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107 W. Main Street
Worthington, PA 16262
Phone: 724.297.3416 Fax: 724.297.5189
http://www.airtak.com
OPERATING INSTRUCTIONS
Refrigerated Air Dryers Models D-320 through D-10,000
4-2002
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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 (
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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
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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
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G. COMPRESSED AIR CIRCUIT 1. Air-to-Air Heat Exchanger: This unique high-efficiency heat exchanger is of a finned shell and tube design. The tubes are of high quality copper and are enhanced by outer fins of corrugated aluminum. The air is first directed into the shell of the heat exchanger and is baffled back and forth across the finned tubes giving off its heat to the cool, dry air as it passes through the tube side of the heat exchanger. 2. Air-to-Refrigerant
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The circuiting within the evaporator is serpentined in such a manner as to guarantee a completely flooded evaporator. Each evaporator is designed to insure adequate refrigerant velocity to eliminate the problem of oil return to the crankcase. 4. Expansion Valves: The thermostatic expansion valve (TXV) is used on Model D-320-A, and larger. This expansion valve is controlled primarily by temperature and requires a hot gas bypass valve to maintain p
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10. Oil Sightglass: The oil sightglass is found on the side of the crankcase on accessible scroll compressors to provide a visual means of checking the oil level. The oil must be checked only while the compressor is in operation. During compressor operation the oil sight glass should be approximately 1/2 full. 11. Refrigerant Liquid Line Filter-Dryer: A liquid line filter-dryer is used on all AIR/TAK refrigerated dryers. The purpose of the filter-dryer is to
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I. START-UP After the installation of your air dryer at a suitable location, the following checks should be made: a) Bypass piping installed and valves set to bypass the dryer. b) Before start-up, the refrigerant analyzer gauge should indicate a dryer shutdown pressure of 125-175 PSIG for R-22 or 74-108 PSIG for R-134a for Models D-320-A through D-10000-A. If analyzer pressure is above or below normal shutdown pressure, do not start the dryer. Pressure may var
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J. DESIGN CONDITIONS Each dryer is shipped complete and ready for installation. Every dryer is tested and preset at the factory for optimum service at the design conditions. The following are the standard design conditions for a refrigerated dryer operating at 60 HZ: 38°F (3.3°C) Pressure Dew Point 100°F (37.8°C) Inlet Temperature (Compressed Air) 100 PSIG (7 bar) Compressed Air Pressure in PSI Gauge
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Cooling Water Requirements MODEL # HEAT TO COOLING WATER KW INPUT (4) COOLING AMBIENT (1) GPM (2) GPM (3) WATER D-400-W 23682 1780 4.7 1.9 1.95 D-500-W 33894 2550 6.8 2.7 2.6 D-600-W 37250 3650 7.5 3.0 2.92 D-800-W 52859 3980 10.6 4.3 4.22 D-1000-W 66150 5360 13.2 5.3 4.8 D-1600-W 90845 7366 18 7.3 6.82 D-2000-W 128646 10431 26 10.3 9.4 D-2
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SYMPTOMS PROBABLE CAUSE REMEDY Dryer not running. a. Disconnect open. a. Close disconnect. High temperature light off, analyzer gauge normal. b. Fuse blown. b. Replace fuse. c. Wiring, improper or broken. c. Check wiring diagram or repair. d. Control transformer d. Replace. defective. e. Unit not turned on. e. Turn unit on. Dryer not running. a. Overload tripped. a. Allow to cool and reset. High temperature light on, Check for overload. analyzer ga
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SYMPTOMS PROBABLE CAUSE REMEDY g. Defective refrigerant g. Repair or replace compressor valves. compressor. h. Suction pressure too high. h. Adjust hot gas bypass valve. a. Leaky refrigerant circuitry. a. Locate and repair. Dryer running. High temperature light on, analyzer gauge pressure low. b. Suction pressure too low b. Adjust hot gas Check refrigerant charge. bypass valve. a. Defective hot gas bypass a. Repla
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a. Excess flow. a. Dryer undersized. High pressure drop across dryer inlet and outlet. Replace with larger dryer. b. Low air pressure. b. Dryer undersized. Replace with larger dryer. c. Partially frozen. c. Shut dryer off until ice melts. a. No cooling water supply to a. Check cooling water supply. Power light “ON” but dryer not running dryer. Reset refrigerant Hi/Lo pressure switch if interrupted. IMPORTANT:
