AST580-Refrigerant Dryers Technician Manual

AST580-Refrigerant Dryers
Technician Guide
AST580-2019 1|Page
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Table of Contents
REFRIGERANT DRYERS PREFACE ............................................................................................................................ 7
CLASS OVERVIEW ...........................................................................................................................................................7
Course Objectives ..................................................................................................................................................7
COURSE SAFETY REMINDERS ............................................................................................................................................7
WARRANTY REMINDERS ..................................................................................................................................................8
TERMINOLOGY AND RESOURCES ........................................................................................................................................8
UNIT 1: REFRIGERANT DRYER IDENTIFICATION AND OVERVIEW ............................................................................ 9
AIR TREATMENT OVERVIEW .............................................................................................................................................9
Dryer Types ...........................................................................................................................................................9
DRYER IDENTIFICATION..................................................................................................................................................10
Data Tags ............................................................................................................................................................10
Dryers at a Glance ...............................................................................................................................................13
NON-ELECTRICAL DRAWINGS AND SYMBOLS .....................................................................................................................14
ELECTRICAL DRAWINGS AND SYMBOLS .............................................................................................................................16
Main Power .........................................................................................................................................................16
Control power .....................................................................................................................................................16
UNIT 2: REFRIGERATION BASICS .......................................................................................................................... 19
HEAT THEORY OVERVIEW ..............................................................................................................................................19
Sensible Heat.......................................................................................................................................................19
Latent Heat .........................................................................................................................................................19
Pressure/Temperature Relationship ...................................................................................................................21
REFRIGERATION OVERVIEW ............................................................................................................................................22
Refrigerant ..........................................................................................................................................................22
Refrigerant Dryer Components ...........................................................................................................................29
Refrigeration Process Overview ..........................................................................................................................33
ADDITIONAL SYSTEM COMPONENTS AND CONTROLS ...........................................................................................................34
UNIT 3: AIR & REFRIGERANT FLOW ..................................................................................................................... 37
REFRIGERANT DRYERS AIR FLOW COMPONENTS.................................................................................................................37
AIR FLOW PROCESS ......................................................................................................................................................38
Compressed Air ...................................................................................................................................................38
Cooling Air ...........................................................................................................................................................40
REFRIGERANT FLOW PROCESS.........................................................................................................................................40
Non-Cycling Dryers ..............................................................................................................................................44
Cycling Dryers......................................................................................................................................................45
UNIT 4: CONTROLS ............................................................................................................................................... 47
XE-90D .....................................................................................................................................................................47
Xe-90D-Overview ................................................................................................................................................47
Xe-90D-Functionality...........................................................................................................................................48
Xe-90D Controller- Alarms/Warnings .................................................................................................................51
DIGITAL PERFORMANCE CONTROL ...................................................................................................................................53
Overview .............................................................................................................................................................53
Controller Functionality.......................................................................................................................................54
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Alarms & Warnings .............................................................................................................................................59
Cycling Dryers......................................................................................................................................................60
Multiplex Dryers with DPC Controllers ................................................................................................................60
COMPUSTAT................................................................................................................................................................61
Compustat-Overview ..........................................................................................................................................61
Compustat-Functionality.....................................................................................................................................61
Alarms/Warnings ................................................................................................................................................63
THERMOSTAR CONTROLLERS ..........................................................................................................................................64
Thermostar Electronic Controller-Overview ........................................................................................................64
Thermostar Electronic Controller-Overview-Functionality ..................................................................................65
Thermostar Electronic Controller-Alarms & Warnings........................................................................................66
Thermostar Intellisys Controller-Overview ..........................................................................................................67
Thermostar Intellisys Controller- Functionality ...................................................................................................68
OMI CONTROLLER .......................................................................................................................................................73
OMI-Overview .....................................................................................................................................................73
OMI-Functionality ...............................................................................................................................................75
Warnings/Alarms ................................................................................................................................................77
UNIT 5: INSTALLATION AND COMMISSIONING .................................................................................................... 79
INSTALLATION..............................................................................................................................................................79
Pre-Installation Checks ........................................................................................................................................79
Installation ..........................................................................................................................................................80
Post-Installation Checks and Tasks .....................................................................................................................81
COMMISSIONING .........................................................................................................................................................83
Pre-Startup Checklist and Tasks ..........................................................................................................................83
Startup Checklist and Tasks ................................................................................................................................84
INSTALLATION AND COMMISSIONING COMPLETION.............................................................................................................86
UNIT 6: MAINTENANCE AND DIAGNOSTICS ......................................................................................................... 87
ROUTINE MAINTENANCE ...............................................................................................................................................87
Maintenance Tools..............................................................................................................................................87
Preventative Maintenance ..................................................................................................................................88
REFRIGERANT RECLAMATION, EVACUATION AND RECHARGE .................................................................................................90
Tools Needed.......................................................................................................................................................90
Recovering and Reclaiming Refrigerant ..............................................................................................................91
Evacuating the System ........................................................................................................................................93
Recharging the System........................................................................................................................................94
DIAGNOSTICS ..............................................................................................................................................................95
All Refrigerant Dryers-First Steps ........................................................................................................................95
Diagnosing Cycling Dryers .................................................................................................................................102
ELECTRICAL SYSTEMS TROUBLESHOOTING .......................................................................................................................104
CSIR Type Compressors .....................................................................................................................................104
CSR Type Compressors ......................................................................................................................................105
Three-Phase Compressors .................................................................................................................................106
GENERAL MAINTENANCE PROCEDURES AND TOOLS ..........................................................................................................108
Brazing ..............................................................................................................................................................108
UNIT 7: DRYERS AT A GLANCE ............................................................................................................................ 113
SUBFREEZING DRYER...................................................................................................................................................113
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General Information..........................................................................................................................................113
Main Components .............................................................................................................................................114
SFD Refrigeration Circuit ...................................................................................................................................115
SFD: Other Key Facts .........................................................................................................................................116
DS AND DSH-DH DRYERS ...........................................................................................................................................117
Dryer Components ............................................................................................................................................118
Troubleshooting ................................................................................................................................................119
TS-DH DRYERS..........................................................................................................................................................120
Key Notes ..........................................................................................................................................................125
TS1-13 DRYERS ........................................................................................................................................................126
Key Notes ..........................................................................................................................................................130
NIRVANA CYCLING DRYERS-D-NC .................................................................................................................................131
Key Notes ..........................................................................................................................................................137
NIRVANA CYCLING DRYERS-NVC200-800 .....................................................................................................................139
Key Notes ..........................................................................................................................................................142
NIRVANA CYCLING DRYERS-NVC1000-1600 .................................................................................................................142
Key Notes ..........................................................................................................................................................145
NVC MULTIPLEX DRYERS ............................................................................................................................................146
Key Notes ..........................................................................................................................................................149
TMS CYCLING DRYERS ................................................................................................................................................152
Key Notes ..........................................................................................................................................................159
D-IN/IT NON-CYCLING DRYERS....................................................................................................................................160
Key Notes ..........................................................................................................................................................166
D-EC 17-212 DRYERS ................................................................................................................................................169
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APPENDIX: TERMINOLOGY ................................................................................................................................ 175
HEAT TERMINOLOGY...................................................................................................................................................175
GENERAL TERMINOLOGY .............................................................................................................................................176
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Refrigerant Dryers Preface
Class Overview
AST580-Refrigerant Dryers is a classroom learning opportunity designed to enhance the knowledge and
basic understanding of Ingersoll Rand refrigerant dryers in order to improve customer service and issue
resolution in the field. Included in this four-day course are several theory-based learning activities as
well as hands-on practical activities in the training lab.
This manual is designed to supplement and preface hands-on practical training that is included in the
course.
Course Objectives
Learning Objectives include:
• Identify components and operation of compressed air flow
• Identify components and operation of cooling air flow
• Define refrigerant dryer terminology
• Identify components and operation of refrigerant cycles
• Demonstrate proper handling of refrigerant
• Define and identify process and instrumentation drawing symbols
• Identify electrical schematics and components
• Demonstrate proper brazing techniques for joints and seams
• Identify appropriate tools for use in diagnostics
• Identify menus and basic functions of controllers
• Demonstrate navigation of controllers
• Demonstrate proper completion of the start-up checklist
Course Safety Reminders

Technicians attending Ingersoll Rand service training are required to wear all PPE required based on
activities to be performed, adhered to company PPE policy. In addition, technicians must remember the
following when working in class and/or with machines in training:
• Utilize the SLAM (stop… look… assess… manage…) tool
• Apply lockout / tag out devices according to policy
• Test for voltage (verify operation of volt meter before and after test)
• All circuits are ENERGIZED / HOT until proven otherwise
• Wear ear plugs in lab when equipment is in operation
• Safety Shoes & Safety Glasses in the Lab – ALWAYS
• Wear all proper PPE while performing switching operations and taking measurements
• Stand to the side and as far away as possible during switching operations
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Warranty Reminders
As with all other Ingersoll Rand machines, dryers may be covered under warranty. Technicians should be
sure to review the warranty process when working on customers’ dryers to ensure all proper steps are
completed.
Terminology and Resources

A guide to basic refrigeration terminology can be found in Appendix A of this manual. In addition,
technicians are encouraged to review articles and TechTubes located in the Technical Support
TechDirect portal for supplemental information, data and processes related to refrigerant dryers.
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Unit 1: Refrigerant Dryer Identification and
Overview
Air Treatment Overview
When there is moisture in compressed air, regardless of the application that compressed air is used for,
costly problems may occur. For example:
• In air-operated equipment water washes away required lubricants, leading to increased wear
and maintenance and decreasing efficiency
• In pneumatic control systems the moisture- along with dirt, scale, compressor oils and other
contaminants- plugs precision orifices, resulting in loss of control or complete shutdown
• In process applications, moisture can contaminate the product or react chemically
• When compressed air lines are exposed to freezing temperatures, moisture freezes in pipelines
resulting in partial or complete blockage
To address the potential problems that occur due to moisture in compressed air, Ingersoll Rand
developed several lines of air treatment machines- refrigerant and desiccant-type dryers. The dryers
address the negative influences of air moisture by drying compressed air to remove the moisture.
Dryer Types
There are two general types of dryers:
• Desiccant Dryers- utilizing desiccant and other tools, desiccant dryers get the air super dry and
cold. These dryers are most often used when the compressed air is being utilized outside
• Refrigerant Dryers- utilizing refrigerant, refrigerant dryers do not lower the air temperature as
low as desiccant dryers and are used primarily with indoor air applications
Desiccant Dryer Refrigerant Dryer
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Within the refrigerant dryer portfolio, there are several types of refrigerant dryers:
• Cycling
• Non-Cycling
• Variable Capacity Drives
Often the decision of which type of dryer is best suited to a customer’s needs depends on the load
conditions at the customer’s facility.
• Low-load or varying load conditions- cycling dryer
• Constant load conditions- non-cycling dryer
In addition, cycling dryers are more expensive to purchase but save energy costs over the long term, so
this may also play into a customer’s choice of machines. Variable capacity drives are not within the
scope of this course, but information regarding these dryer types can be found in TechDirect.
Dryer Identification
The Ingersoll Rand portfolio of refrigerated dryers is extensive, with differences found between different
products within the portfolio. However, the refrigerant cycle is generally consistent across the majority
of machines. These similarities and differences will be discussed throughout the manual.
Data Tags
Data tags- also known as nameplates or identification tags- are located on the side of the dryer. When
providing service to an Ingersoll Rand dryer, technicians must locate and review the data tag to identify
the specifications for the machine as well as to request help when needed from teams like Warranty,
Technical Support and Parts ID. Prior to requesting technical support, always have the following ready:
• Model and serial number
• Maximum system operating pressure
• Type of refrigerant and charge
• Electrical data for compressor and fan
• Horsepower of compressor and fan
Additional information when contacting technical support must include:

• Full name and customer center/distributer
• A brief and clear description of the issue
• A call-back number or email address
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Model Number
The dryer model located on the data tag describes whether the dryer is cycling or non-cycling, the rated
flow of refrigerant and will identify any additional options included on the dryer.
In the highlighted section above, the dryer model number relays the following information:
Data Tag Information Meaning

D Dryer
1020 Rated flow in M3/hr
IN Ingersoll Rand Non-cycling
A Air-cooled
4 460V
00 No added options
There are many types of model numbers for refrigerated dryers. Current West Chester-built model
numbers provide the following information.
• West Chester built non-cycling dryers will have a model number of:
o D (Dryer)
o ### (Rated flow in M3/hr)
o IN (Ingersoll Rand Non-cycling)
o Followed by any options on the dryer
• West Chester Built cycling dryers will have a model number of:
o NVC (Nirvana Cycling)
o ### (Rated flow in CFM)
o Followed by any options on the dryer
• OMI Dryers
o D (Dryer)
o #### (rated flow in M3/hr)
o E- energy efficiency, experience and environmentally friendly
o C-cycling
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Non-Cycling Dryers Cycling Dryers
• DR850IN • TMS012-TMS5000
• DS15H-DS100H • D17EC-D121EC
• D12IN-13600IN • D17ECA-D121ECA
• D24IT-D170IT • D17NC-D255NC
• TS10-TS3000 • NVC200-NVC19200
• TS1A-TS13A
Serial Number
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Dryers at a Glance
Dryer Type Max Ambient Min Ambient Refrigerant Max Inlet Air Control
Pressure Voltage
DS and DSH- 122°F/50°C 40°F/5°C R134a 232psi/16bar 115 VAC
DH
TS-DH 122°F/50°C 41°F/5°C R407C 175psi/12bar 230VAC
TS 1-13 115°F/46°C 35°F/1.7°C R404A 150psi/10.3bar 115 VAC
D17NC- 113°F/45°C 45°F/7.2°C D17-85NC- 230psi/15.9bar 115 VAC
D255NC R22/R404A D127-
D127-255NC- 255NC
R404A Optional
230 VAC
TMS 012- 110°F/43.3°C 32°F/0°C R134a 232psi/16bar 24VAC
2000
TMS 2700 110°F/43.3°C 32°F/0°C R404A 232psi/16bar 24VAC
NVC 200-800 110°F/43.3°C 32°F/0°C R404A 230psi/15.9bar 115 VAC
NVC 1000- 115°F/46°C 35°F/1.7°C R22/R404A 220psi/15bar 24 VAC
1600
NVC Multi- 115°F/46°C 35°F/1.7°C R22/R404A 220psi/15bar 24 VAC
Plex
VCD R Series 100°F/38°C 50°F/10°C R404A 175psi/12bar 115 VAC
D-IN 122°F/50°C 36°F/2°C R134A D12IN-D180IN: D12IN-
203psi/14bar D180IN: 115
D300IN- VAC
D360IN: D300IN-
174psi/12bar D360IN:
230VAC
D-IT 122°F/50°C 36°F/2°C R134A 203psi/14bar 115 VAC
D360SF-A 113°F/45°C 41°F/5°C R452A 203psi/14bar 24 VAC
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Non-Electrical Drawings and Symbols
Component Symbol
Condenser
Filter Drier
Capillary Tube
Hot Gas Bypass Valve
Evaporator
Precooler/Reheater
High Efficiency Air Filter
Compressor
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Symbol Description
1 Air Discharge
40 Condenser
41 Filter Drier
42 Capillary Tube
43 Hot Gas Bypass Valve
44 Evaporator
45 Precooler/Reheater
46 High Efficiency Air Filter
47 High Pressure Safety Switch
48 Fan Pressure Switch
49 Refrigerant Compressor
50 Moisture Separator
51 Condensate Drain Valve 10SV
52 Electronic No Loss Drain (Alternate to 51)
53 Condensate Drain Valve 11SV
54 Electronic No Loss Drain (Alternate to 53)
55 Dryer Dew point Temperature Sensor 5DTT
56 Dryer High Pressure Temperature Sensor 6DTT
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Electrical Drawings and Symbols
Main Power
As main power enters the machine, one circuit normally branches off to
feed the refrigeration compressor, crankcase heater and condenser
fans. This circuit carries the full voltage applied to the system and
delivers it to the motors through a series of contactors. The system
controller operates the contactors and their associated components.
Control power
The main power also branches off into the control power circuit. This circuit branches off and connects
to the main transformer, which lowers the voltage to a usable level for smaller components. This lower
voltage is referred to as control power. Once control power leaves the main transformer, it branches off
into two smaller circuits: one powers the system controller’s internal functions and the other powers
electromechanical components throughout the system.
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Component Symbol
Temperature Probe
OR
Pressure Switch
OR
Fuse
Direct Current Power Supply
Solenoid
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Unit 2: Refrigeration Basics
Heat Theory Overview
Heat is a form of active energy. Energy cannot be created or destroyed, but it can be changed from one
form to another. Heat energy is measured based on its effect on temperature. For more information on
terms and definitions used when discussing heat theory, please see Appendix A.
Sensible Heat
Sensible heat is heat that can be felt and measured, causing changes in the temperature of a substance
without causing a change in state of that substance. Some key facts regarding sensible heat include:
• Thermometers measure heat intensity, not heat quantity
o A candle and a campfire may measure the same temperature (heat intensity), but do not
have the same heat quantity
• The measure of heat quantity- or the amount of heat required to raise the temperature of one
pound of water on degree Fahrenheit- is the British Thermal Unit (BTU)
o BTUs = amount of water (in lbs.) x Δ (delta) T or BTUs = lbs. x (T2-T1)
Latent Heat
When a substance changes from one state to another (solid to liquid, liquid to vapor, liquid to solid, or
vapor to liquid), no change in temperature will be measurable. However, for this change of state to
occur, an increase or decrease in heat is necessary. This type of heat is called latent heat.
Latent Heat of Vaporization

The amount of heat required to make the phase change from liquid to vapor is the latent heat of
vaporization. 970 BTUs (284 W) of latent heat are absorbed before liquid becomes vapor.
Latent Heat of Condensation

Just as 970 BTUs (284 W) were absorbed to change liquid to vapor, 970 BTUs (284 w) are released as
vapor cools and returns to the liquid state. The heat energy released when vapor becomes liquid is
the latent heat of condensation.
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Latent Heat of Fusion
The heat energy released when liquid becomes solid is the latent heat of fusion. 144 BTUs (42 W) are
released as liquid cools and returns to the solid state.
Latent Heat of Melting

The heat energy adsorbed when solid becomes liquid is the latent heat of melting. Just as 144 BTUs (42
W) were absorbed to change liquid to vapor, 144 BTUs (42 W) are absorbed as a solid melts and returns
to the liquid state.
Melting Vaporization
Fusion Condensation
Example
Ice
 A block of ice measures 32°F/0°C
 As heat is applied, the temperature does not rise
o Instead, 144 BTUs/42Ws are absorbed by the ice, which causes it to melt (latent heat)
Water
 Add 180BTUs/53W of sensible heat to the water
 As the sensible heat is applied, the temperature of the water rises
 At 212°F/100°C, the temperature rise stops
o 970BTUs/284W are absorbed by the water, which changes it to steam (latent heat)
Steam
 If heat continues to be added to the steam, it becomes “super-heated”
o Super-heated water vapor is a gas with a temperature above 212°F/100°C
Converting One Pound Ice to Steam

Change from ice to water 144 BTUs 42 Ws
Reaching boiling point 180 BTUs 53 Ws
Change water to steam 970 BTUs 284 Ws
Total BTUS/ W required 1294 BTUs 379 Ws
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Pressure/Temperature Relationship
Stated simply: when volume is held steady, temperature goes up as pressure goes up. Conversely, if
pressure goes down, temperature goes down when volume is held steady.
Constant Volume Volume Changes

Scenario: Heat is applied to 5 gallons of water in Scenario: Heat is applied to 5 gallons of water in
a covered pot an uncovered pot
Outcome: Outcome:
 Water temperature reaches 212°F/100°C  Water temperature reaches 212°F/100°C
 Latent Heat of Vaporization causes the  Latent Heat of Vaporization causes the
boiling water to turn into steam boiling water to turn into steam
 The vapor is trapped in the pot, building  Even when additional heat is applied to
pressure on the water’s surface the water, it remains at 212°F/100°C
 Increased pressure raises the boiling o Heat energy is released in the
point of the liquid rising vapor
o The water continues to increase
in temperature
Just as raising pressure in the water to steam situation raises the boiling point of the water, lowering the
pressure lowers the boiling point.
• At sea level, the atmosphere presses down with 14.7psi/1bar of force
o Boiling point of water at sea level is 212°F/100°C
• At higher elevations, the atmosphere presses down with less force
o 5,000 feet above sea level- the atmosphere presses down with 12.3psi/0.85bar
o Boiling point at 5,000 feet above sea level is 203°F/95°C
• For every 550 feet higher, the boiling point of water is reduced by approximately 1°F/-17°C
Pressure Liquid
Water R134A Refrigerant R22 Refrigerant
28” Vacuum 101°F/38°C -100°F/-73°C -123°F/-86°C
0psi/0bar 212°F/100°C -15°F/-26°C -41°F/-40°C
70psi/4.8bar 303°F/150°C 69°F/20°C 40°F/4°C
99psi/6.8bar 327°F/163°C 121°F/°49C 58°F/14°C
It is important to note that as pressure goes below 0psi/0bar (vacuum), the boiling points of water and
refrigerant lower as well.
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Refrigeration Overview
At the core, refrigerant dryers are designed to best perform the air treatment process of refrigerant
cycling, a process that removes heat from an area where it is not wanted and transferring that heat to a
more desirable (or less impactful) area. For dryers that utilize refrigerant, the transfer of heat from one
area to another is facilitated by the refrigerant flowing in the dryer.
Refrigerant
Refrigerant is a chemical substance that absorbs and transports heat while changing states between
vapor and liquid through the process described in the Latent Heat section above.
It is important to note that the examples in the Latent Heat section above involve the boiling point of
water; most refrigerants boil at temperatures well below 0°F/-18°C. Refrigerants with low boiling points
are capable of refrigerating to extremely low temperatures.
Saturation Point
Saturation point is a combination of pressure and temperature that allows liquid and vapor to co-exist in
a state of equilibrium. Lowering the pressure lowers the boiling point/saturation point and vice versa.
Example
Scenario: A closed container of R-134a refrigerant at 70°F/21°C has a pressure of 70.7psi/4.9bar

