nano aircel AHLD Heatless Desiccant Dryer User Guide

AHLD Series | Heatless Regenerative | 70 - 4,000 scfm

DESICCANT DRYER USER MANUAL

The information in this manual is current as of its publication date and applies to AHLD Series desiccant air dryers until next revision of this manual.

WARRANTY NOTICE

Failure to follow the instructions

and procedures in this manual, or

misuse of this equipment, will void its

warranty.

WARNING!

Users are required to read the entire

User Manual before handling or using

the product. Keep the User Manual in

a safe place for future reference.

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Desiccant Air Dryer User Manual

DRYER DATA SHEET

Model Number: Serial Number:

Date of Manufacture:

Ship Date: Installation Date:

Customer Address:

Customer City: State/Zip:

Other:

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Desiccant Air Dryer User Manual

iii

TABLE OF CONTENTS

Section 1: Safety 1

1.1 Introduction 1

1.2 Safety Signal Words 1

1.3 General Safety Procedures 1

1.4 Safe Operating Procedures 2

1.5 Desiccant Safety Precautions 2

1.5.1 Desiccant First Aid Recommendations 2

1.6 Implementation of lockout/tag-out 2

1.6.1 Procedures 2

1.6.2 General Security 3

Section 2: Description 4

2.1 Introduction 4

2.2 System 4

2.3 Standard Features 5

2.4 Additional Options 5

Section 3: Installation 6

3.1 Inspection on Arrival 6

3.2 Lifting Information 6

3.3 Installation Codes and Procedures 7

3.4 Locating and Installing the Dryer 7

3.5 Preliminary Start-Up Checklist 9

Section 4: Operation 11

4.1 Operating Procedures 11

4.2 Short-Term Shut Down 11

4.3 Short-Term or Long-Term Shut Down 12

4.4 Shut Down Emergency 12

Section 5: Controllers 13

5.1 System Navigation 13

5.2 Dryer Operation Screens 14

5.3 Navigation 18

Section 6: Maintenance 26

6.1 Introduction 26

6.2 Maintenance 26

6.2.1 Daily 26

6.2.2 Weekly 27

6.2.3 Semi-Annual 27

6.2.4 Annual 27

6.3 Desiccant Replacement 27

Section 7: Troubleshooting 29

7.1 Introduction 29

7.2 Initial Checks 30

7.3 AHLD Series Troubleshooting Guide 31

Appendix A: Specifications 33

A.1 Table of Specifications - AHLD Series 33

Appendix B: Material Safety Data Sheets 34

B.1 Activated Alumina Desiccant 34

Appendix C: Drawings 39

C.1 Electrical Schematic Drawings 39

C.2 Main Power & PLC Input Drawings 40

C.3 PLC Outlet & Sensor Drawings 41

C.4 Back Panel Drawings 42

C.5 Enclosure Layout Drawings 43

C.6 Electrical Part Drawings 44

Service Notes 45

Warranty Information 51

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Desiccant Air Dryer User Manual

1.1 Introduction

Thank you for purchasing Aircel’s AHLD E-Series Heatless

Regenerative Desiccant Air Dryer with integrated Energy

Management Purge Reduction System. To ensure maximum

performance and safe operation of an Aircel desiccant dryer

covered by this manual, everyone involved with the dryer’s

installation, operation, and maintenance must read and

carefully follow the instructions in this manual.

Misuse or modification of this equipment may result in

personal injury. Do not misuse or modify. The high efficiency

heated regenerative desiccant dryer is used exclusively for

purifying compressed air in non-hazardous locations.

The state-of-the-art system is designed and constructed

in accordance with the rules and regulations regarding

adsorption technology and industrial safety. There are

hazards accompanying this type of product if not operated

for the intended purpose by trained and specialized

personnel.

1.2 Safety Signal Words

Throughout this manual, signal words are present to advise

of safety precautions and/or standard practices. Obey these

signal words as dened 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.

1.3 General Safety Procedures

• Electrical work must conform to the specifications

indicated by Aircel and any local or state laws that may

apply.

• Personnel must wear appropriate safety gear before

working on any electrical or mechanical aspects of the

machine.

• Appropriate tools have to be used for all installation and

maintenance work. If special tools are required and are

not available to the installation crew, contact the factory

or your Aircel representative.

• A copy of the Operation Manual must be made available

to all personnel involved with the installation, operation,

and maintenance of the equipment.

• Before performing any maintenance operations on

the equipment, the unit must be shut down, isolated,

electrical power removed, and completely depressurized.

• To ensure compatibility and continued trouble free

operation, only genuine Aircel parts must be used.

• DO NOT make any constructional changes to the unit.

Only Aircel or its authorized representatives with the

prior approval can perform any constructional work on

the machine.

• DO NOT use foreign parts.

• DO NOT use compressed air from the dryers for

breathing purposes - install a breathing air package to

ensure conformance with OSHA regulations.

• DO NOT disable or disengage any protective equipment

used on the machine.

NOTICE

For optimum performance, use only Aircel replacement

parts.

SECTION 1: SAFETY

CAUTION!

Misuse / modication hazard

Misuse or modication of this equipment may result

in personal injury.

Do not misuse or modify this equipment under any

conditions.

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Desiccant Air Dryer User Manual

1.4 Safe Operating Procedures

• Pressurize and depressurize compressed air SLOWLY!

Always open air valves slowly when pressurizing the airline

system or equipment. Repair air slowly when depressurizing

your air system or equipment.

• Circuit breakers, fusible disconnect, and wiring should

conform to national and/or local electrical codes. Make

certain that qualified electrical personnel perform the

electrical installation for this unit.

• Only use original fuses for the rated voltage and current.

• Shut down the unit in the correct recommended procedure.

• Before any work on system, always depressurize the unit

and remove all electrical power.

• After shut down, put up warning notice to prevent the unit

from being switched “ON” accidentally.

• Inspect all piping, hoses, and connections. Make sure that

all hoses are in good condition and are rated for the correct

working pressure. Do not allow hoses to come into contact

with oils, chemicals, or sharp objects.

• Secure condensate drain lines. Unsecured, flexible drain

lines may whip violently under pressure and may cause

bodily harm.

1.5 Desiccant Safety Precautions

1.5.1 DESICCANT FIRST AID RECOMMENDATIONS

1.5.1.1 INHALATION

Use a contoured dust mask during loading and unloading

operations. If high concentrations are inhaled, immediately

move to fresh air. Keep person calm. If not breathing, give

articial respiration. If breathing is dicult, give oxygen. Call a

physician.

1.5.1.2 SKIN CONTACT

In case of contact, immediately flush skin with plenty of soap

and water for at least 15 minutes.

1.5.1.3 EYE CONTACT

In case of contact, immediately flush eyes with plenty of water

for at least 15 minutes. Call a physician.

1.5.1.4 SPILLS

Clean accidental spills by vacuuming, sweeping, or flushing to a

sewer treated for suspended solids. Avoid creating excess dust.

1.6 Implementation of lockout/tag-out

The energy control procedure denes actions necessary to

lockout a power source of any machine to be repaired, serviced,

or set-up, where unexpected motion, or an electrical or other

energy source, would cause personal injury or equipment

damage. The power source on any machine shall be locked

out by each employee doing the work except when motion is

necessary during setup, adjustment, or troubleshooting.

1.6.1 PROCEDURES

The established procedures for the application of energy control

shall cover the following elements and actions and shall be

initiated only be Authorized Persons and done in the following

sequence:

1. Review the equipment or machine to be locked and tagged

out.

2. Alert operator and supervisor of which machine is to be

worked on, and that power and utilities will be turned o.

3. Check to make certain no one is operating the machine

before turning power o.

4. Turn o the equipment using normal shut-down procedure.

5. Disconnect the energy sources:

a. Air and hydraulic lines should be bled, drained, and

cleaned out. There should be no pressure in these lines

or in the reservoir tanks. Lockout or tag lines or valves.

WARNING!

Inhalation, Skin, & Eye Irritant

The desiccant used in this equipment is not considered

hazardous. Contact with and disposal of desiccant

must be in accordance with the relevant MSDS and

all local codes and regulations. The following lists the

more common safety measures to be observed during

loading and unloading operations. Reference the

MSDS in the appendix for complete safety measures.

