Johnson Controls A-4400 Series Installation And Maintenance Manual Download

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64- 378- 14, Rev. D

Technical Bulletin A-4400

Issue Date 0316

2016 Johnson Controls, Inc.

Part No. 64-378-14, Rev. D

Code No. LIT-718050T

INTRODUCTION

Product Overview

INSTALLATION PROCEDURES

Location

Unpacking the Unit

Conventional Wall Mounting Arrangement

Air Connections

Base Mounting Arrangement

Activated Carbon Filter Installation

Drain Connections

Permanent Wiring Using Conduit

Wiring to Air Compressor

COMMISSIONING

Gauge Correction

Evaporator Pressure Adjustment

Altitude Compensation

Low Ambient Temperature Compensation

SERVICING PROCEDURES

Particle Filter

Coalescing Oil Removal Filter

A-4400 Series Refrigerated Air Dryers

Installation and Maintenance

Summary of Contents for A-4400 Series

Page 1: ...angement 4 Air Connections 5 Base Mounting Arrangement 6 Activated Carbon Filter Installation 6 Drain Connections 7 Permanent Wiring Using Conduit 8 Wiring to Air Compressor 9 COMMISSIONING 10 Gauge Correction 10 Evaporator Pressure Adjustment 10 Altitude Compensation 10 Low Ambient Temperature Compensation 11 SERVICING PROCEDURES 12 Particle Filter 12 Coalescing Oil Removal Filter 13 A 4400 Serie...

Page 2: ...Element Kit 14 Activated Carbon Oil Vapor Removal Filter 15 Pressure Reducing Valve 15 Power On Fail Lamp 15 Refrigeration Service 16 Condenser Fan Motor Replacement 21 Condenser 23 Air Dryer Compressor Motor Wiring Circuit 23 Excessive Vibration 24 SPECIFICATIONS 25 REPAIR INFORMATION 26 ...

Page 3: ...re reducing valve safety relief valve and power on fail lamp a properly configured system must include a coalescing oil removal filter as well as an activated carbon oil vapor removal filter as outlined in Product Data A 4000 and the Installation and Service Manual for PureFlow Air Compressors Publication No 2629 Table 1 Ordering Data Code Number Flow Capacity at Rated Condition scfm L s Air Purif...

Page 4: ...e shipping chipboard 3 Tip the air dryer slightly on its edge and carefully remove the steel packing band and discard Also slide the shipping chipboard out and discard 4 Remove and discard the packaging cardboard from behind the coalescing filter if applicable Models A 4412 1 A 4417 1 and A 4423 1 Two key slots are provided at the rear of the A 4400 for wall mounting the unit refer to Figure 1 Ins...

Page 5: ...o Locations for 1 4 in Bolts Field Furnished 16 406 14 1 4 362 Figure 1 A 4400 Series Refrigerated Air Dryer Shown with Optional Factory Mounted Air Purification System Dimensions in mm The high pressure side of the compressed air line after the compressor tank must be connected to the 3 8 in compression inlet air connection On models with an optional factory mounted Air Purification System this i...

Page 6: ...urification System the activated carbon oil vapor removal filter is packaged separately within the dryer shipping carton and must be installed on the unit in the field as follows 1 Referring to Table 2 note the life of the activated carbon oil vapor removal filter element being installed 2 Divide the element life noted in Step 1 by the average system scfm or L s to obtain the expected life in days...

Page 7: ...n line to the coalescing oil removal filter assembly if needed the F 400 20 kit is a 1 8 in external NPT x 1 8 in internal NPT coupler and the F 400 10 kit is a 1 8 in internal NPT x 1 4 in O D compression coupler Both coupler kits must be ordered separately Attach tubing to the connections on the automatic condensate drain trap assembly and the coalescing oil removal filter assembly if present ke...

