107 W.

Main Street
Worthington, PA 16262
Phone: 724.297.3416 Fax: 724.297.5189
http://www.airtak.com

OPERATING INSTRUCTIONS
Refrigerated Air Dryers Models D-300 through D-7500

06/01/2016
 Contents

A. INTRODUCTION
B. RECEIVING
C. LOCATION
D. FOUNDATION
E. PIPING
F. ELECTRICAL
G. COMPRESSED AIR CIRCUIT
H. REFRIGERANT CIRCUIT

1. Refrigerant Compressor
2. Air-Cooled Condenser and Condenser Fan Cycling Control (Low Ambient)
3. Air to Refrigerant Heat Exchanger (Evaporator)
4. Expansion Valves
5. Hot Gas Bypass Valve (D-300 and Larger)
6. Low Pressure Switch
7. High Pressure Switch
8. Crankcase Heater (D-300-A thru D-7500-A and D-400-W thru D-7500-W)
9. Automatic Water Regulating Valve
10. Refrigerant Liquid Line Filter Dryer
11. De superheating Valve
12. High Temperature Control

I. START-UP
J. DESIGN CONDITIONS
K. SHUTDOWN
L. WATER-COOLED MODELS: Cooling Water Requirements
M. MAINTENANCE

1. Drain Valves
2. Refrigeration Condenser
3. Condenser Fans

N. REMOTE CONDENSER INSTALLATION (OPTIONAL)

TROUBLESHOOTING GUIDE

WARRANTY PROCEDURES

OTHER AIR/TAK PRODUCTS

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 A. INTRODUCTION

AIR/TAK Refrigerated Compressed Air Dryers are of the high-efficiency type, designed to effectively remove
moisture from compressed air by means of a refrigeration process. The compressed air pressure dewpoint is
reduced to 38°F and then reheated to prevent in-plant air lines from sweating. The 38°F dewpoint can be
maintained under varying conditions from zero load to 100% of the design conditions.

AIR/TAK dryers are completely automatic in all respects. As with all AIR/TAK products, only a minimum of
maintenance is required. It is our recommendation that this manual be followed for any maintenance that might be
required. Any, and all service should be performed by a qualified refrigeration engineer who is trained in the service
of refrigerated air dryers.

B. RECEIVING

Upon receiving your air dryer:

1. Inspect the shipping carton for any apparent damage.

2. After removing the crate, inspect the unit for any hidden damage.

3. Report any damage immediately to the carrier and notify your supplier.

4. Check refrigerant analyzer gauge for positive gauge reading. If at “0”, do not install.

C. LOCATION

Air cooled dryers must have cool ambient air made available to prevent a heat build-up in the area where the dryer
is installed. An exhaust system is recommended to avoid recirculation of hot condenser air.

Ambient temperature at the selected location should not exceed 100°F (38°C) and should not be lower than 50°F
(10°C). High ambient temperature can affect the efficiency of the dryer. Every 10°F increase in ambient temperature
above 100°F (38°C) will result in a 6% decrease in air cooled dryer performance, resulting in higher dew points and
increased operating costs. If ambient temperatures below 50°F (10°C) are anticipated, the dryer should be
equipped with an optional ultra-low ambient package. Ambient temperatures cannot ever be below 35°F (1.7°C).
Water will freeze.

To assure an unrestricted flow of cool air through the refrigeration condenser, a minimum distance from the cabinet
to the nearest wall of 24 inches must be maintained.

All outside installations must have weather protection. Minimum protection should include a shed roof. Air-cooled
units must be protected against the wind.

D. FOUNDATION

All dryers are completely free-standing units. Any reasonably level floor that has sufficient strength will serve as a
foundation.

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 E. PIPING

When piping the main air lines to the dryer, the use of flexible connections or union joints is recommended to avoid
piping stress and vibration when used with reciprocating compressors. Bypass piping and valves are recommended.
The bypass will permit isolation of the dryer for servicing and will eliminate the need to shut down the complete
compressed air system. The bypass must be provided and installed by the customer.

