General Air Products DAP500, DAP1000, DAP2000 Installation Manual
DRY AIR PAC™
FACTORY MUTUAL APPROVED
AIR DRYING UNITS FOR REFRIGERATED AREA AND
DRY PIPE SPRINKLER SYSTEMS
INSTALLATION, OPERATION & MAINTENANCE INSTRUCTIONS
MODELS DAP500, DAP1000 & DAP2000
ENGINEERED COMPRESSED AIR DRYING SYSTEMS FOR COLD
STORAGE/ FREEZER ROOM DRY PIPE SPRINKLER SYSTEMS
MODEL NUMBER SYSTEM
CAPACITY
DAP500 500 GALLON 2 10 375LBS
DAP1000 1000 GALLON 5 20 500LBS
DAP2000 2000 GALLON 5 27 550LBS
COMPRESSOR
HORSEPOWER
DRYER RATING
SCFM
APPROXIMATE
SHIPPING WT.
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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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