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.
WARNING! - indicates a
potentially hazardous situation
which, if not avoided, could
result in death or serious injury.
CAUTION! - indicates a
potentially hazardous situation
which, if not avoided, may result
in minor or moderate injury.
Notice: - used to address
practices not related to personal
injury.
This manual is property of the owner, and should be left with the unit when
start-up is complete. Aircel LLC. reserves the right to change design and
specifications without prior notice.
Installation,
Operation, and
Service Information
Aircel
&DP-Series Regenerative Air Dryer
Models &DP-70, 100, 150, 200, 250, 300, 350,
450, 500
Installation
and Operation Manual
2
WARNING!
General Safety Procedures
• Improperinstallation,operation,ormaintenancemaycontributetoconditionsinthework
areaorfacilitythatcouldresultinpersonalinjuryandproductorpropertydamage.Check
that all equipment is properly selected and sized for the intended use.
• Consultandcomplywithnationalandlocalcodesrelatingtofireorexplosionandall
other appropriate codes when determining the location and operation of this equipment.
• Safeandefficientoperationoftheunitdependsonproperinstallation.
• Authoritieswithjurisdictionshouldbeconsultedbeforeinstallingtoverifylocalcodesand
installationprocedures.Intheabsenceofsuchcodes,installunitaccordingtotheNational
ElectricCode,NFPANo.70-latestedition.
• Aqualifiedinstallationandserviceagentmustcompleteinstallationandserviceofthis
equipment.
• DONOTweldon/topressurevesselormodifyitinanyway.
• DONOTremove,modify,oradjustprotectiveorsafetydevices.
• Lockoutpowersupplyanddepressurizesystembeforeperformingmaintenanceorservice
work.
• DONOToperatetheequipmentwiththecontrolpaneldooropen.
Notice: Foroptimumperformance,useonlyAircelreplacementparts.
Thismanualcontainsspecificprecautionarystatementsrelativetoworkersafety.
Readthoroughlyandcomplyasdirected.Discusstheuseandapplicationofthis
equipmentwitharepresentative.Instructallpersonnelonsafeuseandmaintenance
procedures. Understand and obey the following signal words used in this manual.
•DANGER! - indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury.
•WARNING! - indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
•CAUTION! - indicates a potentially hazardous situation which, if not avoided, may
result in minor or moderate injury.
•Notice: - used to address practices not related to personal injury.
Notice: Foroptimumperformance,useonlyoriginalequipmentreplacementparts.
Notice:Forinformationandnotesspecifictoacustomdesignedandbuiltdryer,referencethe
drawingpackageprovidedwiththeunit.Seewarrantyonmanualbackcoverfor
custom engineered products.
Aircel CDP-Series Models 70 - 500
Heatless Regenerative Air Dryer
3
Introduction
ThankyouforpurchasingAircel’s CDP-Series Regenerative Air Dryer System. You are now the proud owner of
one of the finest air dryers on the market. Aircel CDP-Series regenerative air dryers are engineered and
manufactured to provide you with many years of trouble free service.
To ensure that you get the get first class service from this equipment, we recommend you take some time and
read the contents of this manual.
Thismanualcontainsalltheinformationrequiredforinstallingandmaintainingyournewequipment.It
also includes the safety procedures and corresponding drawings. We strongly suggest that all personnel
involved with the machine, read the entire contents of the manual before proceeding with the installation or
maintenance activities.
Themanufacturerreservestherighttomakechangeswithoutanypriornotificationandisnotobligatedin
anymanner.InformationinthismanualisdeemedcurrentatthetimeofpublicationandAirceldisclaimsall
liability for any errors resulting in any loss or damage.
IfyouhavequestionsorneedadditionalcopiesorwouldliketoscheduleaAircel'sservicemanvisit,contact
your distributor.
Aircel
323 Crisp Circle
Maryville,TN37801
Toll-Free:(800)767-4599
Tel:(865)681-7066
Fax:(865)681-7069
Sales Information:
Order Entry:
www.AircelDryers.com
Contents
SafetyStatements .................................................. 2
Introduction .......................................................... 3
DataSheet ............................................................. 4
SafetySymbols ...................................................... 5
GeneralSafetyInstructions ................................... 6
Description............................................................ 7
Purpose&IntendedUse .............................. 7
Features&Options ..................................... 8
InspectiononArrival ............................................ 9
TechnicalSpecifications ...................................... 10
HowitWorksDiagram ...................................... 11
Installation .......................................................... 12
TypicalInstallation ............................................. 12
InstallationChecklist .......................................... 13
Start-UpProcedure .............................................. 14
Shut-DownProcedure ......................................... 15
SequenceofOperation ........................................ 15
ServiceInformation ............................................. 17
Maintenance&Checklists ......................... 17
Troubleshooting .................................................. 19
Troubleshooting Table ........................................ 20
DesiccantMaterialSafetyDataSheet .................. 22
AircelProgrammableController ......................... 27
ElectricalDrawings ............................................. 36
MainPower&PLCInput.......................... 36
PLCOutput&Sensors .............................. 38
BackPanel .................................................. 40
Enclosure Layout ....................................... 41
ServiceNotes ...................................................... 42
Warranty............................................................. 44
4
Data Sheet
ModelNumber _____________________________________ SerialNumber ________________________________________
DryerType ________________________________________ DateofManufacture __________________________________
ShipDate __________________________________________ InstallationDate ______________________________________
CustomerName ____________________________________ Address ______________________________________________
AddressCont’d __________________________________________________________________________________________
A c c e s s o r i e s ___________________________________________________________________________________________________________________
O t h e r __________________________________________________________________________________________________________________________
DryerInletAirFlowRate ________________________________________________________________________________________
DryerInletTemperature __________________________________________________________________________________________
DryerAmbientTemperature____________________________________________________________________________________
DryerVoltage______________________________________________________________________________________________________
DryerMCAMinimumCircuitAmpacity_____________________________________________________________________
DryerMOPMaximumOvercurrentProtection______________________________________________________________
DryerOperatingPressure________________________________________________________________________________________
DryerMaximumOperatingPressure__________________________________________________________________________
DryerVesselPressureReliefValveSetting____________________________________________________________________
DryerDesiccantType_____________________________________________________________________________________________
DryerDesiccantWeightperVessel_____________________________________________________________________________
DryerDesiccantWeightTotalforSystem_____________________________________________________________________
DryerOutletDewpoint___________________________________________________________________________________________
DryerControlTimeCycle_______________________________________________________________________________________
DryerEMSRHSensorSetting(forsensingmid-bedmoisture)___________________________________________
HighDewpointSetting(option)________________________________________________________________________________
DemandCycleSetting(option)_________________________________________________________________________________
OutletDewpointReadoutonDisplay(option)______________________________________________________________
ElectricalDrawingNo.___________________________________________________________________________________________
MechanicalDrawingNo.________________________________________________________________________________________
PLCSoftwareProgramNo._____________________________________________________________________________________
ControlAirFilterElementNo._________________________________________________________________________________
InletPre-FilterElementNo.(option)___________________________________________________________________________
OutletAfter-FilterElementNo.(option)_______________________________________________________________________
InletValve__________________________________________________________________________________________________________
PurgeExhaustValve______________________________________________________________________________________________
VesselNationalBoardNo.(leftandrightvessels)__________________________________________________________
DryerSystemWeight_____________________________________________________________________________________________
Aircel CDP-Series Models 70 - 500
Heatless Regenerative Air Dryer
5
Safety Symbols Used in Manual
Important Information:Readersofthemanualmustpayextraattentionto
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:
Thismeansthatthereisariskofelectricshockand
only authorized personnel with proper gear must approach it.
High Noise Area: All personnel are required to wear ear protectors before
approaching the vicinity of the equipment.
Hazardous Fumes & Gases:
Personnelmustwearprotectivegeartopreventinhaling
of the gases and fumes.
Suspension Points:
Lookforthesesymbolsbeforemakinganyattempttomoveor
relocate your equipment.
Tips & Suggestions:
Followingthesetipscanmakeyourworkeasier.
Extreme Caution:
Thisindicatesthattheremightbepossibleriskofmaterialdamage
andpersonnelareadvisedtoexerciseextracaution.
Safety Instructions
6
General Safety Instructions
What You Must Do
1. Certified/authorizedelectriciansmustperformelectricalwork
2. ElectricalworkmustconformtothespecificationsindicatedbyAircelandanylocalorstatelawsthat
may apply.
3. Personnelmustwearappropriatesafetygearbeforeworkingonanyelectricalormechanicalaspectsof
the machine.
4. Appropriatetoolshavetobeusedforallinstallationandmaintenancework.Ifspecialtoolsarerequired
and are not available to the installation crew, contact the factory or your Aircel representative.
5. AcopyoftheOperationManualmustbemadeavailabletoallpersonnelinvolvedwiththeinstallation,
operation and maintenance of the equipment.
6. Before performing any maintenance operations on the equipment, the unit must be shut down, isolated,
electrical power removed, and completely depressurized.
