Installation and Operation Manual Installation, Operation, and Service Information Aircel VF Series Non-Cycling Refrigerated Air Dryer Models VF-10, 15, 25, 40, 50, 60, 75, 100, 125, 150, 200, 250, 300, 400, 500 600, 800, 1000, 1200, 1600 and 2000 Throughout this manual, signal words are present to advise of safety precautions and/or standard practices.
Aircel VF Series - Models 10 - 2000 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.
Non-Cycling Refrigerated Air Dryer Contents Safety Statements................................................... 2 Data Sheet.............................................................. 4 Refrigerant Safety Precautions............................... 5 Design Parameters.................................................. 6 Description............................................................ 6 System........................................................... 6 Refrigeration Circuit........................
Aircel VF Series - Models 10 - 2000 Data Sheet Model Number_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Serial Number_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Date of Manufacture _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Ship Date_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Installation Date_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Cus
Non-Cycling Refrigerated Air Dryer Refrigerant Safety Precautions Refrigerant First Aid Recommendations CAUTION! Inhalation, Skin, & Eye Irritant • Use proper safety and protective equipment, including chemical safety goggles or face shield and impervious gloves when handling refrigerants. • Exercise care to ensure that liquid refrigerant does not come in contact with your skin or eyes. • DO NOT SMOKE.
Aircel VF Series - Models 10 - 2000 Design Parameters Type of dryer: Refrigerated Power supply: 115, 230, 460 Volt / single or three phase / 60Hz equipment as the higher operating pressures and improved heat transfer properties allow for smaller condensers, which leads to air dryers with smaller footprints.
Non-Cycling Refrigerated Air Dryer Refrigeration Circuit Refrigerant is compressed by the compressor to a gas with high temperature and high pressure, which then travels to the condenser (air or water cooled) to condense the gas into a liquid. Liquid travels to the evaporator (refrigerant-to-air part of the heat exchanger) and back to the compressor suction side. The process then repeats.
Aircel VF Series - Models 10 - 2000 air inlet air outlet separation cell stainless steel mist eliminator air to refrigerant heat exchanger incoming air pre-cooler / heater exiting air air refrigerant inlet refrigerant refrigerant outlet Typical Schematic Flow Diagram (75 - 1200 scfm rated models) 8
Non-Cycling Refrigerated Air Dryer Purpose and Intended Use Inspection on Arrival Non-cycling refrigerated air dryers are designed to remove moisture from compressed air by use of mechanical refrigeration. They can provide pressure dew points as low as (38° F- 42° F). Referigerated dryers are used to protect industrial compressed air systems, machinery, and tools.
Aircel VF Series - Models 10 - 2000 Lifting Information Installation Codes and Procedures 1. Use all lifting points provided. Special care must be used when lifting the dryer to prevent tipover. WARNING! 2. Use clevis connectors, not hooks, on lifting slings. • 3. Only lift unit under support frame/base by using the fork lift openings provided. Do not lift by piping. Follow proper lock out/tag out procedures before performing service or maintenance work.
Non-Cycling Refrigerated Air Dryer Installation 1. Locate unit on a level foundation. Dryer should be mounted on a suitably structured flat and level floor or base that is free from vibration. 2. Install unit to provide adequate clearance for maintenance services. Dryer and accompanying filters should be installed with at least 2 to 5 feet clearance from the adjoining walls to provide easy access for routine maintenance and adequate air flow across the condensing coil. 3.
Aircel VF Series - Models 10 - 2000 Typical Installation Typical Installation Preliminary Start-Up Checklist Notice: For scfm rated models 10 - 250, wait at least 6 hours after transporting or moving of dryer system before starting the dryers. Turn the main power switch to the dryer on, but do not turn the dryer on/off switch to the on position until 6 hours have passed.
Non-Cycling Refrigerated Air Dryer 5. With the customer-supplied compressed air to the system, OPEN the inlet valve slowly to gradually pressurize the system. Do not open valve too quickly. Opening valve and suddenly pressurizing the system can cause damage to the dryer heat exchanger and other components. d. The refrigeration gauge readings should be as follows: 6. Check the air system piping connections and dryer system connections for leaks at this time. Repair and retest any leaks. 7.
