. Low refrigerant charge Check for leaks and repair; add refrigerant.
2. Suction pressure setting incorrect Adjust hot gas by-pass valve.
3. Incorrect low pressure switch setting Check technical data for proper setting.
4. Hot gas valve sticking Check and repair.
5. Faulty low-pressure transducer. (PT100) Check pressure reading, Calibrate/
replace.(Consult factory for calibration)
6. Defective CPU or component module Check/replace.
7. Refrigerant compressor not unloading Check unloader mechanism/replace.
properly (20 HP and up)
TROUBLE SHOOTING GUIDE
SYMPTOM / FAULT POSSIBLE CAUSES CORRECTIVE ACTION
1. Low oil charge Add oil.
2. Clogged oil suction strainer Clean.
3. Worn oil pump Replace pump assembly.
4. Worn compressor bearings Replace compressor.
5. See: Cold Compressor
6. Suction line filter restricted Check for pressure drop across filter/
replace elements.
7. Air load supplied to unit during start-up. Take air load off dryer to start.
8. 7-1/2 - 15 HP units - compressor could See: SSMP 1, 2, and 3
have tripped on internal overload.
1. Unit overload Check inlet flow, pressure and temperature
and verify if within design conditions.
2. Insufficient cooling Check refrigeration system temperatures.
3. Faulty temperature switch Measure air temperature.
4. No air flow through dryer Check inlet flow
1. Low voltage Check power supply.
2. Line imbalance Check power supply.
3. Excessive return gas temperature. Check liquid injection valve and refrigerant charge.
4. Defective SSMP module Check/replace.
5. Defecitve motor sensor Refer toSection 3.3 of Manual.Check sensors at
room temp.Should be between 500-10,000 ohms.
1. Low voltage Check power supply.
2. Line imbalance Check power supply.
3. Compressor motor drawing excess current Check motor winding resistance.

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TROUBLE SHOOTING GUIDE
SYMPTOM / FAULT POSSIBLE CAUSES CORRECTIVE ACTION
1. Unloader solenoid stuck. Repair.
2. Unloader solenoid coil defective. Replace.
3. Hot gas by-pass valve set too high or sticking. Reset or repair.
4. Faulty low pressure transducer. Check pressure reading.Calibrate/replace.
(Consult factory for calibration).
1. Unloader solenoid stuck open. Reset or repair.
2. Faulty low pressure transducer. Check pressure reading.Calibrate/replace.
(Consult factory for calibration).
1. Excessive fluctuation in suction pressure. Check hot gas valve set point.
2. System load fluctuating. Stabilize load.
3. Hot gas valve set too high. Return valve to factory set point.
1. Low suction pressure. Reset hot gas valve to factory set point.
2. Defective or improperly set expansion valve. Reset to 3-6°F/1.7-3.3°C superheat.
3. Defective or improperly set liquid injection Reset to 65°F/18.3°C return gas temperature
valve. at no load.
4. Suction line filter restricted. Check for pressure drop across filter/replace elements.
1. See: Cold compressor
1. Oil return screen clogged Clean.
2. Freon leak Repair leak.
3. See: Cold compressor
1. Desuperheating valve is out of adjustment Check operation and adjust.
2. Liquid line filter clogged Check/replace.
3. Discharge temperature of 275°F/135°C Check unit application.
4. Compressor internal valves worn or Replace.
damaged
5. Defective liquid injection valve. Replace.
6. Compressor not unloading properly. (20 HP Unloader mechanism. Check/replace.
and up)
7. Refrigeration system leak Leak check/repair and recharge system.
1. Unit overload Check inlet air temperature, must be below
120°F/49°C.
2. DefectiveTemperature sensor. (TT1) Check/Replace.
1. Low suction pressure Reset hot gas valve to factory setting.
2. Incorrect superheat setting on TXV Rest to 3-6°F/1.7-3.3°C superheat.
3. Defective temperature sensor. (TT2) Check/Replace.
1. Incorrect setting on drain valve. Increase drain open time or decrease time
between opening.
