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AIR DRYER SUPPLIER CATR-1600-200, Instruction Manual, Page: 3 / 57

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AIR DRYER SUPPLIER CATR-1600-200 Instruction Manual Download Page 3

AIR DRYER SUPPLIER, INC. 

AIR DRYER INSTRUCTION MANUAL 

Model CATR 

Reference ADS-316 

 

Rev 0 

Page 3 of 40 

 

03/22/2019 

 

TABLE OF CONTENTS 

SECTION 4:  MAINTENANCE 

4.1 Maintenance 

4.1.1 Suggested 

Preventive Maintenance Schedule 

4.2 

Fill-Up / Replacement of Desiccant 

4.2.1 

For First Time Fill-Up 

4.2.2 

To Replace Used Desiccant 

4.3 Filter 

Maintenance 

4.3.1 

General Comments and Use 

4.3.2 Function 
4.3.3 

Assembly and Installation 

4.3.4 Maintenance 
4.3.5 

Instructions for Changing Filter Elements 

4.4 Solenoid 

Valves 

4.5 

Pilot Operated Valves 

SECTION 5:  DOCUMENTATION 

5.1 

Spare Parts List 

5.2 

Data Reports (as applicable) 

SECTION 6:  TROUBLESHOOTING & CUSTOMER SERVICE 

6.1 Troubleshooting 

6.1.1 Short-Term 

Shut-Down 

6.1.2 

Shut-Down in Case of a Fault or for Maintenance 

6.2 Customer 

Service 

6.2.1 Corporate 

Office 

6.2.2 Inquiry 

Information 

SECTION 7:  MSDS 

7.1 Desiccant 

MSDS 

SECTION 8:  WARRANTY 

8.1 Warranty 

SECTION 9:  ENGINEERING DRAWINGS & DOCUMENTS 

9.1 

Engineering Drawings & Documents 

Summary of Contents for CATR-1600-200

Page 1: ... contacting ADS regarding this dryer Model No CATR 1600 200 Serial No 101901 Prior to installation and start up of this dryer please read and implement the Installation Start up section of this manual Prior to operating this dryer it is advised that this entire manual be studied and clearly understood ...

Page 2: ...cation Mounting Specifications 2 2 Preventive Maintenance Prior to Start up 2 3 Air Supply 2 4 Air Discharge Piping 2 5 Drain Piping on mounted prefilter 2 6 Start Up 2 6 1 Purge Rate 2 7 Operation 2 7 1 Standard Inlet Conditions 2 7 2 Description 2 7 3 Theory of Operation 2 7 4 Sequence of Operation 2 7 5 Pressure Vessel Regulations 2 7 6 Airtightness Test SECTION 3 COOLER ASSEMBLY 3 1 Dryer Inle...

Page 3: ...ion 4 3 3 Assembly and Installation 4 3 4 Maintenance 4 3 5 Instructions for Changing Filter Elements 4 4 Solenoid Valves 4 5 Pilot Operated Valves SECTION 5 DOCUMENTATION 5 1 Spare Parts List 5 2 Data Reports as applicable SECTION 6 TROUBLESHOOTING CUSTOMER SERVICE 6 1 Troubleshooting 6 1 1 Short Term Shut Down 6 1 2 Shut Down in Case of a Fault or for Maintenance 6 2 Customer Service 6 2 1 Corpo...

Page 4: ...ualified personnel This training may be carried out by the manufacturer at the request of the user 1 2 Safety Instructions 1 2 1 Identification of Signs and Symbols in this Manual This instruction manual contains important information for safe proper and economic operation The safety tips and advice contained in this instruction manual as well as all safety labels printed directly on or attached t...

Page 5: ...m maintenance on the dryer 1 2 2 3 Do not attempt to remove any dryer parts while the dryer is pressurized First isolate the dryer if bypass valving has been installed or shut off the compressor Then slowly depressurize the dryer through the afterfilter bleed 1 2 2 4 Do not allow tools or other obstructions to interfere with the shaft of the switching valves Keep all body parts away from the switc...

Page 6: ... standard model CATR heatless dryer is equipped with two desiccant vessels and provides pure dry compressed air or gases when used under the design conditions as specified upon purchase Attention Warning Use of the dryer can endanger personnel and can lead to considerable damage to the dryer and other material assets if it is operated by personnel not trained or instructed in its use it is imprope...