Outcome: The refrigerant liquid and vapor are at the saturation point
Scenario: The closed container of R-134a is placed in a freezer and lowered to a temperature of -15°F/-
26°C
Outcome: The container pressure drops to establish the pressure-temperature equilibrium, resulting in
a saturation pressure of 0psi/0bar
Scenario: The container is further chilled to -50°F/-46°C

Outcome: The pressure drops to a saturation point of 18.6” Hg (vacuum)
Scenario: The container is brought back to a pressure of 70.7psi/4.9bar and is poured into an open
container
Outcome: The R134a instantly absorbs heat from its surroundings and violently boils away; room
temperature is warmer than the boiling point of the refrigerant.
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Refrigerant Types
There are several types of refrigerants used in refrigerant dryers. The type of refrigerant used is listed on
the data tag of the dryer; technicians should review the data tag prior to working on the machine to
determine the proper refrigerant to use.
R452A, R404A, R134A and R407C refrigerants are the current refrigerants used in most refrigerant
dryers.
• R452A is a next generation refrigerant blend with low discharge temperature similar to R404A
• R404A is an HFC blend used in low and medium temperature applications
• R134a is also known as Tetrafluoroethane, an HFC refrigerant
• R407C is an HFC blend designed to have similar properties to R22 (which is being phased out)
Older machines may use R22 refrigerant. However, due to the ozone-depleting nature of R22
refrigerant, technicians must take special note of machines utilizing R22 as the refrigerant is
becoming more expensive and harder to find as it is being phased out of use.
Blended refrigerants are a popular choice due to blended refrigerants having different boiling points.
This means the refrigerant has what is known as a “glide” while changing states. The term glide refers to
when one part of the refrigerant is boiling and the other is not. It also means that if blended refrigerant
leaks, it fractionizes, disrupting the blend. An important note is that if a leak occurs, blended refrigerants
do not leak at the same rate, resulting in an imbalance of refrigerants. It is also important to note that
blended refrigerants should not be charged following the normal process of single-refrigerant systems.
It is important to note that refrigerant selection at the design and manufacturing level changes often,
based on global environmental and legal requirements. Ingersoll Rand continuously monitors these
issues and develops phase out/in plans and designs to best meet the sustainability and other
requirements of global customers. Any changes in refrigerant selection, especially if the change affects
machines currently in the field, are communicated via TechNotes and Field Service Bulletins in
TechDirect.
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Pressure/Temperature Chart
The pressure-temperature chart is a tool that technicians should utilize to check proper refrigerant dryer
operation. The chart displays what pressure a refrigerant should be at based on its temperature. It is
important to note that the pressure/temperature relationship displayed on the chart is only valid where
the refrigerant is in a saturation state- where both refrigerant liquid and vapor exist together. In only
two places is this the case- the evaporator and the condenser.
Physical laws controlling refrigerant allow technicians to utilize the pressure/temperature chart to
determine either pressure or temperature, as long as the other value is known.
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Other key notes to remember regarding the use of pressure/temperature charts include:
• At the points in the refrigeration system where the refrigerant is only in vapor form, the actual
temperature should be above the temperature listed on the pressure/temperature chart
o The difference between the measured temperature and the temperature corresponding
to the pressure that exists at the point in question is a measure of superheat
• At the points in the refrigeration system where refrigerant exists only in liquid form, the
measured temperature should be below the temperature listed on the pressure/temperature
chart
o The difference between the measured temperature and the corresponding
pressure/temperature chart measurement is a measure of subcooling
Subcooling and Superheat

Two terms technicians should be aware of when working on dryers are subcooling and superheating.
• Subcooling-a liquid is cooled below its freezing point without changing states to a solid
• Superheating- a vapor is heated to a temperature higher than the liquid’s boiling point after it
has fully boiled off
When reviewing the condition of refrigerant at any point in the system by measuring temperature and
pressure and comparing the measurements to the P/T chart, technicians should remember the
following:
• When liquid and vapor are present together, the measured temperature should correspond to
the P/T chart
• Superheated vapor is present when the measured temperature is above the temperature
corresponding to the P/T chart
• Subcooled liquid is present when the measured temperature is below the P/T chart
o The amount of subcooling is represented by the difference between the measured
temperature and the temperature indicated by the P/T chart
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Refrigerant Dryer Components
A refrigeration machine can include several components:
• Compressor
• Condenser
• Metering device
• Evaporator
• Precooler/Reheater
• Chiller
• Refrigerant
Compressor
Compressors are high-pressure pumps capable of establishing desired system
pressures. Specifically, compressors create high pressure on one side of the
refrigeration system and low pressure on the other to facilitate the movement of
refrigerant and heat energy through the system.
Condenser
The condenser in a refrigerated dryer is located on the outside of the refrigerated compartment and it is
responsible for releasing heat to the outside air. The condenser
consists of tubes to contain the hot refrigerant and hundreds of
delicate fins to transfer heat from the copper tubes to the cooler
air passing around the fins. The fins are tightly attached to the
copper tubes to provide excellent heat transfer. They also
provide an extremely large surface area for maximum exposure
of heat to the cooler ambient air. The fins on the condenser are
either copper or aluminum, as these materials are good conductors of heat energy.
Two key principles of heat transfer are exhibited by the condenser:

• Heat energy always moves from hotter to colder
• Heat energy transfers faster between objects having a larger temperature difference
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Meter Devices
Three different metering devices can be found in refrigerant dryers:
• Expansion Valve
• Capillary Tube
• Constant Pressure Valve
The expansion valve restricts and controls the flow

of liquid refrigerant to the evaporator. This
restriction helps maintain high pressure in the
condenser to keep the boiling/condensation point
high (above ambient). This restriction also allows
low pressure to develop on the outlet side of the
expansion valve. This low pressure reduces
refrigerant pressure, refrigerant temperature, and
the refrigerant’s boiling point in the evaporator.
The expansion valve assembly constantly responds
to changes in evaporator outlet temperature and
Expansion pressure to precisely meter the correct amount of
Valve refrigerant through the evaporator.
Regardless of system or load conditions, the
expansion valve attempts to modulate open and
closed in an attempt to maintain a constant
superheat. Too much refrigerant will "flood" the
evaporator. This will reduce or eliminate the
important boiling effect that must occur for efficient
operation. It also may damage the compressor.
Too little refrigerant will not provide the volume of
moving refrigerant necessary to absorb large
amounts of heat from the refrigerated
compartment.
The capillary tube restricts and controls the flow of
liquid refrigerant to the evaporator. Only with a
capillary tube, the flow will not be regulated. This is
why this type of metering device is used on what is
Capillary normally called a critically charged system.
Tube
A constant pressure valve is a device (usually

adjustable) to maintain a constant pressure in the
evaporator. The setting of the constant pressure
Constant valve is determined by the type of refrigerant used. It
is usually set to maintain the evaporator pressure
Pressure
(temperature) to above freezing.
Valve
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Evaporator
Similar to the condenser, the evaporator consists of copper or aluminum tubes and hundreds of delicate
fins that transfer heat very efficiently. While the condenser releases heat to the outside air, the
evaporator absorbs heat from the refrigerated compartment. The evaporator is always inside the
refrigerated compartment.
Reheater/Precooler
The precooler/reheater component in the refrigerant dryer is responsible for
two key tasks:
• It reduces the amount of mechanical refrigeration required to reach
dew point by reducing the air temperature going into the evaporator
• Eliminates outlet piping condensation by reducing air temperature
prior to the air entering the chiller
Chiller-Cycling Dryer
The chiller is the portion of the exchanger assembly that reduces the air temperature to lower the dew
point. In a cycling dryer the chiller has chilled heat transfer medium (usually a glycol/water mixture) on
one side and the compressed air on the other side of the heat exchanger. As the air travels through the
chiller temperature is lowered, which causes the moisture in the air to separate out of the air in the
separator lowering the dew point of the air.
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Chiller-Non-Cycling Dryer
The chiller is the portion of the exchanger assembly that reduces the air temperature to lower the dew
point. In a non-cycle dryer the chiller has low pressure liquid refrigerant on one side and the
compressed air on the other side of the heat exchanger. As the liquid refrigerant changes state from a
liquid to a gas the temperature is lowered and the temperature of the air is lowered, which causes the
moisture in the air to separate out of the air in the separator lowering the dew point of the air.
It is important to note the following:

Chiller Precooler/Reheater
1 HP = 100 SCFM of drying 1 HP = 200 SCFM of drying
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Refrigeration Process Overview
In general, refrigeration systems remove heat from an area of low pressure and temperature into an
area of high pressure and temperature. As the refrigerant moves through the system, it absorbs the
heat from the space (which in turn cools the surrounding space) and transfers the heat to the high
pressure/temperature side of the dryer, where it is then released by latent heat transfer of vaporization.
A key fact technicians should keep in mind when working on refrigerant dryers is that heat always flows
from a material at a high temperature to a material at a low temperature through radiation, convection
or conduction (see Appendix A for definitions).
Example refrigeration process for non-cycling dryer
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Additional System Components and Controls
There are several additional system components inside refrigerant dryers. These include:
• Filter driers
• Hot gas bypass valve
• Liquid receiver
• Low pressure cut out switch
• High pressure cut out switch
• Sight glass/moisture indicator
• Suction line heat exchanger
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Filter Drier The drier has a sintered charge, solid core. This is pressed by
the spring against the polyester pad and corrugated perforated
plate. The charge or core in the filter drier consists of desiccant
material which effectively removes moisture, harmful acids,
foreign particles, sediment and the products of oil breakdown
Hot gas bypass The hot gas valve is a pressure-regulating valve that maintains
valve the refrigerant pressure in the evaporator at a constant level,
ensuring constant evaporator temperature. If the suction
pressure falls, the valve opens. A hot gas bypass valve is
commonly used on a constant run type of system where the
compressor is operating anytime the dryer is turned on.
Liquid A liquid storage receiver is fitted to the system primarily to

Receiver provide a reserve of refrigerant so that, under all conditions of
(Used with changing thermal load, a supply of liquid refrigerant is available
TXV only) to the expansion valve. The liquid receiver is used to store
refrigerant while maintenance work is carried out on other
parts of the system.
Low pressure A pressure switch installed on the low pressure side of the
cut out switch system to prevent damage to the compressor. The settings of
the cut in and cut out are determined by the type of refrigerant
the system is using. The low pressure switch is brazed to the
suction side of the refrigeration system.
High pressure A pressure switch installed on the high pressure side of the
cut out switch system to prevent damage to the compressor. When pressure
rises above the setting on the high pressure side, the circuit is
broken. The differential is usually fixed and not adjustable.
Moisture The sight glass has a color indicator that changes color when
indicator the moisture content of the refrigerant exceeds the critical
value. The color indication is reversible, it changes back to
normal when the plant has been dried (by replacing the filter
drier and evacuating the system).
The sight glass must be placed immediately before the
expansion valve. It has a glass top so that the flow of
refrigerant liquid can be seen.
Solenoid Valve The solenoid is fitted to the liquid supply pipe before the
expansion valve. The valve is designed to stop liquid passing
into the evaporator during the compressor off cycle and
avoiding the possibility of liquid being drawn into the
compressor suction when it restarts. The solenoid is sometimes
wired in series with the compressor motor so that when the
compressor stops, the solenoid valve will stop the refrigerant
flow, allowing the compressor to pump down and shut off on
the low pressure switch. When the solenoid valve closes, no
further liquid can flow into the evaporator.
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Unit 3: Air & Refrigerant Flow
Refrigerant Dryers Air Flow Components
There are several components involved in refrigerant dryer air flow. Most components are used in both
non-cycling and cycling dryers, while a few are used only in one or the other. Components include:
• Prefilter- The prefilter is tasked with removing dirt and contaminants from incoming air to avoid
having the steel wool demister within the moisture separator from becoming fouled
• Precooler (also known as a reheater)- The precooler/reheater uses outgoing cold air to precool
inlet air in order to increase efficiency of the dryer and uses incoming warm air to reheat cooled
air from the evaporator. The warmer air minimizes any potential pipe sweating from cold air in
downstream piping
• Evaporator
• Outlet- The outlet air piping from the dryer
• Air to Glycol Exchanger-A thermal mass that exchanges heat from the air to the refrigeration
cycle
Air Flow Components by Dryer Type

Non-Cycling Component Cycling
 Prefilter 
 Inlet 
 Precooler/Reheater 
 Evaporator 
Air to Glycol Exchanger 
 Moisture Separator 
 Outlet 
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Air Flow Process
Compressed Air
The compressed air flow process through a refrigerant dryer follows the same process whether the
dryer is a cycling or non-cycling dryer.
Compressed
Air exits
air enters Moisture
Precooler Evaporator Reheater through the
through Separator
dryer outlet
dryer inlet
• Compressed air enters the dryer through the inlet

• The air then goes into the precooler section of the precooler/reheater
o The precooler utilizes outgoing air to cool the air
o The precooler exchanges incoming hot compressed air with the outgoing air from the
evaporator
• The evaporator then cools the air directly from the refrigeration cycle
o In a cycling dryer, air is cooled in the air-to-glycol heat exchanger
• The air then goes to the moisture separator, where it allows the water in the air to fall out by
spinning, changing directions and impinging on surface in the separator
• The air then moves to the reheater section of the precooler/reheater
o The reheater warms the air to prevent sweating on piping in the plant
• The air exits through the outlet of the dryer
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Refrigerant Dryers and Compressed Air
Interaction between a compressed air system and a refrigerant dryer system.
Compressed air and refrigerant dryer systems are self-contained in their own closed systems.
Refrigerant dryers work to absorb heat from the compressed air through the principles of heat transfer.
• Compressed air and refrigerant pass each other while remaining in their own closed systems
• Heat from compressed air is absorbed by the refrigerant as they pass by each other
• The refrigerant carries the heat away from the heat exchanger
• The cooled compressed air enters the separator where the water vapor is removed
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Cooling Air
Cooling air flows through a dryer along the following steps:
• A fan draws air across a condenser covered in aluminum fins for increased surface area
o This increases heat transfer
• The air is then released from a refrigeration cycle to the environment
For water-cooled machines:

• Water draws out the heat from the refrigerant in the condenser
• A water-regulating valve maintains head pressure by controlling the mass flow of the water
Refrigerant Flow Process

Compressor
Refrigerant absorbs heat in the compressor and travels to the condenser, where it is normally 30° or
more above ambient temperature.
Condenser
Heat energy naturally moves from hot areas to cooler areas; as the hot refrigerant vapor passes through
the condenser, it loses enough heat to change from vapor to liquid. A large amount of latent heat
energy is released as vapor cools and changes to the liquid state. The refrigerant exiting the condenser
coil is cooler than the corresponding temperature on the P-T chart, as it has become sub cooled. Key
things technicians should keep in mind:
• The boiling point of refrigerant in the condenser must always be above ambient temperature so
that the "cool" ambient air causes the refrigerant vapor to condense
• If the refrigerant vapor fails to condense, only a small amount of heat will transfer to the
ambient air
• Sub cooling- a liquid existing at a temperature below its normal boiling point. Said another way,
it is when additional sensible heat is removed from refrigerant after the refrigerant has changed
state
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There are two types of condensers used in refrigerant dryers:
• Condensers cooled by water
• Condensers cooled by ambient air
o Fan driven- a fan pulls or pushes ambient air through the condenser
Air Cooled Water Cooled
It is important to note that when servicing a condenser with a fan, the coils must be kept clean and
sufficient clearance must be maintained around the dryer. When installing a customer’s machines, it is
important for technicians to keep other units away from the ambient air intake for fan-driven ambient
air cooled condensers to avoid hot air from being pulled in by the fan.
A fan pulls the air through the condenser
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A fan pushes air through the condenser
Meter Device- Expansion Valve/Capillary Tube/Constant Pressure Valve

After passing through the condenser, the high-pressure liquid refrigerant travels to the metering device.
It is important to note that the type of dryer the customer needs dictates the metering device the dryer
has, as the metering device is used to maintain a preset dew point.
The metering device and the compressor divide the refrigerant system into two sides: the high side and
the low side.
• High side- the high-pressure part of the system between the compressor discharge and the
metering device inlet
• Low side-the low-pressure part of the system between the metering device outlet and the
compressor inlet
Technicians should utilize tools to measure low and high side pressures to provide important clues to
maintenance and troubleshooting.
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Evaporator
As low pressure, liquid refrigerant passes through the evaporator; it absorbs heat from the refrigerated
compartment, and begins to boil. Even if the evaporator temperature is well below 0° F, the refrigerant
boils and takes full advantage of the latent heat of vaporization. As the refrigerant boils, the evaporator
surface is much colder than the air passing through it. Evaporator pressure and refrigerant boiling point
must be lower than the temperature of air passing through it. (Opposite of the conditions required in
the condenser.)
Once the refrigerant has fully boiled off/evaporated in the evaporator coil, additional heat is picked up
by the refrigerant. This additional sensible heat is known as superheat. The superheat value in a system
is a critical measurement. It is important to note that:
• Too much superheat will create problems with compressors overheating, as they are cooled by
cool suction gas
o This results in a capacity loss
• Too little superheat can be cause liquid flood back issues and damage the compressor with
liquid refrigerant getting to the crankcase
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Non-Cycling Dryers
When a consistent load is present on a non-cycling dryer, the refrigeration process includes several
steps:
• The compressor pumps refrigerant as a high temperature, high pressure vapor into the
condenser
• The condenser removes heat from the refrigerant:
o Air-cooled condensers utilize a fan and aluminum finned copper tubing
o Water-cooled condensers use a shell and tube exchanger to utilize water as a cooling
method
• The lower temperature, high-pressure refrigerant is restricted by some type of metering device
• After flowing through the metering device, the refrigerant expands rapidly
• The refrigerant flashes off to a cold, low temperature liquid that is sprayed into the evaporator
• In the evaporator, the cold refrigerant absorbs heat from the compressed air, warming the
refrigerant to evaporation
• The low temperature, low pressure vapor is sent back to the compressor
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When there are varying-load conditions, there are several different control schemes that may be
utilized:
• Smaller dryers may use a pulsing type
variable speed fan that maintains the
dryer process for as long as possible
o When it hits a certain set point,
the compressor will shut off in an
energy saving mode
• Larger non-cycling dryers may have a hot
gas bypass valve. The hot gas valve
maintains a constant refrigerant pressure
in the evaporator. When suction pressure
falls, the valve opens spraying hot gas
into the inlet of the evaporator
o In other schemes the hot gas
bypass valve may bypass hot gas
to the inlet of the compressor,
warming up the entire system
Cycling Dryers
Cycling dryers use some type of thermal mass storage to allow the refrigeration compressor to be cycled
on and off as needed.
• The refrigeration compressor runs until the thermal
mass reaches a predetermined temperature set
point
o The thermal mass is commonly some type of
glycol and water mixture that has a low
freezing point
o The cycle is normally set to cycle off above
freezing to prevent the moisture that is
removed from freezing in the exchanger and
separator, blocking air flow through the
dryer and possibly damaging the exchanger
• The refrigeration compressor then cycles off until
the thermal mass reaches a set number of degrees
above the shutoff set point
• The refrigeration compressor then cycles back on to
return the thermal mass down to the set point
o The difference between the cycling off set
point and the cycling on set point is called the temperature differential. It can range
from 4°F/-15.5°C to 10°F/-12.2°C depending on the controller
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Unit 4: Controls
Refrigerant dryers are fitted with controllers to aid customers and technicians in maintaining the dryers,
setting desired set points, and monitoring the dryer’s functioning. Several different controllers can be
found on dryers in the field, including:
• Xe-90D
• The Digital Performance Control (DPC) Controller
• The Compustat
• The Thermostar
• The OMI Controller
Refrigerant dryer controllers are discussed at a high level in this manual. Technicians should refer to the
specific controller handbooks for more detailed information.
Xe-90D
Xe-90D-Overview
Subfreezing dryers come with the Xe-90D controller, which has been adapted from next generation RS
series contact cooled machines.
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Xe-90D-Functionality
Display Parameters
Factory default display after powering up the system
The factory default display shown upon power up of the system includes several things:
• Dew Point- indicated by the large numbers centered below the color-filled gauge
• Dryer Inlet Temperature- the numbers in the lower left of the screen
• Dryer Discharge Pressure- the numbers and unit of measurement in the bottom right of the
screen
• Run Hours- indicated by the readout at the bottom center of the screen, next to the image of a
running person
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User Interface
The command keys used on the controller are in the chart below.
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To move among the tabbed folders shown on the LCD display, technicians should press the right and left
keys as needed. The navigation rolls over from the last to first (or first to last) folder depending on the
arrow key pressed.
• Use the arrow keys to navigate to the desired folder
• Press the down key to move to the page selection area
• Use the arrow keys to select the desired page
o Press the up key to get back to the folder tabs
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Xe-90D Controller- Alarms/Warnings
The activity log records the last 50 events; the controller has 10 possible warnings and 8 possible trips.
• Active warnings-highlighted in amber
• Acknowledged warnings-amber text
• Active trips-highlighted in red
• Acknowledged trips-red text
• Active start inhibits-highlighted in blue
o The display will indicate the dryer is not ready to start if a start inhibit is active
• Inactive start inhibits-blue text
Display Warning Description