7. To ensure compatibility and continued trouble free operation, only genuine Aircel parts must be used.
What You Must Not Do
1. Donotmakeconstructionalchangestotheunit.OnlyAirceloritsauthorizedrepresentativeswiththe
priorapprovalcanperformanyconstructionalworkonthemachine.
2. Donotuseforeignparts.
3. Compressedairfromthedryersisnottobeusedforbreathingpurposes–installabreathingairpackage
toensureconformancewithOSHAregulations
4. Donotdisableordisengageanyprotectiveequipmentusedonthemachine.
Safe Operating Procedures
1. PressurizeanddepressurizecompressedairSLOWLY!Alwaysopenairvalvesslowlywhenpressurizing
the airline system or equipment. Replace air slowly when depressurizing your air system or equipment.
2. Circuitbreakers,fusibledisconnect,andwiringshouldconformtonationaland/orlocalelectricalcodes.
Makecertainthatqualifiedelectricalpersonnelperformtheelectricalinstallationforthisunit.
3. Only use original fuses for the rated voltage and current.
4. Shutdowntheunitinthecorrectrecommendedprocedure.
5. BeforeanyworkonsystemalwaysDepressurizetheunitandremoveallelectricalpower.
6. Aftershutdown,putupwarningnoticetopreventtheunitfrombeingswitched“ON”accidentally.
7. Inspectallpiping,hosesandconnections.Makesurethatallhosesareingoodconditionandarerated
forthecorrectworkingpressure.Donotallowhosestocomeintocontactwithoil,chemicals,orsharp
objects.
8. Securecondensatedrainlines.Unsecuredflexibledrainlinesmaywhipviolentlyunderpressureandmay
cause bodily harm.
Aircelairdryersdonotremovecarbonmonoxideandisnotsafeforhumanrespiration(breathing).
BreathingairmustbeatleastgradeDqualityasdescribedincompressedairandgasassociation(CAGI)
commodityspecifications67.1-1966.UsermayrefertoOSHA29CFI1910.134forspecialprecautions
and equipment suitable for breathing air applications. Aircel disclaims any liability what so ever for loss,
injury or damage.
Aircel CDP-Series Models 70 - 500
7
Heatless Regenerative Air Dryer
Why We Need Compressed Air Dryers
Untreated compressed air contains many contaminants such as water, compressor oil, pipe scale and
contaminationfromambientair.Allthesecontaminantscauseexcessivecorrosion,erosion,freezingand
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. The end result is that instruments that come in contact with the dry compressed air stay clean and do
notcorrode,thereforelastingmuchlonger.Productsthatmaycomeincontactwithcleandrycompressed
air are virtually unaffected. Therefore rejection rates are reduced.
:K\:H1HHG&RPSUHVVHG$LU'U\HUV
Aircel Regenerative Desiccant Air Dryers can dry compressed air to -100°F PDP (Pressure Dew Point), Standard
Regensrative Desiccant Air Dryers dry compressed air down to -40°F PDP. The compressed air stream is passed
through a desiccant bed, which removes the moisture through the process of adsorption. Twin towers filled with
desiccant alternate between drying and regenerating either based on the Energy Management System (EMS) control
or a fixed time cycle. Aircel manufactures various types of desiccant air/gas dryers. These dryers offer fail-safe
design in the event of power interruption. Air will continue to flow through the dryer without deadheading; also
purge exhaust valves will close preventing loss of air pressure. The tower operating status lights and the highest
quality non-lubricated air/gas inlet valves will ensure reliable operation for many years to come.
Product Description
• 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 -100°F.
• Purge exhaust mufflers for quiet operation.
• Tower pressure gauges for additional visual operation of dryer operation.
• Stainless steel desiccant supports and air diffusers to prevent channeling.
• Counter-current reactivation for efficient desiccant regeneration.
• PLC Controlled Electrical System
• Adjustable (5 min., 10 min.) Cycle times: 10 min. cycle = -40°F PDP, 5 min. cycle = -100°F PDP
• Controlled repressurization to slowly repressurize the regenerated vessel to line pressure prior to switch
over preventing desiccant bed movement and attrition.
• Fail safe design: failure of power and/or pilot air causes the purge exhaust valves to close eliminating
loss of air pressure. The System also provides uninterrupted drying air flow preventing a deadheading
affect.
• Control pilot air filter provides clean air to air control system for long trouble-free reliable operation.
• Desiccant towers are designed, fabricated and stamped according to ASME code.(CDP-70 and up).
• Desiccant fill and drain ports for ease of desiccant replacement.
• Structural steel frame.
• Highly reliable non-lubricated air inlet and outlet valves (APV) Automatic Piston Valve.(CDP-70 —
CDP-500)
• Highly reliable angle seat design purge exhaust valves.(CDP-70 - CDP-500 ).
• Common alarm indicator and common alarm dry relay contact for remote indication.
• Tower Operating L.E.D. status lights (Left/Right Tower Drying, Left/Right Tower Regenerating)
• ON/OFF switch and power ON light.
• NEMA 4 weather resistant electrical system construction.
8
Standard Features
Additional Options
• Tower pressure display and Failure to shift alarm utilizing pressure transducers
• Outlet dew point sensor with dew point readout on system display
• Mounted, piped and wired filtration packages
• Outlet dew point 4-20 mA signal
• High humidity alarm
Aircel CDP-Series Models 70 - 500
Heatless Regenerative Air Dryer
9
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
checkedforthefollowing:
1. Makesureyouhavereceivedallthecrates/
packagesthatareindicatedinthepackingslip.
2. Removethecrateandpackaging.Inspectthe
unit for any visible damage.
3. Report any damage to the delivery carrier.
4. Requestawritteninspectionreportfromthe
ClaimsInspectortosubstantiatetheclaim.
5. Fileclaimswiththedeliverycarrier.
6. Compareunitreceivedwithdescriptionof
productordered.Checktheserialplatelabel
andmakesurethatitisthecorrectModelwas
ordered.NotetheequipmentCapacityand
PowerSupplyrequirementsandensurethatthey
are in accordance with your specifications. The
rated conditions of the dryer are indicated on
theserialplatelabel.Ifthereisanydiscrepancy,
contact your representative listed on the manual
backcover.
7. Shippingstressescanloosenconnections.
All pipe and tubing connections should be
inspected.
8. Reportincompleteshipmentstothe
delivery carrier and your Aircel service
representative.
CAUTION!
• Donotmisuseormodifyunderany
conditions.Misuseormodification
of this equipment may result in
personal injury.
10
Technical Specifications
How Does it Work? (seediagram1)
Moisturesaturatedcompressedairentersthe
coalescingprefilter(F1)whereaerosolsare
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
throughtheAPV(AutomaticPistonValve)(V1)
which diverts the inlet air to one of the towers, in
thisexampletower(T1).Airflowsupwardthrough
the adsorbent bed removing the moisture vapor,
thedriedairflowexitsthetowerthroughtheoutlet
APVvalve(V2)flowingtotheoutletparticulate
afterfilter(F2)whichremovesparticulatesfrom
the air stream. Clean and dry air now flows to the
process air distribution system.
As one tower is drying air, the other tower will be
regenerating(purging)theadsorbentbed.Inthis
example,tower(T2)willberegenerating.Prior
toregeneration,theexhaustvalve(V4)isopened
and the tower is depressurized to near atmospheric
pressure, the tower will now be regenerating.
Duringtheregeneratingprocessasmallportionof
dryoutletcompressedairisused,15%onaverage
basedonstandarddesigncapacityof100psig,
100°Finletair,100°FambientairandPDPof
-100°F.Thedryregenerationairflowischanneled
throughtheoutletAPVvalvetotheregenerating
tower(T2)removingmoisturefromtheadsorbent
bedandexitstheregeneratingtower(T2)through
exhaustvalve(V4)andexhaustmufflertoambient.
Afterregenerationcycleiscomplete,valve(V4)
closescausingtower(T2)torepressurizetoline
pressure.
Next,thetowerswillswitchwhenexhaustvalve
(V3)openscausingtower(T1)todepressurizeand
regenerate,simultaneouslytheinletandoutletAPV
valves(V1)and(V2)willshiftthepistonstothe
lowpressuretower(T1)causingtheinletairflow
tobedivertedtotower(T2)whichwillnowbethe
drying tower. This switching process will continue
repeatedly.
The dryer control system is completely automatic
and cycles the system through the drying and
regeneration cycles. The standard cycle drying time
is2.5minutes,regenerationcycleis1.5minutes,and
repressurizingcycleis1minute.
The Aircel CDP-Series Heatless Dryer
incorporates a unique energy saving control system
to reduce purge air loss with its integrated Energy
Management Purge Reduction System which utilizes
a moisture sensor sampling the air from the outlet of
the dryer, after the fixed purge time is complete the
regenerating/purging tower will
repressurize.
If the moisture sensor senses a low moisture condition
or low load in the drying tower, the drying tower will
remain in the drying mode after the fixed drying time
cycle for an extended period of time. The end result is
an overall purge reduction and significant energy savings.
CAUTION!