AHLD Series Manual |

Desiccant Air Dryer User Manual

b. Any mechanism under tension or pressure, such as

springs, should be released and locked out or tagged.

c. Block any load or machine part prior to working under it.

d. Electrical circuits should be checked with calibrated

electrical testing equipment and stored energy and

electrical capacitors should be safely discharged.

6. Lockout and/or tag out each energy source using the

proper energy isolating devices and tags. Place lockout

hasp and padlock or tag at the point of power disconnect

where lockout is required by each person performing work.

Each person shall be provided with their own padlock and

have possession of the only key. If more than one person is

working on a machine, each person shall ax personal lock

and tag using a multi-lock device.

7. Tag-lock devices shall be used only when power sources

are not capable of being locked out by use of padlocks and

lockout hasp devices. The name of the person axing the

tag to power source must be on tag along with date tag was

placed on power source.

8. Release stored energy and bring the equipment to a “zero

mechanical state.”

9. Verify isolation: Before work is started, test equipment to

ensure power is disconnected.

1.6.2 GENERAL SECURITY

1. The lock shall be removed by the Authorized Person who

put the lock on the energy-isolating device. No one other

than the person/persons placing padlocks and lock out

hasps on power shall remove padlock and lockout hasps

and restore power. However, when the authorized person

who applied the lock is unavailable to remove it, her or his

Supervisor may remove padlock(s) and lock out hasp(s) and

restore power only if it is rst:

a. veried that no person will be exposed to danger..

b. veried that the Authorized Person who applied the

device is not in the facility.

c. noted that all reasonable eorts to contact the Authorized

Person have been made to inform her or him that the

lock out or tag out device has been removed.

d. ensured that the Authorized Person is notied of lock

removal before returning to work.

2. Tag out system - Tags are warning devices axed at points

of power disconnect and are not to be removed by anyone

other than the person placing tag on power lockout. Tags

shall never be by-passed, ignored, or otherwise defeated.

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Desiccant Air Dryer User Manual

2.1 Introduction

Untreated compressed air contains many contaminants such

as water, compressor oil, pipe scale, and contamination from

ambient air. All these contaminants cause excessive corrosion,

erosion, freezing, and 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 not

corrode, therefore lasting much longer. Products that may

come in contact with clean, dry, compressed air are virtually

unaffected. Therefore, rejection rates are reduced.

2.2 System

Moisture saturated compressed air enters the coalescing

pre-filter, where aerosols are coalesced then drained via an

automatic drain system.

The moist water vapor-laden inlet air free of liquid water flows

to the inlet of the dryer through the APV (Automatic Piston

Valve) (A), which diverts the inlet air to one of the towers - in

this example, Tower 1.

Air flows upward through the adsorbent bed removing the

moisture vapor; the dried airflow exits the tower through the

outlet valve (B), flowing to the outlet particulate after filter,

which removes particulates from the air stream. Clean and dry

air now flows to the customer process air distribution system.

As one tower is drying air, the other tower will be regenerating

(purging) the adsorbent bed. In this example, Tower 2 will be

regenerating. Prior to regeneration, the exhaust valve (C) is

opened and the tower is depressurized to near atmospheric

pressure, the tower will now be regenerating. During the

regenerating process, a small portion of dry outlet compressed

air is used, 15% on average based on standard design capacity

of 100 psig, 100°F inlet air, 100°F ambient air, and pressure

dew point of -40°F.

The dry regeneration airflow is channeled through the outlet

orifice to the regenerating tower, removing moisture from

the adsorbent bed and exits the regenerating tower through

exhaust valve (C) and exhaust muffler to ambient. After

regeneration cycle is complete, valve (C) closes, causing Tower

2 to repressurize to line pressure.

Next, the tower will switch when exhaust valve (D)

opens, causing Tower 1 to depressurize and regenerate.

Simultaneously, the inlet and outlet APV valves (A) will shift the

pistons to the low pressure Tower 1, causing the inlet airflow

to be diverted to Tower 2, which will now be the 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 is 5 minutes, regeneration cycle is

4 minutes, and repressurizing cycle is 1 minute.

The Aircel AHLD E-Series Heatless Dryer incorporates a unique

energy saving control system to reduce purge air loss with its

integrated Energy Management Purge Reduction System. This

system utilizes a moisture sensor sampling the air from mid-

bed of the on-stream drying tower, 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.

Pre-Filter

Tower 1 Tower 2

After Filter

FIGURE 2-1: TYPICAL SCHEMATIC FLOW DIAGRAM

AHLD Series 70 - 4,000 scfm rated model

SECTION 2: DESCRIPTION

AHLD Series Manual |

Desiccant Air Dryer User Manual

2.3 Standard Features

• Integrated Energy Management Purge Reduction

System for ecient energy savings and reduced cost of

operation.

• Optimal tower size for low velocities reducing desiccant

uidization, and high contact time for ecient low dew

point performance.

• Tower pressure relief valves.

• Standard design capacity based on 100 psig, 100°F inlet

air, 100°F ambient air, and Pressure dew point of -40°F.

• Purge exhaust muers for quiet operation.

• Tower pressure gauges for additional visual operation of

dryer operation.

• Stainless steel desiccant supports and air diusers to

prevent channeling.

• Counter-current reactivation for ecient desiccant

regeneration.

• PLC Controlled Electrical System

• Adjustable (5 min., 10 min.) cycle times: 10 minute cycle

for the standard -40°F Pressure dew point outlet dew

point systems, 5 minute cycle used in the optional -100°F

Pressure dew point outlet dew point systems.

• 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 ow, preventing a dead heading eect.

• Control pilot air lter provides clean air to air control

system for long trouble-free reliable operation.

• Desiccant towers are designed, fabricated, and stamped

according to ASME code.

• Desiccant ll and drain ports for ease of desiccant

replacement.

• Structural steel frame.

• Highly reliable non-lubricated air inlet and outlet valves

(APV) Automatic Piston Valve (AHLD 70 E - AHLD 750 E)

and high performance, non-lubricated buttery valves

(AHLD-1000 E - AHLD-1500 E).

• Highly reliable angle seat design purge exhaust valves.

• Tower operating LED status lights (left and right tower

dryer, left and right tower regenerating).

• On/O switch and power On light.

• NEMA 4 weather resistant electrical system construction.

2.4 Additional Options

• -100°F outlet pressure dew point.

• Failure-to-shift alarm with pressure transducers.

• Outlet dew point sensor with dew point readout on

system display.

• High humidity alarm.

• Outlet dew point 4-20 ma signal.

• Mounted, piped, and wired ltration packages.

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Desiccant Air Dryer User Manual

3.1 Inspection on Arrival

All regenerative desiccant dryers are tested and operated

before shipment. However, shipping vibration may cause

damage such as loosening of certain parts. To ensure smooth

installation, it is recommended that immediately upon receipt

of the unit, the system is checked for the following:

1. Inspect unity on delivery.

2. Report any damage to the delivery carrier.

3. Request a written inspection report from the Claims

Inspector to substantiate the claim.

4. File claims with the delivery carrier.

5. Compare unit received with description of product ordered.

Check the serial plate label and make sure that it is the

correct Model was ordered. Note the equipment Capacity

and Power Supply requirements and ensure that they are in

accordance with your specifications. The rated conditions

of the dryer are indicated on the serial plate label. If there

is any discrepancy, contact your representative listed on

the manual back cover.

6. Vibration during shipping can loosen the connections.

Inspect all pipe and tubing and make sure they are all

tightened and secured.

7. Report incomplete shipments to the delivery carrier and

your service representative.

3.2 Lifting Information

1. Use all lifting points provided. Special care must be used

when lifting the dryer to prevent tip-over.

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.

4. Check the approximate weight provided on the specification

control drawing to ensure adequate lift truck capacity.

5. Allow only qualified operators to lift the equipment.

6. Refer to applicable OSHA regulations and local codes when

using cranes, forklifts, and other lifting equipment.

SECTION 3: INSTALLATION

WARNING!

Lifting Hazard

Failure to lift the unit correctly can result in severe

personal injury or property damage.

• Use appropriate lifting equipment and adopt

all safety precautions needed for moving and

handling the equipment.

• A forklift, or crane is recommended for unloading

and installation.

• Lift unit by lifting lugs and frame only. Do not lift

by piping.

