Corrosion Dry Air Pak

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Corrosion Dry Air Pak ENGINEERED COMPRESSED AIR DRYING SYSTEMS FOR MIC REDUCTION IN DRY PIPE SPRINKLER SYSTEMS Installation, Operation, & Maintenance Manual MODELS CDP500, CDP1000, & CDP2000 MFG#: 5403584 Rev A Model Number System Capacity Compressor HP Dryer Rating SCFM Approximate Shipping Weight CDP500 500 Gallon 2 10 375lbs CDP1000 1000 Gallon 5 20 500lbs CDP2000 2000 Gallon 5 27 550lbs Potter Corrosion Solutions 1609 Park 370 Place St. Louis, MO 63042 866.572.3005 www.pottersignal.com/corrosion

2

Table of Contents Safety Guidelines...4 Section 1 - Installation Instructions...5 1.1 Location...5 1.2 Changing the Oil...5 1.3 Connecting Voltage...5 1.4 Prior Run Time...6 1.5 Filter...6 1.6 Dew Point Monitor...6 1.7 CDP Outlet...6 1.8 CDP Air Maintenance Device...6 1.9 Electronic Drain Valve...6 Section 2 - Start-Up Instructions...7 Section 3 - Operation...8 3.1 Description of Operation...8 3.2 Setting the Purge Pressure...8 3.3 Coalescing Filter Operation...8 3.4 Dryer Operating Sequence...9 Section 4 - Additional Specifications...10 Section 5 - Desiccant Replacement... 11 Section 6 - Trouble Shooting Guide...12 Section 7 - Corrosion Dry Air Pak General Arrangement...13 Section 8 - Corrosion Dry Air Pak Three Phase...14 Section 9 - Corrosion Dry Air Pak Electrical Point to Point...15 Section 10 - Warranty Information...16 3

Safety Guidelines This manual contains information that is very important to know and understand. This information is provided for SAFETY and to PREVENT EQUIPMENT PROBLEMS. To help recognize this information, observe the following symbols. D Danger indicates an imminently hazardous situation which, if not avoided, WILL result in death or serious injury. Warning indicates a potentially hazardous situation which, if not avoided COULD result in death or serious injury. Caution indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury. Notice indicates important information, that if not followed may cause damage to equipment. 4

Section 1 - Installation Instructions 1.1 Location Corrosion Dry Air Pak 5403584 Rev A 9/10 Install Corrosion Dry Air Pak in a clean, dry location, with ambient temperatures above 50 F at all times, adjacent to the sprinkler system piping outside the room. No more than three systems are to be connected to a single Corrosion Dry Air Pak; capacity of each system should not exceed the rated capacity of the Corrosion Dry Air Pak. The unit must be accessible at the front for servicing all major components. The unit should be leveled and anchored to the floor (the vibration isolators supplied with the unit MUST be utilized). If the location is below freezing at any time the unit must be enclosed in a separate, heated enclosure to keep the temperature above 50 o F. Do not install the Corrosion Dry Air Pak in an area where ammonia vapors or similar contaminants exist. The equipment and desiccant can be damaged by ammonia and other vapors. Locate the Corrosion Dry Air Pak to ensure no ammonia or other vapors are drawn into the intake. 1.2 Changing the Oil The unit has been filled with oil for test purposes. It is strongly recommended to change this oil after the initial run in period on site. 2 Quarts of oil are shipped with each Corrosion Dry Air Pak for this purpose. When adding or replacing oil only use General Part Number ACPO1Q Specially Formulated Compressor Oil. Oil requirements are: CDP 500 CDP 1000 CDP 2000 Approximately 22oz. (middle of oil level window) Approximately 1 ½ qt. (middle of oil level window) Approximately 1 ½ qt. (middle of oil level window) Lightweight lubricants should not be used on heavy gear oils. 1.3 Connecting Voltage Connect proper supply voltage to the power line terminals in the control panel. Required supply voltage is indicat ed on unit s model label on the inside of the control panel door. Wire size must be capable of carrying the unit load, without dropping the voltage at the terminals below normal operating levels. Double check incoming wire size; if there are any questions please call us, we can assist you in ensuring you have selected the correct size. Be sure the control power transformer has its primary side jumpers connected to match the incoming supply voltage. Each unit is run at the factory and results noted for reference so if there are any questions please contact the factory. Motor rotation will always need to be checked. After connecting the power, use the on/off switch on the front of the unit to turn on the compressor briefly to check rotation. An indicating arrow is on the compressor flywheel. If rotation is not correct on three phase units, reverse any two leads. On single phase units refer to the motor nameplate, however it should not require changing as it has been run at the factory. If you feel this is required please consult with factory personnel as there may have been changes made to the unit, which should be discussed with the factory PRIOR TO starting the unit. Please ensure sufficient power is available at the unit. Long feed line runs can cause voltage drops, which can affect the performance of the unit and damage the motor. D Only qualified electrical personnel should connect the unit. 5

