AT&T D-10000, D-320 User Manual

107 W. Main Street

Worthington, PA 16262

Phone: [phone] Fax: [phone]

http://www.airtak.com

OPERATING INSTRUCTIONS

Refrigerated Air Dryers Models D-320 through D-10,000

4-2002

Contents

A. INTRODUCTION
B. RECEIVING
C. LOCATION
D. FOUNDATION
E. PIPING
F. ELECTRICAL
G. COMPRESSED AIR CIRCUIT

1. Air to Air Heat Exchanger

2. Air to Refrigerant Heat Exchanger (Evaporator)

3. Drain Traps

H. REFRIGERANT CIRCUIT

1. Refrigerant Compressor

2. Air-Cooled Condenser and Condenser Fan Cycling Control (Low Ambient)

3. Air to Refrigerant Heat Exchanger (Evaporator)

4. Expansion Valves

5. Hot Gas Bypass Valve (D-320 and Larger)

6. Low Pressure Switch

7. High Pressure Switch

8. Crankcase Heater (D-320-A thru D-2000-A and D-400-W thru D-1000-W)

9. Automatic Water Regulating Valve

10. Oil Sightglass

11. Refrigerant Liquid Line Filter Dryer

12. Water Pressure Switch

13. Desuperheating Valve (D-1600 and Larger)

14. High Temperature Control

15. Start Timer

I. START-UP
J. DESIGN CONDITIONS
K. SHUTDOWN
L. WATER-COOLED MODELS: Cooling Water Requirements
M. MAINTENANCE

1. Drain Valves

2. Refrigeration Condenser

3. Condenser Fans

N. REMOTE CONDENSER INSTALLATION (OPTIONAL)

TROUBLESHOOTING GUIDE

WARRANTY PROCEDURES

OTHER AIR/TAK PRODUCTS

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A. INTRODUCTION

AIR/TAK Refrigerated Compressed Air Dryers are of the high-efficiency type, designed to effectively remove
moisture from compressed air by means of a refrigeration process. The compressed air pressure dewpoint is
reduced to 38°F and then reheated to prevent in-plant air lines from sweating. The 38°F dewpoint can be
maintained under varying conditions from zero load to 100% of the design conditions.

AIR/TAK dryers are completely automatic in all respects. As with all AIR/TAK products, only a minimum of
maintenance is required. It is our recommendation that this manual be followed for any maintenance that might be
required. Any, and all service should be performed by a qualified refrigeration engineer who is trained in the service
of refrigerated air dryers.

B. RECEIVING

Upon receiving your air dryer:

1. Inspect the shipping carton for any apparent damage.

2. After removing the crate, inspect the unit for any hidden damage.

3. Report any damage immediately to the carrier and notify your supplier.

C. LOCATION

Air cooled dryers must have cool ambient air made available to prevent a heat build-up in the area where the dryer
is installed. An exhaust system is recommended to avoid recirculation of hot condenser air.

Ambient temperature at the selected location should not exceed 100°F (38°C), 60 HZ; or 77°F (25°C), 50 HZ; and
should not be lower than 50°F (10°C). High ambient temperature can affect the efficiency of the dryer. Every 10°F
increase in ambient temperature above 100°F (38°C) will result in a 6% decrease in air cooled dryer performance,
resulting in higher dewpoints and increased operating costs.

To assure an unrestricted flow of cool air through the refrigeration condenser, a minimum distance from the cabinet
to the nearest wall of 24 inches must be maintained.

All outside installations must have weather protection. Minimum protection should include a shed roof. Air-cooled
units must be protected against the wind.

Ambient temperatures should not exceed 100°F (38°C) and should not be lower than 50°F (10°C) where a
standard unit is to be located. If ambient temperatures below 50°F (10°C) are anticipated, the dryer should be
equipped with an optional ultra-low ambient package.

D. FOUNDATION

All dryers are completely free-standing units. Any reasonably level floor that has sufficient strength will serve as a
foundation.

E. PIPING

When piping the main air lines to the dryer, the use of flexible connections or union joints is recommended to avoid
piping stress and vibration when used with reciprocating compressors. Bypass piping and valves are
recommended. The bypass will permit isolation of the dryer for servicing and will eliminate the need to shut down
the complete compressed air system. The bypass must be provided and installed by the customer.

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In keeping with good compressed air piping design, the air dryer should be installed on the downstream side of the
air receiver and aftercooler. An AIR/TAK prefilter(s) for oil and dirt removal installed at the inlet of the dryer is
recommended. Contamination can be present in a compressed air system and can reduce the ability of the dryer
heat exchangers to achieve the proper heat transfer. AIR/TAK recommends the use of afterfilter(s) to remove final
trace contaminates.

All water cooled dryers are factory piped for cooling tower water, unless ordered otherwise. A dryer that is piped for
city water cannot be used on cooling tower water without necessary piping changes because of: the higher water
temperature, lower water pressure and the increased water flow needed. All water cooled dryers are supplied with
a factory mounted automatic water regulating valve which is designed to maintain the proper working refrigerant
head pressure under all dryer load conditions. No adjustment will be necessary. (Full water pressure and flow
should be supplied to the water line inlet. Refer to Section L for water cooled water requirements.)

All dryers are supplied with automatic drain valves. On models D-320 to D-2000, an isolation valve/strainer and
solenoid drain valve is provided for the outlet of the air to-refrigerant heat exchanger. Models D-2500 to D-7500
dryers are supplied with two drain outlets with zero air loss valve provided for each outlet. Models D-8000 and
larger are supplied with four drain outlets and two zero air loss drain valves. Solenoid drain valves with isolation

valve/strainer and zero air loss drain valves are to be installed at destination.

F. ELECTRICAL

The dryer is completely wired at the factory. A terminal box at the rear of the dryer, or a control box on the side of
the dryer is provided for the main power connection. Power connections can be made through any knock-out on
the terminal box or through the side or top of the control box. The dryer dataplate must be checked to verify
voltage, phase and cycle. Connect the power leads to the terminal block which is conveniently located within the
box. Always be sure adequate power is available to maintain efficient operation of your dryer.

A properly sized fused main disconnect switch (supplied by the installer) must be located near the dryer. Check the
wiring diagram supplied with the dryer for the recommended fuse size. The use of fusetron time-delay fuses will
permit smaller fuse sizes and, in some instances, a smaller fused disconnect switch may be used.

The dryer wiring must be independent of the air compressor so as not to cycle along with the air compressor.

Fan rotation must be checked to assure proper air flow. Air must be drawn through the finned condenser and exit
through the fan guard. To change fan rotation, switch any two hot power leads on the terminal block located in the
box.

Dryers with scroll compressor(s) need to be checked for proper rotation by making sure the discharge pressure is
greater than the suction pressure. To change rotation, switch inlet power leads L1 and L3. If you have any question
or problems, please consult factory.

Dryers with pre-wired solenoid drain valves need to have the DIN connector attached to the drain valve after the
drain is installed on the dryer.

On units supplied with crankcase heaters, the crankcase heaters are pre-wired at the factory to be energized when
power is supplied to the dryer. It is important that the crankcase heaters be energized at least 24 hours before
initial start-up or after prolonged shut-down. (See Start-Up).

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