High High Suction Occurs if the dryer is on and the suction temperature sensor reads a
Suction T Temperature value above the factory setpoint for an extended period. The warning
stops the refrigerant compressor motor, but allows it to restart once
the temperature falls sufficiently.
This fault only occurs if the sensor option is installed and enabled
Lo Air Inlet Low Package Occurs if the dryer is running and the package inlet pressure sensor
P Inlet reads a value below the threshold setpoint on the factory settings page
Pressure for an extended period. The warning stops the refrigerant dryer
compressor, but allows it to restart once the pressure rises sufficiently.
Hi Ambient High Occurs if the dryer is running and the ambient air temperature sensor
T Ambient Air reads a value above the factory setpoint for an extended period. The
Temperature warning stops the refrigerant compressor motor, but allows it to restart
once the temperature falls sufficiently.
Low Low Ambient Occurs if the dryer is running and the ambient air temperature sensor
Ambient T Air reads a value below the factory setpoint for an extended period. The
Temperature warning stops the refrigerant compressor motor, but allows it to restart
once the temperature rises sufficiently.
Low Air Low Air Inlet Occurs if the dryer is running and the inlet temperature reads below
Inlet T Temperature the factory setpoint for an extended period. The warning stops the
refrigerant compressor motor, but allows it to restart once the
temperature rises sufficiently.
Hi Air Inlet High Air Inlet Occurs if the dryer is running and the inlet temperature reads above
T Temperature the factory setpoint for an extended period. The warning stops the
refrigerant compressor motor, but allows it to restart once the
temperature lowers sufficiently.
Pre Drain Condensate Pre Drain Clog-Pre-cooler; HX1 Drain Clog- Heat Exchanger 1; HX2 Drain
Clog, HX1 Drain Clog-Heat Exchanger 2.
Drain Clog, Clogged
HX2 Drain Occurs for the given condensate drain if the drain is set to automatic
Clog control mode and the controller detects a failure of the liquid level
sensor and switches to timed condensate release.
Long Cycle Long Cycle Occurs if the heat exchanger cycle exceeds expected operation time.
Time The warning stops the refrigerant compressor motor, but allows it to be
restarted
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Check SD Check SD Occurs if the controller is unable to read or write data to its onboard
Card Card micro SD card, indicating there may be a corrupt file on the card.
Technical Support should be contacted for assistance.
Invalid Invalid Occurs if the sensor value is greater than +/- 10% of the scale when a
Calibration Calibration calibration is attempted. Technicians should consult the product
manual in Passport for more details on sensor calibration.
The trip history records dryer data at the time of the trip in order to assist in diagnostics and
troubleshooting. The pages in the Trips History folder document up to the last 15 trips that the
controller has experienced, and time stamps each. The trips are recorded in sequence, with number one
being the newest and 15 being the oldest. When a new trip occurs, it becomes number one and all
others are shifted up in number. Active Trips will be highlighted in red while cleared Trips will have red
text.
Display Trip Description

Compressor OL Compressor Occurs if the compressor motor overload switch opens for a
Motor Overload period of 3 seconds or longer.
Fan Motor OL Condenser Fan Occurs if the condenser fan motor overload switch opens for a
Motor Overload period of 3 seconds or longer.
Rem Stop Fail Remote Stop Occurs if the remote start/stop setpoint is enabled and the
Failure remote stop digital input is open when the remote start digital
input is closed, the local start button is pressed, or a start
command via Modbus or the web server interface is received.
Rem Start Fail Remote Start Occurs if the remote start/stop setpoint is enabled and the
Failure remote start digital input is closed for a period of 7 seconds
after the dryer has entered the charging state.
SF Ref P Sensor Failures Occurs when one of the sensors shows an out of range reading
SF Air Inlet P for at least one second:
SF Air Outlet P • Air Inlet Pressure
PF HX1 T • Air Outlet Pressure
PF HX2 T • Refrigerant Pressure
PF Dew Point • Heat Exchanger 1 Temperature
• Heat Exchanger 2 Temperature
• Pre-Cooler Temperature Dew Point (if installed)
Hi Ref P High Refrigerant Occurs if the refrigerant pressure sensor reads a value above
Pressure the factory setpoint for an extended period.
Hi Air Inlet P High Package Occurs if the dryer is running and the package inlet pressure
Inlet Pressure sensor reads a above factory setpoint for an extended period.
Hi Dew Pint T High Dew Point Occurs if the dryer is running and the Heat Exchanger 1 and
Temperature Heat Exchanger 2 discharge temperature sensors read a value
above the factory setpoint for an extended period.
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Digital Performance Control
Overview
The standard controller used on all West Chester built dryers 1000SCFM/588 M3/H and above is the
Digital Performance Controller (DPC); the DPC is optional on smaller SCFM dryers. Some of the key
features of the DPC controller include:
• 2x16 Character backlit LCD display—Easy-to-read display provides continuous indication of the
dryer default parameters
• Electronic drain with on/off time adjustments. Controls the open and close time of the electric
solenoid drain valve
• Remote Start/Stop—This feature allows the dryer to be operated via a remote user-supplied
switch
o The signal to the Remote Start contact must be 1A at 24V
• Remote Alarm Contact: DPC equipped dryers include a remote alarm contact (internal to the
controller) to provide indication of any of the dryers alarms
o The contact is rated for 2A/120V max
o The end user is required to supply the voltage signal to the controller
• The DPC permits monitoring of the dryer parameters and enunciation of alarm conditions on
both cycling and Non-Cycling dryers
The DPC Controller features three levels of access.
Customer Mode Permits adjustments of dryer parameters to address seasonal variations for
drain timing and pressure dew point (Chiller Temperature in the Cycling dryers
only)
Technician Mode permits access to and manipulation of additional parameters to address the
initial machine set up
Factory Mode A password protected FACTORY MODE is also included and should only be
entered on the advice of the factory Technical Support team
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Controller Functionality
Menu Map
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Controller Display
The DPC controller is capable of displaying a number of system parameters, which can be accessed by
pressing the SELECT DISPLAY button. These include:
• 1-Chiller temperature and compressor on/off status
• 2- Chiller temperature, compressor on/off status and discharge pressure
• 4-Chiller temperature, compressor on/off status, discharge pressure, suction line temperature
and suction pressure
• 8-Chiller temperature, compressor on/off status, discharge pressure, suction line temperature,
suction pressure, inlet air temperature, inlet air pressure, outlet air temperature, outlet air
pressure
In addition, the controller can display:

• Drain interval (DRN INT)- how long the drain has been closed, in minutes
• Drain on (DRN ON)- how long the drain has been open, in seconds
• Percent Savings (% SVGS)- ratio comparing the length of time the compressor is operating versus
the length of time the dryer has been on (this is not applicable for non-cycling dryers)
• Cumulative dryer hours (CUM DRYER HR)
• Cumulative compressor operating hours (CUM CMP HR)
User Interface
The DPC controller provides technicians with operating parameters and their corresponding values.
When power is supplied to the dryer, the DPC lights up and initially defaults to standby mode.
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The buttons used on the controller include:
• ON- turns the dryer on, initiates drain timer, energizes the glycol pump on cycling dryers
• OFF- turns the dryer off, stops all automatic functions (including glycol pump on cycling dryers)
• Select Display-allows technicians to scroll through the available displays. The last display
selected remains displayed until another view is selected
• + and – buttons- Allows for the increasing or decreasing of set point values and allows for the
entering of negative numbers while in factory mode
o It is important to note that set point values cycle through a fixed range
• RESET-pressing this once clears the local alarm indication and de-energizes the remote alarm
contact for many alarm conditions. If the alarm condition continues, the alarm returns after the
alarm inhibit time has expired
o The alarm inhibit time depends on the specific alarm triggered
• SET- used to adjust parameters in technician and factory modes. When used in customer mode,
set allows the user to scroll back through displays
• TEST-allows technicians to manually activate the drain solenoid valve
• i- Restricted level access, for factory use only
• Enter- accepts changed parameters and set point values
In protected Technician Mode, the DPC allows technicians to manipulate and view several parameters
not accessible to other operators. To enter technician mode, technicians should press button numbers 2
and 3 at the same time. Once TECH SET MODE is displayed on the screen, technicians should press the
SELECT DISPLAY button.
Parameters technicians can manipulate in this mode include:

• SOLENOID DRAIN ENABLE—DRAIN ENABLE—ON OR OFF
o This parameter determines whether the DPC controls the electronic solenoid drain
valve. Setting it to on, the DPC controls the valve. Off disables the feature
o Pressing the SET button changes the setting from on/off (or y/n)
o Pressing Enter saves the change
• CRANKCASE HEATER DELAY—CCH DLY—2, 4, 8 OR 12 HOURS—(FACTORY SET AT 8 HOURS)
o This must not be altered unless directed to do so by Technical Support or the factory
as improperly altering the set point may result in damage to the dryer and potentially
voiding the dryer’s warranty
o The DPC records every time the crankcase heater delay is altered
• AUTO RESTART ENABLE—AUTO RESTART—N OR Y
o This mode permits the dryer to operate once power is applied to the dryer, without
requiring operator intervention. This mode is generally beneficial, especially in the case
where there were power outages
o To change from N to Y, technicians should press the SET button, then the ENTER button
o It is important to note that turning on the automatic restart sets the dryer to operate
automatically. Proper signage should be affixed to the dryer to alert users that the dryer
may start without warning
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Parameters technicians can view (but not manipulate) in Technician Mode to help with troubleshooting
the dryer include:
• CONFIGURATION (# OF SENSORS)—CONFIG #:--1, 2, 4 OR 8
o DPC controller version
• OPERATING MODE—OP MODE:--HS OR NC
o HS-Cycling, NC Non-cycling
• REFRIGERANT—REFRIG:--22 OR 404 OR 407
o Type of refrigerant
• CONDENSERE TYPE—COND:--AC OR WC
o Condenser type (air cooled or water cooled)
• OPERATING TEMPERATURE DIFFERENTIAL—T OP DIFF:--4
o The temperature difference between set point to turn off the dryer chiller temperature
and the temperature rise to turn the dryer back on
• ANTI-SHORT CYCLE DELAY—ASC DELAY:03:00 (MINUTES)
o Time delay after the refrigeration compressor cycles off and before the compressor can
cycle back on
• HIGH PRESSURE CUTOUT—HPCO—see table 1
o The discharge pressure set point at which the dryer shuts down
• HIGH PRESSURE CUTOUT DELAY—HPCO DLY—10 (SECONDS)
o Length of time allowed for the DPC to see the HPCO set point pressure before the alarm
is activated and the dryer shuts down
• LOW PRESSURE CUTOUT—LPCO— see table 1
o The suction pressure set point at which the dryer shuts down
• LOW PRESSURE CUTOUT DELAY—LPCO DLY—10 (SECONDS)
o Length of time the DPC can see the LPCO set point before the alarm is activated and the
dryer shuts down
• HIGH TEMPERATURE ALARM—HITEMP ALRM—55F/13C
o The temperature at which the DPC will activate the alarm
• LOW TEMPERATURE ALARM—LOWTEMP ALRM:--30F/-1C
o The temperature at which the DPC activates the alarm and shuts down the dryer to
protect it from freezing up
• LOW TEMPERATURE ALARM DELAY—LOTEMP DLY—2:00 (MINUTES)
o Length of time the DPC can see the low temperature limit before the alarm is activated
and the dryer shut down
• FAN 1 ON PRESSURE—FAN1 ON:-- see table 1
o Discharge pressure needed before the FAN 1 cycles on
• FAN 1 OFF PRESSURE—FAN1 OFF— see table 1
o Discharge pressure needed before the FAN 1 cycles off
• FAN 2 ON PRESSURE—FAN2 ON— see table 1
o Discharge pressure needed before the FAN 2 cycles on
• FAN 2 OFF PRESSURE—FAN2 OFF— see table 1
o Discharge pressure needed before the FAN 2 cycles off
• ALARM LIST—BEGIN ALARM LIST—N/A
o Press SELECT DISPLAY to enter the alarms list. The DPC records the last 15 alarms
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PARAMETER R-22 R-404A R-407C
FAN 1 ON 235psi/16.2bar 275psi/18.96bar 235psi/16.2bar
FAN 1 OFF 195psi/13.44bar 195psi/13.44bar 195psi/13.44bar
FAN 2 ON 265psi/18.27bar 335psi/23.1bar 265psi/18.28bar
FAN 2 OFF 210psi/14.48bar 235psi/16.2bar 210psi/14.48bar
HPCO (AIR COOLED) 400psi/27.58bar 450psi/31.03bar 400psi/27.58bar
HPCO (WATER COOLED) 320psi/22.06bar 320psi/22.06bar 320psi/22.06bar
LPCO 20psi/1.38bar 20psi/1.38bar 20psi/1.38bar
Table 1
To view the non-adjustable parameters, technicians should press the SELECT DISPLAY button repeatedly
until the desired parameter has been reached. To exit Technician Mode, technicians should press the
arrow button (above the SET button) to return to customer mode.
Start Modes
The DPC controller is able to start in one of several modes:
• Auto Mode- After power is supplied to the dryer and the crankcase heater delay has timed out,
the controller displays ASC Delay followed by PRESS ON BUTTON. Provided the thermal mass
temperature is above the setpoint, turning the dryer operation switch on the main power
enclosure to the auto position will start all refrigeration systems simultaneously
• Remote Mode- The user can turn the dryer on and off remotely if a customer-supplied switch
has been installed. To enable this mode with the appropriate switch installed, the dryer
operation switch should be placed in the remote position
• Manual Mode- Once power has been supplied to the dryer and the crankcase heater delay has
timed out, the controller displays ASC Delay followed by the PRESS ON BUTTON on each module
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Alarms & Warnings
The DPC records the last 15 alarms that occurred on the machine. The first displayed is the most recent
alarm, along with the time and it occurred (using 24 time designations and day/month format).
To read the alarm list, technicians must be in Technician Mode on the controller and then use the
SELECT DISPLAY button to scroll down to the end of the Technician Mode menu.
Alarm Notes
HITEMP ALARM High temperature alarm- chiller/exchanger temperature is at or above
55°F/13°C. This alarm does not prevent the dryer from running, and occurs
often when the dryer has been off for an extended period of time.
LOWTEMP ALARM Low temperature safety alarm- when the chiller/exchanger temperature
drops to 30°F/-1°C for two minutes and shuts down the dryer. The alarm
resets automatically once the alarm condition is fixed and the dryer will
restart and run.
HPCO High pressure cutout alarm- this is only available in DPC 2, 4, and 8- the dryer
shuts down when the discharge pressure reaches set point and remains at or
above the set point for three seconds. The controlled must be reset manually
once the condition has been corrected.
It is important to note that the set point depends on the type of condenser
(air or water cooled) and the refrigerant used in the dryer.
EXT SAFETY ALARM Only available for cycling dryers with versions 1 or 2 of the DPC, triggered
when suction pressure is determined to be below the set point of the LPCO
switch for 10 seconds. This shuts the dryer down and the condition must be
corrected to allow the system pressure to get at or above the upper set point.
LPCO ALARM Low pressure cutout alarm- present in DPC 4 & 8 versions
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Cycling Dryers
When used on cycling dryers, the DPC cycles the refrigerant system based on the dryer’s chiller
temperature set point, which is an adjustable set point that customers and technicians can adjust as
needed. Key facts regarding the DPC and chiller temperature include:
• The operating temperature is factory-set at 4°F/2°C above the chiller temperature set point
o Example: If the chiller temperature is 36°F/2°C, the compressor on temperature is
40°F/4°C
• A temperature sensor samples the thermal mass temperature as it enters the chiller exchanger
• Once the sensor has detected a temperature below the chiller temperature set point, the
refrigeration compressor de-energizes
Multiplex Dryers with DPC Controllers

When working with multiplex units with a DPC controller, the chiller temperature set point can be
configured to operate according to site conditions and/or to equalize run time for the compressors. The
controller is shipped from the factory with the chiller temperature of each module preset as shown in
the table below (where the numbers indicate °F/°C).
Module
1 2 3 4 5 6 7 8
NVC4000 34/1.1 35/1.7
NVC4800 34/1.1 35/1.7
NVC6000 34/1.1 35/1.7 36/2.2
NVC7200 34/1.1 35/1.7 36/2.2
NVC8000 33/.6 34/1.1 35/1.7 36/2.2
NVC9600 33/.6 34/1.1 35/1.7 36/2.2
NVC12000 34/1.1 35/1.7 36/2.2 34/1.1 35/1.7
NVC14400 34/1.1 35/1.7 36/2.2 34/1.1 35/1.7 36/2.2
NVC16800 33/.6 34/1.1 35/1.7 36/2.2 33/.6 34/1.1 35/1.7
NVC19200 33/.6 34/1.1 35/1.7 36/2.2 33/.6 34/1.1 35/1.7 36/2.2
To equalize runtime of the compressors, technicians can shift the setpoints in the table above to other
modules. For example, on an NVC6000, Module 2 can be set to 34°F/1.1°C, Module 3 can be set to
35°F/1.7°C and Module 1 can be set to 36°F/2.2°C.
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Compustat
Compustat-Overview
The Compustat is a simple and easy to read interface with LED indications that automatically manages
dryer operation. The controller features a NEMA-1 package protection standard, with an optional
NEMA-4 rating.
Compustat-Functionality
Menu Map
Chiller
Temp C/F
Exchanger Drain Drain Alarm

