pilotair ACT 3T Guide

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REFRIGERATED AIR DRYERS
ACT 3T –160T
User’s Maintenance & Spare Parts Manual

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Dear Customer,
Thank you for choosing our product. In order to get the best performance out of this product,
please read this manual carefully.
To avoid incorrect operation of the equipment and possible physical risk to the operator, please
read and strictly follow the instructions contained in this manual.
Note, these instructions are in addition to the safety rules that apply in the country where the dryer
is installed.
Before packing for shipment, each ACT xxxT series refrigerated air dryer undergoes a rigorous
test to ensure the absence of any manufacturing faults and to demonstrate that the device can
perform all the functions for which it has been designed.
Once the dryer has been properly installed according to the instructions in this manual, it will be
ready for use without any further adjustment. The operation is fully automatic, and the
maintenance is limited to few controls and some cleaning operations, as detailed in the following
chapters.
This manual must be maintained available in any moment for future references and it has to be
intended as inherent part of the relevant dryer.
Due to the continuous technical evolution, we reserve the right to introduce any necessary change
without giving previous notice.
Should you experience any trouble, or for further information, please do not hesitate to contact us.
Best Regards,
PILOT AIR COMPRESSORS
https://www.pilotair.com.au/
Phone: [phone]
Email: [e-mail] / [e-mail]

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CONTENTS
1 Identification plate 5
2 Warranty conditions 5
3 Safety rules 6
3.1 Definition of the conventional signs used in this manual 6
3.2 Warnings 7
3.3 Proper use of the dryer 7
3.4 Instructions for the use of pressure equipment according to PED directive 2014/68/EU 8
4 Installation 9
4.1 Transport 9
4.2 Storage 9
4.3 Installation site 10
4.4 Installation layout 11
4.5 Correction factors 12
4.6 Connection to the compressed air system 13
4.7 Electrical connections 14
4.8 Condensate drain 14
5 Start-up 15
5.1 Preliminary operation 15
5.2 First start-up 15
5.3 Start-up and shut down 16
6 Technical data 17
6.1 Technical data ACT 3T –12T 1/230/50-60 17
6.2 Technical data ACT 18T –160T 1/230/50 18
6.3 Technical data ACT 18T –160T 1/230/60 19
7 Technical description 20
7.1 Control panel 20
7.2 Operation 20
7.3 Flow diagram 21
7.4 Refrigerating compressor 22
7.5 Condenser 22
7.6 Filter dryer 22
7.7 Capillary tube 22
7.8 Alu-Dry module 22
7.9 Hot gas by-pass valve 23
7.10 Refrigerant pressure switches LPS –HPS –PV 23
7.11 Safety thermo switch TS 23
7.12 Electronic instrument DMC15 (standard) 24
7.12.1 How to switch on the dryer 24
7.12.2 How to switch off the dryer 24
7.12.3 How a service warning / alarm is displayed 24
7.12.4 How to control the condenser fan (Not used) 25
7.12.5 How to control the drain solenoid valve 25
7.12.6 How to change the operating parameters –SETUP menu 25
7.13 Electronic instrument DMC14 (optional) 26
7.13.1 How to switch on the dryer 26
7.13.2 How to switch off the dryer 26
7.13.3 How to display the operating parameters 26

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7.13.4 How a service warning / alarm is displayed 26
7.13.5 How to control the drain solenoid valve 27
7.13.6 Operation of the failure / alarm dry contact 27
7.13.7 How to change the operating parameters –SETUP menu 27
7.14 Electronic drainer (optional) 28
8 Maintenance, troubleshooting, spare parts and dismantling 29
8.1 Checks and maintenance 29
8.2 Troubleshooting 30
8.3 Spare parts 33
8.4 Maintenance operation on the refrigeration circuit 34
8.5 Dismantling of the dryer 34
9 Attachments 35
Exploded views –List of components 35
Electric diagrams –List of components 35
9.1 Dryers dimensions 36
9.1.1 ACT 3T –12T 36
9.1.2 ACT 18T –40T 37
9.1.3 ACT 55T –60T 38
9.1.4 ACT 80T –100T 39
9.1.5 ACT 120T –160T 40
9.2 Exploded views 41
9.2.1 ACT 3T –12T 41
9.2.2 ACT 18T –40T 42
9.2.3 ACT 55T –60T 43
9.2.4 ACT 80T –100T 44
9.2.5 ACT 120T –160T 45
9.3 Electric diagrams 46
9.3.1 ACT 3T –23T electronic instrument DMC15 46
9.3.2 ACT 30T –60T electronic instrument DMC15 47
9.3.3 ACT 80T –160T electronic instrument DMC15 48
9.3.4 ACT 3T –23T electronic instrument DMC14 49
9.3.5 ACT 30T –60T electronic instrument DMC14 50
9.3.6 ACT 80T –160T electronic instrument DMC14 51
9.4 Declaration “CE” of conformity 52
10 Pilot Air Warranty Conditions 53