• Donotmisuseormodifyunderany
conditions.Misuseormodification
of this equipment may result in
personal injury.
Aircel CDP-Series Models 70 - 500
11
Heatless Regenerative Air Dryer
Diagram1:HowitWorks
Drying
Tower
Regenerating
Tower
Air Saturated with Moisture
Dry Air
F1
F2
T2
T1
V1
V2
F1 - Mounted Pre-Filter
F2 - Mounted After-Filter
V1 - Automatic Piston Valve
V2 - Automatic Piston Valve
V3 - Purge Exhaust Valve
V4 - Purge Exhaust Valve
T1 - Desiccant Tower 1
T2 - Desiccant Tower 2
V4
V3
Regeneration Air
12
Installation
Pre-requisites for Installation
To ensure a safe and smooth installation, we recommend you go through the steps indicated below:
• MakesurethatallpersonnelinvolvedhavereadthisOperationManualthoroughly.Ifyouhave
any questions, feel free to contact your Aircel representative or the factory and we will be glad
toassistyou.Ifyouneedhelpwiththecommissioning,wewillbegladtoscheduleafactory
serviceman to visit your site and commission the dryer for a nominal fee.
• HaveextracopiesoftheOperationManuals.
• Specialcaremustbetakenwhiletransportingtheunittotheinstallationsite.
• Dryermustnotbemovedorliftedbytheattachedpiping.
Location
• Carefulconsiderationshouldbegiventothelocationofthedryerinordertoassureoptimum
results. Ensure that the load bearing weight of the floor is adequate for the weight of the dryer.
• Thedryershouldbelocatedinanopenareaandalevelground.Dryershouldbeboltedtothefloor
to eliminate vibrations.
• Theambienttemperatureshouldbebetween40°Fand100°F.Lowtemperaturecouldaffectthe
dryer process and result in high outlet dew point.
• Inconditionswheretheambientdropsbelowfreezing,Aircelrecommendstheuseofheattraceon
any coalescing filter sumps and drain lines and the use of heated type drains.
• Dryerandaccompanyingfiltersshouldbeinstalledwithatleast2-5feetclearancefromthe
adjoining walls to provide easy access for routine maintenance.
TypicalInstallation
Aircel CDP-Series Models 70 - 500
13
Heatless Regenerative Air Dryer
Onlyqualifiedpersonnelshouldmakeelectricalandmechanicalconnections.
Equipment for Installation: This dryer does not need any special tools for installation
Foundation:Dryershouldbemountedonasuitablystructuredflatandlevelfloororbasethatisfree
fromvibration.Specialcaremustbeusedwhenliftingthedryertopreventtip-over
Mounting: Bolt dryer to the foundation using the boltholes provided in the frame.
Piping:Connecttheinletofthedryertothemoistgasfromthecompressor/receiver/inletfilter.Install
theInletpipingandtheinletshutoffvalve,InstalltheOutletpipingandtheoutletshutoffvalve(aunion
with a valve by-pass can be installed at the inlet and outlet valves to accommodate isolation of the dryer
formaintenance).Compressedairpipinghastobeatleastthesamesizeasthatoftheinletandoutlet
connections of the dryer. Larger pipe sizes can be used with reducers.
Back Pressure Regulator:
Installbackpressureregulatortopreventanypossibilityoffluidizationofthe
desiccant bed. When there is a sudden increase in the demand for compressed air downstream of the
dryer, a huge pressure drop develops and can affect the performance of the dryer and the drying material
(desiccant).
Desiccant:Makesurethatthedryertowersarefilledwithdesiccant.Largerdryersmayhavedesiccant
shipped separately – in which case, the media has to be filled into the pressure vessels from the desiccant
fillports.Caremustbetakenwhenfillingthemediaanditmustbedonegraduallytopreventpowdering.
Muffler:Iftheeventthatmufflershavebeenshippedloose,theymustbeinstalledandsecured
By-pass:Ifthedryerisnotsuppliedwithoptionalby-passvalveitishighlyrecommendedthatby-pass
valve be installed around the dryer and filters. These by-pass shut-off valves will permit the dryer and
filters to be removed from the compressed air system for servicing without shutting down the entire
compressed air system.
Electrical:
Makeallelectricalconnectionstothedryerasshownonthewiringdiagram.Specialcaremust
betakeninconnectingthepropervoltageasindicatedonthespecificationsheetandwiringschematic.
Additional Valving/Piping:Wheninstallingequipmentorcomponentskeepinmindtheserviceabilityof
the equipment and provide additional valves to isolate, bypass, and to depressurize as needed.
Exhaust:Ifyouintendtoventyourexhaustwithadditionalpiping,thedischargepipingfromtheexhaust
shouldnotbepipedupwardwithoutanarrangementforremovingtrappedcondensate.Makesurethat
youdonotapplyabackpressureonthisexhaustsystem.Ifexhaustpipingistobeextended,trytostay
within15to20feetandusethenextlargerpipesize.
Note: Itismandatorythatdryerbegrounded.Useofyourplantsframeasagroundmaycauseproblems
with the control. A fused disconnect is not supplied with this equipment therefore one must be supplied
bycustomer.Allelectricalfuses,breakers,etc.shouldbeproperlysized.
Aircel is not liable for any code violations; component damage, downtime or consequential damage related
to customer supplied electrical components and connections.
Installation
14
Start-Up Procedure
At any point during the process of startup or shutdown, you notice anything unusual; we recommend you
refertotheoperationmanualimmediately.Ifyoucannotfindtheanswerinthetroubleshootingsection,
contact your Aircel representative or the factory at once.
1. Ensurethatthedryerisconnectedtoa
suitablecompressedairsupply.Makesure
that the pressure of the supply is equal to
the normal operating pressure of the dryer.
2. Checktomakesurethe“shut-off’valves
are closed and that by-pass valve is open.
3. Close all manual drain/vent valves.
4. Slowlypressurizethedryerbygradually
(slowly)openingtheinletshut-offvalveto
theOPENposition.
5. Whenbothtowersofthedryerare
completelypressurized,checkthecomplete
systemforpossibleairleaks.Usesoap
and water to test all joints and fittings.
Ifanyleaksaredetected,immediately
depressurizetheunitandcorrecttheleaks.
6. Makecertainthatanyautomatic
condensate drain isolation valves are in
the open position so proper condensate
draining can occur.
7. Whennormaloperatingpressureis
reached,switchonelectricalpower(Turn
switchtoONposition)
8. Withby-passvalveclosed,opentheoutlet
valve slowly to allow air downstream.
9. Whenenergizedoneofthetowersshould
depressurize.
10.Checktheoperationofseveralcycles
completely by following the control panel
display screen operation, the panel lights
ontheelectricalbox,andthetower
pressuregaugestomakecertainthedryer
system is operating as displayed. Also
refertothehowitworkssection,flow
diagram, electrical drawing, dryer control
display screen descriptions, and sequence of
operation in this manual for reference.
11.Checkthedrainvalveforproperoperation
anddischargeofliquid(filtersand
separators,etc.).
12.Nearthedryeroutlet(APV)valve,check
the control air/ pilot air regulator secondary
pressure, the regulator gauge should read
100psig.Increaseordecreaseregulator
knobtoachievea100psigcontrolair
secondary pressure reading.
13.Makecertainthepurgeexhaustvalves
slowlyopenwithinan8to12secondtime
period, some adjustment of the flow control
valve attached to the actuator may be
required, after adjustment tighten down the
lockingcollar.
14.Make certain a slight amount of air flow is felt
at the end of the Dew Point Sensor (if aplicable).
Adjust the needle valve, as needed, for more or
less flow. Typical flow is +/- .1 SCFM.
15.Reviewthedryersystemdisplayscreen
shots(inthismanual)tomakecertain
the parameters are set as needed in the
customer dryer.
16.Purgeairflowispresetandnotadjustable.
After the initial startup, the dryer operation is completely automatic. To understand the details of the
operation,werecommendyouusethehowitworkssection,flowdiagram,electricaldrawing,dryercontrol
display screen descriptions, and sequence of operation in this manual for reference.
Aircel CDP-Series Models 70 - 500
15
Heatless Regenerative Air Dryer
Shut-Down Procedure
At any point during the process of startup or shutdown, you notice anything unusual; we recommend you
refertotheoperationmanualimmediately.Ifyoucannotfindtheanswerinthetroubleshootingsection,
contact your Aircel representative or the factory at once.
1.SlowlyOPENtheby-passvalve.
2.SlowlyCLOSEtheInletandoutlet“shut-off”valves.
3.TodepressurizethedryeraftertheDryerisisolated.TurnPowerON…apurgeexhaustvalvewill
open and the dryer system starts to depressurize, also the manual vent valve on the outlet afterfilter
canbeopenedtodepressurizetheDryeruntilthetowerpressuregaugesread‘0’psig.
4.Switchoffelectricalpowerafterbothtowershavebeendepressurized.
