Bry-Air Dehumidifier Manual [PDF]

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FLi -SERIES



INSTALLATION, OPERATING & MAINTENANCE INSTRUCTION MANUAL



Please read carefully before installation 2



TABLE OF CONTENTS FOREWORD



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PRINCIPLE OF OPERATION ..................................................................................................... 5 INSTALLATION INSTRUCTIONS............................................................................................. 6 INSPECTION:.................................................................................................................................. 6 PACKING THE MACHINE ............................................................................................................. 6 ELECTRICALS ............................................................................................................................... 6 DUCT WORK .................................................................................................................................. 6 STEAM COIL INSTALLATION RECOMMENDATIONS……………………………………… 7 OPERATING INSTRUCTIONS ................................................................................................... 8 START-UP ........................................................................................................................................ 8 ELECTRIC REACTIVATION CONTROLS: .................................................................................. 8 AIRFLOWS...................................................................................................................................... 9 DESICCANT BED ROTATION ...................................................................................................... 9 PERFORMANCE TESTING ..................................................................................................... 9-10 MAINTENANCE INSTRUCTIONS .......................................................................................... 11 CABINET ....................................................................................................................................... 11 DESICCANT BED ......................................................................................................................... 11 SEALS ……………………………………………………………………………………………11 DRIVE MOTOR............................................................................................................................. 11 FILTERS......................................................................................................................................... 12 FAN AND MOTOR MAINTENANCE INSTRUCTIONS ....................................................... 13 GENERAL MAINTENANCE ....................................................................................................... 13 SERVICE INSTRUCTIONS ....................................................................................................... 14 REMOVING THE DESICCANT BED .......................................................................................... 14 CHANGING BED SEALS ............................................................................................................. 14 INSTALLING BED SEALS ........................................................................................................... 14 TROUBLE SHOOTING GUIDELINES .............................................................................. 15-16 PSYCHROMETRIC CHART



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FOREWORD Congratulations on your purchase of the Bry-Air FLi dehumidifier. The dehumidifier offers the finest in air drying equipment; however, this machine can only provide its maximum service if it is properly installed, operated, and maintained. This manual is provided to acquaint you with the dehumidifier so that installation, operation and maintenance can proceed successfully. Ultimate satisfaction depends on the quality of installation and a thorough understanding of this equipment. The FLI dehumidifier is built around tested engineering principles and has passed a thorough inspection of quality of workmanship and function.



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PRINCIPLE OF OPERATION The function of the Bry-Air dehumidifier is to remove moisture (in the vapor state) from an air stream. This is accomplished by exposing the air to an adsorbing media (desiccant) in a sealed air stream (process). After the desiccant has adsorbed moisture, it is exposed to a second air stream at an elevated temperature (reactivation). This causes the moisture to be driven out of the desiccant preparing it for more moisture adsorption. This process is done on a continuous basis, providing a constant drying process. The two air streams (process and reactivation) are separated by seals which contact the desiccant bed. Figure “A” illustrates the air flow relationship of the seals and air flow pattern. The FLI dehumidifier is designed with the two air streams flowing in opposite directions (counter flow) thereby maximizing the energy efficiency of the equipment. FIGURE –“A”



