Installation and Operation Manual Installation, Operation, and Service Information Aircel AHLD E-Series Heatless Regenerative Desiccant Air Dryer Models AHLD-1000 E, 1250 E, 1500 E, 2000 E, 2500 E, 3000 E, 3500 E, 4500 E, 5000 E Throughout this manual, signal words are present to advise of safety precautions and/or standard practices. Obey these signal words as defined below: DANGER! - indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
Aircel AHLD E-Series - Models 1000 - 5000 WARNING! General Safety Procedures • Improper installation, operation, or maintenance may contribute to conditions in the work area or facility that could result in personal injury and product or property damage. Check that all equipment is properly selected and sized for the intended use. • Consult and comply with national and local codes relating to fire or explosion and all other appropriate codes when determining the location and operation of this equipment.
Heatless Regenerative Desiccant Air Dryer Contents Safety Statements................................................... 2 Introduction........................................................... 3 Data Sheet.............................................................. 4 Safety Symbols....................................................... 5 General Safety Instructions.................................... 6 Description............................................................ 7 Purpose & Intended Use......
Aircel AHLD E-Series - Models 1000 - 5000 Data Sheet Model Number_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Serial Number _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Dryer Type _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Date of Manufacture _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Ship Date_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Heatless Regenerative Desiccant Air Dryer Safety Instructions Safety Symbols Used in Manual Important Information: Readers of the manual must pay extra attention to instructions and information succeeding this symbol. Warning: This indicates that it is dangerous and could result in physical injury and death if the instructions are not followed correctly. Electrical Danger High Voltage: This means that there is a risk of electric shock and only authorized personnel with proper gear must approach it.
Aircel AHLD E-Series - Models 1000 - 5000 General Safety Instructions What You Must Do 1. Certified/authorized electricians must perform electrical work 2. Electrical work must conform to the specifications indicated by Aircel and any local or state laws that may apply. 3. Personnel must wear appropriate safety gear before working on any electrical or mechanical aspects of the machine. 4. Appropriate tools have to be used for all installation and maintenance work.
Heatless Regenerative Desiccant Air Dryer Product Description Why We Need Compressed Air Dryers Untreated compressed air contains many contaminants such as water, compressor oil, pipe scale and contamination from ambient air. All these contaminants cause excessive corrosion, erosion, freezing and product contamination to all components that come in contact with the untreated compressed air. A regenerative type dryer system with all recommended filtration will remove these contaminants to harmless levels.
Aircel AHLD E-Series - Models 1000 - 5000 Standard Features • • • • • • • • • • • • • • • • • • • • • • Integrated Energy Management Purge Reduction System for efficient energy savings and reduced cost of operation. Optimal tower size for low velocities reducing desiccant fluidization, and high contact time for efficient low dewpoint performance. Tower pressure relief valves. Standard design capacity based on 100 psig, 100°F inlet air, 100°F ambient air and PDP of -40°F.
Heatless Regenerative Desiccant Air Dryer Inspection on Arrival All Aircel dryers are tested and operated before shipment. However, shipping stresses have the potential to cause damage to the unit. To ensure smooth installation, it is recommended that immediately upon receipt of the unit, the system is checked for the following: 1. Make sure you have received all the crates/ packages that are indicated in the packing slip. 2. Remove the crate and packaging. Inspect the unit for any visible damage. 3.
Aircel AHLD E-Series - Models 1000 - 5000 Technical Specifications How Does it Work? (see diagram 1) Moisture saturated compressed air enters the coalescing pre filter (F1) where aerosols are coalesced then drained via an automatic drain system. The moist water vapor-laden inlet air free of liquid water flows to the inlet of the dryer through the APV (Automatic Piston Valve) (V1) which diverts the inlet air to one of the towers, in this example tower (T1).
Heatless Regenerative Desiccant Air Dryer Diagram 1: How it Works 11
Aircel AHLD E-Series - Models 1000 - 5000 Installation Pre-requisites for Installation To ensure a safe and smooth installation, we recommend you go through the steps indicated below: • • • • Make sure that all personnel involved have read this Operation Manual thoroughly. If you have any questions, feel free to contact your Aircel representative or the factory and we will be glad to assist you.
Heatless Regenerative Desiccant Air Dryer Installation Only qualified personnel should make electrical and mechanical connections. Equipment for Installation: This dryer does not need any special tools for installation Foundation: Dryer should be mounted on a suitably structured flat and level floor or base that is free from vibration. Special care must be used when lifting the dryer to prevent tip-over Mounting: Bolt dryer to the foundation using the boltholes provided in the frame.
Aircel AHLD E-Series - Models 1000 - 5000 Start-Up Procedure At any point during the process of startup or shutdown, you notice anything unusual; we recommend you refer to the operation manual immediately. If you cannot find the answer in the troubleshooting section, contact your Aircel representative or the factory at once. 1. Ensure that the dryer is connected to a suitable compressed air supply. Make sure that the pressure of the supply is equal to the normal operating pressure of the dryer. 2.
