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INSTALLATION
1. Install DRY AIR PAC in a clean, dry location, with ambient temperatures at all times above 50o F., adjacent to the sprinkler system piping outside the cold room.
NO MORE THAN 3 SYSTEMS ARE TO BE CONNECTED TO A SINGLE DRY AIR PAC;
CAPACITY OF EACH SYSTEM SHOULD NOT EXCEED THE RATED CAPACITY OF
THE DRY AIR PAC. The unit must be accessible at the front for servicing all major
components. The unit should be leveled and anchored to the floor (the vibration isolators
supplied with the unit MUST be utilized). If the location is below freezing at any time the
unit must be enclosed in a separate, heated enclosure to keep the temperature above 50o
F.
NOTE:
Do not install the Dry Air Pac in an area where ammonia vapors or similar
contaminants exist. The equipment and desiccant can be damaged by ammonia and
other vapors. Locate the Dry Air Pac to ensure no ammonia or other vapors are drawn
into the intake.
2. The unit has been filled with oil for test purposes, it is strongly recommended to change this
oil after the initial run in period on site. 2 Quarts of oil are shipped with each Dry Air Pac for this
purpose. When adding or replacing oil only use General Part Number ACPO1Q Specially
Formulated Compressor Oil.
Oil requirements are as follows:
DAP500 22ounces
DAP1000 Approximately 1 1/2 quarts (middle of oil level window)
DAP2000 Approximately 1 1/2 quarts (middle of oil level window)
Lightweight lubricants should not be used nor heavy gear oils.
3. Connect proper supply voltage to the starter line terminals in the control panel.
Note: Wire size must be capable of carrying the unit load, without dropping the
voltage at the terminals below normal operating levels. Double check incoming wire
size; if there are any questions please call us, we can assist you in ensuring you have
selected the correct size. Be sure the control power transformer has its primary side jumpers
connected to match the incoming supply voltage. Each unit is run at the factory and results noted
for reference so if there are any questions please contact the factory. Motor rotation will always
need to be checked. After connecting the power, use the on/off switch on the front of the unit to
turn on the compressor briefly to check rotation. An indicating arrow is on the compressor
flywheel. If rotation is not correct on three phase units, reverse any two leads. On single phase
units refer to the motor nameplate, however it should not require changing as it has been run at
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the factory. If you feel this is required please consult with factory personnel as there may have
been changes made to the unit, which should be discussed with the factory PRIOR TO starting
the unit. Please ensure sufficient power is available at the unit. Long feed line runs can cause
voltage drops, which can affect the performance of the unit and damage the motor.
ONLY QUALIFIED ELECTRICAL PERSONNEL SHOULD CONNECT THE UNIT.
4. Each DRY AIR PAC is shipped with desiccant installed. The unit will need to be run for a
minimum of 8 hours PRIOR TO any air being used from the Dry Air Pac in the sprinkler
system. Air should be bled from the tee after the regulator in an amount to allow the compressor
to run NO MORE than 4 times per hour.
NOTE: If you are connecting to an old piping system there may be existing le aks in the
system which cause the compressor to cycle more frequently than 4 times per hour. If this is
the case there are three suggestions: 1. Fix the leaks. 2. Add a second DRY AIR PAC to
provide enough air to bring the cycle times back to less than 4 times per hour. 3. Add a
receiver, which can act as a storage buffer to supply more air to the system. This should be
discussed with the factory personnel, as it will only work in cases where minor leaks are
involved.
5. The DRY AIR PAC is supplied with a removable, threaded inlet air filter so that if the AHJ
requires the air to be drawn from the cold room this can be done. These units have been FM
Approved with air NOT being drawn from the freezer room. Therefore WE DO NOT
RECOMMEND they be connected to the freezer room. The Dry Air Pac is designed so
that performance will not be adversely affected with the filter left in place directly on the
compressor. If connected in the cold room, the piping back to the compressor must be 1 1/2”
minimum pipe size for this run, bushed down directly at the compressor inlet elbow. This pipe must be heat traced and insulated. The filter should be mounted on the inlet end of this pipe
directly in the cold room. The interconnecting piping should be clean of any foreign matter, which may be drawn into the compressor and cause damage.
6. There is a 1/2” pipe plug installed in the outlet tee. This is provided as a point to install a dew
point monitoring device, should you require one. This is after the regulator and gives you the
pressure dew point of the system. Be careful to follow the dew point monitor manufacturer’s
recommendations as far as installation is concerned.
7. The DRY AIR PAC outlet is from the combination particulate filter with pressure regulator,
mounted on the right lower side of the unit facing the control panel. Connect this outlet to the
sprinkler system air inlet.