Aircel VF Series - Models 10 - 2000 Automatic Drain Valve Adjustments Air Cooled Condenser Requirements The automatic drain valve supplied is standard on the separator and should open regularly and discharge any accumulated water into the drain line. The period between openings varies with the dryer and operating conditions (electronic type). To minimize air losses, the timer should be adjusted to open the drain solenoid just long enough to discharge the accumulated condensate.
Non-Cycling Refrigerated Air Dryer Cooling Water Requirements (water cooled condensing units) Cooling water is required for water-cooled refrigerant condensers. The user is responsible for piping the water to and from the condenser. The required water flow rate depends on the water temperature. A water-regulating valve (supplied with the dryer) automatically adjusts the flow to compensate for variation in water temperature, water pressure, and dryer air load.
Aircel VF Series - Models 10 - 2000 Shut-Down Procedures WARNING! • To avoid possible hazard or injury, the operator should be fully familiar with the refrigerated air dryer system and its operation. • When the system is shutdown and power removed, lock out power supply and depressurize system before performing maintenance or service work to avoid injury to personnel or property damage.
Non-Cycling Refrigerated Air Dryer Service Information To reach a field service technician or for technical support, please call the number on the manual back cover. Daily Maintenance With the dryer on-line: Refrigerated air dryers require very little maintenance for satisfactory operation. Optimum performance can be expected if the following routine maintenance steps are taken.
Aircel VF Series - Models 10 - 2000 Filter Element Replacement 1. Depressurize the air system to release the compressed air from the air dryer. Notice: Shutting down the air compressor will not depressurize the air dryer unit. Close air line valves before and after dryer and then depressurize unit. Depressurize dryer by pushing the test button on the dryer system drain until there is no more pressure in the dryer system. 2.
Non-Cycling Refrigerated Air Dryer Troubleshooting Electrical WARNING! • WARNING! Before any service or maintenance work is performed on the refrigerated air dryer system, disconnect power supply and lock out power supply and depressurize system. • Follow proper lock out/tag out procedures before performing service or maintenance work. • Electrical installation or maintence must be performed by a qualified electrician and comply with all applicable national and local codes.
Aircel VF Series - Models 10 - 2000 1. High refrigerant readings generally indicate: • Dirty condenser - Clean immediately! • Dryer not turned on. • Overloading - Airflow or conditions in excess of dryer capacity. • High ambient temperature (> 100°F) Provide adequate ventilation for proper cooling, or reduce ambient temperature. • Condenser fan(s) not running - Call Technical Support. • Refrigerant control too high - Contact technical support for assistance.
Non-Cycling Refrigerated Air Dryer Troubleshooting Table Problem Probable Cause Water downstream Failed or short circuited of dryer system or no timer on drain. discharge from separator/ filter. Failed drain solenoid. Remedy Replace timer drain. Replace timer drain. Bulk liquid entering the dryer from upstream. Check drains on after cooler or air compressor. Inlet compressed air temperature to dryer exceeds dryer capacity air.
Aircel VF Series - Models 10 - 2000 Troubleshooting Table, continued Problem Probable Cause Remedy Water downstream and dryer system not working properly or not working (Cont). Refrigeration compressor cycles on/off and cannot maintain suction pressure, dryer undersized. Check airflow (cfm) and dryer capacity. Reduce airflow through dryer or replace with a larger rated cfm dryer. Shorted fan motor winding. Check fan motor with ohmmeter and refer to motor specifications for correct value.
Non-Cycling Refrigerated Air Dryer Problem Probable Cause Remedy Low air pressure downstream due to continuous air flow through the moisture drain line. Failed or short circuited timer on drain. Replace timer drain. Failed drain solenoid. Replace timer drain. Solenoid valve stuck open. If power is off and the air stops leaking, replace the timer drain. If power is off and air continues leaking, clean the timer drain. Shipping damage has caused compressor mounting to loosen.
Aircel VF Series - Models 10 - 2000 Troubleshooting Table, continued Problem Probable Cause High Refrigeration Circuit Refrigeration condenser Head Pressure coil fouled or dirty or air (compressor is overloaded flow blocked. and gauge is reading out of recommended pressure range). Condenser fan motor not working properly. Low Refrigeration Circuit Head Pressure (gauge is reading out of recommended pressure range). 24 Remedy Clean / blow off condensing coil of dirt or debris from the inside out.