Page 8: ...e compressor terminal box through Hole 1 as illustrated in Figure 3 12 in 305 mm should be long enough 2 Strip the wires back approximately 1 in 25 mm 3 Attach the strain relief bushing provided with each unit to the line cord approximately 3 in 76 mm from the cut end and insert it into Hole 1 4 Connect the conduit to Hole 2 as illustrated in Figure 3 and join the leads together using the appropri...

Page 9: ... continuous A 4400 operation whenever the disconnect switch is closed while control over the air compressor is retained by the PE switch Note The air dryer motor voltage must match the air compressor motor voltage in order to wire the unit as illustrated in Figure 4 Figure 4 Single Phase Air Compressor Motor Wiring to Air Compressor 115 VAC 60 Hz Air Compressor Disconnect Pressure Switch Air Compr...

Page 10: ...r pressure gauge is at the adjusted pressure Note All of the expansion valve settings are based on no load conditions position the service bypass valve into the bypass mode Allow the unit to run unloaded a minimum of 10 minutes prior to checking evaporator pressure or adjusting the expansion valve If the air dryer is installed in high altitudes the expansion valve will have to be adjusted to compe...

Page 11: ...t for low ambient temperature effects At high altitudes and low ambient temperatures it will be necessary to add both pressure corrections and readjust the expansion valve Refer to the Refrigeration Service section and follow Steps 1 through 5 readjusting the expansion valve setting to properly adjust the expansion valve until the evaporator pressure is at the adjusted pressure Operation of the A ...

Page 12: ...complete assembly See Table 3 Item E ordered separately If the bowl is not cracked clean it using a liquid household detergent 4 Turn the baffle counterclockwise and remove 5 Remove the old particle filter element and discard 6 Install the new particle filter element See Table 3 Item E ordered separately Screw the baffle into the filter body until contact is made with the filter element then tight...

Page 13: ...egral to the top of the unit refer to Figure 7 On a new filter this indicator is green in color As the pressure drop across the filter increases a slide within the indicator moves bringing some red color into view When the pressure drop reaches 7 5 psig 52 5 kPa the indicator becomes entirely red indicating that the filter element needs to be replaced Even if the indicator is not entirely red it i...

Page 14: ...replacement filter element one filter element O ring and one filter bowl O ring refer to Figure 7 To replace the filter element proceed as follows 1 Remove the service bypass valve locking pin and push the plunger to the right into the bypass position Doing so will unload the pressure in the filter bowl 2 Disconnect the drain tubing 3 Depress the lever on the filter bowl clamp and turn it 1 8 revo...

Page 15: ...as been replaced apply the white service label included with the new element and record the next replacement date month and year Determine this date following the procedure outlined earlier in the Activated Carbon Filter Installation section Upon system startup the output of the pressure reducing valve would be approximately 15 to 20 psig 105 to 140 kPa Note For optimal performance it is suggested...

Page 16: ...ion on each unit should be used for all service procedures The A 4400 is factory set to follow the Evaporator Pressure vs Ambient Temperature curve illustrated in Figure 5 If at no load the evaporator pressure rises above the acceptable operating zone one or more of the following conditions may exist The ambient temperature or the air flow may be above the specified limits The expansion valve may ...

Page 17: ... evaporator pressure is still too low the refrigerant charge is probably low To recharge the system proceed as follows 1 Disconnect the power supply to the air dryer 2 Remove the filter bowl and test for possible internal refrigerant leaks by allowing a small amount of supply air to pass through the unit Check for traces of gaseous refrigerant in the escaping air using a HFC 134a detector at the c...

Page 18: ...ameplate 6 Remove the charging manifold and replace the cap securely on the service valve 7 Reinstall the A 4400 cover and reconnect the power supply to the air dryer 8 If the evaporator pressure gauge reading plus correction does not return to normal as illustrated in Figure 5 adjust the expansion valve as described in the Refrigeration Service section Cap Figure 8 Service Valve Detail for Access...

Page 19: ...Air Dryers A 4400 Series Technical Bulletin 19 Figure 9 A 4400 Series Refrigerated Air Dryer with Cover Removed ...