2. Drain valve not operating properly. Repair or replace.
3. Float switch defective Check/Replace.
1. See "HIGH REFRIG PRESS"
water-cooled units
1. Dirty separator element cartridges Replace separator cartridges. See section
4.0 in Manual.
2. Unit overload Check inlet flow, pressure, and temperature and
verify if within design conditions.
3. Inlet and/or outlet pressure transducers Replace and/or calibrate. For calibration
(PT1 and PT2) defective/out of calibration. consult factory.
4. Defective CPU or component module. Check/Replace.
System Noise
Compressor will not unload
Compressor will not load
Rapid Unloader Cycling
Cold Compressor
(Cylinders and Crankcase
Sweating
Compressor Flooding
Low Crankcase Oil Level
High Crankcase Tempera-
ture (should be 100°F/38°C
to 130°F/55°C)
High inlet air temperature to
unit "HI INLET AIR TEMP"
(optional)
Low air temperature in
evaporator "LOW EVAP AIR
TEMP" (optional)
High condensate level in
drains "DRAIN # HI LEVEL"
(optional)
Low water pressure enter-
ing condenser (water-
cooled units) "LOW WATER
PRESS" (optional)
High pressure drop across
dryer air side
"CHECK SEPARATOR"
(optional)
1. Unit foundation improperly isolated. Isolate foundation.
2. Improper support or isolation of piping. Use correct piping techniques, and
support piping with suitable hangers.
3. Slugging due to refrigerant feed back. Check expansion valve setting; check
sensor bulb for looseness and correct location.
4. Piping vibration. Support pipes as required, check piping
connections.
5. Hissing (insufficient refrigerant flow through Reclaim refrigerant, replace strainer, and recharge
expansion valve or clogged liquid line strainer). with the proper amount of refrigerant.
6. Hot gas by-pass valve chattering. The chattering noise is normal and
does not affect the operation of the unit.

20
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H
WARRANTY
The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and
maintained in accordance with procedures and recommendations outlined in manufacturer’s instruction
manuals, to be free from defects in material or workmanship for a period of one (1) year from the date of
shipment to the buyer by the manufacturer or manufacturer’s authorized distributor, or eighteen months
from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and
brought to the manufacturer’s attention within the aforesaid warranty period. The manufacturer will repair or
replace any product or part determined to be defective by the manufacturer within the warranty period,
provided such defect occurred in normal service and not as a result of misuse, abuse, neglect or accident.
The warranty covers parts and labor for the warranty period. Repair or replacement shall be made at the
factory or the installation site, at the sole option of the manufacturer. Any service performed on the product
by anyone other than the manufacturer must first be authorized by the manufacturer. Normal maintenance
items requiring routine replacement are not warranted. Unauthorized service voids the warranty and any
resulting charge or subsequent claim will not be paid. Products repaired or replaced under warranty shall be
warranted for the unexpired portion of the warranty applying to the original product. The foregoing is the
exclusive remedy of any buyer of the manufacturer’s product. The maximum damages liability of the manufac-
turer is the original purchase price of the product or part.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR
STATUTORY, AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR
DAMAGE BY REASON OF STRICT LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN,
MANUFACTURE OR INSPECTION OF THE EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY
LATENT DEFECTS INHERENT THEREIN. THE MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE
LIABLE FOR LOSS OF USE OF THE PRODUCT OR OTHER INCIDENTAL OR CONSEQUENTIAL COSTS, EXPENSES, OR
DAMAGES INCURRED BY THE BUYER, WHETHER ARISING FROM BREACH OF WARRANTY, NEGLIGENCE OR STRICT
LIABILITY IN TORT.
The manufacturer does not warrant any product, part, material, component, or accessory
manufactured by others and sold or supplied in connection with the sale of manufacturer’s products.
01/01/93
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL IS
RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
SERVICE DEPARTMENT: [phone]
SPX Air Treatment
1000 Philadelphia Street
Canonsburg, PA 15317-1700 U.S.A.
Phone: [phone]
• Fax: [phone]
Email: hankison.service
@ airtreatment.spx.com
www.hankisonintl.com
© 2006 SPX Corporation. All rights reserved. 3/03 Inv# 000 000