Pneumatic Air Supply Manual 718 Air Dryers Section Technical Bulletin A-4400 Issue Date 1213 A-4400 Series Refrigerated Air Dryers Installation and Maintenance INTRODUCTION 3 Product Overview 3 INSTALLATION PROCEDURES Location 4 Unpacking the Unit 4 Conventional Wall Mounting Arrangement 4 Air Connections 5 Base Mounting Arrangement 6 Activated Carbon Filter Installation 6 Drain Connections 7 Permanent Wiring Using Conduit 8 Wiring to Air Compressor 9 COMMISSIONING 10 Gauge Correct
Activated Carbon Oil Vapor Removal Filter 15 Pressure Reducing Valve 15 Power On/Fail Lamp 15 Refrigeration Service 16 Condenser Fan Motor Replacement 21 Condenser 23 Air Dryer Compressor Motor Wiring Circuit 23 Excessive Vibration 24 SPECIFICATIONS 25 REPAIR INFORMATION 26 2 Air Dryers—A-4400 Series Technical Bulletin
Introduction Product Overview The A-4400 Series Refrigerated Air Dryers are designed for continuous operation to supply dry air to pneumatic control systems. All components are selected and assembled to provide dependable service over a long period of time with a minimum amount of maintenance.
Installation Procedures Location The A-4400 Series Refrigerated Air Dryer must be located in an open area that will permit free circulation of air through the ends of the unit. The A-4400 requires 12 in. (305 mm) top clearance (as measured from the top of the cabinet) and 12 in. clearance at either end. When the unit is wall mounted, it is recommended that there also be 10 in. (254 mm) bottom clearance. Unpacking the Unit Hand protection is required when removing the A-4400 from its shipping carton.
12-15/16 329 Note: The A-4400 requires 12 in. (305 mm) top clearance and 12 in. clearance on either end. When wall mounting the A-4400, 10 in. (254 mm) bottom clearance is recommended. Also, attach the 3/8 in. discharge main air line to the PRV before mounting. A-4412-1: 17-1/2 445 21-3/4 552 A-4417-1 and A-4423-1: 22-1/16 560 A-4412-1: 16 406 18-1/16 459 In + 12-5/8 321 + Key Slots (Two Locations) for 1/4 in.
Base Mounting Arrangement Several mounting hole patterns are provided in the base of the A4400 (refer to Figure 2) for securing the unit to a platform. These mounting holes are sized for 1/4-20 self-tapping screws or a No. 12 nut and bolt combination (all field furnished). 11/16 17 Mounting Holes (Eight Locations) for 1/4-20 Self-tapping Screws or a No.
3. Use the expected life calculated in Step 2 to determine the replacement date, and record this date on the servicing label on the carbon filter element. 4. Remove the red plastic dust cap from the carbon filter pipe connection. 5. With the black sealing washer in position on the base of the carbon filter element, screw the element onto the male pipe thread and hand tighten to complete the installation.
Permanent Wiring Using Conduit All A-4400 Series Refrigerated Air Dryers are furnished with a cord and plug to fit a standard 115 volt receptacle. If permanent wiring is required using conduit, proceed as follows: 1. Cut the line cord to a sufficient length so that it will reach from the compressor terminal box through Hole 1 as illustrated in Figure 3; 12 in. (305 mm) should be long enough. 2. Strip the wires back approximately 1 in. (25 mm). 3.
Wiring to Air Compressor Wiring may be run through the load side of the air compressor disconnect switch ahead of the Pressure Electric (PE) switch, as illustrated in Figure 4. Doing so will allow continuous A-4400 operation whenever the disconnect switch is closed, while control over the air compressor is retained by the PE switch. Note: The air dryer motor voltage must match the air compressor motor voltage in order to wire the unit as illustrated in Figure 4.
Commissioning Gauge Correction The evaporator pressure gauge is calibrated to a test gauge at the factory. Readings are recorded on a label inside the dryer cabinet base. Apply this correction to the evaporator gauge to obtain a precise reading. Evaporator Pressure Adjustment The A-4400 Series Refrigerated Air Dryers are factory set to protect against air side freeze-up down to ambient temperatures of 40F (4C) and altitudes up to 1500 ft.
43 42 41 40 39 38 Evaporator Pressure (psig) 37 36 35 34 33 32 31 30 29 28 27 26 40 50 60 70 80 90 100 110 120 130 Ambient Temperature (°F) Acceptable Operating Zone Nominal Setting Figure 5: Evaporator Pressure vs.
Servicing Procedures Particle Filter The A-4400 Series Refrigerated Air Dryer is equipped with an automatic condensate drain trap assembly with a particle filter. The particle filter should be replaced annually or whenever the filter element appears dirty. To replace the particle filter element and/or automatic drain valve, refer to Figure 6 and proceed as follows: 1. Remove the service bypass valve locking pin and push the plunger to the right into the bypass position.