8. The DRY AIR PAC has a UL/FM approved Air Maintenance Device built into the unit. It
will require adjustment of the regulator to your system requirements. It replaces the final
regulator, which should be left fully open once the Air Maintenance Device has been adjusted
and valved into the line. If connecting more than one system to the unit, the Air Maintenance
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Device should be left valved out of the system and the individual AMD’s used to control each
system should be utilized.
NOTE: Leaks in the piping system will affect the pump up time of the system. The DRY
AIR PAC has been factory tested to produce the published capacity.
9. An integral electronic drain valve is installed on each unit. The drain is pre-set when the unit
leaves the factory. If necessary you can adjust the time between openings and the length of time
the valve is open using the control knobs located above the hour meter on the front of the
control panel. Under normal circumstances the maximum time between openings should be
sufficient. If more frequent openings are required due to excessive compressor operation simply
decrease the duration between openings. The On/Off - Manual Test switch can be used to
check operation.
START UP
AS NOTED PREVIOUSLY - The unit must run for a minimum of 8 hours PRIOR TO any air
being taken from the Dry Air Pac into the sprinkler system. Air should be bled from the tee after
the regulator in an amount to allow the compressor to run NO MORE than 4 times per hour for
this period.
1. With all the connections made as described in INSTALLATION, the unit is ready to
start. With the valve ahead of the coalescing filter closed, turn the unit on with the switch
on the front of the control panel. The compressor should start to fill the receiver tank
and the tank pressure gauge on the front of the control panel should indicate the
pressure. The unit should pressurize the receiver to approximately 100psig and then shut
off.
Note:
Do not adjust the pressure switch on the unit. It is factory set at the values required for
correct operation of the unit. Warranty may be void if the pressure switch is reset.
The unloader line will operate to bleed off the pressure in the line from the compressor to the
receiver inlet so that the compressor does not start loaded. Air will exhaust from the small valve
at the side of the switch immediately after the compressor is shut off. This should not occur
when the compressor is running or for long periods of time after the compressor shuts off. If this occurs, contact the factory.
2. Open the valve ahead of the coalescing filter and pressurize the rest of the DRY AIR PAC.
The Air Maintenance Device should be in bypass mode, with the 3/4” valve open.
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3. The outlet valve should now be open to allow air to begin to purge into the sprinkler system.
The final regulator is factory set to 40 psig. The regulator should always be set to maintain
pressure on the drying tower between 70 to 100 psig. At no time should the regulator be
opened to bleed all pressure off the drying system, as this will adversely affect drying quality.
4. Open an inspection test point on the far end of the sprinkler system to allow the current wet
ai r in the sprinkler system to be purged out of the system. This leak should be adjusted to allow
the compressor to run, after filling the system to pressure, NO MORE than 4 times per hour.
Allow this to run for 24 hours then close the inspection test port to allow the system to function
normally.
5. The automatic drain is set to a mid position at the factory. You should not need to adjust this
frequency or duration but if you do, be aware that the quicker the cycle and the longer the open
time, the more air will be used and the less will be available at the unit outlet. A light on the
control panel will indicate when the drain is operating. A length of tubing is provided at the drain
valve outlet for piping to a convenient drain water disposal position.
BE SURE TO PIPE THIS DISCHARGE TO A POSITION WHERE THE DISCHARGED
AIR AND WATER WILL NOT BE A HAZARD TO PERSONNEL.
6. Once the system is filled the Air Maintenance Device will need to have the 3/4” valve closed,
the two 1/4” valves opened and the regulator set for final system maintenance pressure. The
final regulator should then be opened to full to allow the Air Maintenance Device to be the
controller.
7. REMEMBER - After the 24-hour period, close the inspection port.
OPERATION
The following is a description of the operation of the DRY AIR PAC.
Typically air is drawn into the compressor intake through the threaded inlet filter. . These units
have been FM Approved with air NOT being drawn from the freezer room. Therefore
WE DO NOT RECOMMEND they be connected to the freezer room. If required by the
AHJ, air is drawn in from the cold room through the inlet filter installed inside the cold room.
This air then travels to the compressor intake via 1 1/2” minimum line size piping.
Upon reaching the compressor, it is drawn into the compressor intake and compressed through
the compression cycle and then discharged into the intercooler. The air then crosses over into
the air cooled aftercooler where ambient air being pulled over the coil cools the hot compressed
air. Water in the compressed air will now drop out of the air as it cools and drops down into the
receiver. A check valve in this line prevents any back flow to the compressor. The water settles
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into the bottom of the receiver and is discharged from the receiver when the automatic drain
valve opens.