1.4 Prior Run Time Corrosion Dry Air Pak 5403584 Rev A 9/10 Each Corrosion Dry Air Pak is shipped with desiccant installed. The unit will need to be run for a minimum of 8 hours prior to any air being used from the Corrosion Dry Air Pak in the sprinkler system. Air should be bled from the system after the regulator in an amount to allow the compressor to run no more than 4 times per hour. If you are connecting to an old piping system there may be existing leaks in the system which cause the compressor to cycle more frequently than 4 times per hour. If this is the case there are three suggestions: 1. Fix the leaks. 2. Add a second Corrosion Dry Air Pak to provide enough air to bring the cycle times back to less than 4 times per hour. 3. Add a receiver, which can act as a storage buffer to supply more air to the system. This should be discussed with the factory personnel, as it will only work in cases where minor leaks are involved. 1.5 Filter The Corrosion Dry Air Pak is supplied with a removable, threaded inlet air filter so that if the AHJ requires the air to be drawn from the cold room this can be done if the CDP is used in a freezer application. The Corrosion Dry Air Pak is designed so that performance will not be adversely affected with the filter left in place directly on the compressor. If connected in a cold room, the piping back to the compressor must be 1 1/2 minimum pipe size for this run, bushed down directly at the compressor inlet elbow. This pipe must be heat traced and insulated. The filter should be mounted on the inlet end of this pipe directly in the cold room. The interconnecting piping should be clean of any foreign matter, which may be drawn into the compressor and cause damage. 1.6 Dew Point Monitor If a dew point monitor is required, mount it at the outlet of the CDP. This is after the regulator and gives you the pressure dew point of the system. Be careful to follow the dew point monitor manufacturer s recommendations as far as installation is concerned. 1.7 CDP Outlet The Corrosion Dry Air Pak outlet is from the combination particulate filter with pressure regulator, mounted on the right lower side of the unit facing the control panel. Connect this outlet to the sprinkler system air inlet. 1.8 CDP Air Maintenance Device The Corrosion Dry Air Pak has a UL/FM approved Air Maintenance Device built into the unit. It will require adjustment of the regulator to your system requirements. It replaces the final regulator, which should be left fully open once the Air Maintenance Device has been adjusted and valved into the line. If connecting more than one system to the unit, the Air Maintenance Device should be in the fill position and the individual AMD s used to control each system should be utilized. Leaks in the piping system will affect the pump up time of the system. The Corrosion Dry Air Pak has been factory tested to produce the published capacity, for systems without leaks. 1.9 Electronic Drain Valve An integral electronic drain valve is installed on each unit. The drain is pre-set when the unit leaves the factory. If necessary you can adjust the time between openings and the length of time the valve is open using the control knobs located above the hour meter on the front of the control panel. Under normal circumstances the maximum time between openings should be sufficient. If more frequent openings are required due to excessive compressor operation simply decrease the duration between openings. The Automatic-Off- Manual Test switch can be used to check operation. Leave this switch in Automatic during normal operation. 6