Non-Cycling Refrigerated Air Dryer Problem Probable Cause Remedy High refrigerant suction pressure, suction gauge reading out of range and water downstream of refrigeration dryer. Refrigeration circuit hot gas bypass valve out of adjustment or defective. Contact technical support for assistance. Refrigeration expansion valve or TXV adjustment fitting out of adjustment. Contact technical support for assistance.
Aircel VF Series - Models 10 - 2000 Appendix Refrigerant Material Safety Data Sheet - R-134A (VF-10 - VF1200) MATERIAL SAFETY DATA SHEET Prepared to U.S. OSHA, CMA, ANSI and Canadian WHMIS Standards 1. PRODUCT IDENTIFICATION CHEMICAL NAME; CLASS: NON-FLAMMABLE GAS MIXTURE Containing One of the Following Components in a Nitrogen or Air Balance Gas: Dichlorodifluoromethane, 0.0005-2.0%; Trichlorofluoromethane, 0.0005-2.0%; 1,1,2-Trichloro-1,1,2-trifluoroethane, 0.0005-2.0%; Tetrafluoroethane, 0.0005-2.
Non-Cycling Refrigerated Air Dryer 3. HAZARD IDENTIFICATION EMERGENCY OVERVIEW: This gas mixture is a colorless, odorless gas. Releases of this gas mixture for which Nitrogen is the balance gas may produce oxygen-deficient atmospheres (especially in confined spaces or other poorly-ventilated environments); individuals in such atmospheres may be asphyxiated.
Aircel VF Series - Models 10 - 2000 R134-A Refrigerant Material Safety Data Sheet, continued 8. EXPOSURE CONTROLS - PERSONAL PROTECTION VENTILATION AND ENGINEERING CONTROLS: No special ventilation systems or engineering controls are needed under normal circumstances of use. As with all chemicals, use this gas mixture in well-ventilated areas. If this gas mixture is used in a poorly-ventilated area, install automatic monitoring equipment to detect the levels of Phosphine and Oxygen.
Non-Cycling Refrigerated Air Dryer 1,1,2-TRICHLORO-1,1,2TRIFLUOROETHANE (continued): LC50 (Inhalation-Mouse) 260 gm/m3/2 hours: Behavioral: somnolence (general depressed activity), ataxia; Lungs, Thorax, or Respiration: cyanosis LC50 (Inhalation-Rabbit) 59,500 ppm/2 hours: Sense Organs and Special Senses (Eye): effect, not otherwise specified; Behavioral: excitement; Lungs, Thorax, or Respiration: respiratory stimulation LC50 (Inhalation-Guinea Pig) >12 pph/2 hours LD (Skin-Rabbit) > 11 gm/kg LDLo (Oral-Gu
Aircel VF Series - Models 10 - 2000 R134-A Refrigerant Material Safety Data Sheet, continued 15. REGULATORY INFORMATION ADDITIONAL U.S. REGULATIONS: U.S. SARA REPORTING REQUIREMENTS: This gas mixture is subject to the reporting requirements of Sections 302, 304, and 313 of Title III of the Superfund Amendments and Reauthorization Act, as follows: SARA 302 (40 CFR 355, Appendix A) SARA 304 (40 CFR Table 302.4) SARA 313 (40 CFR 372.
Non-Cycling Refrigerated Air Dryer Appendix Refrigerant Material Safety Data Sheet - R-404A (VF-1600 and larger) Material Safety Data Sheet R-404A 1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION PRODUCT NAME: DISTRIBUTOR: R-404A National Refrigerants, Inc. 661 Kenyon Avenue Bridgeton, New Jersey 08302 FOR MORE INFORMATION CALL: (Monday-Friday, 8:00am-5:00pm) 1-800-262-0012 2.