AHLD Series Manual |

Desiccant Air Dryer User Manual

3.3 Installation Codes and Procedures

• Safe and efficient operation of the unit depends on proper

installation.

• Authorities with jurisdiction should be consulted before

installing to verify local codes and installation procedures.

In the absence of such codes, install unit according to the

National Electric Code and NFPA No. 70-latest edition.

• A qualified installation and service agent versed in all

regulatory codes must complete installation of this unit.

• All shipping materials, including shipping covers, must be

removed from the unit prior to, or during, unit installation.

3.4 Locating and Installing the Dryer

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. Before bolting dryer skid to the foundation, shim skid(s) as

needed. Additional mounting clip angles can be attached to

base frame for ease of bolting to foundation, if necessary.

The frame(s) must be securely bolted to the foundation

to prevent movement resulting from earth tremors and

induced piping vibration.

3. Make certain all shipping materials have been removed

such as crating, plastic wrap, fitting covers, etc.

4. Install unit to provide adequate clearance for maintenance

services. Dryer and accompanying filters should be installed

with at least three (3) feet clearance from the adjoining

walls to provide easy access for routine maintenance and

adequate air flow.

6. Unit should be located in a weather protected area with

an ambient temperature range between 40 - 100°F. In

conditions where the ambient drops below freezing, Aircel

recommends the use of heat trace on any coalescing filter

sumps and drain lines and the use of heated type drains.

7. Install flanges, fittings, and piping on system using the

correct pipe size and pressure rating. See drawing package

provided with the unit. Connect dryer wet air inlet to the

flange attached to the inlet pre-filter with the automatic

condensate drain on the bottom of the filter bowl. This

typically runs to the bottom of the dryer vessels. Connect

dry air outlet to plant process to the flange attached to

the outlet after-filter with a manual drain/vent valve on

the bottom of the filter bowl. Dryer outlet piping to filter is

typically from top of dryer.

8. Optional system configuration: Install a dryer bypass or

isolation valve to allow isolation of the dryer for service and

maintenance without interrupting the compressed air flow.

9. Provide adequate power supply. See rating and

specification information on dryer data label and drawing

package information. Make certain dryer system is properly

grounded.

10. It is recommended to supply power to the dryer through a

WARNING!

Electric Shock Hazard

This machine is connected to high-voltage power,

which can cause severe electrical shock and injury.

• Follow proper lock out/tag out procedures before

performing service or maintenance work.

• Electrical installation must be performed by a

qualied electrician and comply with all applicable

national and local codes.

WARNING!

Inappropriate tools hazard

Using inappropriate tools for installation or

maintenance work can lead to personal injury or

property damage.

Appropriate tools must be used for all installation and

maintenance work.

CAUTION!

Moisture contamination hazards

Air supplied while the regenerative desiccant dryer is

bypassed will be wet and saturated. Some downstream

processes may not tolerate this air supply due to the

risk of contamination of sensitive equipment.

NOTICE

Adequate sealing

The bypass system valves require bubble tight sealing.

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Desiccant Air Dryer User Manual

customer-supplied disconnect switch to remove all power

to the dryer system.

11. The regeneration air outlet (typically located at the back

of the dryer on the bottom line between the vessels)

should be piped away from all equipment and occupied

spaces. The pressure loss through the regeneration outlet

piping should not exceed two (2) inches of water column

to prevent excessive back pressure on the blower. If the

regeneration outlet line is to be piped upwards, a manual

drain valve must be installed at the lowest point to drain

any liquid water.

12. Connect any remote dry alarm contacts to control room or

signaling device to warn of dryer malfunction. Refer to the

electrical schematic for connections.

13. The dryer relief valves are designed and sized to relieve

excess pressure resulting from the thermal expansion

of air trapped in the vessels in the event the vessels are

subjected to heat, such as in a conflagration. Valves are set

to relieve at the maximum design pressure of the desiccant

vessels.

14. It is recommended to have manual vent valves in strategic

locations to aide in depressurizing the system for repair or

maintenance.

15. Ensure the dryer towers are filled with desiccant. Larger

dryers may have desiccant shipped separately; in which

case, the media has to be filled into the pressure vessels

from the desiccant fill ports at top of each vessel. Care

must be taken when filling the media and must be done

gradually to prevent powdering.

16. Install the Aircel inlet compressed air particulate pre-

filter drain to an open drain system for safety and to

prevent puddling of water at dryer system area. Piping

should be secured and angled slightly downward to drain

condensate. Drain system must have a vented air gap to

prevent a pressurized condition.

17. If there are any changes in the operating conditions of

the system from those published in this manual, contact

Technical Support at the number published on the back of

this manual.

WARNING!

Unsafe personnel conditions hazard

Keep personnel safely away from desiccant dryer relief

valves. In the event of discharge, the relief valves can

cause an unwanted condition or hazard to personnel.

Some discharge ports could be piped to a safe location.

Drain

Valve

Air or Water

Cooled

Condenser

Air

Compressor

Drain

Valve

Dry Air

to Plant

Drain

Valve

Drain

Valve

After Filter

Pre-Filter

Separator

FIGURE 3-1: Typical Installation Setup

NOTICE

Refer to system data label and/or drawing package for

desiccant media type and quantity per each vessel.

AHLD Series Manual |

Desiccant Air Dryer User Manual

3.5 Preliminary Start-Up Checklist

In addition to the below notes, cautions and warnings, refer

to the previous sections on General Safety Procedures, Safe

Operating Procedures and any safety procedures required by

end user.

CAUTION!

Follow local codes

Before connecting condensate to open drainage

system make certain this is allowed, user or local

codes may require treatment before discharging into

drain system.

NOTICE

• Refer mechanical drawing, electrical drawing,

ow diagram, and the display screen shots and

descriptions located in this manual for reference.

• It is recommended to have isolation valves before

and after the dryer to maintain low dew point

when system is not in use in use.

• It may take days to a few weeks of operation to

stabilize the system and produce the specied

dew point. Some customer processes may not

tolerate a higher dew point air supply. DO NOT

use the outlet air from the system until the air

meets the customer’s system requirements.

• During transport and storage of the equipment,

desiccant can become preloaded with atmospheric

moisture and cause poor outlet dew point.

Regenerate both desiccant beds before placing the

dryer in service to avoid contaminating sensitive

downstream systems with higher moisture

concentration. Installation must be complete and

process air available to regenerate the desiccant

beds.

WARNING!

• Tower/vessel relief valves are set from

manufacturer. DO NOT adjust these valves.

• Always pressurize and depressurize the system

slowly.

• This system must be operated or serviced by

qualied persons familiar with pressurized

systems and electrical controls.

• Before servicing any component make certain the

system is depressurized and de-energized.

• Hearing protection is recommended for personnel

protection when the system is in operation and/

or pressurized in order to protect from any loud

bursts of pressurized air to atmosphere. This can

occurs through the depressurization and purge

exhaust muers, vent ports, and lter drain ports.

• Eye protection safety glasses are recommended

for personnel protection when the system is in

operation and/or pressurized in order to protect

from possible ying debris expelled from the

purge exhaust muers during tower, vent, or

drain depressurization or any other possible ying

debris.

• The dryer must not be subjected to low operating

pressures for an extended period of time.

Extremely high velocities in the desiccant bed

would cause serious attrition of the desiccant and

possible rupture the lter elements. Some control

over the ow through the desiccant dryer on start-

up must be exercised.

• Do not use the dryer without the inlet lter

element or outlet lter element.

• Do not use the dryer without the vessel desiccant

media in place.

• DO NOT turn dryer power on until instructed.

• Make certain air inlet and air outlet are connected

correctly.

• Make certain the power supply is connected to the

system properly.

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Desiccant Air Dryer User Manual

1. Check the inlet and outlet connections are the correct size,

pressure rating, and tightened securely.

2. Ensure the inlet air line is connected to the inlet pre-filter

with automatic drain valve (typically, the inlet piping flows

from inlet pre-filter to bottom of vessels).

3. Ensure the dry outlet air is connected to the outlet after

filter with the manual drain valve which is piped from top

of vessels to outlet after filter.

4. Check that the correct power supply is connected to the

desiccant air dryer system with an adequate disconnect

switch.