Page 20: ...p Discharge Line Suction Line Inlet From Air Compressor PRV With Low Pressure Gauge High Pressure Output Regulated Output Safety Relief Valve Coalescing Oil Removal Filter With Automatic Drain Activated Carbon Oil Vapor Removal Filter Evaporator Pressure Gauge Condenser Service Bypass Valve Line Voltage Service Valve Heat Exchanger Tube In Tube Counterflow Evaporator Auto Exp Valve Automatic Conde...

Page 21: ...motor mounting screws and the fan motor support L bracket Retain the screws and bracket for reassembly 9 Noting the orientation of the motor and its leads peel the old fan motor off of the protecting screen leaving as much of the black vibration dampening tape behind as possible 10 Install the replacement fan motor A 4300 601 ordered separately in the same orientation noted in Step 9 11 Secure the...

Page 22: ...18 Check for excessive vibration If the unit is vibrating excessively it is likely that one or more of the fan blades is misaligned To align the blades refer to the Excessive Vibration section in this bulletin 19 Reinstall the cabinet cover and using a 1 4 in hex head wrench blade screwdriver secure it in place using the cover mounting screws retained in Step 2 Figure 12 Condenser Fan Motor Assemb...

Page 23: ...inuity the relay Tecumseh 820 10052 must be replaced 5 Check for continuity between compressor terminals C and M At an ambient temperature of 77 F 25 C the run winding resistance across terminals C and M should be approximately 3 1 ohms If the run winding resistance is drastically different from the above either replace the compressor or the entire air dryer 6 Check for continuity between compress...

Page 24: ...cardboard against the trailing edge of one of the fan blades 3 Manually rotate the fan and observe the relative alignment of all five blades with respect to the reference in Step 2 4 If a blade appears to be out of alignment as compared to the other blades bend the blade back into line by hand Continue until the trailing edges of all five blades are aligned horizontally within 1 4 in 6 mm 5 Reconn...

Page 25: ...rop with A 4412 1 10 psig 70 kPa A 4412 2 4 psig 28 kPa 80 psig 560 kPa Supply and A 4417 1 17 psig 119 kPa A 4417 2 8 psig 56 kPa Rated Flow A 4423 1 33 psig 231 kPa A 4423 2 15 psig 105 kPa Maximum Input Pressure 125 psig 875 kPa Connections 3 8 in Compression Fittings for Polytubing or Copper Tubing Finish Gray Enamel Accessory Order Separately A 4000 154 Manual Override for Coalescing Oil Filt...

Page 26: ...26 Air Dryers A 4400 Series Technical Bulletin Repair Information Figure 14 Repair Parts See Table 3 Figure 15 Repair Parts See Table 3 ...

Page 27: ...A 4000 620 Replacement Drain Valve 0 2 A 4000 6010 Manual Override for Drain Valve 25 A 4000 1054 G Carbon Filter Element Only Air Dryer Model A 4412 1 7 A 4000 632 A 4417 and A 4423 3 8 A 4000 633 H Safety Relief Valve 0 1 A 4000 144 J Condenser Fan Motor 2 2 A 4300 601 K Power On Fail Lamp 0 05 A 4300 602 L Insulating Tape Not Shown Order in multiples of 30 ft 1 2 A 4210 603 M Start Relay Tecums...

Page 28: ...her marks herein are the marks of their respective owners 2016 Johnson Controls Inc European Single Point of Contact NA SA Single Point of Contact APAC Single Point of Contact JOHNSON CONTROLS WESTENDHOF 3 45143 ESSEN GERMANY JOHNSON CONTROLS 507 E MICHIGAN ST MILWAUKEE WI 53202 USA JOHNSON CONTROLS C O CONTROLS PRODUCT MANAGEMENT NO 22 BLOCK D NEW DISTRICT WUXI JIANGSU PROVINCE 214142 CHINA ...

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