Page 7: ...on site to minimize any chances of equipment damage After the adsorption dryer has been delivered it must be checked for damage that may have occurred during transport Any damages should be reported immediately to the transport company to begin the claim process Note For lifting and transportation only the skid or frame lifting points of the dryer may be used Do NOT support the dryer by the interc...

Page 8: ... the factory for leak tight joints and tightness of bolts however during shipment some bolts may vibrate loose We have no control over the handling our compressed air systems receive after leaving our factory To prevent costly problems at start up and operation all bolts should be checked for tightness prior to system pressurization This will assure gasket life as well as prevent possible gasket b...

Page 9: ...50 FLANGE RATING SIZE BOLT QTY BOLT SIZE RECOMMENDED TORQUE BOLT FT LBS MAXIMUM TORQUE FT LBS 1 4 16 64 1 4 32 64 2 4 5 8 64 128 3 4 5 8 110 128 4 8 5 8 78 128 6 8 148 230 8 8 201 230 10 12 7 8 191 372 12 12 7 8 254 372 Based on 1 16 gasket material If other than 150 flange rating consult Air Dryer Supplier Inc Maximum torque for aluminum filter flanges is 75 ft lbs FLANGE BOLT TORQUE PROCEDURE 8 ...

Page 10: ...alve block and bypass valving arrangement should be installed prior to start up to allow for isolating and depressurizing the dryer while still maintaining compressed air delivery Reference the Engineering Drawings Documents section of this manual for the Flow Schematic which will indicate the factory supplied arrangement Note that the bypassed air will not be dried Reference the Maintenance secti...

Page 11: ... must be checked for presence of scale abraded material from the threading or other similar impurities All shut off valves on the dryer prefilter afterfilter and on the bypass line should be closed The ambient temperature must not be less than 33 F 0 56 C Adjust the purge adjustment valve in accordance with the parameters listed in Section 2 6 1 of this manual The 2 purge isolation valves must be ...

Page 12: ...k the purge piping and muffler for cleanliness The purge piping must be kept clean at all times to maintain the proper purge rate The left right tower failed to depressurize alarm will alarm when the back pressure exceeds 5 psig At this time the mufflers MUST be cleaned or replaced to assure satisfactory dryer performance ALTERNATE FLOW PURGE SETTINGS Capacity SCFM Purge PSIG 100 Purge PSIG 125 Pu...

Page 13: ... dryer and disconnected from the electric power supply Never make any changes to the dryer that are not specifically authorized by Air Dryer Supplier Inc Only use original spare and accessory parts 2 7 1 Standard Inlet Conditions At standard inlet conditions of 100ºF 100 psig and providing a 40ºF pressure dew point according to DIN ISO 7183 Note All values given above assume a standard dryer with ...

Page 14: ...rmance butterfly valves 3 and larger or 2 way ball valves 2 and smaller This improved 2 way valve design provides for lower overall system pressure drop and it eliminates undesirable wet air transfer between compressed air streams simultaneously flowing through the same valve internal plug rotor or ball The valves are opened and closed by over sized actuators These actuators are driven by well fil...

Page 15: ... Control Group The complete operation of the CATR heatless dryer is fully automatic and pre programmed to shift drying vessels continuously before the design water load can be reached breakthrough The standard control is done with a PLC which operates the pilot air solenoids which in turn actuate the switching valves all without operator attention 2 7 2 6 Instrument Panel The standard instrument p...

Page 16: ...surized to atmospheric pressure and is used to regenerate the desiccant After removing moisture from the desiccant the purge air exits the dryer through a muffler and is blown out to the atmosphere After a preset time the dryer will shift towers At tower shift the regenerating tower is gradually repressurized the switching valves shift and the offstream tower is depressurized The Flow Schematic ca...

Page 17: ...ZE LEFT TOWER 4 300 SEC ENERGIZE SV4 CLOSES V5 DE ENERGIZE SV1 2 ENERGIZE CR1 302 SEC ENERGIZE SV1 1 OPENS V1 CLOSES V2 LEFT TOWER ONSTREAM ENERGIZE TR1 START 5 SECOND TIME DELAY 5 357 SEC ENERGIZE SV3 OPENS V4 DEPRESSURIZE RIGHT TOWER RIGHT TOWER REGENERATING START TIME DELAY OF 30 SECONDS IF PS2 DOES NOT REACH THE SET POINT OF 10 PSI THEN RIGHT TOWER FAIL TO DEPRESSURIZE 6 570 SEC DE ENERGIZE SV...