Sequence of Operation
Step 1: Vessel 2 Depressurizing
Vessel2(T2)purgeexhaustpilotsolenoidvalveisenergizedwhich
suppliescontrolairtothepurgeexhaustvalve(V4)whichopens
slowly,depressurizingvessel2(T2).Simultaneouslytheinlet
andoutletAPV(AutomaticPistonValveV1&V2)shiftpositions
directingtheinletairtovessel1(T1)tobedryingtheair.Theair
flowsupthroughthedesiccantbedandexitstotheoutletAPV
valve(V2)totheoutletparticulatefilterthentothecustomerdry
process air system.
Step 2: Vessel 2 Regenerating
Step2isacontinuationofstep1exceptvessel2(T2)willbe
regenerating,vessel2(T2)purgeexhaustvalve(V4)isstillopen,
vessel1(T1)isdryingtheinletair.Asmallportionofdryoutletair
fromvessel1(T1)(15%averagebasedonstandarddesigncapacity
of100psig,100°Finletair,100°FambientairandPDPof-100°F)
istakenthroughasmallorificeintheoutletAPVvalve(V2)and
usedtoregeneratethedesiccantbedinvessel2(T2)
until240secondshasbeenreached.
Step 3: Vessel 2 Repressurizing
Vessel2(T2)purgeexhaustpilotsolenoidvalvewillde-energize
causingvessel2(T2)purgeexhaustvalve(V4)toclose,thisallows
vessel2(T2)torepressurizetolinepressure,sinceaircontinues
flowingthoughthesmallorificeintheoutletAPVvalve(V2)
pressurizingvessel2(T2).
16
Step 4: Extended Drying Vessel 1
AfewsecondsbeforetheendofrepressurizationtheCDP
-SERIESController’sintegratedEnergyManagementPurge
ReductionSystemlooksatthemoisturesensor,ifthemoisture
loadislowenough,vessel1(T1)willcontinuetodryforan
extendeddryingperioduntilthemoistureloadhasreacheda
sethighlevel,thecontrollerwillthenadvancetostep5and
the vessels will switch. This feature reduces the overall purge
consumption saving energy and money.
Step 5: Vessel 1 Depressurizing
Vessel1(T1)purgeexhaustpilotsolenoidvalveisenergizedwhich
suppliescontrolairtothepurgeexhaustvalve(V3)whichopens
slowly,depressurizingvessel1(T1).Simultaneouslytheinletand
outletAPV(AutomaticPistonValveV1&V2)shiftpositionsdirecting
theinletairtovessel2(T2)tobedryingtheair.Theairflowsup
throughthedesiccantbedandexitstotheoutletAPVvalve(V2)to
the outlet particulate filter then to the customer dry process
air system.
Step 6: Vessel 1 Regenerating
Step6isacontinuationofstep5exceptvessel1(T1)willbe
regenerating,vessel1(T1)purgeexhaustvalve(V3)isstillopen,
vessel2(T2)isdryingtheinletair.Asmallportionofdryoutletair
fromvessel2(15%averagebasedonstandarddesigncapacity
of100psig,100°Finletair,100°FambientairandPDPof-100°F)
istakenthroughasmallorificeintheoutletAPVvalve(V2)and
usedtoregeneratethedesiccantbedinvessel1(T1)
until240secondshasbeenreached.
Step 7: Vessel 1 Repressurizing
Vessel1(T1)purgeexhaustpilotsolenoidvalvewillde-energize
causingvessel1purgeexhaustvalve(V3)toclose,thisallows
vessel1(T1)torepressurizetolinepressure,sinceaircontinues
flowingthoughthesmallorificeintheoutletAPVvalve(V2)
pressurizingvessel1(T1).
Step 8: Extended Drying Vessel 2
AfewsecondsbeforetheendofrepressurizationtheCDP
-SERIESController’sintegratedEnergyManagementPurge
ReductionSystemlooksatthemoisturesensor,ifthemoisture
loadislowenough,vessel2(T2)willcontinuetodryforan
extendeddryingperioduntilthemoistureloadhasreacheda
sethighlevel,thecontrollerwillthenadvancetostep1and
the vessels will switch. This feature reduces the overall purge
consumption saving energy and money.
Sequence of Operation (cont’d)
Aircel CDP-Series Models 70 - 500
17
Heatless Regenerative Air Dryer
Maintenance
Priortoperforminganymaintenanceonthedryer,allpersonnelarestronglyadvisedtofamiliarize
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. Thepressuredifferentialindicatorreferredtoasthe“Delta-P”isaverygoodindicatorofthestate
ofthefilterelements.Maintenancepersonnelmustpayattentiontothesetokeepthedryerrunning
withfullefficiencyChangefilterelementsonaregularbasis,onceayearmaximumfora1-shift
operation.Changemorefrequentlyifoperating2or3shiftssuchasevery6months.
B. Theusefullifeofafilterelementdependsonthequalityofair.Freeopenareasforinputand
exhaustwillensurelesserintakeofdirtandparticles.
C. Powdereddesiccantcanaccumulateinthemufflerandincreasethebackpressureintheregenerating
tower change mufflers on a regular basis typically every 2-3 months for optimum performance.
D. Oilandoilvaporcandrasticallyreducethelifeofthedesiccant.Takeprecautionstoeliminateall
traces of oil from the airflow
E. Fluctuatingdewpointindicatesunevendryingandregenerationbetweenthetowers,anexhaust
valvemaynotbeworkingproperlyormufflermaybecloggedordirty,alsovesseldiffuserscreen
may be clogged.
Weekly Checklist
1. Checkalldrainvalves,prefilter,afterfilterandseparators
2. Checkanypressuredifferentialindicators(Delta-P)onthepre-filterandafterfilter(filterelements
shouldstillbechangedonregularbasisonceayearmaximumfora1shiftoperation.Changemore
frequentlyifoperating2or3shiftssuchasevery6months.).
3. Checkdryerforcorrectoperation.
4. Verifydryerispurgingatthepurgeexhaust,afterdryerdepressurizes.
5. Checkthedewpoint(ifavailable)toensurethedewpointisbeingachieved.
6. Checkbackpressureinregeneratingtower,ifmorethanafewpsigonthepressuregauge,clean
orreplaceexhaustmufflers(Changemufflersonaregularbasistypicallyevery2-3monthsfor
optimumperformance).
Semi-Annual Checklist
1. Removeandinspectallfiltersforexcessiveparticulateloadingandphysicaldamage–ifrequired
replaceprefilters,afterfilters,pilotairfilterandmufflers(filterelementsshouldstillbechangedon
regularbasisonceayearmaximumfora1shiftoperation.Changemorefrequentlyifoperating2
or3shiftssuchasevery6months.).
2. Checkpressuredifferentialindicatorandifitturnsred,replacetheelement.
3. Removeexhaustmufflers.Knockoutexcessparticulateandbackflowwithdrycompressedair.
Ifparticulatecannotberemovedcompletelychangetheexhaustmufflers.Checkbackpressure
inregeneratingtower,ifmorethanafewpsigonthepressuregauge,cleanorreplaceexhaust
mufflers.(Changemufflersonaregularbasistypicallyevery2-3monthsforoptimumperformance)
4. Checkdesiccantcondition.Powderinthemufflersisaindicationofthestatusofthedesiccant.
5. Checkallsolenoidvalves-coilconditionandcontrolcircuit.
6. Checkdryeroperation.
7. InspectandcleaninletandoutletAPV(AutomaticPistonValves).
Annual Checklist
1. Replaceelementsinprefilters,afterfilters,andpilotairfilter.
2. Replace mufflers.
3. Recalibratedewpointanalyzerprobe(ifused)sendbacktofactoryforrecalibration.
4. ReplaceinletandoutletAPVvalveseals.
5. Checkdryerforproperoperation.
18
Maintenance (cont’d)
WARNING!
• Beforeanyserviceormaintenance
workisperformedonthe
refrigerated air dryer system,
disconnectpowersupplyandlock
out power supply and depressurize
system.
• Followproperlockout/tagout
procedures before performing
serviceormaintenancework.
• Followallsafetyprocedurespriorto
performing any maintenance activity
on the dryer.
Aircel CDP-Series Models 70 - 500
19
Heatless Regenerative Air Dryer
The following section briefly discusses the various faults that can occur in the dryer, the reason of the
faultandhowitcanberectified.Ifyoudonotfindthesolutiontoyourproblem,contactyourAircel
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.
Beforeanyattemptismadetoundertakeanyaction,themachinemustbeshutdown,isolated,
depressurized,andpowereddown.Followtheshutdownprocedures.
Note: Sometroubleshootingwillhavetobedonewhilesystemispressurizedand
energizedsouseextremecaution.