Start/Stop % Savings Drain Test F/C
Temp Open Closed Reset
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Display Parameters
The LCD display on the Compustat controller displays exchanger temperature during normal operation.
It also displays the exchanger temperature set point, alarm condition and timing functions. Other lights
indicate the following:
• System Energized- when illuminated, this indicates power is applied to the unit
• Dryer On- when illuminated, this indicates the on switch has been pressed to place the unit in
operation
o It is important to note that the refrigerant system may start at any time when the light is
on
• Refrigeration Compressor On-a light here indicates that the refrigeration system is operating
• Degrees F/Degrees C-the light indicates the unit of measure being used currently
• High Temp Alarm- a light on here indicates that the exchanger temperature has risen to
10°F/5°C above the exchanger temperature set point
• Low Temp Alarm- when illuminated, this indicates the exchanger temperature has dropped
below 29°F/2°C
o It is important to note that this condition stops the compressor, and the compressor will
not restart until the temperature has risen two degrees above the exchanger set point
User Interface
There are six buttons technicians can use when interacting with the controller:
• On/Off-toggles the dryer operation between online and offline status, energizes the glycol pump
• EXCH Set- when pressed, the controller displays the current exchanger set point in the LCD
window. While the exchange set point is displayed, the up and down arrows may be used to
increase or decrease the exchanger temperature
o It is important to note that the controller allows the technician to configure the dryer’s
exchanger temperature setpoint to operate according to site conditions. The controller
is shipped from the factory with the exchanger temperature default set to 38°F/3.3°C
o The setpoint should not be set above 50°F/10°C
 Running a dryer with an exchanger temperature set any higher may damage the
refrigeration system
• Alarm Reset- pressing this once clears the local alarm indication and de-energizes the remote
alarm contact. If the alarm condition continues, the alarm returns after three minutes
• % Savings-when pressed, this changes the LED display to indicate the refrigeration system
running time vs. the total dryer on time
• °F/°C- This button toggles the LED display between Fahrenheit and Celsius units of measure
• Arrow Keys- these allow the technician to increase set point values within a fixed range
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There are two different start modes available:
• Manual Mode- after power is supplied to the dryer, the LED display indicates the chiller
temperature and displays the time remaining (out of three minutes) for the safety delay. Once
the delay has timed out, pressing the on/off button permits the refrigeration system to
operation, and if the chiller temperature is greater than the setpoint the refrigeration system
energizes. If the chiller temperature is not yet greater than the setpoint, the refrigeration
system remains off until that temperature is achieved
o The dryer automatically restarts on a power outage
• Remote Mode (Optional)- This mode allows the user to control the dryer remotely, and requires
the installation of a customer-supplied contact. In this mode, once power is applied and the
safety delay has timed out, the dryer can be started from the remote switch. In addition, manual
control is also permitted in this mode via the on/off button on the controller.
o If the dryer is turned on from the remote switch and then turned off on the local control
panel, the remote switch must be turned off and then on to reinstate the dryer
Alarms/Warnings
Display Meaning Alarm Set Point
HI TEMP ALARM High Temperature Alarm Exchanger setpoint + 10°F/5°C
LO TEMP ALARM Low Temperature Alarm 28°F/-2.2°C
It is important to note that the high temperature alarm will not shut the dryer down, while the low
temperature alarm will shut it down after a response time delay.
Alert Messages
PF Indicates a probe failure- this condition is usually caused by a probe being unplugged,
probe lead damage or defective probes
CD Indicates the refrigerant compressor will not start until the end of a three-minute safety
delay. The display of CD is immediately followed by the number of minutes left in the
delay. It is important to note that this is a normal function of the controller and is not a
fault indication
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Thermostar Controllers
Several versions of controller fit into the TS/TSA category of controllers. These include:
• Thermostar Electronic Controller
• Thermostar Intellisys Controller
Thermostar Electronic Controller-Overview
The Thermostar Electronic controller is an older style Thermostar controller that features a two-
character display, two-button keypad and four LEDs. Key features of the electronic controller include:
• Ability for the customer to install a remote switch for turning the dryer on and off as long as the
electronic control remains on
• The dew point can be displayed as °C or °F
o During a high dew point situation, the dew point and Hd will be alternately flash
o During a low dew point situation, the dew point and Ld will alternately flash
• The controller has an alarm mode that can display an alarm code
• A status report indicates the most recent status events
The controller also comes with an available remote control for the customer to purchase. With this
remote control, several additional options exist:
• Maintain cold mass- causes the compressor to run for a defined by preset on and off events
o tC-compressor disconnect delay time following opening of the remote off contact
o tA-compressor off time
o tb-compressor on time
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Thermostar Electronic Controller-Overview-Functionality
Display Parameters
When first powered up, the display indicates the unit of measure (°F/°C) for the temperature shown.
During normal operation, the display indicates the dew point temperature. In Status Report mode, the
display indicates the most recent dryer status events.
The Thermostar Electronic Controller is a simple controller with a simple display system- four LED lights
that indicate various conditions on the dryer:
• Alarm light
o Solid red light- one or more alarms have been tripped
o Flashing red light- one or more warning signals have been received
• Yellow Remote Off light: the dryer was shut off by remote control
• Green light: Machine is running
• Yellow light: Power is applied
User Interface
The controller has two buttons with two functions each: on and off, a toggle button for setting
functions, reset and a status report
Button Function
Dryer on and off
Used when the dryer is not in operation to: set the last service date, insert time
for maintain cold mass and for reading the status report
When held for two seconds, this button resets the alarm or warning signal once
the cause of the alarm has been eliminated. It is also used for: temperature scale
selection, clear report, setting last service date and reading the compressor hours
counter
Used to access the status report
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Thermostar Electronic Controller-Alarms & Warnings
Alarm/Warning Notes
Code
HP High pressure switch tripped, the compressor stopped. Press reset once the cause
of the alarm has been addressed to clear the alarm
ST High temperature thermostat trips, the compressor stopped. Press reset once the
cause of the alarm has been addressed to clear the alarm
Ld The temperature fell below 28°F/-2°C for three minutes while the dryer is running,
tripping the low dew point temperature alarm and stopping the compressor. The
alarm message Ld and the temperature reading alternate on the screen. The alarm
is only reset when the temperature rises above the 32°F/0°C
PI Compressor internal protection alarm- the compressor motor is overheated and
the internal thermal protection device has intervened to stop the scroll
compressor to avoid burn out. It automatically resets once it has cooled down.
Hd High dew point temperature warning- the temperature has exceeded 59°F/15°C
when the dryer is running, and has been this way for three minutes. The
compressor will continue to run while the Hd message and temperature
alternately shows on the screen. The alarm resets automatically when the
temperature falls below 55°F/13°C
8.8 or OF The exchanger has been exposed to a temperature below 27°F/-2.7°C or the probe
is reading the wrong temperature
AS Indicates the temperature sensor TO is faulty. The compressor continues to run,
but alarm Ld and Hd are disabled so the dryer can operate safely
EP or Er Indicates the EPROM memory is faulty- disabling all operations and putting the
controller unit into alarm status. To address this, the entire electronic control must
be replaced
FS The temperature reading exceeds the screen display limits (below 10°F/-9°C or
above 99°F/37°C)
SE Maintenance needed- every 4,000 hours of operation, the need for scheduled
maintenance is signaled. The display shows the SE alarm code alternately with the
temperature, the alarm LED flashes, and the alarm relay is activated. The dryer will
continue to operate normally. Pressing the reset key, the warning is silenced for
another 24 hours of operation, then the SE signal returns with the same method.
To reset the alarm, after carrying out all necessary maintenance work, switch on
the dryer by turning the main switch from off to on while keeping the “on off” and
“reset” keys pressed. The warning will reappear after another 4000 hours of
operation.
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Thermostar Intellisys Controller-Overview
The newer-style Thermostar Intellisys controller has several key features, including:
• Four main buttons:
o Toggle
o Start
o Stop
o Reset
• Status LEDs
o Line power
o Unit running
o Energy savings
o Maintenance warning
• Two LED strips that indicate percent relative humidity, evaporator temperature, and ambient
temperature
• Instrumentation LEDs that show alarms and indicators
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Thermostar Intellisys Controller- Functionality
Display Parameters
The display screen on the Thermostar Instellisys Controller has four basic graphic representations. These
include:
• Evaporator temperature and relative humidity indicator
o Evaporator temperature shows a relative scale of its coldest air temperature, which
relates closely to the dew point temperature. Green indicates a good dew point, yellow
indicates cautionary and red indicates a high dew point
o When toggled to, the same scale illustrates an approximate relative humidity of the
compressed air at the discharge of the dryer
 Calculation of this value is based on local ambient air temperature, typical
performance parameters of Ingersoll Rand air compressors when operating at
the same ambient temperature, and the evaporator temperature
• DP- the toggle button will move the display between the two modes:
o Relative humidity
o Evaporator temperature
• Local ambient area temperature
o Illustrates the relative temperature of the air that the dryer is exposed to. When the
dryer operates in green, it indicates the environment should not affect the performance
of a properly-sized dryer. Yellow indicates ambient temperature may start to affect the
dryer, and red indicates the dryer is approaching or has reached the maximum
allowable ambient operating temperature
 The ambient temperature has two scales
• DB- scale associated with DB serial numbers
• DN-scale associated with DN serial numbers
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• Operational status
o Contains four pictographs:
 Lightning bolt-indicates the electrical panel has provided to it
 Running Man- indicates the refrigerant compressor is running
 Star-indicates the dryer is running in the optional energy savings mode
 Wrench-indicates the regular interval for preventative maintenance has been
reached
• Dryer system operating schematic
o Contains LEDs that indicate if a system warning (yellow) or alarm shut down (red) has
occurred and from which primary component
User Interface
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Number Functionality
Button
1 Toggle
2 Start
3 Stop
4 Reset
LED
5 Drain valve alarm indicator
6 Afterfilter maintenance reminder
7 Prefilter maintenance warning reminder
8 Low evaporator temperature warning indicator
9 High evaporator temperature warning indicator
10 High refrigeration compressor discharge temperature alarm indicator
11 High/low refrigeration pressure alarm indicator
12 Preventative maintenance reminder
13 Energy savings option indicator
14 Refrigeration compressor run indicator
15 Control power indicator
16 Ambient temperature display
17 Approximated discharge air percent relative humidity active indicator
18 Coldest air temperature active indicator
To review and update set points on the controller, technicians should press the following buttons in
sequence in the span of 3 seconds or less: reset, toggle, toggle. Once the set point menu is entered, the
two bar graphs on the front of the controller are used to show set point number and value.
• The Evaporator/%RH graph indicates set point function
• The Ambient Temperature graph indicates set point number
o Each light has a specific value- technicians should add the numbers indicated by the
illuminated lights to get the displayed value
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Indicated Value Function Name Values
1 Drain Control Valve Technique 1=Manual
2=Automatic
2 Manual Drain Valve Open Time 1-10 seconds
3 Manual Drain Valve Closed Time 1-45 seconds
4 MODBUS Control State 1=Enabled
2=Disabled
5 MODBUS Local Address 1-247
6 PORO Control State 1=Enabled
2=Disabled
When navigating the set point menu, technicians should utilize the toggle, reset and stop keys.
• Toggle-move through setpoint numbers and change values
• Reset-initiate a data input session and save data input
• Stop-back out of an option and exit the menu
If a setpoint needs to change, technicians should:

• Toggle to the needed setpoint
• Press the reset key to initiate a value input session
• Use the toggle button to change the set point value
o The set point value and function returns to the lowest value once the maximum value
has been reached
• Press the reset key to save the newly entered value
o The controller should then flash the data to confirm the new value has been saved
It is important to note that if the controller does not receive any key presses within a 30 second time
span, it automatically backs out of the setpoint menu.
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Example
Part One-Reading the Display
%RH/Evap Graph
• Lights for values of 1 and 2 are on, indicating the value is 3
• 3 corresponds to Manual Drain Valve Closed Time on the function chart
Ambient Graph
• Lights for values of 2, 4 and 16 are on, indicating a value of 22
Interpretation: The Manual Drain Valve Closed Time is set to 22 minutes
Part Two-Setting the Set Point

• Press in sequence: Reset, Toggle, Toggle
• Press toggle twice to scroll through set point functions to the drain valve closed time function
o Confirm the correct selection: Lights for 1 and 2 should be illuminated
• Press reset to enable changing the set point value
o Review current set point by reviewing current lights on the Ambient graph
• Press toggle to change the set point value to the desired setting
o Confirm desired set point by reviewing current lights illuminated on the Ambient
graph
• Press reset to save the change- the display should blink twice if successful
• Press stop to exit and return to normal operating display
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In the case where a technician needs to reset the maintenance or filter warnings:
• Enter factory set points by pressing the following buttons in sequence” Reset, toggle, stop
• Use the toggle button to select the warning to be reset
o 1-Prefilter
o 2-Post filter
o 3-Preventative maintenance
• Press the reset button to enter data change mode for the selected warning
• Choose the desired value
• Press the Alarm Reset to perform the reset
o The set point value should blink twice if successful
OMI Controller
OMI-Overview
The OMI controller various slightly, depending on whether it is paired with a cycling or non-cycling dryer.
OMI Controller for a cycling dryer
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OMI controller on a non-cycling dryer
The OMI controller is equipped with an electronic control system, where all adjustments and resets can
be performed via the digital panel located on the front of the dryer.
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OMI-Functionality
Menu Map
Dryer
Status/Alarms
and Chiller Temp
On/Off Drain Test Set - +
Display Parameters
Display visualization and signally LEDs
The controller is capable of recognizing certain types of anomalies, where a message blinks on the
display and alternates with current dew point when one of the anomalies is detected.
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User Interface
There are five buttons technicians can utilize when working with the OMI controller. These include:
• TEST-when pressed for three seconds during normal operation, this activates the condensate
drain
• SET—when pressed and released during normal operation, it displays the dew point set value
(decimal). When pressed for 10 seconds, it allows the technician to enter the C8 and C9
condensate drain parameters programming menu
• DOWN—when pressed while setting the drain set point, it decreases the displayed value of one
unit per second during the first 10 seconds, then one unit every 0.1 seconds.
o When pressed for 10 seconds during normal operation, it starts and automatic test cycle
of the controller
• UP—when pressed while setting the drain set point, it increases the displayed value of one unit
per second, during the first 10 seconds, than one unit every 0.1 seconds
• ON/OFF—when pressed, it activates or deactivates the dryer. When the dryer is deactivated the
display shows OFF
• SET + DOWN—when pressed simultaneously for 1 second, the display shows in sequence the
Energy Saving value of the last cycle (lSt) and the value of the last 100 hours (tot)
o The Energy Savings value is the percentage of time in which the dryer is in ESA/ES2
mode
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For an in-depth look at troubleshooting, technicians should review the operator’s manual , which can be
found in Passport.
Warnings/Alarms
Alarm/Warning Notes
Code
ESA Low evaporator temperature warning. Caused when the evaporator temperature
drops below 30°F/-1°C for a period of five minutes. This does not issue a general
alarm.
ES2 Low evaporator temperature warning. Caused as soon as the evaporator
temperature drops below -0.4°F/-18°C. This does not issue a general alarm.
HtA High evaporator temperature alarm. Caused when the evaporator temperature
reaches 58°F/14.5°C for a period of six minutes
Ht2 High evaporator temperature alarm. Caused as soon as the evaporator
temperature reaches 113°F/45°C
ASt HtA or Ht2 alarm activated three or more times within an hour
PF1 Temperature probe error. Occurs when the controller cannot read the probe
resistance within an acceptable range
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Unit 5: Installation and Commissioning
Installation
When installing a refrigerant dryer, technicians must remember that it is vital that the dryer is installed
in the correct environment, with the correct system orientation and with the correct startup
procedures. The following sections provide technicians with a general guideline for installing refrigerant
dryers, however it is important that technicians utilize the appropriate engineering data and installation
instructions for each installation.
Pre-Installation Checks
Before installing a dryer, technicians should perform the following pre-installation checks and tasks:
• Inspect the unit closely
o Look for any signs of rough handling
 Be sure to note these on the delivery receipt
o Check all electrical enclosures for damage
o Inspect all conduit, piping and tubing runs for damage
o Inspect the unit for refrigerant or thermal fluid leaks that may have resulted from
shipping damage
o Inspect the cabinet for dents, dings and scratches
o Obtain the delivery person’s signed agreement to any noted damages
o Check for damage from improper storage or warehousing of the dryer
Freight-damaged unit
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• Ensure proper offloading and movement of dryers upon delivery occurs
o There are designated fork and lifting locations that must be used to move the dryer
o For modular dryers, the inlet and outlet manifolds should always be left in place and
used to lift the dryer
o Forks should extend all the way through the forklift channels in the base the dryer
package is mounded on in order to reduce unnecessary forces on the dryer during
moving
o Slings can be used to lift the crates, but spreader bars must be used to prevent the slings
from exerting a force against the sides of the crates or the dryer
• Confirm the environment is appropriate for the dryer
o Dryers must not be located in direct sunlight
o The installation site should be a temperature controlled environment
 The only work around for this is if the dryer is equipped with a low ambient
option
o The installation site must be located far enough away from walls and other equipment
to allow for proper airflow, access for maintenance and access to control panels.
 Engineering specifications commonly set this distance at 3ft(1m)
o The fuses/circuit breakers must be sized to withstand inrush current at start up
 Must be the correct type per local code.
o Every drain point needs to be piped to its own drain valve
o Proper filtration needs to be installed and a maintenance calendar should be setup to
ensure that filters are changed at the correct intervals per operator manuals and local
maintenance standards
o Verify that room ventilation is adequate to lower temperature and reduce airborne
contamination levels
 Dryer should be located in an area free of chemicals such a chlorine that can
react and degrade brazed joints
Installation
When installing a dryer, technicians must be sure to follow instructions found in the appropriate
engineering data and installation instructions for each dryer. These can be found attached to the unit
upon delivery. If for some reason the manuals are lost, technicians should utilize Passport to locate a
copy.
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Post-Installation Checks and Tasks
Once the dryer is installed, technicians must perform several post-installation checks and tasks prior to
beginning the start up routine. These checks and tasks include:
• Inspect compressed air connections
o Ensure that inlet/outlet distribution header is sized appropriately for application flow
and pressure drop requirements
• Confirm no piping loads are exerted on any dryer or filter piping connections
o Ensure that adequate piping supports are in place to prevent loading
• Ensure that air compressor vibration has been isolated from air system piping
o Ensure that air flow pulsations, if present, are eliminated via a surge tank, receiver or
pulsation dampener
o Make sure that any equipment in proximity to the dryer transmits minimal vibration
through piping system or foundation to the dryer
• Check that all air system distribution piping is as leak free as possible
o Check air connections on the dryer to ensure there are no leaks present
o Check drain lines for air or liquid leaks
o Check all flange connections, if applicable, for gasket compression
o Check that water supply lines and dryer water connections are leak free
o Look for refrigerant leaks
 When possible, technicians should use an electronic leak detector
• Check that glycol levels are correct
• Check for proper drain installation
o Drain connections must be piped into an appropriate reservoir or container
 When possible, it is best practice to install an appropriately sized oil/water
separation device to comply with local regulations for waste water disposal
 When connecting drain valves supplied separately, use a single drain for each
individual device
 It is not recommended that more than one device be connected up to a single
drain valve, due to the pressure differential between the two devices. This
pressure differential can result in backflow into the lower pressure device and
improper draining, eventually resulting in contaminant carryover downstream
o On units with multiple drain lines, technicians may manifold all lines into a single
discharge port
 When this occurs, technicians must ensure that the piping diameter is adequate
to handle the flow of water from all the drains at the same time
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• Check compressed air filtration. Adequate pre- and after-filtration is recommended for all
compressed air systems to account for application differences in the following areas:
o Quality of existing air distribution piping system ahead of the dryer
o Age of air distribution system ahead of the dryer
o Special contaminants present as a result of compressor intake location, special onsite
processes and their associated contaminants, plant location and surrounding area, etc
o Age and type of air compressor(s)
o Amount of oil, pipe scale, rust, liquid condensate, etc. present in air system
o Filters should be mounted as close as possible to the dryer and positioned to allow for
ease of access for element replacement
o All filters must be equipped with automatic drain valves
o All filters should be properly supported so that no piping loads are introduced
• Check isolation and bypass valving for use in dryer and filtration system
o When possible, rising stem gate valves should be used for all manual valve operations to
ensure slow system pressurization
 If ball or butterfly valves are to be used, they should be lockable to prevent
improper adjustment or unauthorized system pressurization
 Technicians should coach customers in the creation of formal procedures that
ensure proper pressurizations occur
o Design for gradual pressurization under all circumstances
o Allow for pressurization of dryer prior to downstream piping system
• Check system bypassing
o The dryer and all filters should be equipped with isolation and bypass valving for
serviceability
• Check other plant air sources to ensure that all air supplied to the downstream air system is
filtered and dried
• Check electrical service to:
o Ensure proper supply voltage and amperage
o Ensure proper circuit breaker and disconnect sizing
o Ensure proper wire and conduit sizing
o Connect appropriate three-phase wiring into the dryer contactor or terminal block
o Ensure proper grounding of the dryer
• Inspect the starter box, checking for tightness and good contact of all wiring connections
o Tug test all wires
o Check for correct transformer taps
• Ensure free unrestricted movement of cooling fans by manually spinning them
• Check glycol pump operation
• Slowly open isolation valves
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Commissioning
After installation and before beginning start up of the machine for the first time, technicians should
ensure the work area where the dryer has been installed has been cleaned up and is ready for
commissioning.
Pre-Startup Checklist and Tasks

If possible, technicians should perform the following at least eight hours prior to the scheduled start up
time:
• Close the starter box door prior to applying power to the machine
• Measure incoming voltage using all require personal protective equipment
• Press the start button
o Verify fans are rotating the correct direction
• When running, measure phase to phase and phase to ground
• Refer to the appropriate technical manual in Passport to understand crank case heater
operation. An example for the DPC operation is below
o Ensure that dryer is energized for a minimum of (8) hours prior to dryer startup
o On the Main Power Enclosure, the On/Off Switch should be ‘ON’ position, and the
Auto/Manual/Remote Switch should be in the ‘Manual’ Position
o Supply power to dryer main control enclosure and engage each individual compressor
disconnect switch for a minimum of (8) hours prior to dryer startup
o The DPC control board will indicate the system is energized and the crankcase heater
delay time remaining
• For hermetic compressors with site glasses, ensure oil level is visible
• Verify that the glycol pump is running if applicable
o Check amp draw
• Stop the dryer, test the emergency stop button it applicable
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Startup Checklist and Tasks
When starting up the machine, technicians may utilize the startup checklist (which can be used on an
iPad) to document the startup process and measurements. Technicians should review and document
data on the checklist once the dryer has been started and is operational. To prepare for collecting data,
technicians should review the following:
• After running the unit under full rated flow for approximately 30 minutes, verify that when the
electric drain opens, all of the accumulated liquid is discharged and then followed by a small
burst of air
• For modular dryers, power up and check each module:
o Press the start button on the DPC controller on Module 1 and observe operation
o The suction pressure display will typically pull down between 30psi/2bar and
50psi/3.4bar and the suction temperature reading will vary between 20°F/-6.7°C and
40°F/4.4°C
 These measurements vary, depending on the glycol temperature when
operating
o The discharge pressure gauges will vary between 195psi/13.4bar to 265psi/18.3bar
o While the glycol temperature is above 50°F/10°C, the DPC will indicate “High Chiller
Temp” condition. This will clear when the temperature drops below 50°F/10°C
o Record operational data on the refrigeration system and check compressor amp draw.
o Once acceptable operation has been observed, and before the glycol temperature drops
more than 5°F/-15°C, depress the Stop button on the DPC
o Repeat for each of the other dryer modules.
• On multiplex dryers:
o Once all refrigeration systems have been operated, the glycol temperature will have
been partially cooled. The main control switch can be turned to auto. The refrigeration
systems will operate in a staggered fashion as described in the technical manual
o Based on the glycol temperature, the individual modules will turn the refrigeration
systems on and off as required to cool the glycol
• Once all refrigeration systems have cycled off, air may slowly be introduced to the dryer and
operation under flow observed
Once the above steps have been followed, technicians should utilize the startup checklist as a guide for
what data to record and what components to review upon startup.
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Installation and Commissioning Completion
Once a dryer has been installed, commissioned and appears to be running smoothing, technicians must
review several things prior to leaving the site:
• Is the dryer and all associated equipment clean?
o Technicians should be sure to wipe down the machine
• Have all the tools and debris from installation been cleaned up and put away?
o The workspace should be cleaned up upon completion of installation and startup, with
the goal of leaving the work site better than the condition it was found in
• Has the end-user maintenance team or representative been educated regarding the use and
routine maintenance of the dryer?
o Take the site contact through the machine, ensuring all their questions are answered
• Does the customer have direct contact information for the appropriate person to call with
questions or to request service?
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Unit 6: Maintenance and Diagnostics
Once a dryer has been installed and commissioned for a customer, that customer’s relationship with
Ingersoll Rand is really just beginning. Moving forward, technicians should work closely with the
customer to ensure their machines are working efficiently and effectively by performing maintenance on
the machine and diagnosing issues as they arise.
When providing service on a machine, technicians should remember several things:

• Only qualified technicians should adjust, perform maintenance or repair refrigerant dryers
• All personal protective gear should be worn properly during service on the machine
• All local and company-wide safety requirements must be followed
o This includes government issued environmental requirements, lock out tag out
requirements and all safety precautions
Routine Maintenance
Maintenance Tools
When servicing refrigerant dryers, technicians should be sure to have the proper tools (along with all
locally-required PPE). The tools listed below are recommended for technicians servicing refrigerant
dryers:
• Two four-port manifolds • Digital Thermometer (Fluke 54 II) W/ 4
o One standard manifold for all Probes
mineral oil (R22) dryers • Schrader Core Replacement Kit
o One high-pressure manifold for • Solder (Silvaloy #10 -#20)
all POE oil (R404, 407, 134 and • CPS Solenoid Magnets (2)
410) • Electronic Leak Detector
• A Fluke 87 meter with thermal leads • Digital Micron Gage
and/or an Electronic Temperature gun • Digital Scales
for measuring refrigerant temperatures • Torch Set W/Blt’s (Or Turbo)
• CPS solenoid magnets for • Nitrogen Btl. and Regulator
troubleshooting of refrigerant solenoids • Reclaimer Containers for Each Type of
• Reclaimer and Hose W/Quick Refrigerants
Disconnect Hose • 2 Service Valve Wrenches
• Vacuum Pump (8CFM Min.) • Reclaim Logs
• Reclaimer ¼”MxFM Filter Driers • Tubing Cutters (1 1/8” and smaller)
• 24” Tool Box for equip (Recommended) • Roto Lok Gasket Kit
• Flaring Kit
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Preventative Maintenance
There are several maintenance activities that should be scheduled on a regular basis, typically based on
running hours. These include:
• Changing filters
• Cleaning solenoid drain valves
Filter Changes
Technicians should review the engineering data sheets to determine how often filters should be
changed on refrigerant dryers. Once it is time to change the filters, technicians should:
• Shut down the dryer
• Follow all appropriate local requirements for safety precautions, including all applicable LOTO
steps
• Unscrew the filter bowl
• Remove the old filter element
• Insert a new filter
• Reassemble the filter housing
• Restore air to the dryer
• Start up the dryer
• Confirm dryer is working properly
Solenoid Drain Valve Cleaning

When cleaning the solenoid drain valve, technicians should be sure the dryer is depressurized or the
isolation valve is closed. After confirming this, technicians should:
• Disconnect the drain body from the filter stop
• Loosen the connector screw to allow the electrical connector assembly to be removed from the
D.I.N. unit solenoid
• Remove the retainer nut and separate the valve body from the D.I.N. unit solenoid
• Unthread the plunger tube assembly in a counter-clockwise direction until the plunger separates
from the valve body
• Clean the beveled washer, thread gasket, spring assembly and strainer with soap and water
o Technicians should NOT use solvents of any kind, as failure to the seals will occur
o Technicians should be careful to clean the center brass orifice and the rubber gasket
orifice on the orifice cup with a straight pin
• Reassemble all drain components after the drain has been cleaned and inspected
• Reposition the orifice hole on the rubber gasket of the orifice cup in the line and closest to the
arrow indicated on the valve body
• Reassemble valve and install in reverse order as described above
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Refrigerant Reclamation, Evacuation and Recharge
It is important to note that all work done with refrigerant must adhere to all safety and environmental
regulations and requirements in the location the work is performed. Where applicable, only certified
technicians may perform work with refrigeration.
Tools Needed
When performing work with refrigerant, technicians should be sure to have the appropriate tools. These
include:
• Manifold gauge set
• Recovery unit—with hose
• Recover cylinder
• Vacuum pump
• ½” or 3/8” vacuum hose
• Core removal tool
• Electronic leak detector
• Nitrogen
• Micron Gauge
• Assorted hand tools—as needed to make repairs
o Brazing torch & supplies
• Refrigerant—enough to recharge the unit after making repairs
• Proper PPE
o Electrical – Lock out tag out tools
o Safety glass
o Cut resistance gloves
o Hearing protection
o Eye protection for brazing
o Other PPE as required by the site
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Recovering and Reclaiming Refrigerant
Technicians should follow the steps below to properly recover/reclaim refrigerant.
• If dryer has access fittings, install the core removal tool on fittings and remove Schrader valves;
o If the unit has Core Max fittings, these core valves do not need to be removed
Max Valve
Schrader Fitting
Core Removal Tool
• Install the Manifold gauge set on the system

• Set a recovery tank on a charging scale (must be a tank that has been
dedicated for the refrigerant to be reclaimed)
• Connect the middle hose of the Manifold gauge set to the inlet fitting
on the reclaimer
• Connect a hose for the outlet fitting of the reclaimer to a recovery
tank. Leave the tank valve in the closed position at this time
• Open the valve on the core removal tool (when used), the valves at the Manifold gauge set, the
inlet valve on the reclaimer and the outlet valve on the reclaimer
o Crack the hose fitting at the recovery tank and bleed the air from the hoses and the
reclaimer
o Tighten the hose fitting
• Close the inlet fitting on the reclaimer
• Open the valve on the recovery tank
• Start the reclaimer
• Slowly open the inlet valve until it is fully open. Make sure the valves on the Manifold gauge set
are still open
• Allow the reclaim to run, and the pressure in the system should start to drop
• Observe the Manifold gauge set and the scale once the gauge set is in a vacuum (at least 10
inches on the compound gage and the scale indicates no more increase in the amount of
refrigerant entering the tank)
o Close the valves on the gauge set and the inlet valve on the reclaimer
• Shut the reclaimer off
• Close the valve on the recovery tank and slowly remove the hose from the valve on the tank
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Once the steps above are complete, technicians should move to the steps below.
• After making any repairs needed to system, leak check the
system with an electronic leak detector
o Add a small amount of refrigerant and pressurize
the system with Nitrogen
o Using an Electronic leak detector check the system
for leaks and repair any found
o Remove the Nitrogen/refrigerant mixture
• Pressurize the system with straight Nitrogen to at least 250psi/17bar
• Let the system sit for at least 30 minutes
o If the system holds the pressure then release the Nitrogen
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Evacuating the System
• With the Manifold gauge set still installed on the system, remove the center hose for the
Manifold if a ½” vacuum hose is available and install the hose on the center port of the gauge
set
o If a ½” hose is not available, leave the ¼” hose installed on the gauge set
• Install the center hose (either the ½” or ¼” hose) to a vacuum pump
• Install a micron gauge to one of the core removal tool secondary ports (if core removal tools are
installed) or to another access fitting on the system
o If none are available, the micron gauge will need to be
installed on the vacuum pump.
 Note: technicians should always use a Micron
gauge- not the compound gauge on the
manifold- to determine the level of vacuum
• Turn on the Micron gauge

• Turn on the vacuum pump
• Open isolation valve on the pump
• Open the valves on the Manifold gauge set
• If core removal tools are in use, technicians should open the valves on the tools
• Allow the vacuum pump to run until there is a micron reading on the Micron gauge below 500
microns
• Shut the valves at the core removal tools, then the Manifold gauge set and finally the isolation
valve on the vacuum pump and then turn off the pump
o It is important to note that if a micron gauge is not installed on the vacuum pump,
technicians should not close the valves on the dryer or the manifold gauge set
• Allow the Micron gauge reading to stabilize and let the system sit for at least 15-30 minutes and
see if it holds below 500 microns
o If the system holds below 500 microns- this indicates the system is likely leak free and
recharging can begin
 Technicians should leave the valves on the core removal tool and gauge set
closed
o If the vacuum rises to between 1000-1500 microns- this indicates that there is still
moisture in the system and evacuation of the refrigerant should begin again
o If the vacuum rises above 1500 microns- this indicates there is a leak in either the
system or the gauge set. At this point, technicians should search for and repair the leak
prior to moving forward
• Once the machine is leak free, technicians should remove the micron gauge for the system
• Remove the vacuum hose from the middle port of the gauge set and reinstall the ¼” hose on the
port
Once the previous steps have been completed, technicians can move on to recharge the system.
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Recharging the System
Once a machine is ready to be recharged, technicians should:
• Install the middle hose to a tank of the correct refrigerant for the unit. Technicians should be
sure to confirm the type of refrigerant in the unit by reviewing the machine’s data tag
o If the tank has two valves, install the hose on the valve indicated for liquid
o If the tank only has one valve open the valve and turn the tank upside down
• Before opening the valves on the gauge set, crack the hose fitting at the manifold gauge set for
the hose and bleed off any air
• Set the tank on a charging scale and “ZERO” the scale
• Open the high side valve of the gauge set and watch the charging scale and charge until the
rated charge amount has been charged into the system and close the valve
o It is important to note that unless there is a quick charge metering device installed at
the suction gauge port, technicians must not charge liquid refrigerant into the suction
side of the system
• Once the correct amount of refrigerant has been charged into the system, close the valve on the
gauge set and on the tank
Once the above steps have been completed, technicians should verify the system runs and that the
chiller/exchanger temperature pulls down. Once confirmed, technicians should shut off the unit and
close the valves on the core removal tool if installed. Additionally, technicians should remove the
gauge set hoses and reinstall the Schrader core in the fitting.
Technicians must always use care when handling nitrogen and refrigerant; nitrogen can be at a very
high pressure and a pressure regulator should always be used on the nitrogen tank. Technicians
should slowly purge off the system to 0psi/0bar before removing the hoses for making repairs when
a unit is under pressure.
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After running and verifying that the unit is operating correctly, technicians should remove the gauge
set. Loosen and slowly remove the hoses as there maybe liquid refrigerant in one of the hoses and
when released there is the possibility of getting frostbite to any exposed skin.
Diagnostics
All Refrigerant Dryers-First Steps
When service is needed outside of routine, scheduled maintenance, technicians should perform several
checks:
• Review any data available from the controller
o Most controllers show the dew point and evaporator temperature at the very least, and
many will also show suction temperature and pressure, discharge temperature and
pressure and cooling water temperatures
• Measure and record values for several components
o Flow rate
o Inlet temperature
o Air pressure
o Ambient temperature
o Cooling water temperature
o Cooling water flow
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There are some occurrences that are common and easy to test once the dryer has been properly
disconnected and the covers have been taken off.
Issue Tests to Perform Cause/Resolution

Compressor will Wait to see if overload resets Common causes include: a voltage
not start Take an amp draw on the compressor issue, internal damage to the
compressor, electrical component
failure
Fan will not come Measure amp draw on the fan Common causes include: failed fan
on Check incoming power motor, loss of power to the fan,
Confirm the fan pressure switch is set failed fan pressure switch or issues
correctly with the discharge pressure, loss of
refrigerant
Temperature Visual review The liquid line filter is clogged and
difference across Physically review sensible temperature should be replaced. This may also
the liquid line filter on the line indicate other issues upstream that
caused the clog
Abnormal Check the ambient temperature There may be numerous causes for
compressor can this issue, including no refrigerant
temperature-too in the dryer and/or the compressor
hot valves may be worn or broken.
Abnormal Check the refrigerant charge, check the The dryer may be low on
compressor can thermal expansion valve refrigerant or the hot gas bypass
temperature-too valve may need adjusting, the
cold temperature probe may not be
reading correctly, failed glycol
pump in a cycling dryer
Diagnosing the Issue

Technicians should consult the end-user customer, any service records and other technicians who have
performed maintenance on the customer’s dryers in order to prepare for diagnosis and troubleshooting
on the customer’s dryer. The following are some of the more common issues encountered by
technicians working on refrigerant dryers, including the symptoms of the issue and recommendations
for what the technician should check.
It is important to note that a few ounces of refrigerant are lost every time gauges are connected. On
smaller dryers, a significant amount of charge may be lost upon gauge installation. The smallest units
may not have access ports for gauges.
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Scenario: Water Downstream, High Dew Point
As with all service, the first step in diagnosing the cause of water downstream in connection with a high
dew point is to review the controller for any alarms or other informative data. Several potential
situations could be in play based on alarms present (or absent) and indications on gauges.
High Pressure Cutout (HPCO)- • High ambient temperature

DPC controllers 2, 4, 8 o If possible, get the customer to reduce the
temperature in the room
o Refer to operator’s manual to determine the
maximum acceptable ambient temperature
• Dirty condenser
o Blow out compressor with compressed air
o Depending on the site, technicians may need to use
soapy water or a mild non-caustic chemical cleaner
• Clogged water-cooled condenser
o Back flush or clean the exchanger
• Water regulating valve (water cooled only) out of adjustment
o Adjust or replace the water regulating valve
• Compressed air inlet temperature is too high
o Reduce compressor outlet temperature
 If this does not address the issue, technicians
should look into the possibility of adding an
aftercooler
• Compressed air flow rate is too high
o Technicians should discuss with the customer the
possible need to change or add to their existing
dryers to ensure the appropriate capacity is met
• Fan is not working as designed
o Test windings phase to phase
o Test for shorts to ground
o Ensure that the controller is sending a signal to start
the fan
o Ensure fan is getting power, test contactors and
relays
• Refrigerant charge is too high
o Check the label plate and other appropriate
documentation to determine the correct charge
o Pull and weigh the charge
• Air and non-condensables are present in the system
o Recover charge and recharge with new refrigerant
• Defective pressure switch
o Check set points
o Check contacts
o Check connections
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High Discharge Temperature • Check the switch contacts. If they are defective- replace the
temperature switch
• Low refrigerant charge
o Pull and weigh the charge
o Leak test the system
o Repair any leaks
o Recharge with the correct amount of refrigerant
• Check the compressor valves. If any are damaged, replace the
compressor and filter drier
• Check the refrigerant filter. If It is clogged, replace filter drier
• Check the fan If the fan is not operating as it should:
o Check the fan pressure switch
o Ohm out fan windings
o Backtrack signal to controller if applicable
• Determine if the thermal expansion valve is defective. If this
appears to be the case:
o Warm up TXV bulb by hand and check to see there is
a change
o Replace thermal expansion valve if it is stuck.
High Dewpoint, Normal • High Flow Rate

Evaporator Temperature, No • High inlet temperature
Other Indications • Drain valve not working
• Inlet and Outlet temperatures are the same
o No power to the dryer
o High suction pressure
 Check and clean condenser
o Refrigerant leak
 Look for leak
 Hang gauges and check for pressure vs P/T
chart
 Recover and weigh the charge
 Repair leak and recharge
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Scenario: High Differential Pressure across the Dryer
In the case where there is high differential pressure across the dryer, the technician should do the
following:
• Determine if this is caused by the dryer freezing up by shutting the compressor down and
allowing it to warm up
o If the high differential pressure goes away, the cause was a freeze up and the technician
should
 Check the thermostat to determine whether it is opening properly
 Check the refrigerant charge
• To correctly perform this, charge must be pumped down and weighed
o If the high differential pressure does not go away, technicians should then check for an
obstruction
 Clean drains and check if the dryer had filled up with water
 Check inlet and outlet filter
 If possible, take out and clean the moisture separator
• If not, hook up an air supply to the outlet of the dryer with a ball valve
and use the ball valve to pulse air back through the dryer in an attempt
to clear out any obstructions
Scenario: Low Dew Point/Evaporator Temperature

It is important to note that most dryers have indications for dew point and/or suction temperature, so
when a technician observes or measures a low dew point/evaporator temperature, several causes may
be present:
• Hot gas bypass is set lower than 34°F / 1.11°C
o If this is the case, technicians should adjust the HGBV by screwing out counterclockwise
for more gas or screwing in clockwise for less gas
• The probe is reading the wrong temperature (check thermocouple)
• Defective hot gas bypass valve
• Fan switch not reading correctly
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Proper positioning of the temperature probe-under the insulation between the capillary device and the
evaporator
Scenario: Compressor Burn Out

In the case of compressor burn out, technicians must first determine the cause of the failure and carry
out all corrective actions identified prior to replacing the burnt-out compressor. If this analysis and
repair is not completed, repetitive failure will occur. Included in the investigation into the causes of burn
out, technicians must be sure to thoroughly clean out the pipe work and dismantle any thermostatic and
solenoid valves to clean them as well as replace the filter/drier. To properly clean, technicians should:
• Clean/replace the thermostatic valves, solenoid valves and any other types of metering devices
the dryer may have
• Change the filter/dryer in the liquid line and mount a burn-out filter in the suction line if needed
o A burn-out filter has connections in order to monitor the pressure drop and
performance of the filter
• Look at the electrical connections for any carbonized or deteriorated contacts
o These must be cleaned or replaced
• Check to ensure the connections to the pressure switch, thermostat and transducers are intact
and functioning
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It is important to note that cleaning must be done by means of a burn-out filter or Rx-11 flush.
Once cleaning and corrective actions are complete, technicians should remember the following when
preparing to replace the compressor:
• Check that the new compressor and the compressor to be replaced have the same electrical and
refrigeration performance characteristics and verify oil type
• The compressor's time of exposure to the atmosphere during installation must be limited to less
than one hour
o The compressor connection must be fast in order to avoid moisture contamination of
the lubricant
• The new rubber mounting grommets supplied with the new compressor should be used
o Rubber grommets must undergo compression until contact is made between the flat
washer and the steel mounting sleeve
• If piping needs to be modified, use only clean, dehydrated and sealed refrigeration copper
tubing
o Technicians should never drill holes in the pipe work after installation
• When brazing, do not introduce contaminants into the circuit, purge piping with nitrogen during
that part of the operation
o All brazing materials are to contain a minimum of 5% silver
To install the new compressor:

• Reclaim the refrigerant in the system
• Pull down to 29.99 inches of mercury
• De-braze
o Heat up and melt the existing braze
• Remove old parts
o The liquid line filter must be removed and replaced anytime the refrigeration system is
opened up
• Clean the copper tubes to remove the old braze and any debris so the new braze will adhere to
the tubes
• Install the new compressor
• Install the new liquid line filter (also known as a filter dryer)
o Braze the liquid line filter in place
• Charge the unit with nitrogen to check for leaks
o Put at least 250psi/17.2bar into the system
 If the system holds the pressure without losing any nitrogen for 30 minutes,
move to the next step
• Install a vacuum pump
o Pull the system to a vacuum of 500 microns
o Have the system hold that vacuum for 15 minutes
• Weigh in the refrigerant
• Charge in a liquid form
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Once the new compressor has been installed, technicians should:
• Install new filter/dryer
• Check system for leaks
• Check power supply voltage and insure that electrical connections are in accordance with the
compressor specifications.
Diagnosing Cycling Dryers

When servicing cycling refrigerant dryers, technicians should keep in mind several key factors that
differentiate cycling from non-cycling dryers.
• When a cycling dryer is powered on the glycol pump should be running, circulating the thermal
mass from the evaporator to the air to glycol exchanger
o The glycol flows through clear plastic tubing. Pulling the insulation back where the glycol
goes back into the reservoir, technicians can check the flow
o On some models the glycol pump can become air bound. Since the pump bearings are
cooled by circulating fluid, the pumps will become seized and will no longer rotate
o On models where the glycol pump is above the glycol tank, the system can be primed
using a large funnel and allowing the air to burp out of the system
For proper heat transfer to take place, it is also important to have a proper glycol level and mixture.
Therefore, technicians should verify glycol level and determine the percent glycol to water mixture. Key
notes technicians should keep in mind include:
• When polypropylene glycol is used, the mixture should be two parts water to one part glycol
o Technicians should verify glycol level based on specification on engineering data sheets
 Level can be determined by using a dipstick or, depending on the dryer, by sight
verification (level should be a couple inches from the top)
o A refractometer should be used to determine the percent glycol to water mixture
 The value should be +10°F or -12°C
Scenario: High Pressure Cutout

When the High Pressure Cutout alarm is present or the conditions exist, several causes should be
investigated:
• The refrigerant may be overcharged
o Technicians should pull and weigh the charge, recharging with the charge listed on the
data plate
• Air and non-condensables are present
o Technicians should pull and weigh the charge, recharging with the charge listed on the
data plate
• The transducer is not functioning properly
o The transducer is responsible for reading refrigerant temperature. Technicians should
use the gauge manifold to verify the reading from the transducer to the controller. If the
reading is not the same, the transducer should be replaced
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Scenario: Low Pressure Cutout
When the Low Pressure Cutout alarm is present or the conditions exist, several causes should be
investigated:
• There may be a restriction in the refrigerant flow
o Refrigerant stop valve stuck
 Use a magnet to attempt to open the valve and equalize pressure
 If the coil is bad on the valve, the coil should be replaced. However, if the valve
body is bad the entire valve should be replaced
o Thermal expansion valve stuck shut
 If the thermal expansion valve is stuck shut, technicians must replace the part
• For water-cooled dryers, the cooling water may be too cold
o Check the temperature of the cooling water- if it is too low, it may slow down the glycol
at a rate that the water regulating valve cannot keep up with
• The water regulating valve may be fully open
• The glycol pump may be malfunctioning
o The technician should Take an amp draw on the pump
o Ensure that water is actually flowing through the lines by visual inspection.
 If there is a stationary leg of water inside of the evaporator, there is no heat sink
for the dryer
• The glycol level may not be adequate
o Technicians should use a dipstick and add any necessary glycol mixture as needed (or
utilize a visual inspection to check the level, depending on the dryer)
o Use a refractometer to ensure that the temperature is +10°F/-12°C
 Glycol needs to be the designed thermal mass
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Electrical Systems Troubleshooting
CSIR Type Compressors
The steps below should be followed when testing a compressor and compressor components of a CSIR
compressor- for units that only have a start capacitor.
The first step is to Turn off power to the dryer and disconnect power leads so that no external wires are
on the terminal connections to the compressor. Also disconnect wires between electrical kit
connections C to 1, S to S, and R to R.
115V
Using a multi-meter, technicians should check resistance (ohms) across the following:
• Check between overload connections 1 & 3
o If no continuity, the overload is open
o Allow time to reset, if still open replace overload
• Check between compressor connections C & S
o If no continuity, the start winding is open and compressor must be replaced
o If continuity, record resistance (ohms)
• Check between compressor connections C & R
o If no continuity, the run winding is open and compressor must be replaced
o If continuity, record resistance (ohms)
• Check between relay connections 2 & R
o If no continuity, there is a bad relay coil, replace relay
• Check between relay connections S & 1
o If continuity, the relay contact is stuck closed, replace relay
• Using a capacitor tester, check start capacitor connected between terminal 1 & 2 on the relay
o Test in accordance with capacitor tester instructions.
• Check each of the compressor connections, (C, S, R) & the shell (ground)
o If continuity between any of the connections and ground, the motor is grounded and
compressor must be replaced
• Verify continuity of all previously disconnected wires
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CSR Type Compressors
Technicians servicing CSR-type compressors should review the best practices listed below when
checking and troubleshooting machines.
D170NC, D212NC,
D255NC & D340NC
D340NC & D340IN