Heatless Regenerative Desiccant Air Dryer Shut-Down Procedure At any point during the process of startup or shutdown, you notice anything unusual; we recommend you refer to the operation manual immediately. If you cannot find the answer in the troubleshooting section, contact your Aircel representative or the factory at once. 1. Slowly OPEN the by-pass valve. 2. Slowly CLOSE the Inlet and outlet “shut-off” valves. 3. To depressurize the dryer after the Dryer is isolated.
Aircel AHLD E-Series - Models 1000 - 5000 Sequence of Operation (cont’d) Step 4: Step 5: Extended Drying Vessel 1 A few seconds before the end of repressurization the AHLD E-SERIES Controller’s integrated Energy Management Purge Reduction System looks at the moisture sensor, if the moisture load is low enough, vessel 1 (T1) will continue to dry for an extended drying period until the moisture load has reached a set high level, the controller will then advance t
Heatless Regenerative Desiccant Air Dryer Maintenance Prior to performing any maintenance on the dryer, all personnel are strongly advised to familiarize themselves with the equipment by reading the entire contents of this operation manual. Aircel strongly recommends the strict adherence of all the safety procedures prior to any performing any maintenance activity on the dryer. A. The pressure differential indicator referred to as the “Delta-P” is a very good indicator of the state of the filter elements.
Aircel AHLD E-Series - Models 1000 - 5000 Maintenance (cont’d) Semi-Annual Checklist 1. Remove and inspect all filters for excessive particulate loading and physical damage – if required replace prefilters, afterfilters, pilot air filter and mufflers (filter elements should still be changed on regular basis once a year maximum for a 1 shift operation. Change more frequently if operating 2 or 3 shifts such as every 6 months.). 2.
Heatless Regenerative Desiccant Air Dryer Troubleshooting The following section briefly discusses the various faults that can occur in the dryer, the reason of the fault and how it can be rectified. If you do not find the solution to your problem, contact your Aircel representative or the factory. All necessary safety and precautionary steps must be followed before attempting to perform any of the recommended measures to resolve any faults in the air dryer.
Aircel AHLD E-Series - Models 1000 - 5000 Troubleshooting (cont’d) Problem High Dewpoint High-Pressure Drop High Back Pressure in Regenerating Tower Probable Cause Remedy High inlet air flow Reduce inlet air flow Inlet air temperature above design spec Reduce inlet air temperature to design spec Poor pre-filtration Check pre-filter element, replace if needed Inlet air pressure below design spec Increase pressure to the dryer Desiccant contaminated Replace desiccant Outlet Purge flow orifice
Heatless Regenerative Desiccant Air Dryer Troubleshooting (cont’d) Problem Dryer Fails to Shift Towers Probable Cause Remedy Exhaust valves(s) not functioning Check pilot valve and pilot air supply, dismantle and clean exhaust valve check flow control valve attached to purge exhaust valve actuator may not be adjusted properly (should be adjusted so exhaust valve opens within a 8-12 second time period) No input power Check that dryer is on with correct voltage.
Aircel AHLD E-Series - Models 1000 - 5000 Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2009/12/04 Version: 3.0 Page: 1/5 (30286124/MDS_GEN_US/EN) 1. Substance/preparation and company identification Company BASF CORPORATION 100 Campus Drive Florham Park, NJ 07932, USA 24 Hour Emergency Response Information CHEMTREC: 1-800-424-9300 BASF HOTLINE: 1-800-832-HELP 2. Composition/information on ingredients CAS Number 1333-84-2 Content (W/W) >= 94.0 - <= 100.
Heatless Regenerative Desiccant Air Dryer Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Version: 3.0 Page: 2/5 (30286124/MDS_GEN_US/EN) If on skin: After contact with skin, wash immediately with plenty of water and soap. Consult a doctor if skin irritation persists. If in eyes: In case of contact with the eyes, rinse immediately for at least 15 minutes with plenty of water. Immediate medical attention required. If swallowed: No hazards anticipated.
Aircel AHLD E-Series - Models 1000 - 5000 Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Version: 3.0 Page: 3/5 (30286124/MDS_GEN_US/EN) Advice on system design: Provide local exhaust ventilation to control dust. Provide local exhaust ventilation to maintain recommended P.E.L. Personal protective equipment Respiratory protection: Wear a NIOSH-certified (or equivalent) particulate respirator. Observe OSHA regulations for respirator use (29 CFR 1910.134).