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INSTALLATION INSTRUCTIONS Proper installation of this dehumidifier is very important for best. service and performance. INSPECTION: Thoroughly inspect the dehumidifier inside and out to insure that no damage has occurred during shipping. (If any damage is found, a claim should be made to the shipping company immediately!). PACKING THE MACHINE The dehumidifier should be carefully set in place and leveled. The equipment must be supported adequately to prevent unnecessary flex in the structural base. Support below the lifting lugs is the minimum required. Remove any external packing or crating before connecting ductwork. Refer to Unit Outline at the back of this manual for minimum clearance, servicing and duct work connections. ELECTRICALS All local and country codes must be strictly adhered to and good electrical practices should be followed to achieve the best installation possible. Power wiring to equipment must be adequately sized for minimum amperage as shown on the unit nameplate. If a disconnect is furnished with your particular package, one should be installed adjacent to the unit for both safety and servicing. Equipment wiring diagram should be examined and thoroughly understood before fieldwiring connections are made. (See Electrical Schematic in the back of this manual). The power supply should be checked to be certain that the supply voltage agrees with the equipment nameplate. Serious damage to motors and controls can occur if improper voltage is applied. DUCT WORK The duct work requirements for this system are much more critical than conventional air conditioning systems. ALL SUPPLY AND RETURN AIR DUCTWORK FOR THE DEUMIDIFIER MUST BE AIRS AND VAPOR TIGHT. This is extremely important for proper dehumidifier performance. Even though the dehumidifier is removing moisture, it may not perform properly if moisture enters the dry air stream through leaks in the ductwork. The air ducts must be properly sized to keep pressure losses at a minimum, and prevent this loss from exceeding the designed fan static capability. It is important to insure that the reactivation discharge air does not enter the process or reactivation inlets. If the unit is installed indoor, the reactivation outlet can be connected by duct to the outside of the building. See Unit Outline drawing for fan external static pressure.



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STEAM COIL INSTALLATION RECOMMENDATIONS • This section is applicable for unit having steam coil. 1. It is important that the steam coils operate at the design pressure. The amount of heat energy in the steam is proportional to the steam pressure. If the steam pressure is allowed to drop, the dehumidifier may not be able to deliver full performance. 2. Be certain that adequate piping flexibility is provided. Stresses resulting from expansion of closely coupled piping and coil arrangement can cause serious damage. 3. Do not reduce pipe size at the coil return connection. Carry the return connection size through the dirt pocket, making the reduction at the branch leading to the trap. 4. Vacuum breakers and air vents must be installed on all applications to prevent retaining condensate or air in the coil. Generally the vacuum breaker is to be connected between the coil inlet and the trap. For a system with a flooded return main, the vacuum breaker should be open to the atmosphere and the trap design should allow venting of large quantities of air. 5. Do not drip steam mains through coils. 6. Insure stream pressure and condensate line pressure differential is sufficient to allow efficient condensate removal from the steam coil, especially when using modulation steam control valves to control the leaving air temperature of the coil. 7. Do not attempt to lift condensate without the assistance of a condensate pump. The pressure required to lift condensate must also be considered for sufficient pressure differential. Check valves are also required to prevent reverse flow of condensate back into the coil. 8. All coils in a system should be piped separately. It is not recommended to put multiple coils on a common trap. 9. Multiple coil installationsa.) Each coil or group of coils that is individually controlled must be individually trapped. b.) Coils in series; separate traps are required for each coil, or bank of coils, in series. c.) Coils in parallel; a single trap may be used but an individual trap for each coil is preferred. 10. Size traps in accordance with the manufacture’s recommendations. Be certain that the required pressure differential will always be available. Do not undersize. 11. Float and thermostatic traps are recommended for high or low-pressure steam systems, but bucket traps may be used. Float and thermostatic traps should be used when air venting is necessary. Bucket traps are recommended for use with on- off control only. It is recommended that traps be located at least 12 inches below the coil return connection. When traps without air venting capabilities are used, air vents are required in the system. 12. Flash trap may be used if pressure differential between steam and condensate return exceeds 5 psi. IMPORTANT NOTE:Steam reactivated systems – Bry-Air will only repair or replace leaking steam coils under warranty when a.) Accompanied by a water quality report from an independent, qualified laboratory showing the chemical analysis of the steam associated with these coils. These test must show pH values and sulphar content within the ranges associated with proper steam operating ranges. Proper steam piping, per manufacturer’s recommendations, must be applied to any steam coil installations to prevent contamination and possible 7 water hammering that could lead to leaks. 7