230V 1PH
To start, technicians should use a voltmeter to check the incoming power source. This should not be
10% more or less than motor rating. From there, technicians should turn off power to the dryer and
disconnect power leads so that no external wires are on the terminal connections to the compressor. In
addition, technicians should disconnect wires between electrical kit connections 5 to 3, C to 1, S to 2,
and R to 4.
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Using a multi-meter, technicians should check resistance (ohms) across the following:
• Check between relay connections 5 & 2
o If no continuity, there is a bad relay coil, replace relay
• Check between relay connections 2 & 1
o If no continuity, the relay contact is stuck open, replace relay
• Check between compressor connections C & S
o If no continuity, the start winding is open and compressor must be replaced. If
continuity, record resistance (ohms).
• Check between compressor connections C & R
o If no continuity, the run winding is open and compressor must be replaced. If
continuity, record resistance (ohms)
• Using a capacitor tester, check the run capacitor connected between terminal 4 & 2 on the
relay. Test in accordance with capacitor tester instructions
• Using a capacitor tester, check the start capacitor connected between terminal 4 & 1 on the
relay. Test in accordance with capacitor tester instructions
• Check between overload connections 1 & 3
o If no continuity, the overload is open. Allow time to reset, if still open replace overload
• Check each of the compressor connections (C, S, R) and the shell (ground)
o If continuity between any of the connections and ground, the motor is grounded and
compressor must be replaced
• Verify continuity of all previously disconnected wires
Contact the factory with findings of testing for appropriate corrective actions.
Three-Phase Compressors
When servicing three-phase NVC and DIN dryers, the following steps should be taken:
• Using a voltmeter, check the incoming power source at L1 & L2, L1 & L3, L2 & L3
o This should not be 10% more or less than motor rating
• With the control ON and the indicator for the compressor stating it is ON, check for voltage at
the compressor contactor CTR-1 and verify that the contactor contacts are pulled in
• Check for the correct voltage between M1 & M2, M1 & M3, M2& M3
• Turn off power to the dryer and disconnect power leads from L1, L2 & L3 so that no external
wires are on the terminal connections to the compressor
• Disconnect wires between the compressor terminal 1, 2 & 3 and the contactor M1, M2 & M3
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Using a multi-meter, check resistance (ohms) across the following:
• Check and record winding resistance between the Compressor terminals 1 & 2, 1 & 3, 2 & 3
• Check and record the windings to ground
o Check between the ground lug of the compressor and terminals 1, 2 & 3
 If the winding resistance is more than 1-2 ohms between any pair of compressor
terminals, this indicates that the compressor has failed
 If the resistance is more than the compressor manufacturer’s stated winding
resistance (which will vary depending on the compressor motor temperature),
this indicates that the compressor has failed
 If the test between the ground lug of the compressor and any or all of the
compressor terminals is not an open circuit, this also indicates that the
compressor has failed
• Take a sample of the Compressor Oil and test it for acidity.
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General Maintenance Procedures and Tools
When working at a customer’s site, technicians may be called upon to perform several common
maintenance procedures to ensure equipment is working correctly. The most common of these
procedures is that of brazing, or joining two or more metal items together by melting and flowing a filler
metal into a joint.
Brazing
Brazing is required when technicians replace parts in the refrigeration line, such as the liquid line filter,
thermal expansion valve, compressor, etc. Brazing connects the copper parts together to make up the
parts inside the refrigeration system.
Brazing Safety Reminders

Technicians must wear all appropriate and required personal protective equipment (PPE) following local
and regional laws and requirements. Technicians should also remember the following safety tips:
• Bleed or purge the line after brazing has been completed
• Brazed parts stay hot long after they appear cool. Always assume all parts are hot
• Holding the torch in a balanced manner helps prevent tendonitis
• Never hold or carry the braze torch when performing a non-brazing task
• Be aware of all people and equipment in the area where the torch is lit
• When in a braze area, be cautious when approaching the braze process occurring
Preparation
When preparing for brazing, technicians should remember the following:
• Tool inspection must be completed prior to starting the brazing process
o Check for leaks from the torch to gas valve
o Check the condition of the hose
o Visually inspect the mixer
• Inspect the brazing site prior to brazing
o Inspect for oil, grease and damage
o Keep flames away from all combustibles
o Confirm there is a fire extinguisher on site and accessible
o Be sure all personal present at the site have removed lighters and other flammable
substances from pockets
o Ensure there is adequate ventilation
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Nine-Step Brazing Process: Overview
Brazing follows nine steps, which are listed below.
1. Check for fit and joint clearances
2. Clean the base metal
3. Flux
4. Assemble, shield and support parts
5. Purge
6. Chose the correct braze filler material
7. Light the torch and check the flame
8. Braze
9. Clean
Step 1. Check for Fit and Joint Clearances

Once the tools and site have been inspected and deemed safe, technicians should check for good fit and
proper clearances. As molten metal is distributed via capillary action- which occurs when a liquid is
drawn into the clearance between mating tubes- consistent, uniform and proper radial clearances are
key. Clearances around 0.001” to 0.006”/0.0254mm to 0.1524mm are ideal.
Capillary action is the force created by two surfaces thatpulls and distributes the molten filler metal
between the metals being joined. Heat aids in drawing of the alloy into the space. The alloy rests at the
bottom of the inside tube, between the inside and outside tube all the way around the joint. Technicians
should ensure the bell or fitting is full of alloy but not overflowing.
It is important to note several things when checking for fit and clearance:
• Alloy is attracted to the hottest area
• Capillary action works in radial gaps less than 0.006”/0.1524mm
o If clearance is greater, the allow will flow through the joint without creating a
satisfactory braze joint
• Radial gaps of less than 0.001”/0.0254mm may restrict flow, possibly causing voids that lead to
leak paths
o These joints will fail in service
• Proper clearance = strong joint
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Step 2. Clean the Base Metal
Capillary action works best when the surface of the metals to be brazed are clean. Technicians must
remove dirt, oil, grease, oxidation and tape adhesive with an approved cleaner and a clean rag. Once
this is complete, scoth-brite pads should be used to remove scale, rust and oxides, It is important to
note that contaminants should not be allowed to enter the refrigerant circuitry.
Step 3. Proper Paste Fluxing

In the case where dissimilar joint surfaces are being brazed, technicians should apply flux to joint
surfaces to protect the assembly from oxidation. Technicians should follow the best practices below
when fluxing:
• Apply flux smoothly on the inserted part using an application brush
• Flux should be applied just before brazing so it has less chance of being contaminated
• Never dip parts into the flux
• Leave approximately 1/8” / 3.175mm of bare tubing at the tube end
• Apply flux around the tube, not lengthwise
Flux changes appearance depending on temperature. When flux is at 1100°F/593.3°C, it is ready to

braze.
Step 4. Assembling, Shielding

and Supporting the Parts
Technicians must ensure they have the proper solder for the brazing process before beginning any
brazing process. Technicians should utilize good quality silver solder only. Soft solder- as used in
plumbing work- is not suitable. Generally, 6% Silver Soft Solder should be used on components that will
not get hot (such as the liquid line filter and thermal expansion valve). Otherwise, the following should
be used:
Material Filler Material Flux

Copper to copper Harris 15% Not required
Copper to steel Harris 15% Required
Brass to copper 6% silver solder Required
To prepare for brazing, technicians must ensure that all surfaces are free of oil, grease, rust, scale and
dirt. To properly do so, technicians should:
• Use a degreasing solvent
• Use wire wool or emery cloth to remove any oxidation from the surface
o Be careful not to remove wall thickness when using an abrasive cleaner
o If rust is on a steel component it may be necessary to use a pickling solution to remove
it
Once a part is thoroughly cleaned, technicians should flux and braze as soon as possible to prevent
further oxidation and recontamination.
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Fluxing
Heating a metal surface accelerates the formation of oxides that form by a reaction of the metal and
oxygen in the air. These oxides can inhibit the brazing filler metal from wetting and bonding to the
material. This is where the chemical flux comes into play. Flux is a chemical that is applied to joint
surfaces before brazing and it can be applied any way that is convenient. Applying the flux immediately-
usually by brushing it on to the needed areas- prior to brazing prevents it from drying out and flaking off.
It is important to use enough flux for the entire heating cycle; the larger the piece of material to be
brazed, the more flux needs to be used.
It is important to note that flux is not recommended for copper to copper brazing.
Assembly
When the materials to be brazed have been cleaned and fluxed, they should be placed in the best
position possible for brazing. While gravity is often the best way to hold the work piece in position, the
components in a refrigerant dryer that need to be brazed are typically wedged into the dryer so the
positioning is taken care of. When multiple joints need to be brazed, determine the best order of
brazing.
Brazing
Brazing itself follows the steps below:
• Heat both parts of the joint to
brazing temperature, with the bulk
of the heat focused on the work
piece that has the most mass
• Hold the brazing filler metal
against the joint area
o The heated assembly will
melt off a portion of the
filler metal and capillary
action will immediately
draw the filler material
into the entire joint area
o Note that the molten
brazing filler metal flows toward the higher temperature. In the heated assembly, the
outer base metal surfaces may be slightly hotter that the interior joint surfaces
 Technicians should be sure to deposit the filler metal immediately adjacent to
the joint
It is important for technicians to remember that the torch should be kept moving to heat as much of the
area around the joint as possible. It is also important to note that it is best practice to heat the opposite
side of the material from where the filler metal is added, as the filler metal always flows toward the
source of heat.
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Unit 7: Dryers at a Glance
Subfreezing Dryer
The Subfreezing Dryer (SFD) is a regenerative refrigerant dryer has been designed specifically for ISO
Class 3 applications that require high quality (-20°C / -4°F) pressure dew point (PDP).
It operates similarly to a desiccant dryer with twin drying chambers that continuously cycle between
drying and regenerating to remove moisture while maintaining constant subfreezing PDP.
During the subfreezing drying process, moisture (condensate) forms as a thin layer of frost on the inner
walls of the heat exchanger.
To regenerate, the dryer switches the airflow path, allowing warm incoming air to pass through the heat
exchanger, melting the frost and discharging the water through a no-loss drain.
The key advantage of this process is the significant reduction in energy required to remove the moisture
from the compressed air.
General Information
DS-DH Dryers General Information
Maximum Ambient Temperature Range 122°F/50°C
Minimum Ambient Temperature Range 41°F/5°C
Refrigerant Type R452a
Refrigerant Oil POE 32/ISO50
Maximum Inlet Air Pressure 200psi/14bar
Control Voltage 24VDC
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Main Components
The main air components included in the SFD include:

• Six airflow control valves
• Three pre-cooler/reheaters
• Two evaporators
• Three moisture separators and drains
Controller
The SFD utilizes the Xe-90D controller, which is an adaptation of the Xe-90 controller used on rotary
compressors. The standard user interface configuration of the controller consists of the membrane and
the LCD display with similar key commands.
Controller commands
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SFD Refrigeration Circuit
In the initial state, refrigeration is sucked from the evaporator and pressurized by the compressor. The
heat gained in the compression cycle is removed in the condenser and the filter then removes
contaminants in the refrigeration circuit. Solenoid valve 1 is open, and Solenoid valve 2 is closed,
preventing any refrigeration flow through evaporator B.
Refrigeration flow through a capillary tube dropping the pressure and temperature inside evaporator A
to around 20°C - 4°F.
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SFD: Other Key Facts
Key facts on SFD units include:

• Equipped with R-452A refrigerant
• Comes with a reciprocating compressor
• Has a finned coil condenser
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DS and DSH-DH Dryers
DS and DSH-DH Dryers are produced by Domnick Hunter. The following is an overview of the key
features of this dryer line.
General Information
DS-DH Dryers General Information
Refrigerant Oil POE 32/ISO 150
Control Voltage 115 VAC
DS-DH Dryers Component Setpoints
Automatic Expansion Valve 30-32psi/2-2.2bar
High Pressure Switch Setting 406psi/28bar
Fan Temperature Switch Setting On/Off 113/104°F, 45/40°C
DSH-DH Dryers General Information

DSH-DH Dryers Component Setpoints
Automatic Expansion Valve 30-32psi/2-2.2bar
Fan Temperature Switch Setting On/Off 113/104°F, 45/40°C
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Dryer Components
DS-DH Refrigeration Components
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Component Key Notes
DS and DSH dryers use an Automatic Expansion (Constant Pressure)
valve
Models DS 50 and all DSH are protected by a manual reset high

pressure switch to protect against damage from over pressure
• The switch trips at 406psi/28bar and cannot be reset until the
pressure falls below 319psi/14bar
The fan temperature cycling switch is for lower ambient conditions to

keep the discharge pressure within a required operating range for
proper pressure differential across the expansion device. The fan
temperature cycling switch setting On/Off (DS25-100):
• On: 113°F/45°C
• Off: 104°F/40°C
Troubleshooting
Scenario 1: High Head Pressure Switch Triggered
Technicians should check the following in the case of a high head pressure switch being triggered:
• If the unit is air-cooled, check the ambient temperature
• Check to see if the condenser is dirty
• Determine if the compressed air temperature going into the inlet is too high
• Determine if the air flow rate is too high
• Check to see if the fan is functioning properly
• Determine if the start up procedure was followed properly
• Check the refrigerant charge
• Verify the pressure switch is working properly
Scenario 2: High Dew Point

High dew point is indicated by the indicator in the red at above 59°F/15°C. If this occurs, several causes
should be examined:
• Excessive thermal load
• Air inlet temperature too high
• Wrong rotation of scroll compressor
• Drain valve not working
• Air flow rate too high
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Scenario 3: Low Dew Point
Several causes may result in a low dew point:
• Automatic expansion valve out of adjustment (or defective)
• Defective fan temperature switch
• Low charge
Other Troubleshooting Notes

It is also important to note that on DS-DH dryers, a stuck (closed) fan temperature fan switch may cause
a freeze up in low ambient conditions.
TS-DH Dryers
TS-DH dryers are non-cycling dryers produced by Domnick Hunter.
General Information
TS-DH Dryers General Information
Refrigerant Type R407c
TS-DH Dryers Component Setpoints
Hot Gas Bypass 68/70psi/4.7-4.8bar
High Refrigerant Temp Switch Setting 248°F/120°C
Fan Pressure Switch Setting On/Off 240/180psi, 16.5/12.4bar
High Dew Point Temperature 59°F/15°C
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TS-DH Refrigerant: R407c
R407c, designed as an R22 replacement, is a blend of three different refrigerants:
• R134a-52%
• R32-23%
• R125-25%
As this is a blended refrigerant, technicians must use dew point values to calculate superheat and
bubble point values to calculate subcooling. The temperature glide of R407c is 9°F/5°C.
In addition, technicians should not that a leak causes fractionalization with blended refrigerants,
meaning refrigerant leaks at different rates and causes the blend to become imbalanced. If a leak is
detected, technicians should replace the entire charge once the leak has been repaired and the
filter/drier has been replaced.
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Dryer Components
Component Key Notes

Cross Flow Heat Exchanger- The demister is a stainless steel wire
mesh that follows behind the evaporator to aid in water removal.
A temperature probe is placed at the lowest point of the
exchanger near the drain port.
It is important to note that because of the mesh separator, a

prefilter should be used.
TS10-TS100- Piston Type Compressor-Piston compressor designs

place the rotating assembly of the compressor in the lowest area
of the shell in order to employ the splash-type lubrication.
TS150-TS200-Rotary Type Compressor
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TS250-TS300-Scroll Type Compressor-It is important to note that
scroll compressors are rotation dependent. If the compressor is
rotating incorrectly, it is not able to product suction pressure and
will be extremely noisy. If rotation is incorrect, technicians should
lock out the power supply and switch two of the wires at the
bottom of the compressor starter.
Capillary Tube Metering Device-The capillary is used on all TS-DH

units and has no moving parts. This component regulates the
liquid refrigerant flow to the evaporator.
Hot Gas Bypass Valve-TS-DH dryers use a modulating hot gas by-
pass valve which is pressure operated, providing a quicker
response than temperature controlled valves. It does this by
sensing low pressure refrigerant leaving the evaporator and re-
directing hot compressor outlet gas back to the compressor
suction side as required, ensuring dew point control under all
operating conditions.
The valve should be set at 68-70psi/4.7-4.8bar

Refrigerant High Pressure Switch- Models TS10-TS3000 are
protected by a manual reset high pressure switch to protect
against damage from over pressure. The switch is set to trip at
406psi/28bar and cannot be reset until the pressure falls below
203psi/14bar.
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High Discharge Temperature Switch-Used to protect the
refrigerant compressor from overheating, it is set at 248°F/120°C.
Due to the system design with the hot gas bypass valve feeding
directly into the suction line, there must be enough liquid feeding
the evaporator to keep the suction temperature down. The
discharge temperature is directly related to the suction
temperature. The ST switch typically trips due to a low refrigerant
charge. If the charge is low, it causes a high superheat condition
due to a lower amount of liquid refrigerant available (low sub
cooling).
Fan Cycling Switch-Models TS50-3000 have fixed fan pressure
cycling switches set at 240psi/16.5bar on/closed and
180psi/12.4bar off/open. The fan cycling switch is used in lower
ambient conditions to keep the discharge pressure within the
required operating range for proper pressure differential across
the expansion device.
Troubleshooting
Scenario 1: High Head Pressure or External Overload
When there is high head pressure or an external overload on a TS1000 or above, technicians should
check the following:
• On TS1000 and above, check the External thermos-amp protection
Scenario 2: High Discharge Temperature (ST)

If the dryer shows a discharge temperature greater than 248°F/120°C, resulting in a high discharge
temperature issue, several possible causes should be explored:
• The switch may have lost its charge
• The charge on the refrigerant may be low
• The compressor valve(s) may be damaged
• The refrigerant filter may be clogged
• The capillary may be blocked
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It is also important to note that operating with no load on the dryer for extended periods of time may
cause intermittent ST alarms due to the hot gas bypass valve trying to maintain the correct evaporator
pressure.

High dew point is indicated by the indicator in the red at above 59°F/15°C. If this occurs, several causes
should be examined:
• Wrong rotation of scroll compressor

Several causes may result in a low dew point:
• Hot gas bypass valve is below 68psi/4.7bar
• Probe may be reading the wrong temperature
o Technicians should be sure to check temperature using the thermal couple
• The hot gas bypass valve may not be functioning properly
Scenario 5: The Unit will not Start

If a dryer will not start and has a reading of 8.8 or OF on the controller , several causes may be possible:
• The room temperature is below the minimum ambient temperature of 41°F/5°C
• The exchanger was exposed to a temperature below 27°F/-2.8°C
• The probe is reading the wrong temperature
o If this is a possibility, technicians should hold the probe in a hand or somewhere else
warm in order to raise the temperature of the probe before retrying the reading
Key Notes
• A pre-filter should be used on all cross flow evaporator units
• Cross flow heat exchangers are present in TS50 and larger dryers
• All TS dryers use a capillary tube as a metering device
• TS10 uses R134a refrigerant
o All TS15 and above dryers use R407C
• If replacing the controller, it must be wired differently
o Technicians should note the type of board when replacing the unit and follow the
appropriate instructions
• For TS15-3000 dryers, the hot gas bypass should be set at 68-70psi/4.7-4.8bar
o Adjustments should be made for site conditions
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TS1-13 Dryers
TS dryers were produced by Ingersoll Rand. In this section, general information and key facts about the
Ingersoll Rand dryers is provided.
General Information
TS1-13 Dryers General Information
Minimum Ambient Temperature Range 35°F/1.7°C
Maximum Inlet Air Pressure 150psi/10.3bar
Hot Gas Bypass 74-80psi/5.1-5.5bar
Thermal Expansion Valve Superheat 6-9°F/3.4-5°C
High Refrigerant Temp Switch Setting 240-210°F/115.5-98.9°C
High Pressure Switch Setting 425-340psi/29.3-23.4bar
Low Pressure Switch Setting (Manual Reset) 40psi/2.8bar
Fan Pressure Switch Setting On/Off 280/240psi, 19.3/16.5bar
High Superheat Fan Switch Setting On/Off 210/180°F, 98.9/82.2°C
High Dew Point Temperature 50°F/10°C
Dryer Components
AST580-2019 126 | P a g e
Component Key Notes
Cross Flow Heat Exchanger- The demister is a stainless steel wire
mesh that follows behind the evaporator to aid in water removal.
A temperature probe is placed at the lowest point of the
exchanger near the drain port.
It is important to note that because of the mesh separator, a

prefilter should be used.
Reciprocating Compressor-All TS1-13 dryers use Manurop MTZ

reciprocating refrigerant compressors
Temperature Control Hot Gas Bypass Valve-This adjustable,

pressure-sensing valve offers freeze-free operation and quick
response times. The valve should be set at 74-80psi/5.1-5.5bar
Freon Sight Glass and Moisture Indicator- The sight glass is green
to indicate dry and yellow to indicate wet. It is important to note
that the sight glass may never be completely clear; technicians
may see bubbles due to load fluctuations. It is also important to
note that if a leaking evaporator coil is suspected, the sight glass
should be checked- the color will be green if the evaporator coil is
leaking
Thermal Expansion Valve-There is a thermal expansion valve for
each of the exchangers. This maintains the required amount of
superheat (6-9°F/3.4-5°C) that is added to the low pressure gas
before leaving the evaporator, ensuring no liquid refrigerant
enters the refrigeration compressor.
Several key notes about the sensing bulb for the TXV: it must be
mounted at a 3:00 or 9:00 position on the suction line at the
evaporator outlet and the bulb must have a clean and corrosion-
free tight fit to the suction line. It should also be well insulated to
prevent overfeeding of liquid refrigerant.
Automatic Reset Refrigerant High Pressure Switch- 425psi open,
340psi close/29.3bar open, 23.5bar close
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Low Refrigerant Pressure Switch Manual Reset- Added to later
model units (serial numbers starting with DN), this switch is wired
in series with the High Pressure Switch and opens at 40psi/2.8bar.
If working on an older model (serial numbers beginning with DB)

without the switch, technicians should add this switch to the
system by wiring it in parallel with the high pressure switch.
Fan Pressure Cycling Switch- Newer TS dryers were supplied with

a non-adjustable fan pressure cycling switch (top picture) while
older versions were supplied with an adjustable Danfoss switch
(bottom picture).
The switch is set at 240psi/16.5bar closed (off) and 280psi/19.3bar

on (open).
It is important to note that if an older-style condenser coil needs

to be replaced, the fan switch flair connection must also be
relocated, as the access fitting moves to the top.
Compressor Discharge Piping with Temperature Switches 1RTS &
2RTS- 1RTS is the compressor High Temperature Switch and is
located closest to the refrigerant compressor. This switch is
normally closed (NC) and opens on a temperature rise. 2RTS is the
High Superheat Fan Switch wired in parallel with the Fan Cycling
Switch. This switch is normally open (NO) and closes on a
temperature rise.
1RTS Set Points: 240/210°F, 115.5/98.9°C

2RTS Set Points: 210/180°F, 98.9/82.2°C
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Condenser Replacement
Original Style Crimped Fitting Original Style Condenser Coil Current Condenser Coil with
Roto Lok Fittings
First generation TS 1-13 dryers used a crimp style lock between the aluminum condenser and the copper
piping. To replace the older style condenser with a current production condenser coil, a Roto Lok
conversion kit must be used with the new condenser. The kit allows technicians to adapt the current
condenser supplied with the existing copper lines. Technicians must also position the replacement
condenser with the existing fitting for the Fan Pressure Cycling Switch pointing up towards the top of
the dryer. This requires modification of the fan shroud as the fitting is up against the panel. Technicians
should use a swivel tee from the other high pressure port to mount the sensing tube for the Fan
Pressure Cycling Switch.
Troubleshooting
Scenario 1: High Head Pressure
When there is high head pressure, technicians should check the following:
Scenario 2: High Discharge Temperature

In the case where the discharge temperature is more than 240°F/115.6°C, technicians should:
• Check the switch contacts to determine if they are functioning properly
• Check the refrigerant charge, it may be low
• Check for damage to the compressor valve(s)
• Check to see if the refrigerant filter is clean
• Determine if the thermal expansion valve is functioning properly
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Scenario 3: High Dewpoint
When there is a dewpoint higher than 50°F/10°C or the ambient temperature is more than 30° above
the evaporator temperature, several causes may have occurred:
Scenario 4: Low Dewpoint

When there is a low dewpoint, several things may have occurred.
• The hot gas bypass may be below 74psi/5.1bar
• The probe may be incorrectly reading the temperature
o This should be checked utilizing the thermal couple
• The hot gas bypass may be defective
• The fan switch may not be operating properly
Key Notes
Available Functions & Options
The TS 1-13 dryers came with several available options, including:
• Remote Sleep/Off- this shuts the unit off by remote input and maintains a stable evaporator
temperature during remote off times
o Input at J1-3 and 1TB-5 on the controller/electrical panel must have a closed signal and
the unit will maintain between 35-48° F/1.7 -8.9° C after operating for four minutes. It
will continue to cycle between 35-48° F/1.7-8.9° C until the contact between 1TB5 and
J1-3 is opened again
• Remote Drain Alarm Input-An alarm occurs in the event that the drain- when equipped with the
optional no-loss drain with an alarm- has a failure
• PORO-Power Outage Restart Option- A jumper between 1TB5 and J1-8 must exist and must be
enabled in both the factory and user/operator set points
• “Smart” Drain Function- allows the controller to calculate the valve open and closed time based
on changes in ambient and evaporator temperatures, as well as performance parameters for IR
compressors
AST580-2019 130 | P a g e
Nirvana Cycling Dryers-D-NC
Nirvana cycling dryers are produced by West Chester and remove moisture from compressed air by
cooling the air temperature to between 34-38°F/1-3°C.
General Information
Dryers General Information
Maximum Inlet Temperature Range 125°F/51.7°C
Refrigerant Type D17-85NC: R22/R404A
D127-255NC: R404A
Refrigerant Oil R404A: POE 32/ISO150
R22: Mineral 32/ISO150
230 VAC Optional-D127-255NC
Glycol Temp Switch Setting 35-38°F/1.7-3.8°C
High Glycol Temp Switch Setting 50°F/10°C
Dryer Model SCFM/m 3/h Rating Dryer Model SCFM/m 3/h Rating
D17NC 10 SCFM/17 m 3/h D127NC 75 SCFM/127 m 3/h
D85NC 50 SCFM/85 m 3/h
AST580-2019 131 | P a g e
Dryer Model
D17NC
D170NC
D212NC
D59NC
AST580-2019 132 | P a g e
Dryer Components
Diagrams
AST580-2019 133 | P a g e
D17NC-D85NC Dryers
• Thermostatic control switch

• Suction pressure gauge
• No on/off switch
• 110 volt power cord
o Optional 230 volt
• Glycol-filled chiller/evaporator
AST580-2019 134 | P a g e
D127-255NC
AST580-2019 135 | P a g e
AST580-2019 136 | P a g e
• Two thermostatic control switches for automatic operation
o One is for dryer operation and turns on the compressor at 38°F/3.3°C and off at
35°F/1.6°C
o One is for the high temperature alarm and is set at 50°F/10°C
 This can be adjusted to meet customer requirements
• High temperature switch and panel-mounted light
• Refrigerant suction pressure gauge
• On/off switch
• 110 volt power cord
o Optional 230 volt
• Glycol-filled evaporator/reservoir
• 110 volt glycol pump to circulate glycol to the chiller
• Electronic Timer Drain for condensate removal
Key Notes
D17NC-D85NC Dryers
• The refrigeration system equalizes typically between 65-100psi/4.8-6.8bar, depending on
ambient conditions
• Operation notes:
o When the refrigeration system is running, the suction pressure should be 30-50psi/2-
3.4bar
o After the thermal mass fluid has been cooled, the refrigeration system shuts off
• Installation location depends on the flow rate of the compressor
o Relatively steady flow rate- connect after the air received
o Widely fluctuating loads- connect ahead of the receiver with sufficient storage capacity
downstream of the dryer
 This prevents excessive air flow through the dryer
• There should be at least 18 inches (0.2 meters) around the unit to allow for free air flow to the
condenser
• A pre-filter is recommend to avoid contamination
• Models D17NC through D41NC are supplied with a three wire, 115v cord assembly as standard
and the only connection required is to plug this into a suitable 115/1/60Hz power. They do not
have an ON/OFF switch
o The D59NC through the D85NC has a power cord and an ON/OFF switch
AST580-2019 137 | P a g e
D127NC-D255NC
• The refrigeration system equalizes typically between 80-150psi/5.5-10.3bar, depending on
ambient conditions
• Operation notes:
o The suction pressure gauge typically pulls between 60-80psi/4.1-5.5bar when the dryer
is first started
 As the system operates and the thermal mass temperature drops, the suction
pressure lowers to between 55-65psi/3.7-4.4bar
o The air exiting the reheater portion of the dryer should be 15-20°F/-9.4 to -6.6°C lower
than the inlet temperature, based on standard conditions
• A High Temp alarm light is provided to indicate an elevated thermal mass temperature
o The light is controlled by a thermostat that monitors the thermal mass fluid and closes
to energize the light at 50°F/10°C
o This light is on when the dryer is first started, and remains on until the temperature
drops below the 50°F/10°C line
• A service valve is installed at the high point of the glycol line to enable venting air from the
glycol system
o This is required on units that have a glycol pump mounted above the glycol reservoir
AST580-2019 138 | P a g e
Nirvana Cycling Dryers-NVC200-800
General Information
NVC200-800 Dryers General Information
Maximum Ambient Temperature Range 110°F/43.3°C
Refrigerant Type R404A
NVC200-800 Dryers Component Setpoints
Glycol Temp Control Setting 36-38°F/2.2-3.3°C
High Glycol Temp Switch Setting 10°F/5°C above set point
Low Glycol Temp Setting 29°F/-1.7°C
High Pressure Switch Setting Cut Out/Cut In (WC 320/270psi, 22/18.6bar
Only)
Low Pressure Switch Setting Cut Out/Cut In 20/60psi, 1.3/4.1bar
Dryer Components
NVC200-400
AST580-2019 139 | P a g e
NVC500-800
AST580-2019 140 | P a g e
The components included in the NVC 200-800 dryers include:
• Controller and control box
o Compustat controller
• Thermal mass reservoir
• Air-cooled condenser
• Pre-cooler/re-heater
• Thermal mass chiller
• Evaporator
Component Key Notes

Low Pressure Switch- A low pressure switch cut
out switch is provided on all 300-800 NVC dryers.
It is factory set to open at 20psi/1.4bar, meaning if
refrigerant suction pressure falls below this set
point, the switch opens and shuts off the
refrigerant compressor. Once open, the switch
prevents the compressor from running until
suction pressure rises above 60psi/4.1bar.
It is important to note that the switch has a

manual reset that must be reset before the
compressor can be re-started.
High Pressure Cut Out Switch-All water-cooled
units come with a high pressure cut out switch,
which is set to open at 320psi/22bar and close at
270psi/18.6bar.
It is important to note that if low water

temperature and/or high water pressure are
expected at the customer’s site, a water pressure
regulator should be installed ahead of the
condenser.
Air Cooled Condenser- The air cooled condenser is
installed diagonally, allowing for easy access for
cleaning and repair. This also allows for easy
access for cleaning and repair. Access to the
electronic no-loss drain is also made easy.
Precooler/Reheater- Air enters the precooler and

then passes through the chiller, where it is cooled
by the thermal mass fluid being pumped through
the chiller. Then the air passes through the
moisture separator, removing condensation
before discharging into the system.
AST580-2019 141 | P a g e
Key Notes
• The thermal mass fluid temperature is maintained by the microprocessor control, which
monitors the temperature and cycles the refrigeration system in response to varying air flow
and temperature
• For water-cooled models, the water valve must be manually opened to ensure that the
condenser is full of water prior to start up
• Technicians must not rinse or wash internal or external components with solvents
• Fan motors require lubrication at both oil ports every six months
• The condensate drain should be checked at regular intervals for proper operation
• On standard dryers, regular inspection and cleaning of the condenser is recommended
• On dryers with the optional ambient air filter, the filter should be cleaned as needed and
replaced once a year
• Filter elements should be changed when a differential is indicated on the differential indicator
or once a year, whichever occurs first
Nirvana Cycling Dryers-NVC1000-1600

General Information
NVC1000-1600 Dryers General Information
Refrigerant Type R22/R404A
Refrigerant Oil R22: Mineral 32/ISO150
R404A: POE 32/ISO150
NVC1000-1600 Dryers Component Setpoints
Thermal Expansion Valve (Superheat) 5-15°F/2.8-8.4°C
Factory Set Point 36-40°F/2-4°C
High Dew Point Set Point 55°F/12.7°C
Low Dew Point Set Point 30°F/-1.1°C
High Pressure Switch Setting Cut Out 400psi/27.6bar
Low Pressure Switch Setting Cut Out 20psi/1.4bar
Fan #1 Cut In/Cut Out 235/195psi, 16.2/13.5bar
AST580-2019 142 | P a g e
Dryer Components
The components included in the NVC 1000-1600 dryers include:

• CFX Evaporator/Chiller/Air-to-Air exchanger
• Expansion valve metering device
• Electronic drains
• Liquid line isolation solenoid valve
• DPC controller
o There are no mechanical pressure switches. All parameters are through the DPC
controller
AST580-2019 143 | P a g e
Component Key Notes
Low Pressure Sensor-The low pressure cutout setting shuts down
the refrigeration system if the suction pressure drops to
20psi/1.3bar
Discharge Pressure Sensor-The high pressure cutout setting shuts

down the refrigeration system if the discharge pressure hits
400psi/27.5bar
Thermal Expansion Valve-meters the flow of liquid refrigerant to
the evaporator. A sensing bulb is connected to the valve; it
monitors the evaporator outlet temperature to increase or
decrease the amount of liquid refrigerant to maintain the
superheat setting and preventing liquid slugging back to the
compressor.
Refrigerant Stop Valve-stops the flow of liquid refrigerant to the

thermal expansion valve upon compressor shutdown. As each
module shuts down due to set point and low demand, the stop
valve closes to prevent liquid refrigerant slugging when the
compressor restarts.
It is important to note that the NVC dryers do not pump down.

Liquid Line Refrigerant Filter Drier-filters the liquid refrigerant and
removes contaminants and moisture from the refrigerant,
preventing contamination of the compressor oil.
It is important to note that any temperature drop across the filter

drier that causes a pressure drop means the filter drier should be
replaced.
AST580-2019 144 | P a g e
Troubleshooting
When there is high head pressure, technicians should check the following:
• Verify the pressure sensor is working properly
Scenario 2: Low Pressure

Technicians should determine if any of these common causes has occurred:
• Refrigerant charge is low
• The pressure sensor is not working properly
• The refrigerant stop solenoid coil has been burned
• The refrigerant stop solenoid is stuck
• The thermal expansion valve is blocked

If a dryer is showing a dew point higher than 55°F/13°C, several things may have caused the issue:
• Ambient temperature is too high
• Air inlet temperature is too high
• The airflow rate is too high
• Refrigerant charge is too low
• The thermal expansion valve is defective
Key Notes
• The SCFM/m 3/h of the dryer determines how many precooler/reheaters and chillers are
present in the dryer
• NVC dryers with the DPC controller have a factory set eight hour crankcase heater delay. This is
active at start up and any time the power is removed from the dryer for more than two hours
AST580-2019 145 | P a g e
NVC Multiplex Dryers
Ingersoll Rand multiple module dryers remove moisture from compressed air by cooling the air to an
adjustable low temperature (between 32-50°F/0-10°C). The multiple module design consists of two or
more air/refrigerant dryer modules, all of which are connected by a common air inlet and outlet
headers.
General Information
NVC Multiplex Dryers General Information
Maximum Inlet Temperature 122°F/50°C
Refrigerant Type R22/R404A
Refrigerant Oil R22: Mineral 32/ISO150
R404A: POE 32/ISO150
NVC Multiplex Dryers Component Setpoints
Chiller Temperature Factory Set Point 36-40°F/2-4°C
High Dew Point Set Point 55°F/12.7°C
Low Dew Point Set Point 30°F/-1.1°C
High Pressure Switch Setting Cut Out 400psi/27.6bar
Low Pressure Switch Setting Cut Out 20psi/1.4bar
AST580-2019 146 | P a g e
Dryer Components
Component Key Notes
Intake and Discharge Manifolds-Mounted on the top of
the dryer, these are also used for safe lifting of the dryer
during installation. This is the only place the dryers
should be lifted from.
Maneurop Compressor-used on each module, these

used to take R22 on older models. Newer and current
models use R404A refrigerant.
Refrigerant Stop Valve- Each module has a refrigerant

stop valve, which stops the flow of liquid refrigerant to
the thermal expansion valve upon compressor shut
down.
Thermal Expansion Valve- meters the flow of liquid

refrigerant to the evaporator. There is a sensing bulb
connected to the valve that monitors the evaporator
outlet temperature to increase or decrease the amount
of liquid refrigerant entering the evaporator.
Liquid Line Refrigerant Filter Drier-filters the liquid

refrigerant and removes contaminants and moisture
from the refrigerant, preventing contamination of the
compressor oil.
It is important to note that the temperature of

refrigerant in and out should be warm. If out is cold
while in is warm, this indicates a pressure drop occurred
and the drier should be replaced.
AST580-2019 147 | P a g e
Low Pressure Cutout Switch-The low pressure cutout
switch shuts down the refrigeration system if the suction
pressure drops to 20psi/1.3bar or below
Glycol System Air Vent- vents air from the glycol system
to prevent cavitation of the glycol pumps and to insure
the system is full at all times. Having a full glycol system
insures proper cooling of the compressed and removal
of the maximum amount of moisture.
Dewpoint Sensing Well
Water Cooled Condenser-For all water cooled units,

each module has a water cooled condenser.
Condenser Water Regulating Valve-Set to maintain

250psi/17.2bar compressor refrigerant discharge
pressure on water cooled units. It is important to note
that, in order to compensate for water temperature
variation, it may be necessary to adjust the valve.
Air Cooled Condensers-for air cooled applications,

condensing fans are cycled on and off by pressure. The
primary fan is cycled on at 235psu/16.2bar and off at
195psi/13.4bar. If the discharge pressure continues to
rise above 265psi/18.2bar, the secondary condensing
fan cycles on. When discharge pressure is reduced
below 210psi/14.4bar, the secondary fan cycles off.
AST580-2019 148 | P a g e
Other components include:
• Precooler/reheater and chiller
• Centrifugal moisture separator
• Y-strainer & isolation valve
• No-loss float drain
• Evaporator
• Thermal mass tank
Key Notes
Several key notes technicians should remember when working on multiplex machines include:
• There is a main disconnect panel on module one and a control panel for each module
Lifting and Installation

• The headers are constructed with lifting lugs to enable the dryer to be offloaded and
moved
o The dryer should only be moved using these lugs or damage to the assembly may
occur
o Technicians must verify the lifting capacity of the lifting equipment to avoid
tipping or dropping the unit
• These dryers are equipped with one blind flange on each of the inlet and outlet headers
• Either side of the header can be used to connect the process air piping
• Bypasses are recommended for service and maintenance on the dryer and filtration
systems
• The optional sentinel system, inlet and outlet circulating valves are installed and shipped from
the factory in the open position
• If the circulating pump needs to be removed, technicians should rotate the valves to the closed
position to avoid loss of fluid
• Drain valves should be piped to an appropriate reservoir or container
o Drain lines must be piped individually
• An optional oil/water separator may be installed in the system
AST580-2019 149 | P a g e
Multiple Module Power Up
• When installation is complete and the unit is ready for start up, technicians should:
o Turn on the main isolation disconnect switch on the wall
o Turn on the service switch on the main power supply panel on the side of the first dryer
module
o Turn on the power to each control panel on the dryer modules
 This supplies power to the crankcase heaters on each module
o The 8-hour timer begins, ensuring all liquid refrigerant is out of the compressors before
they start running
 After the time delay to start has timed out, technicians can start the unit
o Ensure the dryer is isolated from the system (no air flow)
o In manual mode, press the on button
 This causes the glycol pump to start and run
 Repeat this on each module
o Wait for the Anti Short Cycle (ASC) timer to time out
 This must occur before the units can operate
o Press the on button on each unit
Main Power Supply Panel

• All customer connections can be made at the main electrical box located at the left side of the
first dryer module
• All three phase electrical configurations (l1, L2, L3) can be wired in any configuration and not
effect compressor performance
• Some multiplex dryers may use bot single and three phase fan motors
• Single phase motors will turn in the correct rotation
o Three phase motors must be checked for correct rotation on start up
• A suitable fused disconnect switch that meets national and local code requirements is
recommended
o This should be mounted on the wall near the dryer, and supplies power to the main
power panel on the dryer module
• Before applying power to the dryer modules, technicians should check all dryer module panel
electrical connections for tightness
• It is important to note that all Nirvana cycling dryers are equipped with module disconnects for
safety during maintenance and repair
o Each module can be isolated from the main power source using its own dedicated
switch
AST580-2019 150 | P a g e
Other Notes
• Only module one has an expansion adapter and expansion
module
o The remaining modules should have only the DPC
controller
o The expansion module has additional pressure and
temperature sensors for monitoring the operation of
the multiple module dryer
o Temperature and pressure sensors T-3 Inlet Air Temp,
P-3 Inlet Air Pressure, T-4 Outlet Air Temperature and P-
4 Outlet Air pressure are only connected to the
expansion module for the first unit
o Pressure and temperature sensors T-1 Chiller Temp, P-1
refrigeration discharge pressure, T-2 Suction Temp and
P-2 Suction Pressure are all wired into the DPC
controller
AST580-2019 151 | P a g e
TMS Cycling Dryers
TMS dryers come in five basic frame sizes, with additional controls with bigger units.
General Information
TMS 012-2000 Cycling Dryers General Information
TMS 012-2000 Cycling Dryers Component Setpoints
High Ambient Valve (if equipped) 36psi/2.5bar
Glycol Temp Switch Setting ST1 35-39°F/1.7-3.8°C
High Glycol Temp Switch Setting ST3 50°F, 10°C
Low Glycol Temp Switch Setting ST2 33-35°F/0.6-3.8°C
High Pressure Switch Setting Cut Out/Cut In 262/230psi, 18/14bar
Low Pressure Switch Setting Cut Out/Cut In 4.4/21psi, 0.3/1.5bar
AST580-2019 152 | P a g e
TMS 2700 Cycling Dryers General Information
TMS 2700 Cycling Dryers Component Setpoints
High Ambient Valve 72psi/5bar
Glycol Temp Switch Setting ST1 35-39°F/1.7-3.8°C
High Glycol Temp Switch Setting ST3 50°F, 10°C
Low Glycol Temp Switch Setting ST2 33-35°F/0.6-3.8°C
High Pressure Switch Setting Cut Out/Cut In 406/345psi, 28/23.8bar
Low Pressure Switch Setting Cut Out/Cut In 14.5/58psi, 1/4bar
Dryer Components
Component Key Notes
High Ambient Valve (if equipped)-regulates the suction
pressure the refrigerant compressor experiences.
Should be set to 36psi/2.5bar for TMS 50-2000 units and