5. Check that all manual valves are in correct open and

closed positions and that compressed air is available to be

supplied to the desiccant air dryer system.

a. Dryer system block and bypass valving (if applicable):

Initially, dry air outlet isolation block valve should be

closed, and the inlet isolation block valve should be

closed. If a bypass valve is used in system and customer

can tolerate wet air into process for a short amount of

time, the bypass valve can be slowly opened to allow air

into customer process system.

b. Inlet coalescing pre-filter automatic drain isolation valve

should be open.

c. If a manual vent/drain valve is used near the inlet

coalescing pre-filter automatic drain valve to ambient,

this valve should be closed. (This inlet pre-filter manual

drain valve is used in some systems in case of automatic

drain valve failure.)

d. Outlet particulate after filter manual drain/vent valve

should be in closed position.

e. Any filter differential pressure gauge isolation valves

should be in open position.

f. Any pressure gauge isolation valves should be in open

position.

6. With the customer-supplied compressed air to the system,

OPEN the inlet valve slowly (two to three minutes) 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.

7. Check the complete dryer system for leaks. If found, repair

all leaks and re-test.

8. Check the control pilot air pressure is set to between

80 - 100 psi. Typical setting is 100 psig; adjust control air

pressure regulator if needed.

9. Turn on the customer-supplied main disconnect switch

and verify correct voltage to dryer electrical panel.

10. Near the dryer outlet (APV) valve, check the control air/

pilot air regulator secondary pressure, the regulator gauge

should read 100 psig. Increase or decrease regulator

knob to achieve a 100 psig control air secondary pressure

reading.

11. Make certain the purge exhaust valves slowly open within

an 8 to 12 second time period, some adjustment of

the flow control valve attached to the actuator may be

required, after adjustment tighten down the locking collar.

12. Make certain a slight amount of air flow is felt at the end

of the EMS RH sensor sample cell exhaust coil tube (this is

normally located at the back of the dryer) adjust the needle

valve to give more or less flow.

13. Check the operation of several cycles completely by

following the control panel display screen operation, the

panel lights on the electrical box, and the tower pressure

gauges to make certain the dryer system is operating as

displayed. Also refer to the how it works section, flow

diagram, electrical drawing, dryer control display screen

descriptions, and sequence of operation in this manual for

reference.

14. After the preliminary start up checklist has been completed,

system as been verified, and outlet dew point is at an

acceptable low level, the compressed air outlet isolation

valve on the dryer system can now be slowly opened to

supply clean dry compressed air to the facility.

15. Make certain a slight amount of air flow is felt at the end

of the EMS RH sensor sample cell exhaust coil tube (this is

normally located at the back of the dryer) adjust the needle

valve to give more or less flow.

16. Review the dryer system display screen shots (in this

manual) to make certain the parameters are set as needed

in the customer dryer.

17. Purge air flow is preset and not adjustable.

18. After approximately one to two weeks of service, replace

the depressurization mufflers. New systems may have

more desiccant dusting and cause the mufflers to become

clogged, which could cause a depressurization or muffler

failure. Check flange bolts for tightness, torque as needed.

AHLD Series Manual |

Desiccant Air Dryer User Manual

4.1 Operating Procedures

After the initial startup, the dryer operation is completely

automatic. To understand the details of the operation, see

Figure 2-1: Typical Schematic Flow Chart on page 4.

4.2 Short-Term Shut Down

(For Maintenance)

The desiccant air dryer system can be shut down at any time.

Some systems may have a customer supplied bypass valve.

This can be slowly opened to allow air downstream.

• If applicable, slowly open the bypass valve.

• Slowly close the outlet shut off valve.

• Slowly close the inlet shut off valve.

• To depressurize the dryer after the dryer is isolated, turn

the power on. A purge exhaust valve will open and the

dryer system starts to depressurize. The manual vent valve

on the outlet after filter can be opened to depressurize the

dryer until the tower pressure gauges read 0 psig.

• Next, turn on power off/on switch to off position at the

dryer system electrical enclosure.

• Disconnect main electrical power supply to dryer system by

switching the upstream electrical power supply disconnect

to the off position.

SECTION 4: OPERATION

WARNING!

Electric Shock Hazard

This machine is connected to high-voltage power,

which can cause severe electrical shock and injury.

• Follow proper lock out/tag out procedures before

performing service or maintenance work.

• 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.

WARNING!

• Some circuits may be still be active or have voltage

even with main power disconnect in o position

such as, the dryer customer alarm contacts which

may have a separate external power source

connected to the dryer alarm contacts.

• If possible, remove any external power sources to

electrical enclosure

• Always remove ttings slowly in case some residual

pressure is remaining in system, and double check

to make certain electrical power is not present.

WARNING!

Regenerate both desiccant beds before unit shutdown.

When the system is shut down and power removed,

open the dryer bypass valve and close the inlet valve to

prevent the adsorption vessel from moisture overload.

WARNING!

Non-purified/moist bypass air could damage

sensitive downstream equipment components. Some

operations may not tolerate the contaminated air.

In these situations, do not utilize a bypass valve.

| AHLD Series Manual

Desiccant Air Dryer User Manual

4.3 Short-Term or Long Term

Non-Usage Period Shut Down

The most ideal time to shut the system down is in the

re-pressurization mode when both vessels are pressurized to

line pressure.

For best purity, the system is best left isolated and pressurized.

Some systems may have a customer supplied bypass valve.

This can be slowly opened to allow air downstream.

• Slowly close the outlet shut off valve (customer supplied).

• Slowly close the inlet shut off valve (customer supplied)

• Next, turn on power off/on switch to off position at the

dryer system electrical enclosure.

• The system should now be isolated and pressurized and

power switch at the dryer system is off.

• If needed, main electrical power supply can be fully

removed from dryer system by switching the upstream

customer supplied electrical power supply disconnect to

the off position.

4.4 Shut Down Emergency

The dryer can be shut down under emergency conditions at

any time by using the dryer power off/on switch or by turning

the customer main disconnect switch off for the dryer system.

Some systems may have a customer supplied bypass valve.

This can be slowly opened to allow air downstream.

• Slowly close the outlet shut off valve (customer supplied).

• Slowly close the inlet shut off valve (customer supplied)

• Next, turn on power off/on switch to off position at the

dryer system electrical enclosure.

• Make certain the two outlet dew point sensor flow control

needle valves attached to the sample cell are closed,

isolating the dew point sensor while steam is down for

maintenance. These are located upstream and downstream

of the dew point sensor.

• The system should now be isolated and pressurized and

power switch at the dryer system is off.

WARNING!

Electric Shock Hazard

This machine is connected to high-voltage power,

which can cause severe electrical shock and injury.

Main electrical power supply will still be supplied to

dryer and the dryer customer alarm contacts may be

energized from customer supplied external power

source.

WARNING!

Non-purified/moist bypass air could damage

sensitive downstream equipment components. Some

operations may not tolerate the contaminated air.

In these situations, do not utilize a bypass valve.

WARNING!

Make certain air is not owing through dryer system

when dryer is not operating.

If air ows through dryer it will overload the dryer

vessel with moisture.

WARNING!

Some circuits may be still be active or have voltage

even with main power disconnect in “OFF” position.

Dryer customer alarm contacts which may have a

separate external power source connected to the

dryer alarm contacts

AHLD Series Manual |

Desiccant Air Dryer User Manual

SECTION 5: CONTROLLERS

5.1 System Navigation

System display shows the dryer operations and provides the

user the ability to change certain dryer settings. The functions

are as follows:

A. Text display

B. Delete key

C. Escape key

D. Arrow and OK keys

E. Red LED 1: Common alarms

• Standard alarms: EMS humidity probe failure and

drain fault

• Optional alarms: High humidity, dew point probe

failure and failure to shift

F. Red LED 2: Energy savings light active

G. Alt key

H. * key

FIGURE 5-1: Running Screen

| AHLD Series Manual

Desiccant Air Dryer User Manual

5.2.2 STEP TWO: Vessel 2 Regenerating (6 - 240

seconds)

Vessel 2 is regenerating, Vessel 2 purge exhaust valve is still

open, Vessel 1 is drying the inlet air.

A small portion of dry outlet air from Vessel 1 (15% average

based on standard design capacity of 100 psig, 100°F

ambient air and PDP of -40°F) is taken through a small orifice

in the outlet line and used to regenerate the desiccant bed in

Vessel 2 until 240 seconds has been reached.