OPERATING INSTRUCTIONS START-UP At this point it is assumed that the installation is complete and that the recommendations and instructions have been followed. The following will outline the proper procedures for starting and adjusting the FLI dehumidifier. Note: Before starting the dehumidifier, check to insure that the outlet air dampers are at least partially opened. At this point, the dehumidifier can now be started using the ‘Auto Manual’ selection switch. The Auto-Manual selector switch can be set on the Auto or Manual position depending on automatic or manual humidity control. A humidity control device, such as humidistat is required to be connected for ‘Auto’ operation.. This will start the dehumidifier, energizing the fan motors, bed drive, and the reactivation heat source. The fan rotations should be checked at this time, if not previously done, to insure they are rotating in the proper direction. ELECTRIC REACTIVATION CONTROLS: Dehumidifiers with electric reactivation incorporate an air proving pressure switch and two adjustable temperature-limiting devices. All three of these devices must be energized to allow the reactivation heaters to be energized. One temperature limit automatically resets and the second is manual reset. The manual reset limit may have to be reset open start-up. The reactivation temperature limits are safety limits only and are not operating controls ! If on-off cycling of the heaters occur, the auto reset limit must be adjusted to a higher setting until the heaters are continuously on (10-15° C higher than the reactivation entering temperature after the heaters.) The manual reset limit is a fail-safe device and should be set 20° C above the auto reset limit. Note : The dial indication on the thermostats is for reference only. The actual setpoint values may differ slightly. To check the calibration, turn the knob to a lower setting until the heaters cut off, then increase the setting until the heaters come on. Increase the setting 15° C above this point. The Air Flows section of this manual will provide the information on adjusting airflows through the dehumidifier. This is extremely important because the electric heaters are sized for a temperature rise based on design air volume. Consult the dehumidifier set-up sheet or system flow schematic included in this manual for the proper reactivation temperature. This temperature is achieved through the proper air volume and is measured at the dry-bulb temperature test ports in the reactivation inlet. The ideal temperature is 150°–160° C. Note :It is important to insure the reactivation air flow is sufficient before increasing the limit set points.



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AIRFLOWS The FLI dehumidifier uses two distinct air streams positively sealed from each other. This eliminates the requirement to “balance” the air streams. It is recommended to use the pressure gauges or manometer to establish the proper air flows through the dehumidifier. The pressure differential across the desiccant bed is a simple way of determining the proper air volumes. Adjust pressure values to that shown on the dehumidifier set-up sheet or flow schematic provided with the unit.



DESICCANT BED ROTATION The desiccant bed rotation is accomplished by a fixed speed gear motor and sprocket. No adjustment is required.



PERFORMANCE TESTING Note : Allow the dehumidifier to run for a minimum of one hour at proper reactivation temperatures and airflows before beginning any performance tests. The dehumidifier set-up sheet or flow schematic will provide the necessary information on temperatures and pressure values. The following procedures will outline the steps to performance test the dehumidifier : 1. Check the reactivation inlet temperature using a 300°C thermometer or other sensible temperature sensor. 2. Check the reactivation outlet temperature using a 100°C thermometer or other sensible temperature sensor. 3. Take the wet bulb* and dry-bulb temperature of the process inlet. Take reading simultaneously using two 50° C calibrated thermometers. 4. Take the wet-bulb* and dry-bulb temperature of the process outlet using the same thermometers as in step 3. * The thermometers best suited for use in the field are a bimetallic dial type with 200mm stem. The wet-bulb and dry-bulb thermometers should be a matched pair with divisions no less than 0.5°C. The wet-bulb thermometer requires a full length sock. The sock should fit tightly on the stem of the thermometer. Distilled water, cooled to 5°C if possible should be used to wet the sock. In taking the wet-bulb temperature, the wet-bulb thermometer should be placed in an air stream (approximately 5 m/s velocity) and observed until the lowest stabilized temperature is obtained. It is necessary to take two or more readings to verify the correct wet-bulb. 9



In cases of very low humidity (condition below 2°C WB) the above procedure may be difficult to apply accurately. Other instruments may be used to take humidity readings for this performance test. It is important to use an accurate device to obtain an accurate evaluation of the dryer performance. Most relative humidity sensors are not accurate below 10%-20% relative humidity. At these conditions, it is suggested that a laboratory quality dew point sensor be used to obtain accurate humidity readings. If there are any questions about the performance of the Bry-Air dehumidifier, completely fill out the Dehumidifier Test Report Form included with this manual and contact the Bry-Air factory or local sales representative. The system will be analyzed and proper recommendations returned promptly.