1. Depressurizetheunit
2. Checktomakesureiftheunithasbeendamagedexternallyorifanypartismissing.
3. Checkifthereisproperpowersupplyandifitcorrespondstothatmentionedonthedataplate.
4. Checktoseeifthereispoweratalltheelectricalconnectionsinthemachineandthepropervoltage.
5. Checkifcontrolairisavailableandtheproperpressureatallpneumaticallyoperatedcomponents.
6. Makesureallshut-offvalvesareinthecorrectposition.
7. Checktheairflow,inlettemperatureandpressureandmakesureitfallswithintheoperatingrange.
Troubleshooting
20
Troubleshooting (cont’d)
Problem Probable Cause Remedy
High Dewpoint High inlet air flow Reduce inlet air flow
Inletairtemperatureabove
design spec
Reduce inlet air temperature to design spec
Poorpre-filtration Checkpre-filterelement,replaceifneeded
Inletairpressurebelow
design spec
Increasepressuretothedryer
Desiccantcontaminated Replace desiccant
Purgefloworificeinthe
outletAPVvalvemaybe
clogged
DismantleoutletAPVvalve,andcleanoutthe
orifice
Backpressurein
regenerating chambers
Mufflersareclogged,installnewmufflers
Exhaustvalve(s)notfully
opening or closing
Checkpilotvalveandpilotairsupply,
dismantleandcleanexhaustvalve,checkflow
controlvalveattachedtopurgeexhaustvalve
actuatormaynotbeadjustedproperly(should
beadjustedsoexhaustvalveopenswithina
8-12secondtimeperiod)
APVvalveleaking
Dismantleandclean,replacesealsandpistonif
needed
Noinputpower Checkthatdryerisonwithcorrectvoltage
Noinputpower Checkthatdryerisonwithcorrectvoltage
Controller failure Check,replaceifneeded
High-Pressure Drop Low inlet pressure Increaseinletpressuretodesignpressure
Desiccantdusting High inlet flow velocities due to high flow
Inletprefilterdirty Inspectandreplaceasneeded
High inlet flow rate Reduce inlet flow rate to meet dryer spec
Outlet filter dirty
Inspectandreplaceasneeded
Desiccantdiffuserscreens
clogged
Inspectedandcleanifneeded
High Back Pressure in
Regenerating Tower
Purgemufflerclogged Clean and replace if needed
Desiccantdiffuserscreens
clogged
Inspectedandcleanifneeded
Restrictivepurgeexhaust
piping
Clean and replace with larger pipe if required
Aircel CDP-Series Models 70 - 500
Heatless Regenerative Air Dryer
21
Troubleshooting (cont’d)
Problem Probable Cause Remedy
Dryer Fails to
Shift Towers
Exhaustvalves(s)not
functioning
Checkpilotvalveandpilotairsupply,dismantle
andcleanexhaustvalvecheckflowcontrolvalve
attachedtopurgeexhaustvalveactuatormay
notbeadjustedproperly(shouldbeadjustedso
exhaustvalveopenswithina8-12secondtime
period)
Noinputpower Checkthatdryerisonwithcorrectvoltage.
Controller failure Check,replaceifneeded
Pilotairsupplyrestricted Checkpilotfilter,andpilottubingrestriction.
Purgefloworificeinthe
outletAPVvalvemaybe
clogged
DismantleoutletAPVvalve,andcleanoutthe
orifice
InletAPVvalvemalfunction Dismantle,clean,andreinstall
OutletAPVvalve
malfunction
Dismantle,clean,andreinstall
Purge Failure Purgemufflerclogged Remove and clean, replace if needed
Purgefloworificeinthe
outletAPVvalvemaybe
clogged
DismantleoutletAPVvalve,andcleanoutthe
orifice
Controller failure
Check,replaceifneeded
Exhaustvalves(s)not
functioning
Checkpilotvalveandpilotairsupply,dismantle
andcleanexhaustvalvepurgeexhaustvalve
actuatormaynotbeadjustedproperly(should
beadjustedsoexhaustvalveopenswithina8-12
secondtimeperiod)checkcontrolsystem
Pressurization
Failure
Purgefloworificeinthe
outletAPVvalvemaybe
clogged
Reduce inlet air flow
Exhaustvalves(s)not
functioning
Checkpilotvalveandpilotairsupply,dismantle
andcleanexhaustvalvepurgeexhaustvalve
actuatormaynotbeadjustedproperly(should
beadjustedsoexhaustvalveopenswithina8-12
secondtimeperiod)checkcontrolsystem
22
Desiccant Material Safety Data Sheet
2
.
Composition/information on ingredients
CAS Number
Content (W/W)
Chemical name
1333-84-2
>= 94.0 - <= 100.0 %
Aluminum oxide (Al2O3), hydrate
3
.
Hazard identification
Emergency overview
CAUTION: MAY CAUSE EYE, SKIN AND RESPIRATORY TRACT IRRITATION
.
May cause difficulty breathing
.
Prolonged or repeated contact may result in dermatitis
.
Contact with the eyes or skin may cause mechanical irritation
.
Contains material which may indicate/cause the possibility of sensory and pulmonary irritation
.
Avoid contact with the skin, eyes and clothing
.
Avoid inhalation of dusts
.
Use with local exhaust ventilation
.
Wear a NIOSH-certified (or equivalent) particulate respirator
.
Wear safety glasses with side-shields
.
Wear chemical resistant protective gloves
.
Wear protective clothing
.
Eye wash fountains and safety showers must be easily accessible
.
Potential health effects
Primary routes of exposure
Routes of entry for solids and liquids include eye and skin contact, ingestion and inhalation
. Routes of entry for
gases include inhalation and eye contact
.
Skin contact may be a route of entry for liquified gases
.
4
.
First-aid measures
If inhaled:
Keep patient calm, remove to fresh air
.
If necessary, give oxygen
.
If not breathing, give artificial respiration
.
Seek medical attention if necessary
.
Page: 1/5
(30286124/MDS_GEN_US/EN)
Company
BASF CORPORATION
100 Campus Drive
Florham Park, NJ 07932, USA
Safety data sheet
F200
Revision date : 2009/12/04
Version: 3.0
1
.
Substance/preparation and company identification
24 Hour Emergency Response Information
CHEMTREC: 1-800-424-9300
BASF HOTLINE: 1-800-832-HELP
Aircel CDP-Series Models 70 - 500
23
Heatless Regenerative Air Dryer
Desiccant Material Safety Data Sheet
6
.
Accidental release measures
Cleanup:
Vacuum up spilled product
.
Place into suitable container for disposal
.
7
.
Handling and storage
Handling
General advice:
Avoid dust formation in confined areas
.
Avoid contact with the skin, eyes and clothing
.
Ensure adequate
ventilation
.
Storage
General advice:
Keep container tightly closed in a cool, well-ventilated place
.
Storage stability:
Keep container dry.
8
.
Exposure controls and personal protection
Components with workplace control parameters
Aluminum oxide (Al2O3),
OSHA
PEL 5 mg/m3 Respirable fraction ; PEL 15 mg/m3 Total
hydrate
dust ;
ACGIH
TWA value 1 mg/m3 Respirable fraction ;
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
.
If large quantities are ingested, seek medical advice.
5
.
Fire-fighting measures
Flash point:
Additional information:
Use extinguishing measures to suit surroundings
.
Hazards during fire-fighting:
No particular hazards known
.
Non-flammable.
Protective equipment for fire-fighting:
Wear self-contained breathing apparatus and chemical-protective clothing
.
NFPA Hazard codes:
Health : 0 Fire: 0
Reactivity: 1
Special:
24
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)
.
Wear appropriate certified respirator when exposure limits may be exceeded
.
Hand protection:
Wear chemical resistant protective gloves., Consult with glove manufacturer for testing data
.
Eye protection:
Safety glasses with side-shields
.
Body protection:
Body protection must be chosen based on level of activity and exposure
.
9
.
Physical and chemical properties
Safety data sheet
F200
Revision date : 2008/12/04
Version: 3.0
Page: 3/5
(30286124/MDS_GEN_US/EN)
Form:
Odour:
Colour:
pH value:
Melting point:
Boiling point:
Vapour pressure:
Density:
Bulk density:
Partitioning coefficient
n-octanol/water (log Pow):
Viscosity, dynamic:
Solubility in water:
10
.
Stability and reactivity
powder, granules, pellets, balls
odourless
off-white
9.4 - 10.1
2,050 °C
No data available
.
No data available
.
No data available
.
approx
.
650 kg/m3
38.0 - 52 lb/ft3
( 68 °F)
No data available
.
No data available
.
insoluble
Substances to avoid:
water
Hazardous reactions:
The product is chemically stable
.
Addition of water leads to increase in temperature
.
11
.
Toxicological information
Oral:
Information on: Aluminum oxide
LD50/rat: > 5,000 mg/kg (OECD Guideline 401)
----------------------------------
Desiccant Material Safety Data Sheet
Aircel CDP-Series Models 70 - 500
25
Heatless Regenerative Air Dryer
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
.
The statement has been derived from products of a similar structure and
composition
.
----------------------------------
Information on: Aluminum oxide
Acute toxicity to aquatic invertebrates:
OECD Guideline 202, part 1 static
Daphnia magna (48 h): > 100 mg/l
----------------------------------
13
.
Disposal considerations
Waste disposal of substance:
Dispose of in accordance with local authority regulations
.
Check for possible recycling
.
Disposal requirements are dependent on the hazard classification and will vary by location and the type of
disposal selected
.
All waste materials should be reviewed to determine the applicable hazards (testing may be necessary)
.