In keeping with good compressed air piping design, the air dryer should be installed on the downstream side of the
air receiver and aftercooler. An AIR/TAK pre filter(s) for oil and dirt removal installed at the inlet of the dryer is
recommended. Contamination can be present in a compressed air system and can reduce the ability of the dryer
heat exchangers to achieve the proper heat transfer. AIR/TAK recommends the use of after filter(s) to remove final
trace contaminates.

All water cooled dryers are factory piped for cooling tower water, unless ordered otherwise. A dryer that is piped for
city water cannot be used on cooling tower water without necessary piping changes because of: the higher water
temperature, lower water pressure and the increased water flow needed. All water cooled dryers are supplied with a
factory mounted automatic water regulating valve which is designed to maintain the proper working refrigerant head
pressure under all dryer load conditions. No adjustment will be necessary. (Full water pressure and flow should be
supplied to the water line inlet. Refer to Section L for water cooled water requirements.)

All dryers are supplied with automatic drain valve(s). On models D-300 to D-2000, an isolation valve/strainer and
solenoid drain valve is provided. Models D-2500 to D-7500 dryers are supplied with two drain outlets with zero air
loss valve provided for each outlet. Models D-8000 and larger are supplied with four drain outlets and two zero air
loss drain valves. Solenoid drain valves with isolation valve/strainer and zero air loss drain valves are to be
installed at destination.

F. ELECTRICAL

The dryer is completely wired at the factory. A terminal box at the rear of the dryer, or a control box on the side of
the dryer is provided for the main power connection. Power connections can be made through any knock-out on the
terminal box or through the side or top of the control box. The dryer data name plate must be checked to verify
voltage, phase and cycle. Connect the power leads to the terminal block which is conveniently located within the
box. Always be sure adequate power is available to maintain efficient operation of your dryer.

A properly sized fused main disconnect switch (supplied by the installer) must be located near the dryer. Check the
wiring diagram supplied with the dryer for the recommended fuse size. The use of fusetron time-delay fuses will
permit smaller fuse sizes and, in some instances, a smaller fused disconnect switch may be used.

The dryer wiring must be independent of the air compressor so as not to cycle along with the air compressor.

Fan rotation must be checked to assure proper air flow. Air must be drawn through the finned condenser and exit
through the fan guard. To change fan rotation, switch any two hot power leads on the terminal block located in the
box.

Dryers with scroll compressor(s) need to be checked for proper rotation by making sure the discharge pressure is
greater than the suction pressure. To change rotation, switch inlet power leads L1 and L3. If you have any question
or problems, please consult factory.

Dryers with pre-wired solenoid drain valves need to have the DIN connector attached to the drain valve after the
drain is installed on the dryer.

On units supplied with crankcase heaters, the crankcase heaters are pre-wired at the factory to be energized when
power is supplied to the dryer. It is important that the crankcase heaters be energized at least 24 hours before initial
start-up or after prolonged shut-down. (See Start-Up).

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 G. COMPRESSED AIR CIRCUIT

1. Air-to-Air Heat Exchanger:

This unique high-efficiency heat exchanger is of a finned shell and tube design. The tubes are of high quality
copper and are enhanced by outer fins of corrugated aluminum. The air is first directed into the shell of the heat
exchanger and is baffled back and forth across the finned tubes giving off its heat to the cool, dry air as it
passes through the tube side of the heat exchanger

2. Air-to-Refrigerant Heat Exchanger (Evaporator):

This heat exchanger is also of the finned shell and tube design. The evaporator is engineered with maximum
efficiency in mind. It also incorporates the high quality copper tubes with corrugated fins and is baffled in the
same manner as the air-to-air heat exchanger. The heat is transferred from the compressed air to the refrigerant
within the tubes and is then dissipated to atmosphere through the condenser coil in the refrigeration system.
Designed into the lower half of the heat exchanger is an ultra-low velocity separator section which extracts and
discharges the moisture as it is condensed. This separation process traps and keeps the moisture from re-
entering the compressed air flow.

3. Drain Valves:

TYPE: Solenoid Drain Valve (D-300 to D-2000).

Zero Loss Valve (D-2500 to D-7500).

H. REFRIGERANT CIRCUIT

1. Refrigerant Compressor:

The refrigerant compressor used is an industrial type, of full hermetic, semi-hermetic or scroll design. These
compressors can be either single phase or three phase, depending on the application. The compressors used
are designed for high temperature applications which allow an evaporation temperature range of 20°F (-7°C) to
50°F (10°C). Each compressor motor is fully protected by either an internal or external overload which is of the
automatic reset type. All compressors used are suction gas-cooled and have a wide working range. The
connected electrical load can vary with the compressor load, ambient temperature or cooling water
temperature.

2. Air-Cooled Condenser and Condenser Fan Cycling Control (Low Ambient):

All air cooled condensers used in the AIR/TAK dryers are industrial plate fin type coils, designed for maximum
ambient conditions. Each condenser has a sub-cooling system which permits the condensed refrigerant to be
sub-cooled below the normal condensing temperature to within 10°F of the ambient temperature.

The condensers are forced convection type and the fan motor(s) is controlled by a pressure switch(s) (low-
ambient control). This pressure switch is activated by the condenser head pressure. This pressure will vary with
the ambient temperature and evaporator load.

As the pressure increases to a factory set cut-in pressure, the fan switch closes and the fan motor starts. The
fan removes the heat within the condenser and lowers head pressure to the factory set cut-out point. With the
fan switch controlling the upper and lower pressure limits, the dryer can operate through a wide range of
ambient and load conditions. When the ambient is high and the dryer is operating at full load, the condenser
pressure and temperature will stabilize and the fan(s) will run continuously.

3. The Evaporator Air-to-Refrigerant Heat Exchanger:

The evaporator is constructed of high quality copper tubing that utilizes an extended surface of corrugated
aluminum fins. The tubes are set in a staggered pattern for maximum heat transfer. Each refrigerant circuit is
fed by a venturi type refrigerant distributor which insures that cold liquid refrigerant is efficiently distributed to
the bottom of each circuit.

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 The circuiting within the evaporator is serpentined in such a manner as to guarantee a completely flooded
evaporator. Each evaporator is designed to insure adequate refrigerant velocity to eliminate the problem of oil
return to the crankcase.

4. Expansion Valves:

The thermostatic expansion valve (TXV) is used on Model D-300-A, and larger.

This expansion valve is controlled primarily by temperature and requires a hot gas bypass valve to
maintain suction pressure.

The temperature that is sensed by the (TXV) thermal bulb is the superheat temperature of the
refrigerant at the outlet of the evaporator. Superheat temperature is the temperature increase of the
refrigerant above its saturation temperature corresponding to the existing evaporator pressure.

5. Hot Gas Bypass Valve:

The hot gas bypass valve or capacity regulator permits medium to larger type refrigerated dryers to operate
through the range from zero load to 100% load while maintaining evaporator and suction line pressure and
temperature.

6. Low Pressure Switch:

The low pressure switch is a safety device that protects the refrigeration compressor from running with low
suction pressure that could result from a loss of refrigerant charge.

7. High Pressure Switch:

The high pressure switch is a safety device that limits the discharge pressure from the refrigerant compressor.
If the discharge pressure exceeds the factory set point, the high pressure switch opens the electrical circuit to
the compressor and the system is shut down. High discharge pressures may result from conditions such as:
plugged or dirty condensers, high ambient temperature, high compressed air inlet temperatures, high
compressed air flows, non-condensables (air inside the refrigeration system) or fan motor failures.

8. Crankcase Heater (Where Required):

The crankcase heater is standard on models D-300-A to D-2000-A and D-400-W to D-1000-W. The
crankcase heater is a low wattage heater that is connected to or immersed in the refrigerant compressor
crankcase. The wattage of this heater is normally 50 to 65 watts. This heater is not controlled by the
operational switch of the dryer, but is factory wired directly to the incoming power.

The purpose of the crankcase heater is to prevent liquid refrigerant migration back to the crankcase while the
compressor is not in operation. This migration of the liquid refrigerant occurs when the compressor crankcase is
at a lower vapor pressure than the evaporator and other system components.

The crankcase heater must raise the temperature of the crankcase and oil to a temperature higher than the
evaporator and all of the interconnecting piping. To accomplish this, the crankcase heater must be energized
24 hours before the dryer is started. This is accomplished by turning the dryer operational switch to "OFF"
and switching on the main power. The dryer is then allowed to warm up for 24 hours after which time the
operational switch may be turned to the "ON" position.

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9. Automatic Water Regulating Valve (Water Cooled only):

This control is found only in dryers equipped with water cooled condensers. The purpose of the valve is to
control the flow of water through the condenser at a rate that is factory set to maintain a constant condensing
pressure.

10. Refrigerant Liquid Line Filter-Dryer:

A liquid line filter-dryer is used on all AIR/TAK refrigerated dryers. The purpose of the filter-dryer is to eliminate
the possibility of moisture, or other foreign particles, from moving throughout the system. These particles, such
as carbon, can cause early compressor failure. The filter-dryer also has a high quality desiccant which is
capable of removing moisture to a very low point and can also remove a reasonable quantity of acid.

11. De superheating Valve (D-1250 and larger):

This valve is used on larger capacity dryers. Due to the larger refrigerant charges associated with these
models the addition of the de superheating valve is necessary. The valve's purpose is to provide liquid
refrigerant to de superheat hot discharge gas used to establish suction gas pressure.

12. High Temperature Control:

This control is used to protect the compressor from excessive return gas temperature. During the start-up
phase, the high temperature light may be lit until the refrigeration system reaches its normal running
temperatures and pressures. (See Start-up; Section I).

During normal operation on Models 300 SCFM through 2000 SCFM, this control will activate the high
temperature light when return gas temperatures become excessive. Immediate action is required by the
customer to turn off the dryer.

On models 2500 SCFM and above, this control will activate the high temperature light and will also
open the electrical circuit on the compressor and shutdown the dryer. The dryer will not restart without
the customer turning the selector switch to off and then back on. Customer evaluation should be
undertaken to determine the cause of the high temperature condition.

After start-up, the high temperature light condition may result from: plugged or dirty condensers, high ambient,
high compressed air inlet temperatures or high compressed air flow.

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 I. START-UP

After the installation of your air dryer at a suitable location, the following checks should be made:

a) Bypass piping installed and valves set to bypass the dryer.

b) Before start-up, the refrigerant analyzer gauge should indicate a dryer shutdown pressure of
153-210 PSIG for R-404a or 100-210 PSIG for R-407c for Models D-300-A through D-7500-A.
If analyzer pressure is above or below normal shutdown pressure, do not start the dryer.
Pressure may vary with ambient temperature. Dryers with pump down may read lower.

c) The operational switch must be in the "OFF" position.

d) The main electrical disconnect energized.

ON UNITS SUPPLIED WITH CRANKCASE HEATERS, THE CRANKCASE HEATERS

MUST BE ENERGIZED 24 HOURS BEFORE INITIAL START-UP OR AFTER ANY
PROLONGED SHUT DOWN. After the 24 hour period, the dryer may be started.
The Refrigerant Analyzer pressure will drop and bring itself to the normal running
pressure of 69-81 PSIG for R-404a or 50-56 for R-407c. When the red high
temperature light goes out, the dryer is ready to assume full load operation.

e) When the operational switch is turned to the “on” position, the amber dryer running
light should be “on”.

Dryers having dual condenser fans will have one (1) fan which may start when the
operational switch is turned on. The cycling of the fan(s) is controlled by the low
ambient fan controls which are factory preset to maintain the proper head pressure
within the refrigerant system.

Dryers with scroll compressor(s) need to be checked for proper rotation by making
sure the discharge pressure is greater than the suction pressure. To change
rotation, switch inlet power leads L1 and L3. Any questions or problems, consult
factory.

f). Open water supply valve (water-cooled units only).

g). Adjust solenoid drain valves for appropriate “open” time.

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 J. DESIGN CONDITIONS

Each dryer is shipped complete and ready for installation. Every dryer is tested and preset at the factory for optimum
service at the design conditions. The following are the standard design conditions for a refrigerated dryer operating
at 60 HZ:

38°F (3.3°C) Pressure Dew Point

100°F (37.8°C) Inlet Temperature (Compressed Air)

100 PSIG (7 bar) Compressed Air Pressure in PSI Gauge

100°F (37.8°C) Ambient Temperature (Room Temperature)

SCFM (Model #/min.) Rated Flow in Standard Cubic Feet per Minute.

K. SHUT-DOWN

All dryers may be shut down by simply turning the operational switch to "OFF." Models D-300-A and larger require
the main power disconnect to remain on unless service or maintenance work is to be performed. They have one
fan motor wired to run to lower head pressures after shut-down.

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 L. WATER-COOLED MODELS: COOLING WATER REQUIREMENTS

Cooling Water Requirements

MODEL # HEAT TO COOLING WATER KW INPUT (4)
COOLING AMBIENT (1) GPM (2) GPM (3)
WATER
D-400-W 23682 1780 4.7 1.9 1.95
D-500-W 33894 2550 6.8 2.7 2.6
D-600-W 37250 3650 7.5 3.0 2.92
D-800-W 52859 3980 10.6 4.3 4.22
D-1000-W 66150 5360 13.2 5.3 4.8
D-1600-W 90845 7366 18 7.3 6.82
D-2000-W 128646 10431 26 10.3 9.4
D-2500-W 135330 10185 27 10.8 9.4
D-3200-W 186550 14040 37 15 12.9
D-4000-W 206480 15540 41 16.5 14.2
D-5000-W 268075 20175 54 21.5 18.9
D-6250-W 367117 27632 73.4 29.4 28.9
D-7500-W 472231 35544 78.0 31.4 34.5
D-8000-W 412960 31080 82.0 33.0 38.7
D-10000-W 536150 40350 108 43.0 41.8

Notes:
(1) Approximately 7% of the total heat load is rejected to ambient air, the balance to the
water-cooled condenser.
(2) Based on cooling tower water 85°F to condenser, 95°F out of condenser, 78°F ambient wet
bulb temperature.
(3) Based on water into condenser @ 60°F (city water). Water temperature out of condenser, 85°F.
(4) Kilowatt (Power) consumption by the refrigeration compressor motor.
(5) Heat amounts are expressed in B.T.U.H.

M. MAINTENANCE

A properly installed Air/Tak refrigerated air dryer requires very little maintenance to provide years of trouble-free
service. A very simple routine maintenance program is all that is required. This program will consist of three (3)
check points:

1. Drain Valve(s): Inspect and clean the Drain Valve(s) on a periodic basis.

2. Refrigeration Condenser: Inspect the refrigeration condenser for lint and dirt.

a) The refrigeration condenser should be checked for lint or dirt monthly in a clean environment
and more often in a dirty environment. If the condenser is found to be dirty, it must be cleaned with
low pressure dry air.

Inspect condenser fans for bent or broken blades, and for free rotation.

a) Check condenser fan(s), brackets and on motor shaft for tightness.

3. Check refrigerant lines for oily connections and vibration in lines. Check wiring for loose and broken
wire ties. Check refrigerant sight glass for moisture. (See Troubleshooting Guide).

N. INSTALLATION OF REMOTE CONDENSER (OPTIONAL)

During installation of a Remote Condenser option, Air/Tak recommends the use of check valves or P-traps at
condenser inlet and outlet.

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 TROUBLESHOOTING GUIDE

SYMPTOMS PROBABLE CAUSE REMEDY

Dryer not running. a. Disconnect open. a. Close disconnect.

High temperature light off,
analyzer gauge normal. b. Fuse blown. b. Replace fuse.

c. Wiring, improper or broken. c. Check wiring diagram or

repair.

d. Control transformer d. Replace.

defective.

e. Unit not turned on. e. Turn unit on.

Dryer not running. a. Overload tripped. a. Allow to cool and reset.
High temperature light on, Check for overload.
analyzer gauge normal.
b. High pressure switch open b. Reset and check for cause.
(if supplied).

c. Low water pressure c. Increase water pressure.

(water cooled).

d. Low oil pressure switch d. Reset and check oil level.

(if supplied).

e. High suction gas e. Check for high ambient or

temperature. overloaded condition.

Dryer running. a. High inlet temperature. a. Check aftercooler.

Analyzer gauge high.
b. High ambient b. Cool ambient or relocate
temperature. unit.

c. Dirty or plugged c. Clean condenser coil.

condenser coil. Blow with compressed air.

d. Defective water regulator d. Repair or replace.

(water cooled).

e. Defective fan control. e. Replace.

f. Defective fan motor. f. Replace.