The timer on this step counts to 240 seconds (4-minutes).

A warning sign will flash in the upper right hand portion of

the screen and a red LED alarm light will flash on the PLC

display for any alarm. To view alarms, press the left arrow

once from the main screen.

The screen also displays the relative humidity reading and

dew point (optional).

5.2 Dryer Operation Screens

System display shows the dryer operations and provides the user the ability to change certain dryer settings. Review the

following menu screens for navigation.

5.2.1 STEP ONE: Select Vessel 2 Depressurizing

(0 - 5 seconds)

Vessel 2 purge exhaust pilot solenoid valve is energized,

supplying control air to slowly open the purge exhaust valve,

depressurizing vessel 2.

Simultaneously, the inlet valves and shift positions with a

pneumatic signal from vessel 2 purge exhaust pilot solenoid

valve to the inlet tower selector pneumatic pilot valve. This

action supplies a pneumatic signal to the inlet valves to open

valve and close valve, directing the inlet air to vessel 1 to dry

the air.

The air flows up through the desiccant bed and exits outlet

valve to the outlet particulate filter. The air then moves down

the line, to the customer dry process air system.

FIGURE 5-2: Step One FIGURE 5-3: Step Two

AHLD Series Manual |

Desiccant Air Dryer User Manual

5.2.3 STEP THREE: Opens Vessel 2 Repressurizing

(241 - 300 seconds)

Vessel 2 purge exhaust pilot solenoid valve will de-energize,

causing Vessel 2 purge exhaust valve to close, repressurizing

Vessel 2.

The inlet tower selector pneumatic pilot valve maintains the

inlet valve positions.

5.2.4 STEP FOUR: Vessel 1 Extended Drying

A few seconds before the end of repressurization, the

integrated Energy Management Purge Reduction System’s

moisture sensor determines the tower moisture load. If

Vessel 1’s moisture load is low enough, the tower will

continue to dry for an extended drying period until the

moisture load has reached a set high level or an additional

30 minutes, whichever comes first. After 30 minutes, the

unit will switch and continue normal operation until the next

extended savings step.

At the start of each extended savings step, the PLC checks

for faults, EMS relative humidity sensor value, and high outlet

dew point setting (optional) to ensure if the dryer needs to

continue drying. If so, the dryer will go into extended drying.

This feature reduces the overall purge consumption, saving

energy and money.

FIGURE 5-4: Step Three FIGURE 5-5: Step Four

NOTICE

If the dryer needs to continue to the next step to

regenerate based on humidity, the extended savings

step 4 will be skipped.

| AHLD Series Manual

Desiccant Air Dryer User Manual

5.2.6 STEP SIX: Vessel 1 Regenerating (6 - 240

seconds)

Vessel 1 is regenerating, Vessel 1 purge exhaust valve is still

open, Vessel 2 is drying the inlet air.

A small portion of dry outlet air from Vessel 2 (15% average

based on standard design capacity of 100 psig, 100°F

ambient air and PDP of -40°F) is taken through a small orifice

in the outlet line and used to regenerate the desiccant bed in

Vessel 1 until 240 seconds has been reached.

The timer on this step counts to 240 seconds (4-minutes).

5.2.5 STEP FIVE: Vessel 1 Depressurizing (0 - 5

seconds)

Vessel purge exhaust pilot solenoid valve is energized,

supplying control air to the purge exhaust valve,

depressurizing vessel 1.

Simultaneously, the inlet valves and shift positions with

a pneumatic signal from vessel 1’s purge exhaust pilot

solenoid valve to the inlet tower selector pneumatic pilot

valve. This supplies a pneumatic signal to the inlet valves to

open valve and close valve, directing the inlet air to vessel 2

to begin drying the air. The air flows up through the desiccant

bed and exits to the outlet valve to the outlet particulate filter

and through to downstream equipment.

FIGURE 5-5: Step Five FIGURE 5-6: Step Six

AHLD Series Manual |

Desiccant Air Dryer User Manual

5.2.7 STEP SEVEN: Vessel 1 Repressurizing (241 -

300 seconds)

Vessel 1 purge exhaust pilot solenoid valve will de-energize,

causing Vessel 1 purge exhaust valve to close, repressurizing

Vessel 1.

The inlet tower selector pneumatic pilot valve maintains the

inlet valve positions.

5.2.8 STEP EIGHT: Vessel 2 Extended Drying

A few seconds before the end of repressurization, the

integrated Energy Management Purge Reduction System’s

moisture sensor determines the tower moisture load. If

Vessel 2’s moisture load is low enough, the tower will

continue to dry for an extended drying period until the

moisture load has reached a set high level or an additional

30 minutes, whichever comes first. After 30 minutes, the

unit will switch and continue normal operation until the next

extended savings step.

At the start of each extended savings step, the PLC checks

for faults, EMS relative humidity sensor value, and high outlet

dew point setting (optional) to ensure if the dryer needs to

continue drying. If so, the dryer will go into extended drying.

This feature reduces the overall purge consumption, saving

energy and money.

FIGURE 5-7: Energy Savings FIGURE 5-8: Parallel Cooling Mode

| AHLD Series Manual

Desiccant Air Dryer User Manual

5.2.9 MAIN SCREEN

FIGURE 5-9: Main Screen Navigation

5.3 Navigation

LEFT/RIGHT

ALARM

SCREEN

CONTROL

LEFT/RIGHT

AHLD Series Manual |

Desiccant Air Dryer User Manual

5.2.9 CONTROL MENU

FIGURE 5-10: Control Menu Navigation

LEFT/RIGHT

MAIN

SCREEN

SETTINGS

LEFT/RIGHT

5.2.9.1 CONTROL MENU: Operation

• Push OK to engage the menu

• Scroll to the desired selection and push OK

5.2.9.2 SETTINGS MENU: Operation

For use with optional dew point display and high humidity

alarm.

• 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 unselect the

screen. Push ESC again to exit to the main screen or use

the left or right arrows to scroll to the next screen.

| AHLD Series Manual

Desiccant Air Dryer User Manual

5.2.10 TIME CONTROL MENU

FIGURE 5-11: Time Control Menu Navigation

LEFT/RIGHT

SETTINGS

ANALOG

SCREEN

LEFT/RIGHT

5.2.10.1 TIME CONTROL MENU: Operation

This time cycle control menu allows the user to choose

between a 10 minute standard time cycle and a shorter 5

minute cycle for lower dew point option.

• 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.

AHLD Series Manual |

Desiccant Air Dryer User Manual

5.2.11 ANALOG SCREEN: Analog Output Signals

FIGURE 5-12: Analog Screen Navigation

LEFT/RIGHT

TIME

CONTROL

SCREEN

HOURS OF

OPERATION

LEFT/RIGHT

| AHLD Series Manual

Desiccant Air Dryer User Manual

5.2.12 HOURS OF OPERATION

Displays the amount of run time as well as the total amount of hours saved with the energy management system.

FIGURE 5-13: Hours of Operation Navigation

LEFT/RIGHT

ANALOG

SCREEN

ALARM

SCREEN

LEFT/RIGHT

AHLD Series Manual |

Desiccant Air Dryer User Manual

5.2.13 ALARM SCREEN

FIGURE 5-14: Alarm Screen Navigation

LEFT/RIGHT

HOURS OF

OPERATION

MAIN

SCREEN

LEFT/RIGHT

5.2.13.1 ALARM SCREEN MENU: Operation

• No Alarm: Alarm has been corrected

• Bad Probe: The EMS sensor has reached an out of range

signal (check sensor and cable)

• High Outlet Dew Point (Option): Dew point has reached

set point (check desiccant, pre-filters, control system)

• Failure to Shift (Option): Tower did not properly

repressurize

| AHLD Series Manual

Desiccant Air Dryer User Manual

5.2.14 ALARM POP-UP SCREENS

FIGURE 5-15: No Alarm

5.2.14.1 NO ALARM

• The normally closed state of the common alarm relay.

5.2.14.2 DRAIN FAULT

• Displays when the relative humidity (EMS) probe is out of range. This can

be either high out of range or low out of range. When this happens, the

signal has either been lost or the sensor may need to be replaced.