Heatless Regenerative Desiccant Air Dryer Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Version: 3.0 Page: 4/5 (30286124/MDS_GEN_US/EN) Skin irritation: Information on: Aluminum oxide rabbit: non-irritant (OECD Guideline 404) ---------------------------------- 12. Ecological information Information on: Aluminum oxide Acute and prolonged toxicity to fish: DIN 38412 Part 15 static golden orfe/LC50 (96 h): > 500 mg/l The product has not been tested.
Aircel AHLD E-Series - Models 1000 - 5000 Desiccant Material Safety Data Sheet Safety data sheet F200 Revision date : 2008/12/04 Version: 3.
Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller System display shows the dryer operations and provides the user the ability to change certain dryer settings.
Aircel AHLD E-Series - Models 1000 - 5000 Aircel Programmable Controller Step 1: Vessel 2 Depressurizing (0-5 secs) Vessel 2 (T2) purge exhaust pilot solenoid valve is energized which supplies control air to the purge exhaust valve (V4) which opens slowly, depressurizing vessel 2 (T2).
Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Step 5: Vessel 1 Depressurizing (0-5 secs) Vessel 1 (T1) purge exhaust pilot solenoid valve is energized which supplies control air to the purge exhaust valve (V3) which opens slowly, depressurizing vessel 1 (T1).
Aircel AHLD E-Series - Models 1000 - 5000 Aircel Programmable Controller Main Screen Navigation LEFT/RIGHT ALARM SCREEN LEFT/RIGHT CONTROL MENU Control Menu Navigation LEFT/RIGHT MAIN SCREEN 30 LEFT/RIGHT SETTINGS MENU
Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Control Menu Operation • Push OK to engage the menu • Scroll to the desired selection and Push OK CONTROL MENU Settings Screen Operation For use with optional outlet dewpoint display and high humidity alarm.
Aircel AHLD E-Series - Models 1000 - 5000 Aircel Programmable Controller Time Control Menu Navigation This time cycle control menu allows the user to choose between a 10 minute standard time cycle and a shorter 5 minute cycle for lower dewpoint option. TIME CYCLE CONTROL LEFT/RIGHT LEFT/RIGHT SETTINGS MENU ANALOG SCREEN Time Control Menu Operation TIME CONTROL MENU 32 • To change the time cycle, Push OK then scroll to the time cycle to be selected.
Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Analog Screen Navigation The analog screen simply displays the analog output signals ANALOG SCREEN LEFT/RIGHT LEFT/RIGHT TIME CONTROL SCREEN HOURS OF OPERATION Hours of Operation Screen Navigation The hours of operation screen gives the user the amount of run time as well as the total amount of hours saved with the energy management system.
Aircel AHLD E-Series - Models 1000 - 5000 Aircel Programmable Controller Alarm Screen Navigation ALARM SCREEN LEFT/RIGHT TOTAL HOURS OF OPERATION LEFT/RIGHT MAIN MENU Alarm Pop-Ups • • • • 34 No Alarm: alarm has been corrected High Outlet Dew Point (option): dew point has reached set point (check desiccant, prefilters, control system) Failure to Shift (option): tower did not properly repressurize Bad Probe: the EMS sensor has reached an out of range signal (check sensor an
Heatless Regenerative Desiccant Air Dryer Aircel Programmable Controller Alarm Pop-Up Screens No Alarm is the normally closed state of the common alarm relay. The Drain Fault is an alarm that triggers when there is no air present on the drain or when the liquid level has reached a point that needs to Drain and cannot. The drain will also fault if there is a loss of power to the drain. The Bad RH Probe is an alarm that shows when the relative humidity (EMS) probe is out of range.
Aircel AHLD E-Series - Models 1000 - 5000 Electrical Drawings Main Power & PLC Input: All AHLD E Models 36
Heatless Regenerative Desiccant Air Dryer Electrical Drawings Main Power & PLC Input: All AHLD E Models 37
Aircel AHLD E-Series - Models 1000 - 5000 Electrical Drawings PLC Output & Sensors: All AHLD E Models 38
Heatless Regenerative Desiccant Air Dryer Electrical Drawings PLC Output & Sensors: All AHLD E Models 39
Aircel AHLD E-Series - Models 1000 - 5000 Electrical Drawings Back Panel: All AHLD E Models 40
Heatless Regenerative Desiccant Air Dryer Electrical Drawings Enclosure Layout: All AHLD E Models 41
Aircel AHLD E-Series - Models 1000 - 5000 Service Notes Date 42 Service Performed Notes
Heatless Regenerative Desiccant Air Dryer Service Notes Date Service Performed Notes 43
Aircel Compressed Air & Gas Warranty Aircel warrants that its Standard Refrigerated Air Dryers are free from defects in materials and workmanship for two years from the date of invoice. Warranty coverage for this time period will be parts and labor for the first year and parts only for the second. Custom engineered products, desiccant dryers, chillers and nitrogen generators are warranted to be free from defects in materials and workmanship for one year from date of invoice.