This air then leaves the receiver and goes into the coalescing filter where it has entrained oil
removed. This air then travels to the dryer inlet. The air is diverted to the corresponding tank via
two solenoid valves. The air travels upwards through the desiccant bed and exits through the
top of the tank. A portion of this dried air is diverted to the opposite tank via the purge valve
and gauge/orifice combination. The pressure gauge setting is factory set (see following settings
for each model). If re-setting is required, consult the factory for assistance. The purge air enters
the top of the tower and travels in a downward direction to pick up the water molecules from
the desiccant as the pressure drops to atmosphere. The wet purge air then exits the bottom of
the tank and is vented to atmosphere via the purge mufflers. These mufflers act to quiet the
discharging air and also reduce the noise when the towers depressurize. These mufflers are
removable for cleaning with soap and water periodically. Cleaning will ensure no build up, which
will create back pressures in the tanks and decrease dryer performance. Both inlet and outlet of
the tanks have screens to retain the desiccant. The exiting air then goes to the Air Maintenance
Device. (See Start Up above for operating positions). From the Air Maintenance Device the air
goes into the final filter regulator. The air up to this point has been at 70 – 100 psig. When it
leaves the filter regulator it is reduced to system pressure.
NOTE: THE DRYER MUST OPERATE AT THE HIGHER PRESSURE IN ORDER TO
FUNCTION CORRECTLY. THE AIR MAINTENANCE DEVICE REGULATOR MUST
BE SET AND VALVED INTO THE SYSTEM.
SETTING PURGE PRESSURE
The purge pressure set valve is located between the two tanks just over the top of the control
panel. This valve is pre-set at the factory, however should it need to be adjusted for any reason,
the following listing shows the correct set pressures.
DAP500 20psig
DAP1000 30psig
DAP2000 27psig
COALESCING FILTER - OPERATION
The coalescing filter is there to protect the desiccant dryer from oil carryover from the
compressor. The filter has a built in differential pressure indicator with three color bands. Green
is normal condition, yellow is warning that the element is going to need to be replaced, and red
indicates the filter is overdue for replacement.
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The filter has a built in automatic drain, which in normal service will expel accumulated oil or
moisture from the bottom of the bowl. The drain can be tested by pushing up on the needle
valve stem, which is in the mouth of the black outlet nipple on the bottom of the filter.
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SERVICE KITS ARE AVAILABLE AS DETAILED BELOW. MODEL AND SERIAL
NUMBERS ARE REQUIRED WHEN ORDERING SERVICE KITS
KIT# KSMB01 Compressor Intake Filter Element(s),
Coalescing Filter Element, Particulate
After Filter Element and Compressor Oil
KIT# KAMA01 Same as Kit # KSMB01 and full
desiccant charge for both dryer towers
OPERATING SEQUENCE - DRYER
The dryer operates on a 4-minute total cycle. There are four valves at the inlet manifold, and
four at the outlet manifold. The timing cycle diagram shows the sequence of operation of the
four inlet valves. The outlet valves are check valves, which sequence automatically with the
operation of the inlet valves. SV1 and SV2 are the inlet valves to the towers, SV3 and SV4 are
the opposite purge valves such that when the left tower is drying and its inlet valve is open, the
purge valve on that tower is closed.
0 min 2 min 4 min
A
B SV1
A
B SV2
A
B X SV3 X
A SV4
B X X
A=VALVE CLOSED B=VALVE OPEN X = 15 seconds
With the unit turned on and the tank pressurized, air is ready to be used from the unit. As air is
withdrawn from the unit into the sprinkler system, the pressure will drop and the pressure switch
will start the compressor. As the compressor runs, the dryer is energized. The drying tower is
indicated by a light on the front of the panel, as shown in the mimic panel. The drying tower will
show tank pressure and the opposite tank, when purging will show no pressure; when
repressurizing prior to switch over, it will show tank pressure. The purge valve can only be
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adjusted during the time the off line tower is purging and is showing no pressure. At this time, if
necessary, adjust the purge pressure to the value in the above table. The dryer cycle timer runs
only when the compressor is running and accumulates time so that the length of the cycle on any
one tower does not get out of line with its normal operation and does not saturate one desiccant
bed.
The frequency of change for the oil, filter elements and desiccant is highly dependent upon the
following:
Number of times the unit has to operate to satisfy the system air requirement. The tighter
the system, the less the unit will have to run.
Cleanliness of the environment in which the compressor is located.
Maintenance schedule for the equipment.
As the desiccant will degrade (age) slightly over time, it is recommended that the desiccant be
changed once every year.
Consult the factory for type and quantity per unit.
ADDITIONAL SPECIFICATIONS
MODEL COMPRESSOR
HP
DAP5002 10 2.9 AMPS 5.8 AMPS 12 GA 12 GA
DAP1000 5 20 6.2 AMPS 12.4 AMPS 12 GA 10 GA*
DAP2000 5 27 6.2 AMPS 12.4 AMPS 12 GA 10 GA*
*IF UNDER 50’ RUN 12 GA CAN BE USED HOWEVER, CHECK VOLTAGE WHILE RUNNING TO ENSURE NO
UNDERVOLTAGE CONDITION EXISTS. FOR RUNS OVER 100’ INCREASE WIRE SIZE TO CORRECT FOR VOLT
DROPS.
DRYER
RATING
CFM
CURRENT
LOAD 460V
CURRENT
LOAD 230V
WIRE SIZE
460V
WIRE SIZE
230V
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DESICCANT REPLACEMENT
NOTE: You will need the following in order to service the unit:
Annual Service Kit - “General” part number: KAMA01
1. Close the outlet valve of the unit and turn the power to the unit off.
2. Depressurize the unit completely by opening the petcock on the bottom of the receiver and
checking the pressure gauges to ensure all air is removed. If air remains in the desiccant tanks,
pull on the relief valve toggles to depressurize the tanks.
ALL PRESSURE MUST BE OUT OF THE UNIT PRIOR TO WORKING ON THE
UNIT.
3. The tanks have separate desiccant fill and drain ports at the top and bottom.
TANK OUTLET
FILL PORT
DRAIN PORT
TANK INLET
4. Once the pressure has been removed from each tank, remove the lower (drain) port plug.
Desiccant will start to drop out of the 1/2” port. It is easiest to vacuum the desiccant out with a
shop vac; however, the desiccant will drop out of the tower. You may have to probe the outlet
with a thin probe in order to keep the desiccant from jamming together at the port. The
desiccant is white in color; yellow means the desiccant has oil on it.
5. Ensure that all desiccant is removed from the tower. Replace the plug ensuring the threads
are cleaned and re-doped with thread sealant before replacing.
CHECK the condition of the lower desiccant. As flow is upward through the bed, the lower
desiccant will see any major contaminants and any carryover from the inlet filter if this has not
been serviced correctly. Oil on the lower desiccant means that the filter element has been over
saturated allowing oil to be carried over into the desiccant bed.
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CHECK the filter drain and element before putting the new desiccant into the towers.
Consult the factory if any oil is in the towers.
6. Remove the upper plug from the fill port.
7. Using “General” part number 34006-50, refill the tower with new, white desiccant.
NOTE:
Only add desiccant beads to towers when refilling. Avoid adding chips and dust, which may be
in the bottom of the bag of desiccant, to the towers.
8. Reinstall the fill port ensuring that you clean the threads and re-dope prior to installation.
9. Remove and replace the pre & afterfilter elements prior to putting the unit back in service.
This is accomplished by unscrewing the bowls and following the kit instructions to replace the
elements. We would be happy to look at the old elements if you feel there is any question as to
the condition. Please contact the factory for shipping instructions. Replace the filter bowls and
tighten securely prior to re-pressurizing the unit.
10. Turn the power back on to the unit (see 11.).
11. Open the discharge valve of the unit, then the valve ahead of the coalescer, turn power back
on to the unit and allow the unit to repressurize.
12. Operate the drain valve manually to bleed air to force the dryer through a full cycle to
ensure that the towers pressurize and repressurize correctly and go through their cycle. This is
simply a check to see that the unit is operating normally. The unit is now ready to go back in
operation.
Run the unit for the 8 hours as above in INSTALLATION, item 4, before letting air feed back
into the system.
NOTE:
The purge mufflers must be removed during the first 2 hours of the 8-hour break-in period
detailed above. Reinstall the mufflers only after 2 hours of operation.
Once this has been done, valve the unit back into the system.
Should you have any questions, please call the factory and ask for Customer Service at 1800-345-8207.
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TROUBLE SHOOTING GUIDE
PROBLEM PROBABLE CAUSE SOLUTION
POOR DEWPOINT
PERFORMANCE
Check to see that Air
Check compressor output to
Check no leaks have
Excessive water &/or oil in
Low purge flow . Check purge pressure setting.
Desiccant contamination. Check compressor intake is
Check when the last time the
Check condition of coalescing
High inlet temperature to
EXCESSIVE PRESSURE
DROP
Low pressure on desiccant
dryer.
dryer.
dryer.
Low inlet pressure. See alternatives above.
Switching valve failure. Check tower-operating
Desiccant breakdown.
Dryer is set to operate at 70 to
100 psig. Re-set regulator on
DAP Air Maintenance Device
to hold back pressure on dryer
side to normal settings.
Maintenance Device bypass
valve has not been opened.
ensure compressor is running
normally.
developed in DAP system
such as drain valve sticking
open, filter drain valves
sticking open, etc.