5.2.14.3 BAD RH PROBE

• Displays when the relative humidity (EMS) probe is out of range. This can

be either high out of range or low out of range. When this happens, the

signal has either been lost or the sensor may need to be replaced.

AHLD Series Manual |

Desiccant Air Dryer User Manual

5.2.14 ALARM POP-UP SCREENS (CONT.)

FIGURE 5-15: No Alarm

5.2.14.4 BAD DEW POINT CONTROL

• 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.

5.2.14.5 HIGH HUMIDITY ALARM

• 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.

5.2.14.6 FAILURE TO SHIFT ALARM

• Alarm present when a vessel does not depressurize correctly or if a

vessel that is to be drying does not have pressure at or above a certain

set pressure.

| AHLD Series Manual

Desiccant Air Dryer User Manual

6.1 Introduction

To reach a field service technician or for technical support,

please call the number on the manual back cover.

6.2 Maintenance

Desiccant air dryers require regular maintenance for satisfactory

operation. Optimum performance can be expected if the

following routine maintenance steps are taken.

1. The pressure differential indicator referred to as the

“Delta-P” is a very good indicator of the state of the filter

elements. Maintenance personnel must pay attention

to these to keep the drying running with full efficiency

Change filter elements on a regular basis, once a year

maximum for a 1-shift operation. Change more frequently

if operating 2 or 3 shifts such as every 6 months.

2. The useful life of a filter element depends on the quality

of air. Free open areas for input and exhaust will ensure

lesser intake of dirt and particles.

3. Powder desiccant can accumulate in the muffler and

increase the back pressure in the regenerating tower

change mufflers on a regular basis typically every 2-3

months for optimum performance.

4. Oil and oil vapor can drastically reduce the life of the

desiccant. Take precautions to eliminate all traces of oil

from the airflow.

5. Fluctuating dew point indicates uneven drying and

regeneration between the towers, an exhaust valve may

not be working properly or muffler may be clogged or

dirty, also vessel diffuser screen may be clogged.

6.2.1 DAILY CHECKLIST

With the dryer on-line:

• Verify the after-filter vent valve is closed and the inlet pre-

filter drain isolation ball valve is open.

• Verify the control air pressure is reading between 80 - 100

psig on the control air pressure gauge; adjust as needed

(normal setting is 100 psig).

• Document the general operating data/conditions of the

dryer system in a maintenance log (refer to Section 5 for

sample). Data includes vessel pressures and outlet dew

point, found in the flow diagram screen during heating

mode.

• Check the Alarm Log screen. For any alarms have been

logged, note the time and date of any alarms are listed.

This may help in determining possible cause for the listed

alarm(s). The alarm(s) can be cleared for ease of use when

near 50 alarms have been logged or if no longer needed.

SECTION 6: MAINTENANCE

WARNING!

Electric Shock Hazard

This machine is connected to high voltage power,

which can cause severe electrical shock and injury.

• Follow proper lock out/tag out procedures before

performing service or maintenance work.

• Prior to performing any maintenance on the dryer,

all personnel are strongly advised to familiarize

themselves with the equipment by reading the

entire contents of this operation manual.

• Follow all safety procedures prior to performing

any maintenance activity on the dryer.

CAUTION

Inappropriate Tools Hazard

Using inappropriate tools for installation or

maintenance work can lead to personal injury or

property damage.

Appropriate tools must be used for all installation and

maintenance work.

WARNING!

Refer to shutdown procedures for maintenance in

Section 3 prior to starting any maintenance on the

dryer system

AHLD Series Manual |

Desiccant Air Dryer User Manual

6.2.2 WEEKLY CHECKLIST

• Repeat all daily inspections and record data in the

Maintenance Log in this manual.

• Check all drain valves, pre-filter, after filter and separators.

• Check any pressure differential indicators (Delta-P) on the

pre-filter and after filter (filter elements should still be

changed on regular basis once a year maximum for a 1

shift operation. Change more frequently if operating 2 or 3

shifts such as every 6 months).

• Check dryer for correct operation.

• Verify dryer is purging at the purge exhaust, after dryer

depressurizes.

• Check the dew point (if available) to ensure the dew point

is being achieved.

• Check back pressure in regenerating tower, if more than a

few psig on the pressure gauge, clean or replace exhaust

mufflers (change mufflers on a regular basis typically every

2-3 months for optimum performance).

6.2.3 SEMI-ANNUAL CHECKLIST

• Remove and inspect all filters for excessive particulate

loading and physical damage – if required replace pre-filter,

after filters, pilot air filter and mufflers (filter elements

should still be changed on regular basis once a year

maximum for a 1 shift operation. Change more frequently

if operating 2 or 3 shifts such as every 6 months).

• Check pressure differential indicator and if it turns red,

replace the element.

• Remove exhaust mufflers. Knock out excess particulate and

back flow with dry compressed air. If particulate cannot be

removed completely change the exhaust mufflers. Check

back pressure in regenerating tower, if more than a few

psig on the pressure gauge, clean or replace exhaust

mufflers. (Change mufflers on a regular basis typically

every 2-3 months for optimum performance).

• Check desiccant condition. Powder in the mufflers is an

indication of the status of the desiccant.

• Check all solenoid valves – coil condition and control circuit.

• Check dryer operation.

• Inspect and clean inlet and outlet APV (Automatic Piston

Valves).

6.2.4 ANNUAL CHECKLIST

With the dryer on-line:

• Repeat all monthly inspections.

• Replace elements in pre-filter, after filters, and pilot air

filter.

• Replace mufflers.

• Recalibrate dew point analyzer probe (if used) or send back

to factory for recalibration.

• Check inlet and outlet valve seals. Clean or replace as

needed.

• Check dryer for proper operation

6.3 Desiccant Replacement

The following is the basic procedure for desiccant unloading

and desiccant loading. There are other methods (not discussed

below) that could be used for larger systems to reduce change-

out time; such as, vacuum, pneumatic, or mechanical loading/

unloading.

WARNING!

Electric Shock Hazard

This machine is connected to high voltage power,

which can cause severe electrical shock and injury.

• Follow proper lock out/tag out procedures before

performing service or maintenance work.

• Prior to performing any maintenance on the dryer,

all personnel are strongly advised to familiarize

themselves with the equipment by reading the

entire contents of this operation manual.

• Follow all safety procedures prior to performing

any maintenance activity on the dryer, making sure

the system is depressurized and de-energized.

WARNING!

Refer to shutdown procedures for maintenance in

Section 3 prior to starting any maintenance on the

dryer system

| AHLD Series Manual

Desiccant Air Dryer User Manual

1. Turn electrical power off, depressurize the compressed air

dryer to zero (0) psi, and lock-out / tag-out.

2. To drain the desiccant, place a bucket or a bin beneath the

desiccant drain port located on the lower section of the

desiccant vessel.

3. Loosen the bolts on the blind flange, or loosen the threaded

plug at the desiccant drain port. If a blind flange is used,

remove all bolts except for the upper flange bolt. This bolt

can be used as a pivot to open and close the flange while

draining the desiccant into buckets. If a plug is used, the

plug is removed to drain the desiccant into a bucket. The

plug can be reinserted slightly to stop flow of desiccant or

place palm of hand over drain port to temporarily stop the

desiccant from draining.

4. When the smaller bucket is nearly full of desiccant, stop

the desiccant from draining as described above, dump the

desiccant from the smaller bucket into a larger container or

drum for proper disposal when finished.

5. Replace the bucket or bin under the drain port and repeat

the draining process until all of the desiccant is removed

from the tower.

6. On the desiccant drain port, reposition the blind flange,

install and secure bolts to flange, or re-install the threaded

plug.

7. Repeat the desiccant removal process as described above

on the second vessel. After desiccant has been removed

from both vessels, properly dispose of the spent desiccant.

8. To load the new desiccant, remove the desiccant fill port

flange or plug located on the top vessel head.

9. Install the amount and type of desiccant listed on the data

label or other specifications listed for the system into each

vessel.

10. Spread the desiccant evenly during several stages of the

filling process

11. Reinstall the flange covers or plugs on the desiccant fill

ports.

12. Leak test all plugs and flanges removed in the change

process. Repair and retest leak sites if necessary.

CAUTION

Inappropriate Tools Hazard

Using inappropriate tools for installation or

maintenance work can lead to personal injury or

property damage.

Appropriate tools must be used for all installation and

maintenance work.

NOTICE

Refer to the mechanical drawing, electrical drawing,

flow diagram, and the display screen shots and

descriptions for reference.

NOTICE

The desiccant fill port, located at the top of each

desiccant vessel, is where the desiccant will be loaded

into the vessel when vessel is empty. This fill port

may have either a plug, blind flange or relief valve

attached to the port.

The desiccant drain port, located at the bottom of

each vessel, is where the desiccant will be drained or

removed from each vessel. This drain port may have

either a plug or blind flange attached to the port.

AHLD Series Manual |

Desiccant Air Dryer User Manual

SECTION 7: TROUBLESHOOTING

7.1 Introduction

The following section briefly discusses the various faults

that can occur in the desiccant air dryer, the reason of the

fault, and how it can be rectified. If you do not find the

solution to your problem, contact your Aircel representative

or the factory. All necessary safety and precautionary steps

must be followed before attempting to perform any of the

recommended measures to resolve any faults in the air

dryer. Before any attempt is made to replace any electrical

or mechanical component the machine must be shut down,

isolated, depressurized, and electrical power disconnected (see

Section 3 for more information).

Do not assume these are the only problems that may occur. All

available data concerning a problem should be systematically

analyzed before undertaking any repairs or component

replacement procedures.

WARNING!

Electric Shock Hazard

This machine is connected to high voltage power,

which can cause severe electrical shock and injury.

• Follow proper lock out/tag out procedures before

performing service or maintenance work.

• Prior to performing any maintenance on the dryer,

all personnel are strongly advised to familiarize

themselves with the equipment by reading the

entire contents of this operation manual.

• Follow all safety procedures prior to performing

any maintenance activity on the dryer.

• Some troubleshooting may have to be done while

system is pressurized and energized. Use extreme

caution.

WARNING!

Pressure Hazard

This machine contains contents under low to medium

pressure, which can cause injury.

• To avoid possible hazard or injury, the operator

should be fully familiar with the refrigerated 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.

CAUTION

Inappropriate Tools Hazard

Using inappropriate tools for installation or

maintenance work can lead to personal injury or

property damage.

Appropriate tools must be used for all installation and

maintenance work.

WARNING!

In addition to the below notes and warnings,

refer to general safety procedures, safe operating

procedures, and any safety procedures required by

end user. Section 3 prior to starting any maintenance

on the dryer system

| AHLD Series Manual

Desiccant Air Dryer User Manual

7.2 Initial Checks

1. Check for external damage or missing parts from system.

2. Verify electrical power supply corresponds to that

mentioned on the dryer data plate.

3. Verify there is proper electrical power and voltage to all

electrical connections in the machine.

4. Ensure control air is available at the proper pressure to all

pneumatically operated components.

5. Verify all isolation valves and vent valves are in the correct

positions.

6. Check the airflow, inlet temperature, and pressure falls

within the operating range on the data label.

7. When ready to perform maintenance, depressurize and

de-energize the dryer system. Refer to Section 3 in this

manual for more information.

AHLD Series Manual |

Desiccant Air Dryer User Manual

7.3 AHLD Series Troubleshooting Guide

Problem Probable Cause Remedy

High Dew Point

High inlet air ow Reduce inlet air ow

Inlet air temperature above design spec Reduce inlet air temperature to design spec

Poor pre-ltration Check pre-lter element, replace if needed

Inlet air pressure below design spec Increase pressure to the dryer

Desiccant contaminated Replace desiccant

Purge ow orice in the outlet APV valve

may be clogged

Dismantle outlet APV valve, and clean out the orice

Back pressure in regenerating chambers Muers are clogged, install new muers

Exhaust valve(s) not fully opening or

closing

Check pilot valve and pilot air supply, dismantle and clean exhaust

valve, check ow control valve attached to purge exhaust valve

actuator may not be adjusted properly (should be adjusted so

exhaust valve opens within a 8-12 minute time period)

APV valve leaking Dismantle and clean, replace seals and piston if needed

No input power Check that dryer is on with correct voltage

Controller failure Check, replace if needed

High Pressure

Drop

Low inlet pressure Increase inlet pressure to design pressure

Desiccant dusting High inlet ow velocities due to high ow

Inlet pre-lter dirty Inspect and replace as needed

High inlet ow rate Reduce inlet ow rate to meet dryer spec

Outlet lter dirty Inspect and replace as needed

Desiccant diuser screens clogged Inspect and clean as needed

High Back Pressure

in Regenerating

Tower

Purge muer clogged Clean and replace if needed

Desiccant diuser screens clogged Inspect and clean as needed

Restrictive purge exhaust piping Clean and replace with larger pipe if required

| AHLD Series Manual

Desiccant Air Dryer User Manual

7.3 AHLD Series Troubleshooting Guide

Problem Probable Cause Remedy

High Dew Point

High inlet air ow Reduce inlet air ow

Inlet air temperature above design spec Reduce inlet air temperature to design spec

Poor pre-ltration Check pre-lter element, replace if needed

Inlet air pressure below design spec Increase pressure to the dryer

Desiccant contaminated Replace desiccant

Purge ow orice in the outlet APV valve

may be clogged

Dismantle outlet APV valve, and clean out the orice

Back pressure in regenerating chambers Muers are clogged, install new muers

Exhaust valve(s) not fully opening or

closing

Check pilot valve and pilot air supply, dismantle and clean exhaust

valve, check ow control valve attached to purge exhaust valve

actuator may not be adjusted properly (should be adjusted so

exhaust valve opens within a 8-12 minute time period)

APV valve leaking Dismantle and clean, replace seals and piston if needed

No input power Check that dryer is on with correct voltage

Controller failure Check, replace if needed

High Pressure

Drop

Low inlet pressure Increase inlet pressure to design pressure

Desiccant dusting High inlet ow velocities due to high ow

Inlet pre-lter dirty Inspect and replace as needed

High inlet ow rate Reduce inlet ow rate to meet dryer spec

Outlet lter dirty Inspect and replace as needed

Desiccant diuser screens clogged Inspect and clean as needed

High Back Pressure

in Regenerating

Tower

Purge muer clogged Clean and replace if needed

Desiccant diuser screens clogged Inspect and clean as needed

Restrictive purge exhaust piping Clean and replace with larger pipe if required

AHLD Series Manual |

Desiccant Air Dryer User Manual

APPENDIX A: SPECIFICATIONS

A.1 Tables of specifications - AHLD Series

For dimensions, weights, and connection sizes, see the drawing of the dryer model provided at purchase.

Type of dryer: Desiccant

Power supply: 460 VAC, 3 Ph, 60 Hz

Desiccant type: Premium grade activated alumina

Parameter Description Air Pressure Air Inlet Temperature Ambient Temperature

Maximum 135 psig 120°F 120°F

Standard Operating 100 psig 100°F 100°F

Minimum 60 psig 40°F 38°F

Normal Settings

Heat Control 400°F

Dew Point Demand - 50°F

High Humidity - 10°F

| AHLD Series Manual

Desiccant Air Dryer User Manual

APPENDIX B: MATERIAL SAFETY DATA SHEETS

Composition/information on ingredients

CAS Number

Content (W/W)

Chemical name

1333-84-2

>= 94.0 - <= 100.0 %

Aluminum oxide (Al2O3), hydrate

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

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

Substance/preparation and company identification

24 Hour Emergency Response Information

CHEMTREC: 1-800-424-9300

BASF HOTLINE: 1-800-832-HELP

B.1 Activated Alumina Desiccant

AHLD Series Manual |

Desiccant Air Dryer User Manual

B.1 Activated Alumina Desiccant

Accidental release measures

Cleanup:

Vacuum up spilled product

Place into suitable container for disposal

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.

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.

