pilotair ACT 180T Guide

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REFRIGERATED AIR DRYERS
ACT 180T –1500T
Air-Water Cooled
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 97/23/EC 8
4 Installation 8
4.1 Transport 8
4.2 Storage 8
4.3 Installation site 9
4.4 Installation layout 10
4.5 Correction factors 11
4.6 Connection to the compressed air system 12
4.6.1 Inlet / outlet flanged air connections (only ACT 180T –360T) 12
4.7 Connection to the cooling water network (Water-Cooled) 13
4.8 Electrical connections 14
4.9 Condensate drain 15
5 Start-up 15
5.1 Preliminary operation 15
5.2 First start-up 16
5.3 Start-up and shut down 17
6 Technical data 18
6.1 Technical data ACT 180T –1500T 3/400/50 18
6.2 Technical data ACT 180T –1500T 3/460/60 19
7 Technical description 20
7.1 Control panel 20
7.2 Operation 20
7.3 Flow diagram (Air-Cooled) 21
7.4 Flow diagram (Water-Cooled) 21
7.5 Refrigerating compressor 22
7.6 Condenser (Air-Cooled) 22
7.7 Condenser (Water-Cooled) 22
7.8 Condenser water regulating valve (Water-Cooled) 22
7.9 Filter dryer 22
7.10 Capillary tube 23
7.11 Alu-Dry module 23
7.12 Hot gas by-pass valve 23
7.13 Refrigerant pressure switches LPS –HPS 24
7.14 Compressor crankcase heater 24
7.15 Electronic instrument DMC24 25
7.15.1 How to switch on the dryer 26
7.15.2 How to switch off the dryer 26
7.15.3 How to display the operating parameters –INFO Menu 26
7.15.4 How a service warning is displayed 27
7.15.5 How an alarm is displayed 28
7.15.6 How to show the alarm memory –LOG Menu 29
7.15.7 How to control dryer with remote control 29
7.15.8 Operation of the failure / alarm dry contact (potential free) 29
7.15.9 Connection to serial line 29
7.15.10 How to change operating parameters –SETUP Menu 30
7.16 Electronic drainer 31

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8 Maintenance, troubleshooting, spare parts and dismantling 32
8.1 Checks and maintenance 32
8.2 Troubleshooting 33
8.3 Spare parts 38
8.4 Maintenance operation on the refrigeration circuit 40
8.5 Dismantling of the dryer 40
9 Attachments 41
Exploded views –List of components 41
Electric diagrams –List of components 41
9.1 Dryers dimensions 42
9.1.1 ACT 180T –360T 42
9.1.2 ACT 400T –720T 43
9.1.3 ACT 900T –1100T 44
9.1.4 ACT 1200T –1500T 45
9.2 Exploded views 46
9.2.1 ACT 180T –360T Air Cooled 46
9.2.2 ACT 180T –360T Water Cooled 47
9.2.3 ACT 400T –720T Air Cooled 48
9.2.4 ACT 400T –720T Water Cooled 49
9.2.5 ACT 900T –1100T Air Cooled 50
9.2.6 ACT 900T –1100T Water Cooled 51
9.2.7 ACT 1200T –1500T Air Cooled 52
9.2.8 ACT 1200T –1500T Water Cooled 53
9.3 Electric diagrams 54
9.3.1 ACT 180T –360T Sheet 1 of 3 54
9.3.2 ACT 180T –360T Sheet 2 of 3 55
9.3.3 ACT 180T –360T Sheet 3 of 3 56
9.3.4 ACT 400T –720T Sheet 1 of 4 57
9.3.5 ACT 400T –720T Sheet 2 of 4 58
9.3.6 ACT 400T –720T Sheet 3 of 4 59
9.3.7 ACT 400T –720T Sheet 4 of 4 60
9.3.8 ACT 900T –1500T Sheet 1 of 6 61
9.3.9 ACT 900T –1500T Sheet 2 of 6 62
9.3.10 ACT 900T –1500T Sheet 3 of 6 63
9.3.11 ACT 900T –1500T Sheet 4 of 6 64
9.3.12 ACT 900T –1500T Sheet 5 of 6 65
9.3.13 ACT 900T –1500T Sheet 6 of 6 66
9.4 Declaration “CE” of conformity 67
10 Pilot Air Warranty Conditions 68

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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, but no longer that 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 its 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

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Safety Rules

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Installation

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Installation

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Installation

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Installation

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Installation

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Installation

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Installation

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Start-Up

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Start-Up

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Start-Up

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Technical Data

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Technical Data

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Technical Description
7 Technical Description
7.1 Control Panel
The control panel illustrated below is the only dryer-operated interface.
1 Main Switch
2 Electronic Instrument DMC24
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 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 valve circuit.