Section 2 - Start-Up Instructions As noted previously, the unit must run for a minimum of 8 hours prior to any air being taken from the Corrosion Dry Air Pak into the sprinkler system. Air should be bled from the system after the regulator in an amount to allow the compressor to run no more than 4 times per hour for this period. With all the connections made as described in Installation Instructions, the unit is ready to start. With the valve ahead of the coalescing filter closed, turn the unit on with the switch on the front of the control panel. The compressor should start to fill the receiver tank and the tank pressure gauge on the front of the control panel should indicate the pressure. The unit should pressurize the receiver to approximately 100psig and then shut off. Do not adjust the pressure switch on the unit. It is factory set at the values required for correct operation of the unit. Warranty may be void if the pressure switch is reset. The unloader line will operate to bleed off the pressure in the line from the compressor to the receiver inlet so that the compressor does not start loaded. Air will exhaust from the small valve at the side of the switch immediately after the compressor is shut off. This should not occur when the compressor is running or for long periods of time after the compressor shuts off. If this occurs, contact the factory. Open the valve ahead of the coalescing filter and pressurize the rest of the Corrosion Dry Air Pak. The Air Maintenance Device should be in fill mode, with the 3/4 valve open. The outlet valve should now be open to allow air to begin to purge into the sprinkler system. The final regulator is factory set to 40 psig. The outlet valve should always be set to maintain pressure on the drying tower between 70 to 100 psig. At no time should the outlet valve be opened to bleed all pressure off the drying system, as this will adversely affect drying quality. Open an inspection test point or other valve on the far end of the sprinkler system to allow the current wet air in the sprinkler system to be purged out of the system. This leak should be adjusted to allow the compressor to run, after filling the system to pressure, no more than 4 times per hour. Allow this to run for 24 hours then close the inspection test port valve to allow the system to function normally. The automatic drain is set to a mid position at the factory. You should not need to adjust frequency or duration but if you do, be aware that the quicker the cycle and the longer the open time, the more air will be used and the less will be available at the unit outlet. A light on the control panel will indicate when the drain is operating. A length of tubing is provided at the drain valve outlet for piping to a convenient drain or collection point. Be sure to pipe this discharge to a position where the discharged air and water will not be a hazard to personnel. Once the system is filled the Air Maintenance Device will need to have the 3/4 valve closed, the two 1/4 valves opened and the regulator set for final system maintenance pressure. The final regulator should then be opened to full to allow the Air Maintenance Device to be the controller. 7

Section 3 - Operation Corrosion Dry Air Pak 5403584 Rev A 9/10 3.1 Description of Operation The following is a description of the operation of the Corrosion Dry Air Pak. Typically air is drawn into the compressor intake through the threaded inlet filter. If required by the AHJ, air is drawn in from the cold room through the inlet filter installed inside the cold room. This air then travels to the compressor intake via 1 1/2 minimum line size piping. Upon reaching the compressor, air is drawn into the compressor intake and compressed through the compression cycle and then discharged into the intercooler. The air then crosses over into the air cooled aftercooler where ambient air being pulled over the coil cools the hot compressed air. Water in the compressed air will now drop out of the air as it cools and drops down into the receiver. A check valve in this line prevents any back flow to the compressor. The water settles into the bottom of the receiver and is discharged from the receiver when the automatic drain valve opens. This air then leaves the receiver and goes into the coalescing filter where entrained oil is removed. This air then travels to the dryer inlet. The air is diverted to the corresponding tank via two solenoid valves. The air travels upwards through the desiccant bed and exits through the top of the tank. A portion of this dried air is diverted to the opposite tank via the purge valve and gauge/orifice combination. The purge pressure gauge setting is factory set (see following settings for each model). If re-setting is required, consult the factory for assistance. The purge air enters the top of the offstream tower and travels in a downward direction to pick up the water molecules from the desiccant as the pressure drops to atmosphere. The wet purge air then exits the bottom of the tank and is vented to atmosphere via the purge mufflers. These mufflers act to quiet the discharging air and also reduce the noise when the towers depressurize. These mufflers are removable for cleaning with soap and water periodically. Cleaning will ensure no build up, which will create back pressures in the tanks and decrease dryer performance. Both inlet and outlet of the tanks have screens to retain the desiccant. The exiting air then goes to the Air Maintenance Device. (See Start Up above for operating positions). From the Air Maintenance Device the air goes into the final filter regulator. The air up to this point has been at 70-100 psig. When it leaves the AMD regulator it is reduced to system pressure. The dryer must operate at 70 to 100psig to function correctly. The air maintenance device regulator must be set and valved into the system. 3.2 Setting the Purge Pressure The purge pressure set valve is located between the two tanks just over the top of the control panel. This valve is pre-set at the factory, however should it need to be adjusted for any reason, the following listing shows the correct set pressures. Model CDP 500 CDP 1000 CDP 2000 Set Pressure 20 psig 30 psig 27 psig 3.3 Coalescing Filter Operation The coalescing filter protects the desiccant dryer from oil carryover from the compressor. The filter has a built in differential pressure indicator with three color bands. Green is normal condition, yellow is warning that the element is going to need to be replaced, and red indicates the filter is overdue for replacement. The filter has a built in automatic drain, which in normal service will expel accumulated oil or moisture from the bottom of the bowl. The drain can be tested by pushing up on the needle valve stem, which is in the mouth of the black outlet nipple on the bottom of the filter. Service kits are available as detailed below. (Model and serial numbers are required when ordering service kits. Model/Kit Serial Number Description CDP-MK 1119750 Compressor Intake Filter Element(s), Coalescing Filter Element, Particulate After Filter Element and Compressor Oil CDP-DMK 1119755 Same as Kit CDP-MK and full desiccant charge for both dryer towers CDP-TK 1119745 Moisture Indicator Kit 8