14
.
Transport information
Land transport
USDOT
Not classified as a dangerous good under transport regulations
Sea transport
IMDG
Not classified as a dangerous good under transport regulations
Air transport
IATA/ICAO
Not classified as a dangerous good under transport regulations
15
.
Regulatory information
Federal Regulations
Safety data sheet
F200
Revision date : 2008/12/04
Version: 3.0
Skin irritation:
Information on: Aluminum oxide
rabbit: non-irritant (OECD Guideline 404)
----------------------------------
12
.
Ecological information
Page: 4/5
(30286124/MDS_GEN_US/EN)
Desiccant Material Safety Data Sheet
26
Desiccant Material Safety Data Sheet
HMIS uses a numbering scale ranging from 0 to 4 to indicate the degree of hazard
.
A value of zero means that the substance
possesses essentially no hazard; a rating of four indicates high hazard
.
Local contact information
IMPORTANT: WHILE THE DESCRIPTIONS, DESIGNS, DATA AND INFORMATION CONTAINED HEREIN
ARE PRESENTED IN GOOD FAITH AND BELIEVED TO BE ACCURATE , IT IS PROVIDED FOR YOUR
GUIDANCE ONLY
.
BECAUSE MANY FACTORS MAY AFFECT PROCESSING OR APPLICATION/USE, WE
RECOMMEND THAT YOU MAKE TESTS TO DETERMINE THE SUITABILITY OF A PRODUCT FOR YOUR
PARTICULAR PURPOSE PRIOR TO USE
.
NO WARRANTIES OF ANY KIND, EITHER EXPRESSED OR
IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE, ARE MADE REGARDING PRODUCTS DESCRIBED OR DESIGNS, DATA OR INFORMATION
SET FORTH, OR THAT THE PRODUCTS, DESIGNS, DATA OR INFORMATION MAY BE USED WITHOUT
INFRINGING THE INTELLECTUAL PROPERTY RIGHTS OF OTHERS
.
IN NO CASE SHALL THE
DESCRIPTIONS, INFORMATION, DATA OR DESIGNS PROVIDED BE CONSIDERED A PART OF OUR
TERMS AND CONDITIONS OF SALE
.
FURTHER, YOU EXPRESSLY UNDERSTAND AND AGREE THAT
THE DESCRIPTIONS, DESIGNS, DATA, AND INFORMATION FURNISHED BY BASF HEREUNDER ARE
GIVEN GRATIS AND BASF ASSUMES NO OBLIGATION OR LIABILITY FOR THE DESCRIPTION,
DESIGNS, DATA AND INFORMATION GIVEN OR RESULTS OBTAINED, ALL SUCH BEING GIVEN AND
ACCEPTED AT YOUR RISK
.
END OF DATA SHEET
Safety data sheet
F200
Revision date : 2008/12/04
Version: 3.0
Registration status:
TSCA, US
OSHA hazard category:
Page: 5/5
(30286124/MDS_GEN_US/EN)
State RTK
MA, NJ, PA
released / listed
ACGIH TLV established
SARA hazard categories (EPCRA 311/312):
Acute
SARA 313:
CAS Number
1333-84-2
State regulations
State RTK
CAS Number
1333-84-2
Chemical name
Aluminum oxide (Al2O3), hydrate
Chemical name
Aluminum oxide (Al2O3), hydrate
16
.
Other information
HMIS III rating
Health: 1
Flammability: 0 Physical hazard:
1
Aircel CDP-Series Models 70 - 500
Systemdisplayshowsthedryeroperationsandprovidestheusertheabilitytochangecertaindryersettings.
27
Heatless Regenerative Air Dryer
Aircel Programmable Controller
Text Display
DEL Key
ESC Key
Left Arrow Key
Down Arrow Key
On Key
* Key
Right Arrow Key
Up Arrow Key
ALT Key
Red LED: Common alarm light
Standard alarms: EMS Humidity
Probe failure and Drain fault
Optional alarms: High Humidity,
Dew Point probe failure and
Failure to Shift
Red LED: Energy Savings
Active Light
Step 1: Vessel 2 Depressurizing
Vessel2(T2)purgeexhaustpilotsolenoidvalveisenergizedwhich
suppliescontrolairtothepurgeexhaustvalve(V4)whichopens
slowly,depressurizingvessel2(T2).Simultaneouslytheinletand
outletAPV(AutomaticPistonValveV1&V2)shiftpositions
directingtheinletairtovessel1(T1)tobedryingtheair.Theair
flowsupthroughthedesiccantbedandexitstotheoutletAPV
valve(V2)totheoutletparticulatefilterthentothecustomer
dry process air system.
Step 2: Vessel 2 Regenerating
Step2isacontinuationofstep1exceptvessel2(T2)willbe
regenerating,vessel2(T2)purgeexhaustvalve(V4)isstillopen,
vessel1(T1)isdryingtheinletair.Asmallportionofdryoutletair
fromvessel1(T1)(15%averagebasedonstandarddesigncapacity
of100psig,100°Finletair,100°FambientairandPDPof-100°F)is
takenthroughasmallorificeintheoutletAPVvalve(V2)andusedtoregeneratethedesiccantbed
invessel2(T2)untiltimehasbeenreached.Thescreenalsoshowsthe (optional) dew point when
applicable. The timer on this step counts to 90 seconds (1.5-minutes).
Thereisawarningsignthatwillflashintheupperrighthandportionofthe
screenforanyalarm.ThereisalsoaredLEDalarmlightthatwillflashonthePLCdisplayforany
alarm.Theusermustscrolltothealarmscreentoviewthealarms(presstheleftarrowoncefrom
themainscreentoviewthealarmscreen).
Step 3: Vessel 2 Repressurizing
Vessel2(T2)purgeexhaustpilotsolenoidvalvewillde-energize
causingvessel2(T2)purgeexhaustvalve(V4)toclose,this
allowsvessel2(T2)torepressurizetolinepressure,sinceair
continuesflowingthoughthesmallorificeintheoutletAPV
valve(V2)pressurizingvessel2(T2).
Step 4: Extended Drying Vessel 1
AfewsecondsbeforetheendofrepressurizationtheALDP
-SERIESController’sintegratedEnergyManagementPurge
ReductionSystemlooksatthemoisturesensor,ifthemoisture
loadislowenough,vessel1(T1)willcontinuetodryforan
extendeddryingperioduntilthemoistureloadhasreacheda
sethighlevel,thecontrollerwillthenadvancetostep5andthe
vessels will switch. This feature reduces the overall purge consumption saving energy and money.
Theextendeddryingcycletimerwillcountto30 minutesunlesstheoutlet dew pointsensor
ishigherthanthesetpoint.After30 minutes,theunitwillswitchandcontinuenormaloperation
untilthenextextendedsavingsstep.AtthestartofeachextendedsavingsstepthePLCchecksfor
faults,outlet dew pointsensorvalue(optional)toensureif the dryer needs to continue drying and the
dryer will go into extended drying. If the dryer needs to continue to the next step to regenerate, the
extended savings step 4 will be skipped. This step will also be skipped if the dew point option is not installed.
28
Aircel Programmable Controller
Aircel CDP-Series Models 70 - 500
Step 5: Vessel 1 Depressurizing
Vessel1(T1)purgeexhaustpilotsolenoidvalveisenergized
whichsuppliescontrolairtothepurgeexhaustvalve(V3)which
opensslowly,depressurizingvessel1(T1).Simultaneouslythe
inletandoutletAPV(AutomaticPistonValveV1&V2)shift
positionsdirectingtheinletairtovessel2(T2)tobedryingtheair.
Theairflowsupthroughthedesiccantbedandexitstotheoutlet
APVvalve(V2)totheoutletparticulatefilterthentothecustomer
dry process air system.
Step 6: Vessel 1 Regenerating
Step6isacontinuationofstep5exceptvessel1(T1)willbe
regenerating,vessel1(T1)purgeexhaustvalve(V3)isstillopen,
vessel2(T2)isdryingtheinletair.Asmallportionofdryoutlet
airfromvessel2(15%averagebasedonstandarddesign
capacityof100psig,100°Finletair,100°Fambientairand
PDPof-100°F)istakenthroughasmallorificeintheoutlet
APVvalve(V2)andusedtoregeneratethedesiccantbedin
vessel1(T1)until90secondshasbeenreached.
Step 7: Vessel 1 Repressurizing
Vessel1(T1)purgeexhaustpilotsolenoidvalvewillde-energize
causingvessel1purgeexhaustvalve(V3)toclose,thisallows
vessel1(T1)torepressurizetolinepressure,sinceaircontinues
flowingthoughthesmallorificeintheoutletAPVvalve(V2)
pressurizingvessel1(T1).