Aircel VF Series - Models 10 - 2000 R-404A Refrigerant Material Safety Data Sheet, continued R-404A INGESTION: Ingestion is unlikely because of the low boiling point of the material. Should it occur, discomfort in the gastrointestinal tract from rapid evaporation of the material and consequent evolution of gas would result. Some effects of inhalation and skin exposure would be expected. DELAYED EFFECTS: None known. Ingredients found on one of the OSHA designated carcinogen lists are listed below.
Non-Cycling Refrigerated Air Dryer R-404A UNUSUAL FIRE AND EXPLOSION HAZARDS: R-404A is not flammable at ambient temperatures and atmospheric pressure. However, this material will become combustible when mixed with air under pressure and exposed to strong ignition sources. Contact with certain reactive metals may result in formation of explosive or exothermic reactions under specific conditions (e.g. very high temperatures and/or appropriate pressures).
Aircel VF Series - Models 10 - 2000 R-404A Refrigerant Material Safety Data Sheet, continued R-404A EYE PROTECTION: For normal conditions, wear safety glasses. Where there is reasonable probability of liquid contact, wear chemical safety goggles. RESPIRATORY PROTECTION: None generally required for adequately ventilated work situations.
Non-Cycling Refrigerated Air Dryer R-404A 10. STABILITY AND REACTIVITY NORMALLY STABLE? (CONDITIONS TO AVOID): The product is stable. Do not mix with oxygen or air above atmospheric pressure. Any source of high temperature, such as lighted cigarettes, flames, hot spots or welding may yield toxic and/or corrosive decomposition products. INCOMPATIBILITIES: (Under specific conditions: e.g.
Aircel VF Series - Models 10 - 2000 R-404A Refrigerant Material Safety Data Sheet, continued R-404A 13. DISPOSAL CONSIDERATIONS RCRA Is the unused product a RCRA hazardous waste if discarded? If yes, the RCRA ID number is: Not a hazardous waste. Not applicable. OTHER DISPOSAL CONSIDERATIONS: Disposal must comply with federal, state, and local disposal or discharge laws. R-404A is subject to U.S.
Non-Cycling Refrigerated Air Dryer R-404A STATE RIGHT-TO-KNOW In addition to the ingredients found in Section 2, the following are listed for state right-to-know purposes. INGREDIENT NAME No ingredients listed in this section WEIGHT % COMMENT ADDITIONAL REGULATORY INFORMATION: R-404A is subject to U.S. Environmental Protection Agency Clean Air Act Regulations at 40 CFR Part 82.
Aircel VF Series - Models 10 - 2000 Wiring Diagram, SCFM Rated Models 10 to 75: 1 Phase, 120 Volt, 60 Hz 38
Non-Cycling Refrigerated Air Dryer Wiring Diagram, SCFM Rated Models 100, 125, and 150: 1 Phase, 120 Volt, 60 Hz 39
Aircel VF Series - Models 10 - 2000 Wiring Diagram, SCFM Rated Model 200: 1 Phase, 208/230 Volt, 60 Hz 40
Non-Cycling Refrigerated Air Dryer Wiring Diagram, SCFM Rated Model 250: 3 Phase, 230 Volt, 60 Hz 41
Aircel VF Series - Models 10 - 2000 Wiring Diagram, SCFM Rated Model 250: 3 Phase, 460 Volt, 60 Hz 42
Non-Cycling Refrigerated Air Dryer Wiring Diagram, SCFM Rated Model 300 to 1200: 3 Phase, 460 Volt, 60 Hz 43
Aircel VF Series - Models 10 - 2000 Wiring Diagram, SCFM Rated Models 1600 and 2000: 3 Phase, 460 Volt, 60 Hz 44
Non-Cycling Refrigerated Air Dryer Service Notes Date Service Performed Notes 45
Aircel VF Series - Models 10 - 2000 Service Notes, continued Date 46 Service Performed Notes
Non-Cycling Refrigerated Air Dryer Service Notes, continued Date Service Performed Notes 47
Aircel Compressed Air & Gas Warranty The Manufacturer warrants it standard Refrigerated Dryers are free from defects in materials and workmanship for two years (1st year parts and labor, 2nd year parts only) from the date of invoice. Custom engineered products, desiccant air dryers, and nitrogen generators are warranted to be free from defects in materials and workmanship for one year (parts and labor coverage) from date of invoice.