3.4 Dryer Operating Sequence Corrosion Dry Air Pak 5403584 Rev A 9/10 The dryer operates on a 4-minute total cycle. There are four valves on the inlet manifold, and four on the outlet manifold. The timing cycle diagram shows the sequence of operation of the four inlet valves. The outlet valves are check valves, which sequence automatically with the operation of the inlet valves. SV1 and SV2 are the inlet valves to the towers, SV3 and SV4 are the opposite purge valves such that when the left tower is drying and its inlet valve is open, the purge valve on that tower is closed. With the unit turned on and the tank pressurized, air is ready to be used from the unit. As air is withdrawn from the unit into the sprinkler system, the receiver pressure will drop and the pressure switch will start the compressor. As the compressor runs, the dryer timer is energized. The drying tower is indicated by a light on the front of the panel. The drying tower will show receiver pressure and the opposite tank, when purging will show no pressure; when repressurizing prior to switch over, it will rise to receiver pressure. The purge valve can only be adjusted during the time the off line tower is purging and is showing no pressure. At this time, if necessary, adjust the purge pressure to the value in the above table. The dryer cycle timer runs only when the compressor is running and accumulates time so that the length of the cycle on any one tower does not get out of line with its normal operation and does not saturate one desiccant bed. The frequency of change for the oil, filter elements and desiccant is highly dependent upon the following: Number of times the unit has to operate to satisfy the system air requirement. The tighter the system, the less the unit will have to run. Cleanliness of the environment in which the compressor is located. Maintenance schedule for the equipment. As the desiccant will degrade (age) slightly over time, it is recommended that the desiccant be changed once every year. 9

Section 4 - Additional Specifications Corrosion Dry Air Pak 5403584 Rev A 9/10 Model Compressor HP Dryer Rating CFM Current Load 460V Current Load 230V Wire Size 460V Wire Size 230V CDP 500 2 10 4.3Amps 8.6 Amps 12GA 12GA CDP 1000 5 20 6.5Amps 13.0 Amps 12GA 10GA* CDP 2000 5 27 6.5Amps 13.0 Amps 12GA 10GA* *If under 50 run 12GA can be used however, check voltage while running to ensure no undervoltage condition exists. For runs over 100 increase wire size to correct for volt drops. 10