Step 8: Extended Drying Vessel 2
AfewsecondsbeforetheendofrepressurizationtheALDP
-SERIESController’sintegratedEnergyManagementPurge
ReductionSystemlooksatthemoisturesensor,ifthemoisture
loadislowenough,vessel2(T2)willcontinuetodryfor
anextendeddryingperioduntilthemoistureloadhasreached
asethighlevel,thecontrollerwillthenadvancetostep1and
the vessels will switch. This feature reduces the overall purge
consumptionsavingenergyandmoney.Theextendeddryingcycle
timerwillcountto30 minutesunlesstheoutlet dew point
sensorishigherthanthesetpoint.After30 minutes,theunitwill
switchandcontinuenormaloperationuntilthenextextended
savings step. At the start of each extended savings step the PLC
checks for faults and high outlet dewpoint setting (optional) to ensure
if the dryer needs to continue drying and the dryer will go into extended
drying. If the dryer needs to continue to the next step to regenerate, the
extended savings step 8 will be skipped. This step will also be skipped
if the dew point option is not installed.
29
Heatless Regenerative Air Dryer
Aircel Programmable Controller
30
Aircel Programmable Controller
Main Screen Navigation
LEFT/RIGHT
LEFT/RIGHT
ALARMSCREEN
CONTROLMENU
Control Menu Navigation
LEFT/RIGHT
LEFT/RIGHT
MAINSCREEN
SETTINGSMENU
Aircel CDP-Series Models 70 - 500
Heatless Regenerative Air Dryer
31
Aircel Programmable Controller
Control Menu Operation
Settings Screen Operation
Forusewithoptionaloutletdewpointdisplayandhighhumidityalarm.
CONTROLMENU
• Push OK to engage the menu
• Scroll to the desired selection and Push OK
SETTINGSSCREEN
• To engage, Push OK then scroll to the desired
set point to be changed
• Push OK on the set point to be changed and use
the up or down arrows to change the set point
• Push OK to complete the change and ESC to
de-select the screen. Push ESC again to exit to
the main screen or use the left or right arrows to
scroll to the next screen.
32
Aircel Programmable Controller
Time Control Menu Navigation
Thistimecyclecontrolmenuallowstheusertochoosebetweena10minutestandardtimecycleanda
shorter5minutecycleforlowerdewpointoption.
Time Control Menu Operation
LEFT/RIGHT
LEFT/RIGHT
TIMECYCLECONTROL
SETTINGSMENU
ANALOGSCREEN
TIMECONTROLMENU
• To change the time cycle, Push OK then scroll
to the time cycle to be selected. Push OK then
Push ESC.
• When changes are complete, Push ESC to exit
changes. Push ESC again to return to the main
screen.
Aircel CDP-Series Models 70 - 500
LEFT/RIGHT
LEFT/RIGHT
HOURSOFOPERATION
TIMECONTROLSCREEN
ANALOGSCREEN
Heatless Regenerative Air Dryer
33
Aircel Programmable Controller
Analog Screen Navigation
The analog screen simply displays the analog output signals
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.
LEFT/RIGHT
LEFT/RIGHT
ANALOGSCREEN
HOURSOFOPERATION
ALARMSCREEN
34
Aircel Programmable Controller
Alarm Pop-Ups
• No Alarm: alarm has been corrected
• High Outlet Dew Point (option):dewpointhasreachedsetpoint(checkdesiccant,prefilters,
controlsystem)
• Failure to Shift (option): tower did not properly repressurize
• Bad Probe (option): the Dew Point sensor has reached an out of range signal (check sensor and cable)
Alarm Screen Navigation
LEFT/RIGHT
LEFT/RIGHT
MAINMENU
TOTALHOURSOFOPERATION
ALARMSCREEN
Aircel CDP-Series Models 70 - 500
Heatless Regenerative Air Dryer
35
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
thatneedstoDrainandcannot.Thedrainwillalsofaultifthereis
a loss of power to the drain.
The Bad DEW-P Probe is the alarm for the dew point sensor probe
out of range. The out of range can be either high or low. This
can be either a complete loss of signal/voltage, the resistor can be
disconnected or the sensor may need to be calibrated. (option)
The High Humidity Alarm is an alarm that is visible when the
dew point is higher than the set point. The set point for the high
humidity alarm can be changed but it is not recommended. (option)
The FTS Alarm (Failure-to-Shift) is an alarm that is present when
a vessel does not depressurize correctly or if a vessel that is to be
drying does not have a pressure at or above a certain set pressure.
(option)
36
Electrical Drawings
Main Power & PLC Input: All CDP Models
Aircel CDP-Series Models 70 - 500
200
201
202
203
204
205
208
207
208
209
210
211
212
213
214
215
218
217
218
219
220
221
222
225
224
225
228
227
228
229
230
231
232
233
234
235
238
237
238
L1
L2
GND
l
=
-PB209
--'--
3tt2094
s
5
L
r------------,
I
ClJS'l"OMER
SUPPLY
POWER
I
115
VOLT/1 PHASE/60
HZ
I USE COPPER CONDUCTORS ONLY I
I
MCA
- 0.5
AMP
I
MOP
- 1.0
AMP
I
L
___________
...J
L/18/RD
~/2.12
RHS1/2.66
SYCOM/2.12
N/18/WH
L/18/RD
-PWR211
L
"""
1l1WllfY
1606-XI.P15A
8/18/BU
SVC/24/BK
NOT
USED
N
r
JBW
8/18/BU
8/24/YW
-'
"'
• 511C/24/BK
SVC/24/BK
'JWHT
NOT
USED
r
-PB209
' '
N/18/WH
6
XI,
,X2
N/18/WH
SV/16/BN SVC/24/BK
SVDCJ2.02
+
N'UT~~jl5V·
-
svcoJ/2.04
..,r-f-0
GNO
-·~
V2
UGHTS
DRYING
LIGHTS
L/18/RO
-~\"
13/18/RD
,.
13/16/RD
-CR5
N/18/WH
,~H4
AI
A2
700-II.T
-
RHJEIO
\--
RH
/
N
N
V1
LIGHTS
DRYING
UGHTS
I!
1,81:1
L/16/RD
-c;:~
14/16/RD
-cos
13/16/RD
11~2
11
14
0215
L/18/RD
-PWR129
N/18/WH
L
N
L
"""
"""""'
N
24V/16/BU
1606-XIP15E
COM/18/WH/BU
+
'7~o.U5V·
-
~f-0
GND
-·~
DRYING
UGHTS
VJ.
'!"'l"coM/18/WH/BU
24V/1B/BU
-c~
15/16/RD
15
21~1~
6
XI,
,X2
Y1
UGHTS
Vl,~"WWi/18/WH/BU
24-V/16/BU -CR4
16/16/RD
16
21
24
I
o325
XI,
,X2
~
DRYING
UGHTS
~
24-V/18/BU -CRS
17/16/RD
17
\'{,~
CDW/16/WH/BU
21
24
6
o215
XI,
,X2
V2
UGHTS
V1
l!fGEN~t.t/16/WH/BU
24-V/16/BU
-CRJ
18/16/RD
16
2WV/16/BU
2
cl,,J
4
I
XI,
'
X2
COM/16/WH/B
COM
L/3.01 2-i-V/2.·U 24V/3.40 24Y/3.32 COM/3.40 cot.l/2.-i-2: N/3.01
Heatless Regenerative Air Dryer
37
Electrical Drawings
Main Power & PLC Input: All CDP Models
eDO
OHMS
239
240
241
24V
242
12/24/BN
-RES240
RES2/2.75~-----~---,
1 2
F
500
OHMS
I
2.36
11/24/BN
-RES242 I
COM
RES/2.73-------
--/W---
-j
1 2 I
2.36
243
244
D
500
OHMS
I
7/18/BU
-RES245
I
COM/16/WH/BU
RES1/2.63
...._-----
----m-----'-
-------
240
PART
1
OF
2
"
m
246
DISCREIE
INPUTS
!
1760-IB12XCM'41
-PLC110
247
248
24V
24V/16/BU
,.
~
~
24YDC
8
COM
249
eJ
COM
250
251
eJ
1:01
SPARE
202
253
eJ
'"'
SPARE
254
255
24V
24V/16/BU
,.
'"'
256
257
4/16/BK
4
,.
4/3.31
~
1<14
208
209
eJ
'"'
CO
FN.l.T
(OPilON!l)
260
"
261
m
;;,.
262
j;;
~
N
263
eJ
'"'
I
RES1/2.45-----l
·I
D
7/16/BU
J7
7/18/BU
7/3.82~
1<17
264
265
8/18/YW
8
,.
RHS1/2.03
~
'""
HUYIDITY
266
267
268
~
24Y/18/BU
WIRE
THIS
WHEN
OPTlON
T
IS
NOT
SELECTED
-eJ
--------------------------------
'"'
I
F1S
BYPASS
(OPilON!l)
269
I
24V/16/BU
WIRE
THIS
WHEN
OPTION
"D•
IS
NOT
SELECTED
L--------------------------------
-eJ
1:10
DEW
POINT
BYPASS
(OPTIONAL)
270
271
272
273
274
275
11/2-4/BN
11
11/2-4/BN
,.
FTS1/3.52
~---
~
1:11
11/24/BN
!
F
RES/2.-42._
____
j
12/24/BN
12
12/24/BN
FTS2/3.57
~---
,,,.