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Identification Plate
1 Identification plate
The identification plate is located on the back of the dryer and shows all the primary data of the machine. This
data should always be referred to when calling the manufacturer or distributor. The removal or alteration of the
identification plate will void the warranty rights.
2 Warranty conditions
For 12 months from the installation date, but no longer than 14 months from the delivery date, the warranty
covers eventual faulty parts, which will be repaired or replaced free of charge, except the travel, hotel and
restaurant expenses of our engineer.
The warranty doesn’t cover any responsibility for direct or indirect damages to persons, animals or equipment
caused by improper usage or maintenance, and it’s limited to manufacturing faults only.
The right to warranty repairs is subordinated to the strict compliance with the installation, use and maintenance
instructions contained in this manual.
The warranty will be immediately voided in case of even small changes or alterations to the dryer. To require
repairs during the warranty period, the data reported on the identification plate must be notified.

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Safety Rules
3 Safety rules
3.1 Definition of the conventional signs used in this manual
Carefully read instruction manual before attempting any service or maintenance procedures on the dryer.
Caution warning sign. Risk of danger or possibility of damage to equipment, if related text is not followed
properly.
Electrical hazard. Warning message indicates practices or procedures that could result in personal injury or
fatality if not followed correctly.
Danger hazard. Part or system under pressure.
Danger hazard. High temperature conditions exist during operation of system. Avoid contact until system or
component has dissipated heat.
Danger hazard. Treated air is not suitable for breathing purposes; serious injury or fatality may result if
precautions are not followed.
Danger hazard: In case of fire, use an approved fire extinguisher, water is not an acceptable means in
cases of fire.
Danger hazard. Do not operate equipment with panels removed.
Maintenance or control operation to be performed by qualified personnel only [1].
Compressed air inlet connection point
Compressed air outlet connection point
Condensate drain connection point
Operations which can be performed by the operator of the machine, if qualified [1].
NOTE: Text that specifies items of note to be taken into account does not involve safety precautions.
In designing this unit a lot of care has been devoted to environmental protection:
• CFC free refrigerants
• CFC free insulation parts
• Energy saving design
• Limited acoustic emission
• Dryer and relevant packaging composed of recyclable materials
This symbol requests that the user heed environmental considerations and abide with suggestions annotated
with this symbol.
[1] Experienced and trained personnel familiar with national and local codes, capable to perform the needed activities, identify and avoid
possible dangerous situations while handling, installing, using and servicing the machine. Ensuring compliance to all statutory regulations.

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Safety Rules
3.2 Warnings
Compressed air is a highly hazardous energy source.
Never work on the dryer with pressure in the system.
Never point the compressed air or the condensate drain outlet hoses towards anybody.
The user is responsible for the proper installation of the dryer. Failure to follow instructions given in the
“Installation chapter will void the warranty. Improper installation can create dangerous situations for
personnel and/or damages to the machine could occur.
Only qualified personnel are authorized to service electrically powered devices. Before attempting
maintenance, the following conditions must be satisfied:
• Ensure that main power is off, machine is locked out, tagged for service and power cannot be
restored during service operations.
• Ensure that valves are shut and the air circuit is at atmospheric pressure. De-pressurize the dryer.
These refrigerating air dryers contain R134a or R407C HFC type refrigerant fluid. Refer to the
specific paragraph - maintenance operation on the refrigerating circuit.
Warranty does not apply to any unit damaged by accident, modification, misuse, negligence or
misapplication. Unauthorized alterations will immediately void the warranty.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases of
electrical fire.
3.3 Proper use of the dryer
This dryer has been designed, manufactured and tested for the purpose of separating the humidity normally
contained in compressed air. Any other use has to be considered improper.
The Manufacturer will not be responsible for any problem arising from improper use; the user will bear
responsibility for any resulting damage.
Moreover, the correct use requires the adherence to the installation instructions, specifically:
• Voltage and frequency of the main power.
• Pressure, temperature and flow-rate of the inlet air.
• Ambient temperature.
This dryer is supplied tested and fully assembled. The only operation left to the user is the connection to the
plant in compliance with the instructions given in the following chapters.
The purpose of the machine is the separation of water and eventual oil particles present in
compressed air.
The dried air cannot be used for breathing purposes or for operations leading to direct contact with foodstuff.
This dryer is not suitable for the treatment of dirty air or of air containing solid particles.