Section 5 - Desiccant Replacement Corrosion Dry Air Pak 5403584 Rev A 9/10 NOTE: You will need the following in order to service the unit: Annual Service Kit - Potter part number: 1119745 1. Close the outlet valve of the unit and turn the power to the unit off. 2. Depressurize the unit completely by opening the petcock on the bottom of the receiver and checking the pressure gauges to ensure all air is removed. If air remains in the desiccant tanks, pull on the relief valve toggles to depressurize the tanks. All pressure must be out of the unit prior to working on the unit. 3. 4. 5. The tanks have separate desiccant fill and drain ports at the top and bottom. Once the pressure has been removed from each tank, remove the lower (drain) port plug. Desiccant will start to drop out of the 1/2 port. It is easiest to vacuum the desiccant out with a shop vac; however, the desiccant will drop out of the tower. You may have to probe the outlet with a thin probe in order to keep the desiccant from jamming together at the port. The desiccant is white in color; yellow means the desiccant has oil on it. Ensure that all desiccant is removed from the tower. Replace the plug ensuring the threads are cleaned and re-doped with thread sealant before replacing. CHECK the condition of the lower desiccant. As flow is upward through the bed, the lower desiccant will see any major contaminants and any carryover from the inlet filter if this has not been serviced correctly. Oil on the lower desiccant means that the filter element has been over saturated allowing oil to be carried over into the desiccant bed. CHECK the filter drain and element before putting the new desiccant into the towers. Consult the factory if any oil is in the towers. 6. 7. Remove the upper plug from the fill port. Using General part number 34006-50, refill the tower with new, white desiccant. Only add desiccant beads to towers when refilling. Avoid adding chips and dust, which may be in the bottom of the bag of desiccant, to the towers. 8. Reinstall the fill port ensuring that you clean the threads and re-dope prior to installation. 9. Remove and replace the pre & afterfilter elements prior to putting the unit back in service. This is accomplished by unscrewing the bowls and following the kit instructions to replace the elements. We would be happy to look at the old elements if you feel there is any question as to the condition. Please contact the factory for shipping instructions. Replace the filter bowls and tighten securely prior to re-pressurizing the unit. 10. Turn the power back on to the unit (see 11.). 11. Open the discharge valve of the unit, then the valve ahead of the coalescer, turn power back on to the unit and allow the unit to repressurize. 12. Operate the drain valve manually to bleed air to force the dryer through a full cycle to ensure that the towers pressurize and repressurize correctly and go through their cycle. This is simply a check to see that the unit is operating normally. The unit is now ready to go back in operation. 13. Run the unit for 8 hours (as noted in INSTALLATION, item 4) before letting air feed back into the system. Once this has been done, valve the unit back into the system. If you have questions, call Potter Customer Service at 1-866-956-0988. The purge mufflers must be removed during the first 2 hours of the 8-hour break-in period detailed above. Reinstall the mufflers only after 2 hours of operation. 11

Section 6 - Trouble Shooting Guide Corrosion Dry Air Pak 5403584 Rev A 9/10 Problem Probable Cause Solution Dryer is set to operate at 70 to 100psig. Re-set regulator on CDP Air Maintenance Device to hold back pressure on dryer side to normal settings Low pressure on desiccant dryer Check to see that Air Maintenance Device bypass valve has not been opened Check compressor output to ensure compressor is running normally Poor Dewpoint Performance Excessive water &/or oil in dryer Low purge flow Desiccant contamination Check no leaks have developed in CDP system such as drain valve sticking open, filter drain valves sticking open, etc. Check coalescing filter & automatic drain operation Check purge pressure setting Check compressor intake is not in an area where chemicals can be drawn into the intake filter with air Check when the last time the desiccant was changed. Recommended frequency of change, 1 to 2 years Check condition of coalescing filter element and drain Switchover Failure Excessive Pressure Drop High inlet temperature to dryer due to high flow rate High inlet temperature to dryer due to high ambient temperature Electric power loss Solenoid valve failure Low inlet pressure Switching valve failure Desiccant breakdown Clogged filters Valve shut Purge flow control valve orifice clogged Lower flow rate from unit. Fix system leakage. Lower ambient temperature or move unit to area less than 100 o F Turn dryer off; check connections to cam timer and inlet to unit Check valve operating sequence, replace valve Lower flow rate to system Check tower-operating sequence to verify and identify which valves are operating Change desiccant Change filter elements Open valve Clean or replace Repressurization Failure or Purge Failed check valve Replace Failure/ Tower Back-pressure Purge exhaust solenoid valve failure Purge exhaust muffler clogged Turn dryer off, check connections to cam timer, inspect valve and solenoid, replace if necessary Clean or replace 12