4 7 3 6 2 8 1 5 Figure 6: Particle Filter/Auto Drain Replacement Coalescing Oil Removal Filter The coalescing oil removal filter is equipped with an automatic drain for discharging accumulations of entrapped liquids. This filter also features a pressure drop indicator integral to the top of the unit (refer to Figure 7). On a new filter, this indicator is green in color. As the pressure drop across the filter increases, a slide within the indicator moves, bringing some red color into view.
Pressure Drop Indicator Note: Even if the indicator is not entirely red, it is recommended that the filter element be replaced annually. Coalescing Filter Element, and O-rings Replacement Drain Valve Complete Assembly Universal O-ring Kit Figure 7: Coalescing Oil Removal Filter Replacement Coalescing Oil Removal Filter Element Kit Each kit includes one replacement filter element, one filter element O-ring, and one filter bowl O-ring (refer to Figure 7).
4. Viewing the old filter from the bottom, turn the element counterclockwise to remove it. 5. Clean the small screen around the drain seat of the automatic drain valve by turning the filter bowl upside down and tapping it lightly. 6. Visually inspect the bowl for signs of cracking. If the bowl is cracked, it will be necessary to replace the complete assembly (A-4000-1048 or A-4000-1049 ordered separately).
Refrigeration Service 3. Slide the old lamp forward out of its cutout and discard; a pliers may be required. 4. Splice the replacement bulb to the existing leads using wire nuts (field furnished). 5. Slide the replacement lamp (A-4300-602 ordered separately) into the cutout and push in until it reaches the chrome stop. 6. Reconnect the power supply to the air dryer. 7. Check that the lamp is illuminated when the compressor is running.
3. Turn the expansion valve adjusting screw to provide an evaporator pressure that corresponds to the ambient temperature determined in Figure 5. Turning the screw clockwise increases the pressure; counterclockwise decreases the pressure. One complete revolution (360 degrees) equals a pressure change of approximately 10.5 psi (73.5 kPa).
4. Using a vacuum pump, evacuate any remaining air and moisture. 5. Charge the unit with R-134a refrigerant to within 1/4 ounce of the amount specified on the air dryer nameplate. 6. Remove the charging manifold and replace the cap securely on the service valve. 7. Reinstall the A-4400 cover and reconnect the power supply to the air dryer. 8.
Figure 9: A-4400 Series Refrigerated Air Dryer with Cover Removed Air Dryers—A-4400 Series Technical Bulletin 19
Service Bypass Valve Inlet From Air Compressor Safety Relief Valve Evaporator Pressure Gauge Suction Line Discharge Line Service Valve Heat Exchanger Condenser Line Auto Exp.
Condenser Fan Motor Replacement To replace the condenser fan motor, refer to Figure 12 and proceed as follows: 1. Disconnect the power supply to the air dryer. 2. Remove the cover mounting screws and take the cover off the unit. Retain screws for reassembly. 3. Remove the cable tie securing the cord to the protecting screen. 4. Working from underneath the cabinet and using a 3/8 in. wrench, remove the two mounting screws that secure the fan assembly to the cabinet base. Retain screws for reassembly.
16. Splice the two leads of the replacement fan motor to the existing leads using wire nuts (field furnished). 17. Reconnect the power supply to the air dryer. 18. Check for excessive vibration. If the unit is vibrating excessively, it is likely that one or more of the fan blades is misaligned. To align the blades, refer to the Excessive Vibration section in this bulletin. 19. Reinstall the cabinet cover, and using a 1/4 in.
Condenser Air Dryer Compressor Motor Wiring Circuit Check the condenser periodically for dust/particle buildup between the fins; this buildup could eventually lead to a reduction in heat transfer. If there is a buildup, remove it using a vacuum cleaner and a soft brush. If there is power to the air dryer and the compressor is not operating, using an ohmmeter and referring to Figure 13, check the electrical service as follows: 1. Disconnect the power supply to the air dryer. 2.
Figure 13: Air Dryer Compressor Motor Wiring Diagram Excessive Vibration If the A-4400 appears to be vibrating excessively, it is likely that one or more of the condenser fan blades is misaligned. To align all five fan blades, proceed as follows: 1. Disconnect the power supply to the air dryer. 2. Place a reference (such as a piece of cardboard) against the trailing edge of one of the fan blades. 3.
Specifications Product Electrical Rating A-4400 Series Refrigerated Air Dryers 115 Volt 60 Hz, Single-phase Electrical Service Current Draw 5.
Repair Information Figure 14: Repair Parts (See Table 3) Figure 15: Repair Parts (See Table 3) 26 Air Dryers—A-4400 Series Technical Bulletin
Table 3: Repair Parts Item Description Shipping Weight lb* Date Codes through RY1 9923 CodeNumber Date Codes after RY1 9923 A System Pressure Gauge 0.1 G-2010-5 B Evaporator Pressure Gauge 0.2 A-4300-603 C Pressure Reducing Valve 1.7 R-130-14 D Service Bypass Valve 0.
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