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Safety Rules
3.4 Instructions for the use of pressure equipment according to PED directive 2014/68/EU
To ensure the safe operation of pressure equipment, the user must conform strictly to the above directive and
the following:
1. The equipment must only be operated within the temperature and pressure limits stated on the
manufacturer’s data nameplate.
2. Welding on heat-exchanger is not recommended.
3. The equipment must not be stored in badly ventilated spaces, near a heat source or inflammable
substances.
4. Vibration must be eliminated from the equipment to prevent fatigue failure.
5. Automatic condensate drains should be checked for operation every day to prevent a build up of
condensate in the pressure equipment.
6. The maximum working pressure stated on the manufacturer’s data nameplate must not be exceeded. Prior
to use, the user must fit safety / pressure relief devices.
7. All documentation supplied with the equipment (manual, declaration of conformity etc.) must be kept for
future reference.
8. Do not apply weights or external loads on the vessel or its connecting piping.
TAMPERING, MODIFICATION AND IMPROPER USE OF THE PRESSURE EQUIPMENT ARE
FORBIDDEN. Users of the equipment must comply with all local and national pressure
equipment legislation in the country of installation.

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Installation
4 Installation
4.1 Transport
Check for visible loss or damage, if no visible damage is found place the unit near to the installation point and
unpack the contents.
• To move the packaged unit we recommend using a suitable trolley or forklift truck. Hand carrying is not
recommended.
• Always keep the dryer in the upright vertical position. Damage to components could result if unit is laid on its
side or if placed upside down.
• Handle with care. Heavy blows could cause irreparable damage.
4.2 Storage
▪Even when packaged, keep the machine
protected from severity of the weather.
▪Keep the dryer in vertical position, also when
stored. Turning it upside down some parts
could be irreparably damaged.
▪If not in use, the dryer can be stored in its
packaging in a dust free and protected site at
a temperature of +1°C…+50°C, and a specific
humidity not exceeding 90%. Should the
stocking time exceed 12 months, please
contact the manufacturer.
The packaging materials are recyclable. Dispose of material in compliance with the rules and
regulations in force in the destination country.
SCC0001

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Installation
4.3 Installation site
Failure to install dryer in the proper ambient conditions will affect the dryer’s ability to condense
refrigerant gas. This can cause higher loads on the compressor, loss of dryer efficiency and
performance, overheated condenser fan motors, electrical component failure and dryer failure due to
the following: compressor loss, fan motor failure and electrical component failure. Failures of this type
will affect warranty considerations.
Do not install dryer in an environment of corrosive chemicals, explosive gasses, poisonous gasses;
steam heat, areas of high ambient conditions or extreme dust and dirt.
In case of fire, use an approved fire extinguisher, water is not an acceptable means in cases offire.
Minimum installation requirements:
• Select a clean dry area, free from dust, and protected from atmospheric disturbances.
• The supporting area must be smooth, horizontal and able to hold the weight of the dryer.
• Minimum ambient temperature +1°C.
• Maximum ambient temperature +50°C.
• Ensure a proper cooling air replacement.
• Allow a sufficient clearance on each side of the dryer for proper ventilation and to facilitatemaintenance
operations.
The dryer does not require attachment to the floor surface.
Do not block, even partially, ventilation grid.
Avoid any possible re-circulation of the exhaust cooling air.
Protect the dryer from air drafts or forced cooling air conditions.
NOTE: Dryers models ACT 3T –12T can be wall-mounted. See fixing dimensions on dimensional
drawings in the attachment section.
The hanging mounting inevitably causes the obstruction of the ventilation grid positioned on the panel
facing the wall fixing. This obstruction, in any case, does not prejudge the efficiency of the ventilation
inside the dryer which is guaranteed by other grids on the other panels.