Page 18: ...own a For 5 minutes STEP TIME alters to the following i STEP 1 0 sec 2 sec ii STEP 2 7 sec iii STEP 3 120 sec iv STEP 4 150 sec 152 sec v STEP 5 157 sec vi STEP 6 270 sec vii STEP 7 300 sec 2 7 5 Pressure Vessel Regulations Never weld on or alter a pressure vessel in any way The pressure vessels are designed according to the standard technical requirements They fulfill the test and the certifying ...

Page 19: ...ion of the assembly The cooler should be located in an area to permit free movement of the air around it The warm discharge air must be free to dissipate to avoid being recycled into the cooler inlet The cooler assembly has an outlet temperature gauge and this temperature should be monitored to assure the dryer inlet temperature does not exceed sizing limitations or the dryer will no longer mainta...

Page 20: ...rson or have the fan blade assembly replaced The cooling fan may need replacement every 1 2 years depending on severe duty found at site Caution The exhaust stream from the pneumatic motor may contain solid particles or oil aerosol Wear eye and skin protection at all times while in the proximity of this equipment Ensure the oil mist delivery to the motor is properly adjusted A data table of adjust...

Page 21: ...sembly A regulator discharge pressure gauge is provided and will allow the operator to set the necessary secondary pressure Review the below bullet points for more detail Caution The pneumatic regulator secondary discharge pressure must not exceed 100 psig or pneumatic cooler motor damage can result If the cooler motor is out of service the regulator and mist lubricator should be depressurized by ...

Page 22: ... the gauge provided When set depress the adjustment knob to lock the device Do not wash down the regulator with solvents as some of the composite materials may be damaged 3 4 Data Table For Cooler Assembly for units with air motors only Dryer Model Regulator Pressure Oil Drip Rate Luber Volume Air Motor Consumption CATR 60 PSI 3 DPM 60 OZ 150 CFM Note THE OIL DRIP RATE DPM FOR LUBRICATING THE PNEU...

Page 23: ...ubricator For a leaner oil delivery turn clockwise for a richer oil delivery turn counter clockwise The drops per minute DPM can be counted in the sight dome located on the mist lubricator A service valve is provided on the dryer system to isolate the lubricator when service or oil filling is required 3 6 The Separator The separator located at the outlet of the cooling core is a high efficiency co...

Page 24: ...l the following is a minimum requirement Recheck desiccant level one month after start up and refill as necessary desiccant should be filled through the standpipe 4 1 1 1 DAILY 1 Check operating conditions inlet flow inlet pressure temperature and purge flow 2 Check dryer operating cycle 3 Check oil level in lubricator every 8 hours of use Note Maintenance steps above can be accomplished while the...

Page 25: ...ryer fill through the standpipe it is important to make certain the standpipe is completely filled with desiccant 9 Make certain all air and electrical connections are sound 10 Repressurize the dryer or filters and place onstream 11 Reconnect power to the dryer 4 1 1 3 EVERY 16 000 HOURS OR 24 MONTHS 1 Perform steps 1 through 8 as outlined in EVERY 1 000 HOURS OR 6 MONTHS Attention Warning DO NOT ...

Page 26: ...al for the Specification Sheet and Spare Parts list which indicate the required desiccant quantity Reference the Maintenance Fill Up Replacement of Desiccant section of this manual for the desiccant fill up replacement instructions On the CATR heatless air dryer fill through the standpipe it is important to make certain the standpipe is completely filled with desiccant 3 Rebuild the actuators and ...

Page 27: ...xtinguishing material The desiccant Material Safety Data Sheet MSDS can be referenced in the Desiccant MSDS section of this manual 4 2 1 For first time fill up For first time fill up remove nuts bolts yokes cover and gasket from the manway at the top of the tower ON LARGE TOWERS WITH MANWAYS Remove plug from the desiccant fill standpipe ON SMALL TOWERS WITH THREADED DESICCANT FILLS Pour specified ...

