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DIGITAL DRY GUARD™ (DDG) 
CONTROLLER OPERATION 

 

 

 
(Available on some models as standard, and others as 
an option.) 

The DDG Controller is capable of 4-channel temperature 
display, drain control, and service due and alarm 
indication. 
 

Temperature Display 

The DDG controller is capable of 4-channel temperature 
display. The unit displays refrigerant suction temperature 
(measured immediately downstream from the refrigerant/ 
air heat exchanger), incoming air temperature, ambient 
air temperature (or incoming water temperature for units 
with a water-cooled condenser), and dew point 
temperature (optional). Only one temperature can be 
displayed on the LCD screen at a time. In the normal 
operational mode, pushing the UP (

) or DOWN (

arrow keys will cycle the temperature displayed, while 
LEDs on the DDG unit indicate which temperature is 
being displayed. Pushing the SELECT key will cycle 
between Fahrenheit and Celsius temperature scales. 
The LED labeled “OPTIONAL” corresponds to the dew 
point temperature. If your unit does not include this 
option, the temperature displayed when the “OPTIONAL” 
LED is lit will be about 30°F (-1°C) by default. This does 
NOT indicate that the dew point is actually 30°F (-1°C). 
 

Drain Operation 

Locking/Unlocking Drain Time Settings: 

The ON 

TIME and OFF TIME settings for all modes of drain 
operation can be unlocked or locked to avoid inadvertent 
changes to these settings. In the unlocked condition, the 
time settings will flash after the SELECT key is pressed 
momentarily, indicating that the values can be changed 
by pressing the UP (

) or DOWN (

) arrow keys. In the 

locked condition, the SELECT key must be held down 
for 5 seconds before the display will flash and the 
settings can be changed. With the display flashing, 
pushing the SELECT key momentarily will return to 
normal unlocked operation and holding the SELECT key 
down for 5 seconds will return to normal locked 
operation.

 

 

Setting Drain ON TIME and OFF TIME: 

1.  Press the UP (

) or DOWN (

) arrow keys until the 

LED indicates that ON TIME or OFF TIME has been 
selected. 

 
2.  Press SELECT momentarily (if unlocked) or hold 

until the display starts flashing (if locked). If you do 
not know whether the setting is locked or not, simply 
press the select button momentarily. If the digits on 
the LCD display do not start flashing, the setting is 
locked. 

 
3.  Press UP (

) or DOWN (

) arrow keys to change the 

settings. The ON TIME is indicated in seconds and 
changes in 0.5-second increments in a range of 0 to 
60 seconds. The OFF TIME is indicated in minutes 
and changes in 0.5-minute increments in a range of 
0 to 60 minutes. 

 

Modes of Drain Operation: 

The DDG Controller has

 

two modes of drain operation 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.  Timed Drain Mode (model 4477 A, B, or C drains): 

Set ON TIME and OFF TIME to non-zero values. 
Settings should be such that fluid is adequately 
drained without allowing excessive air loss. 

 
B.  Demand Drain Mode (model 4488 drains): Set ON 

TIME and OFF TIME to zero. Drain is given 
continuous power supply and will operate normally. 
In this mode, pushing the DRAIN TEST button will 
have no effect. 

 

Alarm Indication 

The following conditions can cause the alarm indicator to 
light: 
 
• Compressor overload 
• Low refrigerant suction pressure 
• High refrigerant discharge pressure 
• Low oil pressure (semi-hermetic compressors only) 
 
A qualified refrigeration mechanic should identify and 
correct the problem if an alarm condition occurs. 

In most

 

cases it will be necessary to firmly depress the reset 
push-button located on the dual-pressure switch, 
which is inside the electrical enclosure. 

Follow all 

safety procedures applicable to electrical equipment 
when opening the electrical enclosure. 

 
 
 

 

 

Summary of Contents for AD Series

Page 1: ...Noncycling Refrigerated Air Dryers AD 750 to 4000 Series Owner s Manual 9829 2103 73 August 2009 ...

Page 2: ...DATE OF PURCHASE MODEL SERIAL NO Record above information from nameplate Retain this information for future reference 1 ...

