Pneumatech AD-1500 Owner'S Manual Download Page 17

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Pub. No. OM-A-75 REV. 4 — March 2006

TROUBLESHOOTING

The following conditions can cause abnormal operation or malfunction of the air dryer

• High inlet air temperatures

• High cooling water inlet temperatures

• Untreated cooling water

• Dirty condenser

• Low ambient temperatures

• Malfunctioning automatic drains at aftercooler, or

dryer

• Refrigerant overcharge

• Leaky evaporator

• Electrical power supply more than ±10% of the rated

voltage

• Low inlet air pressures

• Contaminated cooling water

• Condenser water pressure below 35 PSIG

• High ambient temperatures

• Compressed air flow greater than rated capacity

• Undersized fuses

• Refrigerant undercharge

• Clogged air compressor air intake filter

If any of these symptoms are noticed, refer to
Troubleshooting Guide.

Table 1 — Troubleshooting Guide

Symptoms

Cause

Remedy

A. Unit does not run.

1. Motor line open.
2. Fuse blown.
3. Tripped overload.

4. Safety controls open.
5. Air switch open. (Dead end

control)

6. Frozen (locked) compressor.
7. Wiring improper or loose.

1. Close disconnect switch, to start.
2. Replace fuse.
3. Turn switch off, wait 15 minutes,

check for overload condition.

4. Repair or replace.
5. Check air pressure. Adjust air

and/or switch. If defective repair
or replace.

6. Repair or replace.
7. Check wiring against diagram.

B. Unit short cycles.

1. Motor compressor overload

cutting out.

2. Shortage of refrigerant.
3. Suction pressure low.

4. Sticking expansion valve.

1. Check for high head pressure,

clogged condenser, high ambient,
or air overload. Check high
pressure cutout, repair or replace.

2. Repair leak and recharge.
3. Check hot gas bypass adjust,

repair or replace.

4. Repair or replace.

C. Compressor will not start – hums.

1. Improperly wired.
2. Low line voltage.
3. Starting capacitor defective.
4. Relay or contactor not closing.

5. Start winding open.

6. Single-phasing.

1. Check wiring against diagram.
2. Check voltage – correct.
3. Replace.
4. Check for reason – repair or

replace.

5. Check leads, if leads OK replace

motor.

6. Check fuses.

Summary of Contents for AD-1500

Page 1: ...Printed in U S A Publication No OM A 75 March 2006 Rev 4 Owner s Manual NON CYCLING REFRIGERATED AIR GAS DRYER ...

Page 2: ... Doing this will extend the warranty to 24 months from date of shipment from Company s factory See back page for actual Warranty details DATE OF PURCHASE MODEL SERIAL NO Record above information from nameplate Retain this information for future reference Replacement Price 25 00 ...

Page 3: ...art Up and Operation 6 Design Conditions 6 Start Up Procedure 6 Operating Range and Control Settings 7 Digital Dry Guard DDG Controller Operation 7 Shutdown Procedure 9 Operating Conditions 9 Maintenance 10 Air Dryer Maintenance 10 Automatic Drains 10 Compressor 12 Expansion Valve 12 Hot Gas Bypass Valve 12 Refrigerated Air Dryer Service CheckList 14 Troubleshooting 15 ...

Page 4: ...aged in any manner Notify authorized service facility for examination repair or other adjustments 3 USE SUITABLE PARTS ACCESSORIES Do not use air pressurized accessories or parts in the air system not suitable for the maximum air pressure 4 RELEASE AIR PRESSURE SLOWLY Fast moving air will stir up dust and debris which may be harmful Release air pressure slowly when depressurizing your system to av...

Page 5: ...URE GAUGE REMOVES 66 MOISTURE AIR COOLED AFTERCOOLER 2 P RECEIVER T C PREFILTER REGENERATIVE AIR DRYER PARTICULATE AFTERFILTER 4 5 TO PLANT USE 37 F RECEIVER REFRIGERATED COALESCING AFTERFILTER DRAIN R OPTIONAL 3 VALVE SYSTEM BYPASS P 6 P CONTROL OPTIONAL AUTO DRAIN 1 SEE PNEUMATECH BULLETIN PWC 1 2 SEE PNEUMATECH BULLETIN A 3 3 SEE PNEUMATECH BULLETIN A 16 4 SEE PNEUMATECH BULLETIN A 8 5 SEE PNEU...

Page 6: ...pressed air to the air dryer which will cause premature failures Aftercoolers must be followed by a separator and an automatic drain to remove the condensed moisture before the compressed air reaches the air dryer If the condensed water is not removed at the aftercooler separator drain it will reduce the cooling capacity of the air dryer Aftercoolers will condense approximately 2 1 2 to 3 times mo...

Page 7: ... to the dryer must meet the national NEC and local code requirements Check the voltage specified on the nameplate to the electrical power connecting to the dryer Electrical connections must be made by an electrician SCROLL COMPRESSOR Air dryers with a scroll compressor are uni directional and to function properly they must be phased correctly To turn the com pressor clockwise use a phase sequence ...