Section 7 - Corrosion Dry Air Pak General Arrangement PURGE GAUGE LEFT TOWER RIGHT TOWER HOUR METER OUTLET PRESSURE GAUGE RIGHT TOWER PRESSURE GAUGE LEFT TOWER PRESSURE GAUGE CONTROL PANEL RECEIVER PRESSURE GAUGE AUTO DRAIN VALVE COMPRESSOR AFTERCOOLER PRESSURE SWITCH 70" MUFFLERS MOTOR PIGGY BACK FILTER REGULATOR COALESCING FILTER 30 GALLON RECEIVER 1/2" FNPT OUTLET TO SYSTEM AIR MAINTENENCE DEVICE 18" MOUNTING HOLES VIBRATION PAD (4) SHIPPED LOOSE 12" MOUNTING HOLES 45" 29" AUTO DRAIN DISCHARGE 1/4" PLASTIC TUBING NOTES: 1) MOUNT UNIT TO A FIRM LEVEL BASE, USING SUPPLIED VIBRATION PADS. 2) ACCEPTABLE AMBIENT TEMPERATURE RANGE IS 50 DEG F. TO 100 DEG F. 3) CONNECT CORRECT SUPPLY VOLTAGE TO STARTER LINE TERMINALS IN CONTROL PANEL. POWER SUPPLY VOLTAGE MUST MATCH VOLTAGE ON UNITS MODEL/SERIAL NUMBER LABEL ON THE INSIDE OF THE CONTROL PANEL DOOR. 4) ALLOW CLEARANCE ON ALL SIDES OF DRY AIR PAC FOR MAINTENANCE. MINUMUM CLEARANCE BETWEEN AFTERCOOLER AND WALL IS 12" FOR AIR FLOW. 5) WEIGHT: CDP 1000 = 500 POUNDS SHIPPING = 450 POUNDS N CDP 2000 = 550 POUNDS SHIPPING = 500 POUNDS NE 6) THE CDP TANK, MOTOR AND COMPRESSOR SYSTEM HAS BEEN TESTED AND COMPLIES WITH CAL OSHA SAFETY ORDERS TITLE 8, PARAGRAPH 462 (L) (2). 13

Section 8 - Dry Air Pac Electrical Schematics 8.1 Electrical Schematic Guide For Units with IEC Starter: Three Phase, 60/50 Hz - see section 8.2 (Drawing Number: E-210129) Single Phase, 208-230v / 220-240v, 60/50 Hz - see section 8.3 (Drawing Number: E-210182) Single Phase, 115v / 110v, 60/50 Hz - see section 8.4 (Drawing Number: E-210181) For units with NEMA Starter: Three Phase, 60/50 Hz - see section 8.5 (Drawing Number: E-204028) Single Phase, 208-230v / 220-240v, 60/50 Hz - see section 8.6 (Drawing Number: E-204024) Single Phase, 115v / 110v, 60/50 Hz - see section 8.7 (Drawing Number: E-206072) NOTICE If Serial # is CDP-132033A or before use NEMA version Electrical Schematics If Serial # is CDP-132247A or after use IEC version Electrical Schematics 14

Section 8 - Dry Air Pac Electrical Schematics 8.2 Electrical Schematic - 3 Phase IEC Version 15

Section 8 - Dry Air Pac Electrical Schematics 8.3 Electrical Schematic - Single Phase, 208-230v / 220-240v IEC Version 16

Section 8 - Dry Air Pac Electrical Schematics 8.4 Electrical Schematic - Single Phase, 115v / 110v IEC Version 17

Section 8 - Dry Air Pac Electrical Schematics 8.5 Electrical Schematic - 3 Phase NEMA Version 18

Section 8 - Dry Air Pac Electrical Schematics 8.6 Electrical Schematic - Single Phase, 208-230v / 220-240v NEMA Version 19

Section 8 - Dry Air Pac Electrical Schematics 8.7 Electrical Schematic - Single Phase, 115v / 110v NEMA Version 20

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