Page 3: ... 7 Design Conditions 7 Start Up Procedure 7 Operating Range and Control Settings 8 Digital Dry Guard DDG Controller Operation 9 Shutdown Procedure 10 Operating Conditions 10 Maintenance 11 Air Dryer Maintenance 10 Automatic Drains 10 Compressor 13 Expansion Valve 13 Hot Gas Bypass Valve 13 Refrigerated Air Dryer Service Check List 17 Troubleshooting 18 ...

Page 4: ...with damaged wiring or after the unit or air handling parts have been dropped or damaged 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 wh...

Page 5: ...INSTALLATION INSTRUCTIONS 4 FIGURE 1 COMPRESSED AIR SYSTEMS RECOMMENDED INSTALLATION FLOW DIAGRAM ...

Page 6: ...igh inlet temperature compressed 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 approxim...

Page 7: ... 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 a qualified electrician CAUTION SCROLL COMPRESSOR Air dryers with a scroll compressor are unidirectional and to function properly they must be phased correctly To turn the compressor clockwise use a phase sequence ind...

Page 8: ... DRYER WITHOUT ENERGIZING THE CRANKCASE HEATER WILL CAUSE PREMATURE FAILURE OF THE REFRIGERANT COMPRESSOR Failure to comply with procedure of energizing crankcase heater before start up may void warranty 2 Check the temperature on the crankcase of the compressor to make sure the crankcase heater is working before starting the dryer 3 For water cooled Air Dryers ADW make sure the water supply Minim...

Page 9: ...ure 25 to 33 PSIG Blue color range Refrigerant Discharge Pressure 75 to 170 PSIG Air cooled units 115 to 135 PSIG Water cooled units Refrigerant Low Pressure Switch Cut Out 20 PSIG Cut In 40 PSIG Refrigerant High Pressure Switch 250 PSIG Air cooled units 225 PSIG Water cooler units Fan Control Cut Out 110 PSIG Cut In 150 PSIG R 404a Refrigerant Suction Pressure 69 to 76 PSIG Orange color range Ref...

Page 10: ...ME and OFF TIME 1 Press the UP or DOWN arrow keys until the LED indicates that ON TIME or OFF TIME has been selected 2 Press SELECT momentarily if unlocked or hold until the display starts flashing if locked If you do not know whether the setting is locked or not simply press the select button momentarily If the digits on the LCD display do not start flashing the setting is locked 3 Press UP or DO...

Page 11: ... DOWN keys simultaneously This can not be done while a service due timer test is in progress SHUTDOWN PROCEDURE 1 Open the bypass valve to allow process flow to continue downstream Then close the outlet isolation valve on the dryer bypass piping 2 Close the inlet isolation valve on the dryer bypass piping At this time the dryer is isolated and can be depressurized ready for servicing 3 Turn the po...

Page 12: ...ified range after a few minutes of 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 pr...

Page 13: ...vailable H Assemble the valve parts 12 I Connect the solenoid coil 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 CAUTION ...

Page 14: ...se the suction pressure and counterclockwise to lower the suction pressure This adjustment should be made under a no load condition only When the adjustment is made turn one quarter of a turn at a time and wait 3 to 5 minutes between adjustments Once the adjustment is complete secure the adjusting stem with the locknut that is provided Careful adjustment of this valve is necessary for normal opera...

Page 15: ...14 FIGURE 6 FLOW DIAGRAM AD 750 to 1000 ...

Page 16: ...15 FIGURE 7 FLOW DIAGRAM AD 1200 to 2000 ...

Page 17: ...FIGURE 8 FLOW DIAGRAM AD 2500 to 4000 16 ...

Page 18: ...______________________________________________________ 6 Air in pressure PSIG ___________________________________________________________________________ 7 Air out pressure PSIG __________________________________________________________________________ 8 Refrigerant suction pressure when unit is operating PSIG ______________________________________________ 9 Refrigerant suction pressure when unit ...

Page 19: ...ols 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 ov...

Page 20: ...efective 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 1 Refrigerant shortage 2...

Page 21: ...ooler 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 11 3 Increase line size and or correct piping as required 4 Reduce overload 5 Add another unit or replace with larger unit 6 Check drain repai...

Page 22: ...21 ...

Page 23: ...22 ...

Page 24: ...Pneumatech 4909 70th Avenue Kenosha WI 53144 Phone 262 658 4300 Fax 262 658 1945 www pneumatech com ...

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