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 TROUBLESHOOTING GUIDE continued

SYMPTOMS PROBABLE CAUSE REMEDY

g. Defective refrigerant g. Repair or replace

compressor valves. compressor.

h. Suction pressure too high. h. Adjust hot gas bypass

valve.

Dryer running. a. Leaky refrigerant circuitry. a. Locate and repair.

High temperature light on,
analyzer gauge pressure low. b. Suction pressure too low b. Adjust hot gas
Check refrigerant charge. bypass valve.

Dryer running. a. Defective hot gas bypass a. Replace.

High temperature light off, valve.
analyzer gauge pressure low.
b. Defective fan control b. Replace.
(low ambient control).

c. Low ambient temperature. c. Heat ambient or relocate

dryer.

d. Low refrigerant charge. d. Repair leak and add

refrigerant.

Dryer not running. a. Low pressure switch open. a. Check for leak and repair.
High temperature light on,
analyzer gauge pressure low. b. Service valves closed. b. Open valves.

c. High suction gas c. Check for leak.

temperature.

Water downstream of a. Trap not functioning. a. Clean or repair trap.

the dryer.
b. High inlet temperature. b. Check aftercooler.

c. Excess flow. c. Dryer undersized.

Replace with larger dryer.

d. Low air pressure. d. Dryer undersized.

Replace with larger dryer.

e. Bypass valve open. e. Close valve.

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 TROUBLESHOOTING GUIDE continued

SYMPTOMS PROBABLE CAUSE REMEDY

High pressure drop across a. Excess flow. a. Dryer undersized.

dryer inlet and outlet. Replace with larger dryer.

b. Low air pressure. b. Dryer undersized.

Replace with larger dryer.

c. Partially frozen. c. Shut dryer off until

ice melts.

Power light “ON” but dryer a. No cooling water supply to a. Check cooling water supply.
not running dryer. Reset refrigerant Hi/Lo
pressure switch if interrupted.

IMPORTANT: Consult factory before making adjustments on any controls noted in the Troubleshooting
Guide. The adjustments noted must be made by an authorized refrigeration repair serviceman and are
listed as a guide for service personnel. The adjustments should not be made by unauthorized personnel
since all controls are preset at the factory.

AIR/TAK WARRANTY POLICY

Air/Tak products will be warranted to be free from defects in materials and workmanship for a period of one year from
date of shipment or up to one year from the verified date of installation not to exceed 15 months. Date of installation
will be verified upon receipt of the completed Warranty Registration Card. All Air/Tak refrigerated dryers will
additionally be warranted on parts only (excluding fan motors and drain valves) for a period of two years from the date
of shipment. Also, refrigerated air dryer heat exchangers have a 5-year prorated warranty.

All defective heat exchangers returned to AIR/TAK for warranty consideration must be returned freight prepaid.
Warranty will be determined after factory inspection. Failure to return a defective heat exchanger will result in warranty
denial.

Repairs, adjustments, parts, etc. are limited to actual labor cost provided that such defects are promptly reported and
approved following AIR/TAK's warranty procedures. In no event shall the cost of repairs exceed the actual cost of
materials and labor.

AIR/TAK or its representatives reserve the right to decide which warranty items are authorized. AIR/TAK shall not be
liable for incidental or consequential damages which may result from a breach of the warranty described above.

For more information on warranty policies and procedures, contact your authorized AIR/TAK Distributor.

AIR/TAK's line of quality compressed air system products includes:

COMPRESSED AIR SYSTEM FILTERS * AIR-COOLED AFTERCOOLERS
REFRIGERATED AIR DRYERS * * HEATLESS REGENERATIVE AIR DRYERS
HLD-PAK HEATLESS REGENERATIVE AIR DRYER/FILTER PACKAGES
BLOWER PURGE REGENERATIVE AIR DRYERS * EXTERNALLY HEATED REGENERATIVE AIR DRYERS
AIR CHILLERS * FLUID CHILLERS * INDUSTRIAL CLOSED LOOP FLUID COOLING SYSTEMS
For an authorized distributor near you, contact Air/Tak at: Air/Tak Inc. 107 W. Mailn Street, Worthington, PA 16262
Phone: 724.297.3416 Fax: 724.297-5189
URL: http://www.airtak.com
e-mail: airtak@airtak.com

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