Page 28: ... no handhole drain desiccant from tower by removing the plug at the bottom of the tower and catch the old desiccant in a suitable container On large towers with flange remove bolts and blind flange from the desiccant fill standpipe On small towers with threaded desiccant fill remove pipe cap from the desiccant fill standpipe The tower can be blown clean with an air hose or may be washed out with a...

Page 29: ...indicate the required desiccant quantity or contact Air Dryer Supplier Inc S N required Do not tamp the desiccant Replace the manway cover and components or desiccant fill standpipe flange pipe cap and tighten A new gasket will be needed for re assembly Repeat process for the other tower Make sure all drain and fill ports are in place and properly tightened Soap test for leaks before returning the...

Page 30: ...d installation The piping system must be cleaned before assembling filter The filter must always be installed vertically 4 3 4 Filter Element Specifications Red Filter Element for Afterfilter Rough Coalescing Prefilter Blue Filter Element for Coalescing Prefilter Part number ADS 241 000 999 ADS 241 100 999 Particle removal 1 micron 0 01 micron Maximum particle size class 2 1 Maximum oil content 2 ...

Page 31: ...Using a drive ratchet handle unscrew and remove the top cover from the filter housing Remove the filter element by pulling straight up with a slow steady pressure Install the replacement filter element by slowly inserting it straight down into the filter housing and gently seating it into place The flow direction should be in to out as shown by the arrow on the label on the filter housing The wide...

Page 32: ...ol Circuit Check the terminal strip on the controller for the proper voltage If the voltage is present and the valve does not activate replace the solenoid coil High or Low Voltage Voltage should read within 10 of the nameplate reading 4 5 Pilot Operated Valves If the pilot operated valves fail to operate disconnect the pilot line to check if the valve is receiving pilot pressure If the valve is r...

Page 33: ...spare parts that the user should keep in stock in case of an emergency We cannot guarantee that specific parts needed will be available immediately from our stock 5 2 Data Reports as applicable The manufacturer s Data Reports for pressure vessels which are included on the following pages in this section are specific to the air dryer identified on this instruction manual s cover reference Model No ...

Page 34: ...cant 1 176 5 lbs tower ADS 110 020 100 3 Ball float drain FD1 3 ADS 120 101898 00 1 3 Y strainer cast iron YS1 ADS 225 101898 00 1 Afterfilter F4 Red filter element 230 299 000 ADS 241 000 999 2 1 HEF 60 filter high efficiency F1 16D33F filter element Housing seal ADS 250 090 000 ADS 240 751 000 ADS 570 738 300 1 1 1 Coalescer F3 Blue filter element 250 298 000 ADS 241 100 999 2 1 Rough coalescer ...

Page 35: ...off 2 way ADS 680 707 200 1 Switch toggle SPST 20A 115 1 60 ADS 680 808 000 1 Valve ball 1 brass w SR actuator normally open V5 Valve only actuator ready Valve repair kit not available Repair kit actuator ADS 723 060 077 B N O ADS 724 060 070 ADS 720 009 952 16 1 1 2 Valve ball 2 brass w SR actuator V3 4 Valve only actuator ready Valve repair kit not available Repair kit actuator ADS 723 090 079 B...

Page 36: ...erial No 101901 Reference 209 Rev 0 Page 3 of 3 07 05 2012 Qty Description Part Rec Spare Qty 1 4 way single coil solenoid SV4 ADS 823 115 600 1 1 4 way dual coil solenoid SV1 ADS 827 115 600 1 2 1 x 1 200 bronze relief valve PRV1 2 ADS 840 101898 00 1 ...

Page 37: ...Air Dryer Supplier Inc 1626 Wind Chase Drive Talbott TN 37877 101901 Air Dryer Supplier Inc 1626 Wind Chase Drive Talbott TN 37877 ...

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Page 39: ...design condition 4 Check intercooler at compressor 5 Entrained water entering desiccant bed 5 Check separator and pre filter Replace desiccant if necessary 6 Desiccant contamination due to oil from a lubricated compressor 6 Replace desiccant Excessive Pressure Drop in Dryer 1 Excessive flow rate 1 Reduce flow rate 2 Inlet pressure below design condition 2 Increase pressure Failure to Switch Towers...