-
12/24/BN
I
~
RES2/2.40
..._
-
--
- J
Y1
FAL
TO
SHFT
(OPTIOfW.)
VZ
FAL
10
SHFT
(OPTIONAl.)
276
277
38
Electrical Drawings
PLC Output & Sensors: All CDP Models
Aircel CDP-Series Models 70 - 500
300
L/236
N/236
301
302
303
304
305
306
-PLC110
~
~
PART
2
OF
2
5
~
~
307
OSCRETE
llUIPII1S
17BO-IB12XOW4IF
308
309
V1
INLEI'
310
311
Q:01
[~1
CDHM[JII
ALARM
~/16/RD
20
-CR1
N/16/WH
~2
A1
A2
N
700-HLT
1!1::1
312
313
V2
INL.Er
314
<>.02
[
21/1
~·
21
315
~2
V2 UGITS
316
317
V1
PUlGE
318
22/16/RD
-CR3
N/18/WH
~
[
A1
A2
<>.03
~.J1
22/16/RD
22
-~L219
N/16/WH
700-ILT
I!
12151
...
1
N
319
2
H '
N
320
321
V2
PUlGE
322
323
324
325
~
L
~
[~1
T.f
'
<>.04
+
z
23/16/RD
23
-stp"
N/16/WH
2
I
H '
N
V1
LIGHTS
I
23/16/RD
--<:R4
N/18/WH
I
A1
A2
N/18/WH
r------------------------J
N
700-ILT
I!
1
218
1
..
71
326
I
:
327
-0328
328
c
DRAIN
OPTlON
Wm-1
FILTER
PACKAGE
ONLY
"""'
...
s
329
330
331
5
3.2
PUSH
TO
TEST
~
3.1
4/16/BK
~
4/2.58---------
2.4
NORM.OPEN
24V/16/BU
2.3
COMMON
2-i-V/2.36~-------
332
2.2
NORM.CLOSED
333
334
~--------
1.3
GND
N/16/WH
L---------------------
1.2
N-
NUETRAL
335
L---------~~~~---------
1.1
L1-
120VAC
336
337
338
Heatless Regenerative Air Dryer
39
Electrical Drawings
PLC Output & Sensors: All CDP Models
"'"
24V
340
341
342
"
~
~
~
347
348
349
350
J51
J52
355
356
357
"""
J59
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
I
I
I
I
I
I
I
2.36
co•
2.36
r-------------------~
I I
I
COMMON
ALARM
I
I
50
S0/16/0R
-CR1
e1/18/0R
51
I
I
11
12
I
"
I I
m
I I
!
I
COMMON
ALARM
I
'
I
/16/0R-CR1
52/16/0R
52
I
"
I
11
114
c
I
8
L-------------------~
COM
2~----..rh.
___
_
~--------------~
f.---------------
I
I
I
I
I
I
L---
FTS1/2.72
0-500
"'
----------------~
f.---------------
t-----------
1
I
I
I
I
I
I
L
_________
_
F FTS2/2.74
0-500
PSI
"~-----------··-:-·~
7/24/BN
7/2.644--------------
-166
10
68"F
I""~
co:
I
LEFT
TOWER
FAIL
TO
SHIF1
RD
=
24V
WH
•
SIG
l"""co(l
RD
•
24V
RIGHT
TOWER
FAIL
TO
SHIF
WH
•
SIG
I
BK
a:
WH
NOT
USED
I
BL
•
24V
BN
•
SIG
40
Electrical Drawings
Back Panel: All CDP Models
Aircel CDP-Series Models 70 - 500
END
ANCHOR
RELAY
()
END
ANCHOR
RELAY
L1
N
L2
N
GND
N
50
N
51
L
52
L
END
ANCHOR
L
10
L
11
4
10
5
11
6
12
7
13
8
14
11
15
12
END
ANCHOR
18
13
33
GND
17
15
GND
18
16
4V
PWR
SPLY
19
17
5V
PWR
SPLY
20
18
SPLITTER
21
20
END
ANCHOR
22
21
23
22
24
23
24V
28
24V
27
24V
28
24V
29
COM
30
COM
31
COM
32
GND
35
RELAY
38
RELAY
37
RELAY
311
END
ANCHOR
1
6
2
1
4
33
2
4
4
3
3
3.5
3.5
0
1"
WIREWAY
-
CUT
TO
3-3/8"
1"
WIREWAY
-
CUT
TO
9-5/8"
1"
WIREWAY
-
CUT
TO
0
0
9-5/8"
0
I-
I-
::::>
u.
0
IZ
I")
~I
$:N
w~
0:::
3:
0
ITEM
NUMBER
1
2
AG3934769
POWER SUPPLY, 5VDC
3
AG3251901 ANCHOR,
SCREW
END, GRAY
4
AG3253101
TERMINAL BLOCK, GRAY 22-10
AWG
6
AG3253001 TERMINAL BLOCK, GREEN/YELLOW 7
AG3933672
TERMINAL BLOCK, BLU,
FEED
THRU 8
AG3933345
TERMINAL BLK,GRY,FEED THROUGH 9
AG3948856
RELAY,
SCREW
TYPE
TERMINAL
10
AG3182201 DUCT, WHITE, NARROW
SLOT,
1"X2"
11
AG3480590 COVER, WHITE DUCT,
1"
12
AG3933346 TERMINALBLK,
GRN/YELGROUNDT
13
AG3948855
RELAY,
SCREW
TYPE
TERMINAL, DPD
14
AG3182201 DUCT, WIRE,
1"x2",
WHITE
15
AG3480590 COVER, DUCT, WHITE,
1"
16
Heatless Regenerative Air Dryer
41
Electrical Drawings
Enclosure Layout: All CDP Models
QTY
1
1
1
[Til
L!JI
L!JI
2
2
2
2
2
r-----------------------------------------------------------,
r~~-----------------------------------------------------(!_~1
o6w~o
o9~Qo
I
l~X--------------------------------------------------~2.
I
L-----------------------------------------------------------J
'-===================================================---=======.J
PART
NUMBER
DESCRIPTIC
N
AG3934778
EZD
DISPlA'
AG3934775
EZD
PROCESSC
~R
AG3934777
EZDI/0
MODL
LE
AG3935996
I
ENCLOSURE, MODIFI
D,
14x12
AG3935091
I
SWITCH, PUSHBUTTO
N,
ROUND
AG3935094
I CONTACT BLOCK
FOR
PI
~SHBUTTON
AG3935997 LIGHT, GREEN, 6
MM
AG3935998 LIGHT,
BLUE,
61
~M
AG3288701 MYERS
HUB~
AG3342801 1/2XCLOSE CONDUI
NIPPLES
AG3101501 VALVE, SOLENOID, 3 W
~V,
NEMA4
ITEM
NUMBER
50
51
52
54
55
56
57
58
59
60
62
42
Service Notes
Date Service Performed Notes
Aircel CDP-Series Models 70 - 500
Service Notes
Date Service Performed Notes
Heatless Regenerative Air Dryer
43
©2013AircelLLC. PrintedinUSA
August2013
Aircel LLC.
323 Crisp Circle
Maryville,TN37801
www.AircelDryers.com
Parts and Service
ForgenuineAircelreplacementparts,call:
800-767-4599
www.AircelDryers.com
Forfasterservice,haveunit’smodelandserialnumber,
part number, description, and quantity available.
Aircel LLC. is a leading designer and
manufacturer of dryer systems and components.
Aircel Compressed Air & Gas Warranty
AircelwarrantsthatitsStandardRefrigeratedAirDryersarefreefromdefectsinmaterialsand
workmanshipfortwoyearsfromthedateofinvoice.Warrantycoverageforthistimeperiodwill
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
andworkmanshipforoneyearfromdateofinvoice.Warrantycoverageforthistimeperiodwillbefor
parts and labor.
Aircelwarrantyexcludesdamagesduetocorrosion,lackofpropermaintenance,incorrectinstallation,
modification, or misapplication of equipment. Routine maintenance or adjustment required under
normal operation as outlined in the Aircel operation and maintenance manuals are not covered under
warranty.
OnceAircelhasbeengivenadequateopportunitytoremedyanydefectsinmaterialorworkmanshipin
accordancewithAircelWarrantyPolicyandProcedures,Aircelretainsthesoleoptiontoacceptreturn
of the goods, with freight paid by the purchaser, and to refund the purchase price for the goods after
confirmingthegoodsarereturnedundamagedandinusablecondition.Sucharefundwillbethefull
extentofAircelliability.Aircelshallnotbeliableforanyothercosts,expensesordamageswhether
direct, indirect, special, incidental, consequential or otherwise. The terms of this warranty may be
modifiedonlybyaspecialwarrantydocumentsignedbyaCEO,GeneralManagerorVicePresident
of Aircel.
Thereexistnootherrepresentations,warrantiesorguaranteesexceptasstatedinthisparagraphand
allotherwarranties,includingmerchantabilityandfitnessforaparticularpurposewhetherexpressor
implied,areherebyexpresslyexcludedanddisclaimed.