72psi/5bar for TMS 2700 units.
Pump Down Solenoid Valve-Controlled by ST1 (TC) between
35°/39°F, 1.7°/3.8°C (closed, open). The valve is normally
closed and has a 24 VAC coil
TMS Air to Glycol and Refrigerant Evaporators
Air to Air Exchanger
TMS012-035
AST580-2019 153 | P a g e
TMS 12 – 35 Air Cooled P& I Diagram
(1)
K
L
(19) TC
(2)
A
(5)
(4)
(7)
(3) (8a)
(3b)
B
(6)
• No air-to-air exchanger
• Capillary tube metering device
• Separator is field-installed outside the unit at the discharge of the air dryer
• Float drain
• One control thermostat
• On/Off switch acts as a power on light
TMS 50-280
AST580-2019 154 | P a g e
TMS 140-280 dryers
• Air to air exchanger

• Float drain valve
• TMS100 utilizes an SSD valve
• Internal separator
• TMS 140-280 contain a thermometer
• Do not use a pump down cycle
• TMS 50-200 Capillary tube metering device
• TMS 280- Thermal Expansion valve
• TMS 140-280- Compressor on light
AST580-2019 155 | P a g e
TMS 380-2000
• Air to air exchanger

• Thermostat control
• Tank temperature gauges
• Utilizes a pump down cycle
• Expansion valve
• Inlet air temperature gauge
• Outlet air pressure gauge
• Thermal overload protection
• TMS 780-2000: High glycol warning
o The High Glycol Temperature Switch ST3 (TA) turns on a yellow LED light for high glycol
temperature
o Set for 10°C or 50°F (only scaled in °C)
o Also acts as the remote alarm contacts
AST580-2019 156 | P a g e
TMS2700
AST580-2019 157 | P a g e
Other Components
• Temperature Control Switch ST1 (TC) and ST2 (TE)
o TC (ST1) switch is to cycle the pump down solenoid
 It pumps down the system where the compressor will cycle on the pressure switch
 It lights the green compressor on LED on the indicator board
 It is the same type of switch as the TE, just set to 35-39°F/1.7-3.8°C
o TE (ST2) switch is for freeze protection
 It cuts off the refrigerant compressor without pumping down the system
 It lights the red LED on the indicator board
 Same type of switch as the TC, set to 33-35°F/0.6-3.8°C
Troubleshooting
Technicians should check several things to determine root cause of high head pressure on a TMS dryer.
These include:
• Ambient temperature being too high on an air-cooled unit
• The condenser being dirty
• Compressed air inlet temperature being too high
• Compressed air flow rate being too high
• One or more fans not operating properly
• Incorrect start up procedure performed
• Charge of the refrigerant being incorrect
• Pressure switch not working properly
• High ambient valve not adjusted correctly or not working properly
Scenario 2: Low Pressure

In the case of low pressure, technicians should review the following:
• Is the refrigerant charge too low?
• Is the pressure switch working properly?
• Has the high ambient valve been adjusted properly?
o Is it working properly?
• Has the pump down solenoid coil been burned?
• Is the pump down solenoid stuck closed?
• Is the thermal expansion valve blocked?
• Is the high ambient valve blocked?
• Has ST1 (TC) been set correctly?
o Is it working properly?
AST580-2019 158 | P a g e
If a unit is showing a high dew point (greater than 50°F/10°C), technicians should review the following
potential causes:
• Ambient temperature too high
• Inlet temperature too high
• Refrigerant charge too low
• Defective thermal expansion valve
• Defective high ambient valve
• Refrigerant compressor not working

When a unit shows a low dew point, technicians should check the following:
• Is the ST1 (TC) not set correctly?
o Is it not working properly?
• Is the ST2 not set correctly?
o Is it not working properly?
• Is the compressor contactor stuck closed?
• Is the pump down solenoid stuck open?
Key Notes
TMS 012-035
• Due to the full refrigerant starting amperage going through the contacts of the thermostat, if it
is replaced technicians must be sure to use a thermostat that has contact amp ratings to keep
from premature failures
AST580-2019 159 | P a g e
D-IN/IT Non-Cycling Dryers
General Information
D-IN Non-Cycling Dryers General Information
Maximum Inlet Air Pressure D12IN-D180IN: 203psi/14bar
D300IN-D360IN: 174psi/12bar
Control Voltage D12IN-D180IN: 115 VAC
D300IN-D360IN: 230 VAC
D-IN Non-Cycling Dryers Component Setpoints
High Dew Point Temperature (HTA) 58°F/14.5°C for six minutes
High Dew Point Temperature (HT2) 113°F/45°C immediate
Low Dew Point Temperature (ESA) 30°F/-1°C for six minutes
Low Dew Point Temperature (ES2) 0°F/-18°C immediate
Hot Gas Bypass (D300IN-D360IN) 30-32psi/1.5-2.5bar
D-IT Non-Cycling Dryers General Information

Maximum Inlet Temperature 200°F/94°C
D-IT Non-Cycling Dryers Component Setpoints
High Dew Point Temperature (HTA) 58°F/14.5°C for six minutes
High Dew Point Temperature (HT2) 113°F/45°C immediate
Low Dew Point Temperature (ESA) 30°F/-1°C for six minutes
Low Dew Point Temperature (ES2) 0°F/-18°C immediate
AST580-2019 160 | P a g e
Dryer Model CFM Dryer Model CFM
D12IN 7 CFM D25IT 15 CFM
D72IN 42CFM D170IT 100 CFM
D108IN 64 CFM
D144IN 85 CFM
D180IN 106 CFM
D300IN 176 CFM
D360IN 212 CFM
Dryer Components
D12IN-D180IN
AST580-2019 161 | P a g e
D300IN-D360IN
AST580-2019 162 | P a g e
D-IT
AST580-2019 163 | P a g e
Internal Components
AST580-2019 164 | P a g e
Other Components
Component Key Notes

Cross Flow Heat Exchanger-Like other units, a pre filter
should be used on all cross flow evaporator units in D-
IN/D-IT dryers
ECO-Fan Control- in both D-IN/IT dryers, the fan is

controlled by a temperature sensor mounted on the
refrigerant line going into the evaporator after the
capillary tube. It is important to note that it does not
have a fan pressure switch.
Temperature changes due to load conditions cause the

controller to send a 115/240 VAC signal to the condenser
fan, causing it to run. The faster the pulses, the faster the
fan runs.
The purpose of the controller modulating the fan is to

control the mass flow of liquid to the evaporator. As the
temperature sensor detects an increase in the refrigerant
line pressure, the fan starts to produce more liquid
refrigerant for the evaporator. It is important to note
that the discharge pressure operates above what is
normally found on an R134a refrigeration system.
High Pressure Cutout Control-The high pressure cutout
switch monitors the high side pressure. If it exceeds
435psi/30bar, the compressor shuts down. Several key
notes:
• That port it is mounted in has a Schrader valve for
ease of replacement
• On the D-IN Series, this is the location where the high
pressure side of the refrigeration circuit can be
checked- but the switch must be removed
• The cause of the compressor shutdown should be
identified and repair prior to manually resetting the
switch
AST580-2019 165 | P a g e
Filter/Drier
Compressor Overload Protection-The compressor has a

Klixon type overload switch to shut down the compressor
in an overload situation or if the compressor goes over
rated temperature conditions in order to avoid
compressor damage. The switch is mounted on top of the
compressor and has a plastic cap with a rubber gasket to
protect it.
Key Notes
• Technicians must check/calibrate the controller and sensor any time either is replaced
• Under no load conditions, the unit may shut off on an energy savings mode (ESA), which is
normal
AST580-2019 166 | P a g e
Temperature Probe Calibration
Any time the controller is replaced, technicians must calibrate the temperature probe. To calibrate the
probe, technicians must have: refrigerant charging gages and manifold, ball valves for the hoses, R134a
refrigerant, and a copy of the R134a PT chart. Once the correct tools and parts are available, technicians
should:
• Install charging hoses on the low and high sides, striving to keep refrigerant losses to a minimum
• Switch on the dryer without a load
• Press down and up keys simultaneously, holding for five seconds
• Confirm the LED display has flashed POn for three seconds, indicating access has been unlocked
• Press and hold the set key for 10 seconds
o The display should change to C1 and the corresponding value
• Press and hold the set key until C12 is displayed on the controller
• Using the up and down keys, set to 1 for 50hz machines and 0 for 60hz machines
• Press the set key
• Change the parameter C13 to 1 (decimal) and Dsp to OMI (temperature visualization)
• Exit the program mode
• Run the dryer for at least five minutes in order to allow the refrigerant temperature and
pressure to stabilize
• Ensure the low side pressure is 30-32psi/1.5-2.5bar
o If this pressure has not been achieved, adjust the hot gas bypass valve by turning it by a
maximum of 5° and allowing two minutes before making the next adjustment
• Verify the controller temperature reading again using the R134a PT chart
o If the reading does not match the PT chart, enter the programming mode & modify
parameter C11 so the LED display is equal to the low side temperature
• Before exiting the factory mode, reset controller parameters as follows:
o C12=1
o C13=0
o Dsp=Ute
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Hot Gas Bypass Valve Adjustment-D300IN and D360IN
When a hot gas bypass valve adjustment is needed on a D300IN or D360IN dryer, technicians should:
• Install pressure gauges on the LP and HP circuits
• Switch the unit on without any load
• Temporarily change the controller settings in order to show the value of temperatures with one
decimal
o The controller must be unlocked and factory programming must be accessed to do so
o C11=-1.5 initial reading offset for new probes or replacements
o C12=1 for °F visualization/0 for °C
o C13=1 for decimal visualization
 Example: when C13 displays 20, it means 2.0
o Dsp=0 for integer or decimal display instead of lines
• Let the dryer operate for at least five minutes without a load before taking the steps below
• Verify in the evaporator pressure gauge and evaporator temperature at display are aligned
o If not, modify offset C11 using the PT chart
• Modify setting of the hot gas bypass valve in order to obtain the following condition:
o Each time the condenser temperature at the gauge is = 129-131°F (54-55°C), verify that
evaporator pressure at the gauge is within 30-32psi (1.5-2.5bar)
 Use the PT chart
 Note: Adjust the screw of HGBV max 5° angle/time and wait each time 2
minutes before new adjustments
• After completion of the setting, verify if the reading at display is aligned with the evaporator
temperature at gauge
o If not, modify the offset C11
• Set the controller parameters back to:
o C12=1
o C13=0
o Dsp=1
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D-EC 17-212 Dryers
General Information
D-IN Non-Cycling Dryers General Information
Maximum Ambient Temperature 113°F/50°C
Minimum Ambient Temperature -36°F/2°C
Control Voltage D17EC-D170EC: 115VAC
D212EC: 115VAC (230VAC optional)
D-IN Non-Cycling Dryers Component Setpoints
High Dew Point Temperature (HTA) 58°F/14.5°C (for six minutes)
High Dew Point Temperature (HT2) 113°F/45°C (immediate)
Dryer Model CFM/m 3/h Rating Dryer Model SCFM/m 3/h Rating
D17EC 10cfm/17 m 3/h D85EC 50cfm/85 m 3/h
D59EC 35cfm/59 m 3/h D212EC 125cfm/ 212 m 3/h
AST580-2019 169 | P a g e
Dryer Components
D17EC-D255EC Refrigerant Circuit
AST580-2019 170 | P a g e
Number Component
1 Controller
2 Temperature sensors
3 Compressor
4 Cooling fan assembly
5 Condensate drain line
6 Condenser
7 Filter drier
8 Filter stop
9 Heat exchanger
10 Glycol tank
11 Glycol circulating pump
AST580-2019 171 | P a g e
Other Components
Component Key Notes

Cross Flow Heat Exchanger-Like other units, a pre filter
should be used on all cross flow evaporator units
D-EC fan control and discharge temperature probe P-2.

The fan is controlled by a temperature sensor that is
mounted on the discharge line. It is important to note
that it does not have a fan pressure switch. As a result of
temperature changes due to load conditions, the
controller sends a 115/230VAC constant signal to the
condenser fan causing it to run continuously, not in a
pulsing fashion. When the temperature of the refrigerant
gets to 150°F/66°C, the LED goes on and the fan comes
on
Compressor overload protection- the compressor has a
Klixon-type overload switch to shut the compressor down
in an overload or compressor over temperature condition
to avoid compressor damage. The switch is mounted on
top of the compressor and has a plastic cap with a rubber
gasket to protect it
AST580-2019 172 | P a g e
AST580-2019 173 | P a g e
Troubleshooting
Condenser Fan Not Operating
To troubleshoot this scenario, technicians should:
• Check the output to the fan using the auto-test function
• If the fan fails to operate, check the wiring to the fan for loose wires
• If there are no loose wires, remove the plug to the controller
o Check pin 5 for 115/230V output (depending on the control voltage)
• If no voltage is present, the controller is defective
Water in the System/High Pressure Dew Point

In this situation, technicians should check for several of the most probably causes:
• High compressed air load- if this is the cause, check the correction factor for correct sizing
• Condenser is dirty or the fan is only working intermittently- if this appears to be the case, clean
the condenser and check the fan motor and switches to ensure they are working properly
• High ambient temperature- check the ambient temperature, it should not exceed 122°F/50°C
• Condensate drain not functioning- check, clean or replace the condensate drain if necessary
o Check the output pin on the controller while activating the condensate test. If the there
is no voltage, replace the controller
• Wrong condensate drain timing adjustment-check and change C8 and C9 parameters for correct
drainage timing
AST580-2019 174 | P a g e
Appendix: Terminology
Heat Terminology
Term Definition
Temperature A measure of the intensity of heat
Sensible Heat The intensity of heat, something that can be felt and measured (measured in
degrees)
Absolute Zero The total absence of heat is -460°F (-238 °C)
Heat Quantity Heat quantity is a measure that takes not only the temperature of a substance into
account but also the quantity of heat in the substance
Radiation Heat Radiation heat transfer does not rely on contact between heat source and heated
Transfer object. Energy from the sun is a prime example of radiation heat transfer- energy
from the sun must pass through 93 million miles of space before reaching Earth’s
atmosphere. As it travels those empty miles, the energy does not warm the
emptiness of outer space; only when the energy is absorbed by an object does that
energy become heat energy
Conduction Heat Heat transfer via conduction occurs when heat energy moves from one solid to
Transfer another of a different temperature when the two solids are touching. Heat
transfer through conduction always moves from the hot object to the cool object,
such as when a hot spoon is placed in a cup of ice water. The heat from the spoon
is conducted from the spoon into the surrounding water. If the reverse occurs- a
cold spoon is placed into a cup of hot water- heat energy flows from the hot water
to the cold spoon.
Refrigeration units utilize conduction heat transfer to move heat from one place to
another.
Convection Heat Movement of heat within a moving fluid. The fluid can be a liquid or a gas. For
Transfer example, in an engine cooling system, convection contributes to coolant flow
between the engine and radiator. A pump, fan or blower is often used to increase
fluid movement. Refrigeration units often include powerful fans to force air
movement throughout the temperature-controlled compartment.
AST580-2019 175 | P a g e
General Terminology
During the standard course of business, the following basic terminology is often used and should be
understood by technicians.
Term Definition
Absolute The sum of atmospheric and gauge pressure
Pressure
Absolute The temperature of a body referred to the Absolute Zero. On the Fahrenheit scale
Temperature this is –459.67 degrees, and on the Celsius scale –273 degrees.
Absorption The process of attracting one substance into the mass of another, so that the
absorbed substance disappears physically.
Aftercooling The removal of heat from a gas after compression is complete.
Ambient The environmental temperature surrounding the equipment being considered.
Temperature
Atmospheric The Dew Point measured at atmospheric pressure.
Dew Point
Atmospheric The pressure exerted on the surface of the earth due to the weight of the
Pressure atmosphere. (This pressure is 14.7 PSI at sea level)
Back Seated Refers to refrigeration system service valves. i.e. valve turned fully in an
anticlockwise direction, thus allowing flow of refrigerant through the system.
Condensate The liquid formed from vapor due to a reduction in temperature and/or an
increase in pressure.
Condenser A heat exchanger wherein the process of condensation takes place.
Condensation The process where due to heat loss gas molecules slowdown and are pulled
together to form a liquid.
Dew Point The Temperature at which point a vapor begins to condense with reference to a
specific pressure.
Exothermal The process of giving off heat as a result of a chemical reaction.
Evacuation Refers to the process of removing contaminating air and moisture from a
refrigeration plant.
External A pipe used to connect the evaporator outlet to the underside of the bellows unit
Equalizer of a thermostatic expansion valve.
Evaporation The process where due to heating of a liquid, the molecules within that liquid
speed up enough to break the surface tension layer to become a gas.
Evaporator A heat exchanger where the process of evaporation takes place.
Expansion Valve A valve operated by pressure differential due to temperature and pressure,
designed to regulate a liquid flow into the evaporator.
Flash Gas The instantaneous evaporation of liquid refrigerant, which cools the remainder to
a lower temperature in an evaporator.
Flushing The process of removing refrigeration system components by purging with
refrigerant or similar fluid.
Free Air Air at atmospheric conditions. It is usual for the output rating of a compressor to
be given as free air delivered at specific atmospheric conditions
Freon A trade name for a family of synthetic liquids with low boiling points, used as
refrigerants in modern refrigeration systems.
AST580-2019 176 | P a g e
Front Seated Refers to refrigeration system service valve turned in a fully clockwise direction
thus closing off the refrigerant in and out of the compressor.
Fusible Plug A fitting made with low melting point metal which acts as a safety device to
release pressure in the case of a fire.
Hot Gas Bypass Pressure controlled valve installed in the refrigerant circuit to maintain a constant
Valve evaporating pressure.
Kinetic Energy The energy a substance possesses due to its motion or velocity.
Liquid Line The pipe which carried liquid refrigerant from the condenser (or liquid receiver if
fitted) to the expansion valve
Pumping Down The action of using the refrigeration compressor against a closed valve on the
suction side to reduce pressure
Purging The action of releasing vapor from the system in order to remove contaminants
from the section through which the vapor passes and discharge them to
atmosphere.
Relative The ratio of actual water content in air to the maximum water content it can hold
humidity at a specific temperature and pressure usually expressed as a percentage.
Slugging A condition in which liquid refrigerant of oil enters the compressor which
maintains a constant pressure in the evaporator when the compressor is running.
Sub Cooled Liquid cooled below its condensing temperature but remaining at the normal
condensing temperature.
Superheat Temperature of vapor above boiling temperature of its liquid at specific pressure.
Pressure Pressure is force exerted upon an object. Amount of force is expressed per unit of
area, such as pounds per square inch
Pounds Per A common pressure reading. Other commonly used terms include: Pounds Per
Square Inch Square Inch Absolute (PSIA) and Pounds Per Square Inch read on a gauge (PSIG)
AST580-2019 177 | P a g e

AST580-Refrigerant Dryers Technician Manual

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AST580-Refrigerant Dryers

Confidential and Trade Secret Information

Course Safety Reminders

Terminology and Resources

Desiccant Dryer Refrigerant Dryer

Additional information when contacting technical support must include:

Data Tag Information Meaning

Hot Gas Bypass Valve

High Efficiency Air Filter

Direct Current Power Supply

Latent Heat of Vaporization

Latent Heat of Condensation

Latent Heat of Melting

Converting One Pound Ice to Steam

Constant Volume Volume Changes

Scenario: A closed container of R-134a refrigerant at 70°F/21°C has a pressure of 70.7psi/4.9bar

Scenario: The container is further chilled to -50°F/-46°C

Subcooling and Superheat

Two key principles of heat transfer are exhibited by the condenser:

The expansion valve restricts and controls the flow

A constant pressure valve is a device (usually

It is important to note the following:

Example refrigeration process for non-cycling dryer

Liquid A liquid storage receiver is fitted to the system primarily to

Air Flow Components by Dryer Type

• Compressed air enters the dryer through the inlet

Interaction between a compressed air system and a refrigerant dryer system.

For water-cooled machines:

Refrigerant Flow Process

Air Cooled Water Cooled

A fan pulls the air through the condenser

Meter Device- Expansion Valve/Capillary Tube/Constant Pressure Valve

Factory default display after powering up the system

Display Warning Description

Display Trip Description

The DPC Controller features three levels of access.

In addition, the controller can display:

Parameters technicians can manipulate in this mode include:

Multiplex Dryers with DPC Controllers

Exchanger Drain Drain Alarm

Thermostar Electronic Controller-Overview

If a setpoint needs to change, technicians should:

Interpretation: The Manual Drain Valve Closed Time is set to 22 minutes

Part Two-Setting the Set Point

OMI Controller for a cycling dryer

On/Off Drain Test Set - +

Display visualization and signally LEDs

Pre-Startup Checklist and Tasks

When providing service on a machine, technicians should remember several things:

Solenoid Drain Valve Cleaning

Core Removal Tool

• Install the Manifold gauge set on the system

• Turn on the Micron gauge

Issue Tests to Perform Cause/Resolution

Diagnosing the Issue

High Pressure Cutout (HPCO)- • High ambient temperature

High Dewpoint, Normal • High Flow Rate

Scenario: Low Dew Point/Evaporator Temperature

Scenario: Compressor Burn Out

To install the new compressor:

Diagnosing Cycling Dryers

Scenario: High Pressure Cutout

D340NC & D340IN