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Installation
4.4 Installation layout
1 Air compressor
2 Aftercooler
3 Condensate separator
4 Pre-Filter (min. 5 micron)
5 By-pass group
6 Dryer
7 Compressed air tank
8 Final filter
9 Condensate drain
In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend the
additional installation of a pre-filter (5 micron minimum) to prevent a clogging of the heat
exchanger.
Type A installation is suggested when the compressor operates at reduced intermittence and the total
consumption equals the compressor flow rate.
Type B installation is suggested when the air consumption can consistently change with peak values highly
exceeding the flow rate of the compressors. The capacity of the tank must be sized in order to compensate
eventual instantaneous demanding conditions (peak air consumption).

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Installation
4.5 Correction factors

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Installation
4.6 Connection to the compressed air system
Operations to be performed by qualified personnel only.
Never work on system under pressure.
The user is responsible to ensure that the dryer will never be operated with pressure exceeding the
maximum pressure rating on the unit data tag.
Over-pressurizing the dryer could be dangerous for both the operator and the unit.
The air temperature and the flow entering the dryer must comply within the limits stated on the data nameplate. The
system connecting piping must be kept free from dust, rust, chips and other impurities, and must be consistent with
the flow-rate of the dryer. In case of treatment of air at particularly high temperature, the installation of a final
refrigerator could result necessary. In order to perform maintenance operations, it is recommended to install a dryer
by-pass system.
In case of heavily polluted inlet air (ISO 8573.1 class 3.-.3 or worse quality), we recommend the
additional installation of a pre-filter (5-micron minimum) to prevent a clogging of the heat exchanger.
In realising the dryer, particular measures have been taken in order to limit the vibration which could occur during the
operation. Therefore, we recommend to use connecting pipes able to insulate the dryer from possible vibrations
originating from the line (flexible hoses, vibration damping fittings, etc.).
CAUTION:
PIPING THE DRYER, INLET/OUTLET CONNECTIONS MUST BE SUPPORTED AS SHOWN IN
THE DIAGRAM.
FAILING WILL RESULT IN DAMAGE.

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Installation
4.7 Electrical connections
Qualified personnel should carry out connecting unit to the main power.
Be sure to check the local codes in your area.
Before connecting the unit to the electrical supply, verify the data nameplate for the proper electrical information.
Voltage tolerance is +/- 10%.
Dryer are supplied with power cord and plug (two poles and ground).
Be sure to provide the proper fuses or breakers based on the data information located on the nameplate.
A residual-current device (RCD) with In =0.03A is suggested. The cross section of the power supply cables
must comply with the consumption of the dryer, while keeping into account also the ambient temperature, the
conditions of the mains installation, the length of the cables, and the requirements enforced by the local power
provider. Important: ensure that the dryer is earthed.
Do not use any socket adapters at the mains plug.
If the mains plug needs to be replaced, this must only be done by a qualified electrician.
4.8 Condensate drain
The condensate is discharge at the system pressure.
Drain line should be secured.
Never point the condensate drain line towards anybody.
The dryer comes already fitted with a timed condensate drainer (solenoid valve controlled by electronic
instrument) or with an electronic condensate drainer (optional).
Connect and properly fasten the condensate drain to a collecting plant or container.
The drain cannot be connected to pressurized systems.
•Don’t dispose the condensate in the environment.
•The condensate collected in the dryer contains oil particles released in the air by the
compressor.
•Dispose the condensate in compliance with the local rules.
•We recommend to install a water-oil separator where to convey all the condensate drain
coming from compressors, dryers, tanks, filters, etc.