Page 8: ...tart up Power to the air dryer can be left on to energize the crankcase heater for the off cycle during evening or weekend shutdowns 3 Check the temperature on the crankcase of the compressor to make sure the crankcase heater is working before starting the dryer 4 For water cooled Air Dryers ADW make sure the water supply Minimum Pressure 35 PSIG is available at the condenser inlet The water regul...

Page 9: ...G R 22 air cooled units with fan cycling 190 to 210 PSIG R 22 water cooled units 3 Refrigerant Discharge Pressure R 134a 75 to 170 PSIG R 134a air cooled units 115 to 135 PSIG R 134a water cooled units 4 Refrigerant Low Pressure Switch CUT OUT 20 PSIG R 134a CUT IN 40 PSIG R 134a CUT OUT 45 PSIG R 22 CUT IN 70 PSIG R 22 5 Refrigerant High Pressure Switch 250 PSIG R 134a air cooled units 405 PSIG R...

Page 10: ...on for different drain types The mode of operation for timed drains i e 4477 A B or C models is described below as item A The mode of operation for fully automatic float operated drains i e model 4488 is described as item B For all modes the DRAINS POWER ON LED indicates that the drain is receiving power Pushing the DRAIN TEST key will send power to the drain if it is not already receiving power A...

Page 11: ...on the dryer bypass piping At this time the dryer is isolated and can be depressurized ready for servicing 3 Turn the power switch to the OFF position NOTE The alarm indication light red signifies the refrigerant compressor is not running The reasons can be Low suction pressure High discharge pressure Electrical problems Loss of refrigerant Dirty condenser Leaking evaporator etc Refer to Troublesh...

Page 12: ...f start up Suction pressure below the range will cause freeze up inside the air system increasing the pressure drop across the air dryer Suction pressure above the range will reduce the refrigeration cooling capacity 5 Check the pressure drop across the air dryer at full capacity flow If it is higher than specified value normally 5 PSI or less consult factory If pressure drop increases over years ...

Page 13: ...il J Install the drain valve in the system FIGURE 3 DRAIN VALVE Recommended Operation and Maintenance for the Particle Strainer The particle strainer should be cleaned once every week or as needed 1 Close the shut off valve on the particle strainer 2 Depressurize the drain by pressing the drain PRESS TO TEST or DRAIN TEST key 3 Unscrew bottom of the particle strainer and clean the screen FIGURE 4 ...

Page 14: ... adjustments are needed only at the time of valve replacement Expansion valve service must be performed by a qualified refrigeration technician HOT GAS BYPASS VALVE Model AD 10 and larger air dryers come equipped with modulating hot gas bypass valves This valve maintains the refrigerant suction pressure in varying load conditions The dryer will run from no load to full load conditions without free...

Page 15: ...Pub No OM A 75 REV 4 March 2006 13 FIGURE 6 FLOW DIAGRAM ...

Page 16: ... _______________________________________________________________________________ 6 Air in pressure PSIG _________________________________________________________________________________ 7 Air out pressure PSIG ________________________________________________________________________________ 8 Refrigerant suction pressure when unit is operating PSIG __________________________________________________...

Page 17: ...d 4 Safety controls open 5 Air switch open Dead end control 6 Frozen locked compressor 7 Wiring improper or loose 1 Close disconnect switch to start 2 Replace fuse 3 Turn switch off wait 15 minutes check for overload condition 4 Repair or replace 5 Check air pressure Adjust air and or switch If defective repair or replace 6 Repair or replace 7 Check wiring against diagram B Unit short cycles 1 Mot...

Page 18: ...er 4 Location too hot 5 Defective condenser pressure switch 6 Defective fan motor 7 Fan operating in wrong direction 8 Defective water regulating valve 1 Purge or vacuum and recharge 2 Check for reason repair 3 Blow clean with compressed air 4 Cool ambient relocate unit add ventilation 5 Repair or replace 6 Replace 7 Switch two wires at disconnect 8 Adjust repair or replace H Head pressure too low...

Page 19: ...System pressure low 2 Precooler and or evaporator clogged 3 Incorrect piping 4 Air overload 5 Unit too small 6 Excess water in unit 7 Evaporator freeze up 8 Clogged air compressor intake filter 9 Dirty air system 1 Increase pressure 2 Back flush using mild detergent Figure 2 on Page 10 3 Increase line size and or correct piping as required 4 Reduce overload 5 Add another unit or replace with large...

Page 20: ...nd valves on Intermediate Controls for defects in material or workmanship covering Components only provided a Customer notified the Company of any claim of defect in material or workmanship within sixty 60 months from date of shipment from the Company s factory b Customer holds the Product or Component for inspection by the Company s representative c Customer returns the Component s only with Comp...

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