Page 40: ...ryer will remain pressurized The following sequence is to be heeded when switching off the dryer First close all the shut off valves up and downstream of dryer Then immediately switch off the dryer 6 1 2 Shut down in Case of a Fault or for Maintenance Danger Before any kind of maintenance or repair work is done the dryer must be depressurized and disconnected from the power source Apply the genera...

Page 41: ...Customer Service E mails Dale airdryersuppliers com Allan airdryersuppliers com 6 2 2 Inquiry Information When contacting Air Dryer Supplier Inc please have the following information available Serial Number which can be found on the front cover of this manual on the ASME code nameplate on the dryer towers or in the electrical enclosure Model Number which can be found on the front cover of this man...

Page 42: ...v 0 Page 37 of 40 03 22 2019 SECTION 7 MSDS CUT SHEETS 7 1 Desiccant MSDS The Desiccant MSDS Material Safety Data Sheet which is included on the following pages in this section is specific to the air dryer identified on this instruction manual s cover reference Model No and Serial No ...

Page 43: ... 1 800 424 9300 Other means of identification Chemical family metal oxides 2 Hazards Identification According to Regulation 2012 OSHA Hazard Communication Standard 29 CFR Part 1910 1200 Classification of the product No need for classification according to GHS criteria for this product Label elements The product does not require a hazard warning label in accordance with GHS criteria Hazards not oth...

Page 44: ... 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 Most important symptoms and effects both acute and delayed Symptoms No significant reaction of the human body to the product known Indication of any immediate medical attention and special treatme...

Page 45: ...xplosive Conditions for safe storage including any incompatibilities Segregate from reducing agents Suitable materials for containers carbon steel iron Low density polyethylene LDPE High density polyethylene HDPE Further information on storage conditions Keep container tightly closed in a cool well ventilated place Storage stability Storage temperature 35 C Keep container dry 8 Exposure Controls P...

Page 46: ...n not applicable Vapour pressure not applicable Bulk density 38 0 52 lb ft3 68 F Vapour density not applicable Partitioning coefficient noctanol water log Pow The value has not been determined because the substance is inorganic Self ignition temperature not self igniting Thermal decomposition No decomposition if used correctly Viscosity dynamic not applicable the product is a solid Solubility in w...

Page 47: ...ntry for liquefied gases Acute Toxicity Effects Acute toxicity Assessment of acute toxicity Virtually nontoxic after a single skin contact Virtually nontoxic by inhalation Virtually nontoxic after a single ingestion Oral Information on Aluminum oxide Type of value LD50 Species rat Value 10 000 mg kg similar to OECD guideline 401 The data refer to a preparation of the substance No mortality was obs...

Page 48: ...tances products of a similar structure or composition Tested above maximum solubility Aquatic invertebrates Information on Aluminum oxide No observed effect concentration 48 h 100 mg l Daphnia magna OECD Guideline 202 part 1 static Tested above maximum solubility The details of the toxic effect relate to the nominal concentration Aquatic plants Information on Aluminum oxide No observed effect conc...

Page 49: ...ions Waste disposal of substance Dispose of in accordance with local authority regulations Check for possible recycling Disposal requirements are dependent on the hazard classification and will vary by location and the type of disposal selected All waste materials should be reviewed to determine the applicable hazards testing may be necessary 14 Transport Information Land transport USDOT Not class...

Page 50: ...NTED 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 MAD...

Page 51: ...d whereupon Air Dryer Supplier Inc shall at its option correct such nonconformity by suitable repair to such equipment or furnish a replacement part F O B point of shipment provided the Purchaser has stored installed maintained and operated such equipment in accordance with good industry practices and has complied with specific recommendations of Air Dryer Supplier Inc The Purchaser shall make eve...

Page 52: ...dryer it must be checked for damage that may have occurred during transport If there is any evidence of damage due to shipping immediately enter a claim with the carrier Shipping damage is not covered by warranty Air Dryer Supplier Inc shall not be liable for any repairs replacements or adjustments to the equipment or any costs of labor performed by the Purchaser or others without Air Dryer Suppli...

Page 53: ...v 0 Page 40 of 40 03 22 2019 SECTION 9 ENGINEERING DRAWINGS DOCUMENTS 9 1 Engineering Drawings Documents The drawings which are included on the following pages in this section are specific to the air dryer identified on this instruction manual s cover reference Model No and Serial No ...

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