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Start-up
5 Start-up
5.1 Preliminary operation
Verify that the operating parameters match with the nominal values stated on the data nameplate of
the dryer (voltage, frequency, air pressure, air temperature, ambient temperature, etc.).
This dryer has been thoroughly tested, packaged and inspected prior to shipment. Nevertheless, the unit could
be damaged during transportation, check the integrity of the dryer during first start-up and monitor operation
during the first hours of operation.
Qualified personnel must perform the first start-up.
When installing and operating this equipment, comply with all National Electrical Code and any
applicable federal, state and local codes.
Who is operating the unit is responsible for the proper and safe operation of the dryer.
Never operate equipment with panels removed.
5.2 First start-up
This procedure should be followed on first start-up, after periods of extended shutdown or following
maintenance procedures. Qualified personnel must perform the start-up.
Sequence of operations (refer to paragraph 7.1 Control Panel).
• Ensure that all the steps of the “Installation” chapter have been observed.
• Ensure that the connection to the compressed air system is correct and that the piping is suitablyfixed
and supported.
• Ensure that the condensate drain pipe is properly fastened and connected to a collection system or
container.
• Ensure that the by-pass system (if installed) is closed and the dryer is isolated.
• Ensure that the manual valve of the condensate drain circuit is open.
• Remove any packaging and other material which could obstruct the area around the dryer.
• Activate the mains switch.
• Turn ON the switch - pos. 1 on the control panel.
• Ensure that electronic instrument is ON.
• Ensure the consumption matches with the values of the data plate.
• Check the rotation direction of the fan –wait for its first interventions
• Allow the dryer temperature to stabilise at the pre-set value.
• Slowly open the air inlet valve.
• Slowly open the air outlet valve.
• Slowly close the central by-pass valve of the system (if installed).
• Check the piping for air leakage.
• Ensure the drain is regularly cycling - wait for its first interventions.

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Start-up
5.3 Start-up and shut down
Start-up (refer to paragraph 7.1 Control Panel)
• Check the condenser for cleanliness
• Turn ON the switch - pos. 1 on the control panel.
• Ensure that electronic instrument is ON.
• Wait a few minutes; verify that the DewPoint temperature displayed on electronic instrument is correct and
that the condensate is regularly drained.
• Switch on the air compressor.
Shut down (refer to paragraph 7.1 Control Panel)
• Check that the DewPoint temperature indicated on the electronic instrument is within range.
• Shut down the air compressor.
• After a few minutes, turn OFF the switch - pos. 1 on the control panel.
NOTE:
Electronic instrument DMC15 (standard): A DewPoint included in the green operating area of the electronic
controller is correct according to the possible working conditions (flow-rate, temperature of the incoming air,
ambient temperature, etc.)
Electronic instrument DMC14 (optional): A DewPoint within 0°C and +10°C displayed on electronicinstrument
is correct according to the possible working conditions (flow-rate, temperature of the incoming air, ambient
temperature, etc.).
During the operation, the refrigerant compressor will run continuously. The dryer must remain on during the full
usage period of the compressed air, even if the air compressor works intermittently.
The number of starts must be no more than 6 per hour.
The dryer must stop running for at least 5 minutes before being started up again.
Frequent starts may cause irreparable damage.
The user is responsible for compliance with these rules.

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Technical Data
6 Technical Data
6.1 Technical data ACT 3T –12T 1/230/50-60

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Technical Data
6.2 Technical data ACT 18T –160T 1/230/50

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Technical Data
6.3 Technical data ACT 18T –160T 1/230/60

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Technical Description
7 Technical description
7.1 Control panel
The control panel illustrated below is the only dryer-operator interface.
ACT 3T –23T instrument DMC15 (standard) ACT 30T –160T instrument DMC15 (standard)
ACT 3T –23T instrument DMC14 (optional) ACT 30T –160T instrument DMC14 (optional)
1 ON-OFF Switch
2 Electronic instrument
3 Air and refrigerant flow diagram
7.2 Operation
Operating principle - The dryer models described in this manual operate all on the same principle. The hot
moisture laden air enters an air to air heat exchanger. The air then goes through the evaporator, also known as
the air to refrigerant heat exchanger. The temperature of the air is reduced to approximately 2°C, causing water
vapor to condense to liquid. The liquid is continuously coalesced and collected in the separator for removal by
the condensate drain. The cool moisture free air then passes back through the air to air heat exchanger to be
reheated to within 8 degrees of the incoming air temperature as it exits the dryer.
Refrigerant circuit - Refrigerant gas is cycled through the compressor and exits at high pressure to a condenser
where heat is removed causing the refrigerant to condense to a high-pressure liquid state. The liquid is forced
through a capillary tube where the resulting pressure drop allows the refrigerant to boil off at a predetermined
temperature. Low-pressure liquid refrigerant enters the heat exchanger where heat from the incoming air is
transferred causing the refrigerant to boil; the resulting phase change produces a low pressure, low temperature
gas. The low-pressure gas is returned to the compressor, where it is re- compressed and begins the cycle again.
During those periods when the compressed air load is reduced the excess refrigerant is by-passed automatically
back to the compressor via the hot gas by-pass valvecircuit.
1
0
I
I
ON
PQS0051
PQS0008
PQS0024
PQS0052