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:

| AHLD Series Manual

Desiccant Air Dryer User Manual

B.1 Activated Alumina Desiccant

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

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:

Stability and reactivity

powder, granules, pellets, balls

odourless

off-white

9.4 - 10.1

2,050 °C

No data available

approx

650 kg/m3

38.0 - 52 lb/ft3

( 68 °F)

No data available

insoluble

Substances to avoid:

water

Hazardous reactions:

The product is chemically stable

Addition of water leads to increase in temperature

Toxicological information

Oral:

Information on: Aluminum oxide

LD50/rat: > 5,000 mg/kg (OECD Guideline 401)

----------------------------------

AHLD Series Manual |

Desiccant Air Dryer User Manual

B.1 Activated Alumina Desiccant

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

----------------------------------

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)

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

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)

----------------------------------

Ecological information

Page: 4/5

(30286124/MDS_GEN_US/EN)

| AHLD Series Manual

Desiccant Air Dryer User Manual

B.1 Activated Alumina Desiccant

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

[email protected]

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

Other information

HMIS III rating

Health: 1

Flammability: 0 Physical hazard:

AHLD Series Manual |

Desiccant Air Dryer User Manual

APPENDIX C: DRAWINGS

C.1 Electrical Schematic Drawings

| AHLD Series Manual

Desiccant Air Dryer User Manual

C.2 Main Power & PLC Input Drawings

AHLD Series Manual |

Desiccant Air Dryer User Manual

C.3 PLC Outlet & Sensor Drawings

| AHLD Series Manual

Desiccant Air Dryer User Manual

ITEMNUMBER PARTNUMBER DESCRIPTION QTY

1 AG3197201 BACKPLATEFITS14x12 1

2 AG3948924 POWERSUPPLY,24VDC 1

3 AG3934769 POWERSUPPLY,5VDC 1

4 AG3251901 ANCHOR,SCREWEND,G RAY 6

6 AG3253101 TERMINALBLOCK,GRAY,J4 2

7 AG3253001 TERM INAL BLK,GREEN/YELLOW,J4 1

8 AG3933672 TERMINALBLOCK,BLUE,J3 4

9 AG3933345 TERMINALBLK,GRAY,J 3 30

10 AG3948856 RELAY,SCREWTYPETERMINAL,SPDT 1

11 AG3182201 DUCT,WHITE,NARROWSLOT,1"X2" 3

12 AG3480590 COVER,WHITEDUCT,1" 3

13 AG3933346 TERMINALBLK, GREEN/Y ELLOW,J3 3

14 AG3948855 RELAY,SCREWTYPETERMINAL,DPDT 3

C.4 Back Panel Drawings

AHLD Series Manual |

Desiccant Air Dryer User Manual

ITEMNUMBER QTY P ARTNUMBER DESCRIPTION

50 1 AG3934778 EZDDISPLAY

51 1 AG3934775 EZDPROCESSOR

52 1 AG3934777 EZDI/OMODULE

54 1 AG3935996 ENCLOSURE,MODIFIED,14x12

55 1 AG3935091 SWITCH,PUSHBUTTON,ROUND

56 1 AG3935094 CONTACTBLOCKFORPUSHBUTTON

58 4 AG3935998 LIGHT,BLUE,6MM

59 2 AG3288701 MYERSHU BS

60 2 AG3342801 1/2XCLO SECONDUITNIPPLES

62 2 AG3101501 VALVE,SOLENOID,3WAY,NEMA4

C.5 Enclosure Layout Drawings

| AHLD Series Manual

Desiccant Air Dryer User Manual

AHLDE‐SERIESELECTRICALDRAWING,AIRCEL

PROGRAMMABLE

CONTROLLER,NEMA‐4WITHENERGY

MANAGEMENT.

StockNumber StockDescription Quantity Spare?

AG3934778 EZDCONTROLLER,PROCESSOR 1 Y

AG3934775 EZDCONTROLLER,12DCINP UTS 1 Y

AG3934777 EZDCONTROLLER,CPU 1 Y

AG3935996 ENCLOSURE,MODIFIED,14X12 1 N

AG3935091 SWI TCH,PUSHBUTTON,ROUND 1 Y

AG3935094 SWITCH,CONTACTBLOCK,FORALL 1 Y

AG3935095 LIGHT,FOR800BSWITCH,LED 1 Y

AG3935096 LENSFORPUSHBUTTON,GREEN 1 Y

AG3935998 LIGHT,PILOT,115V,8MM,BLUE 4 Y

AG3288701 HUB,MYERS,1/2" 2 Y

AG3342801 NIPPLE,CONDUIT,1/2"XCLOSE, 2 N

AG3481168 STRAI NRELIEF,3/8" 3 N

AG3481158 LOCKNUT,3/8" 3 N

AG3481159 RINGSEAL,3/8" 3 N

AG3948855 RELA Y,SCREWTYPETERMIN AL,DPDT 3 Y

AG3197201 PANEL,BACKPLATE,FITS14x12 1 N

AG3948924 POWERSUPPLY,24VDC 1 Y

AG3934769 POWERSUPPLY,5VDC 1 Y

AG3251901 ANCHOR,SCREWEND,GRAY 6 N

AG3253101 TERMINALBLOCK,GRAY,J4 2 N

AG3253001 TERMINALBLOCK,GREEN/YELLOW,J4 1 N

AG3933672 TERMINALBLOCK,BLU,J3 4 N

AG3933345 TERMINALBLOCK,GRAY,J3 30 N

AG3948856 RELAY,SCREWTYPETERMINAL,SPDT 1 Y

AG3182201 DUCT ,WHITE,NARROWSLOT,1x2 3 N

AG3101501 VA LVE,SOLENOID,3WAY,NEMA4,1/4" 2 Y

AG3933346 TERM INALBLK,GREEN/YELLOW,J3 3 N

AG3480590 COVER,WHITEDUCT,1" 3 N

AG3481460 CORD,SJEEO W,18/3 10 N

AG3480463 WIRE#18,BL UE 80 N

AG3480947 WIR E#18,RED 98 N

AG3480948 WIRE#18,WHITE 17 N

AG3480991 WIRE #18,WHITE/BLUE 9.5 N

AG3373901 WIRE#16,ORANGE 6 N

AG3372301 WIRE#16,GREEN 12 N

C.6 Electrial Part Drawings

AHLD Series Manual |

Desiccant Air Dryer User Manual

DATE SERVICE PERFORMED NOTES

NOTES

| AHLD Series Manual

Desiccant Air Dryer User Manual

DATE SERVICE PERFORMED NOTES

NOTES

AHLD Series Manual |

Desiccant Air Dryer User Manual

DATE SERVICE PERFORMED NOTES

NOTES

| AHLD Series Manual

Desiccant Air Dryer User Manual

DATE SERVICE PERFORMED NOTES

NOTES

AHLD Series Manual |

Desiccant Air Dryer User Manual

DATE SERVICE PERFORMED NOTES

NOTES

| AHLD Series Manual

Desiccant Air Dryer User Manual

DATE SERVICE PERFORMED NOTES

NOTES

AHLD Series Manual |

Desiccant Air Dryer User Manual

WARRANTY INFORMATION

Aircel warrants that its Standard Refrigerated Air Dryers are

free from defects in materials and workmanship for two

years from the date of invoice. Warranty coverage for this

time period will be parts and labor for the rst year and parts

only for the second. Custom engineered products, desiccant

dryers, chillers and nitrogen generators are warranted to be

free from defects in materials and workmanship for one year

from date of invoice. Warranty coverage for this time period

will be for parts and labor.

Aircel warranty excludes damages due to corrosion, lack of

proper maintenance, incorrect installation, modication,

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.

Once Aircel has been given adequate opportunity to remedy

any defects in material or workmanship in accordance with

Aircel Warranty Policy and Procedures, Aircel retains the sole

option to accept return of the goods, with freight paid by the

purchaser, and to refund the purchase price for the goods

after conrming the goods are returned undamaged and in

usable condition. Such a refund will be the full extent of Aircel

liability. Aircel shall not be liable for any other costs, expenses

or damages whether direct, indirect, special, incidental,

consequential or otherwise. The terms of this warranty may

be modied only by a special warranty document signed by a

CEO, General Manager or Vice President of Aircel.

There exist no other representations, warranties or guarantees

except as stated in this paragraph and all other warranties,

including merchantability and tness for a particular purpose

whether express or implied, are hereby expressly excluded

and disclaimed.

Parts & Service

For genuine Aircel replacement parts, call

800.767.4599

For faster service, please have your unit model

and serial number, part number, or description.

Aircel LLC | 323 Crisp Circle | Maryville, TN 37801 | 865.767.4599 | airceldryers.com