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MAINTENANCE INSTRUCTIONS CABINET Compression latch fasteners are used to seal front service panel as well as electrical control panel. All rear panels, filter access use manual cap screw fasteners. All access covers, hardware, and screws should be secured after any servicing activity. Care should be taken not to over-tighten and deform panels. The condition of the access panel gasket should be observed during inspection and servicing to insure a good seal. Any leaks must be sealed for proper dehumidifier operation. DESICCANT BED The state of the art desiccant bed supplied with the dehumidifier will last idenfinitely under ideal conditions. Due to the nature of desiccants they make very good filters. The life of the desiccant is directly related to the air born contaminates passed through it. atmospheric contaminants, exposure to acidic gases / or air streams, and contact with desiccant bed. Although the desiccant bed is considered a clean able / washable media, the preferred method of cleaning is to blow dust out with low pressure compressed air and to reactivate the bed at 170° C (max) for 15 minutes. Washing the rotor, although possible, is not recommended as wash water impurities may contaminate the desiccant. Proper filtration, and preventing contact with chemicals will greatly improve the life of the desiccant. Inspect the face of the bed to see that no surface damage has occurred. The bed should turn smoothly upon the shaft. SEALS All of the silicon ‘A’ seals which separate the process from the reactivation compartments are manufactured specifically for Bry-Air. Normally, the seals will not require service or replacement. However, should damage occur, or if air leakage is suspected of causing poor performance, the seals should be replaced : Seal inspection schedule:



Upon installation After 1 week of operation. After 3 months. Annually thereafter or upon loss of performance.



DRIVE MOTOR The bed drive motor is permanently lubricated and requires no further maintenance.



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FILTERS The maintenance intervals for filters depends directly on the cleanliness of the air entering the dehumidifier. It is suggested that a program be established to assure that the filters are replaced or cleaned prior to becoming clogged to the point they create a system problem. The filters supplied as standard are of a disposable, non-washable media. Cleanable, washable filters may be supplied in some cases. In any case, minimum 30% ASHRAE / E U-3 standard filtration must be used to protect the desiccant bed.



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FAN AND MOTOR MAINTENANCE INSTRUCTIONS GENERAL MAINTENANCE 1. A definite time schedule for inspecting all rotating parts and accessories should be established. The frequency of inspection depends on the severity of operation and the locality. Inspections might be weekly at first in order to set up the schedule. 2. Alignment – shaft must not be cocked in the bearings. Misalignment can cause overheating, wear to dust seals, bearing failure, the unbalance. 3. Hardware – checks tightness of all bolts and set screws. 4. Lubrication – checks fan and motor bearings and add lubricant if necessary. Be careful not to over-grease as this can damage bearing seals. 5. Airflow – make sure there are no obstructions to airflow in outlet or inlet ductwork. 6. Bearings – bearings on high-speed fans tend to run hot. Therefore, do not replace a bearing because it feels hot to the touch. Place a pyrometer or contact thermometer against the pillow block and check the temperature. Ball / pillow blocks can have total running temperature of 75° C before the cause of overheating should be investigated. 7.Fans wheel – inspect wheel blades for accumulation of dust and dirt. Clean thoroughly with stream of water jet, compressed air or a wire brush. This will help prevent an unbalanced condition. If blades are alumimium, be careful not to damage them. Cover the bearings so water won’t enter the pillow block. The wheel should be centered to prevent the proper direction. Never run the fan at a higher speed than it was designed for unless you check with Bry-Air first.



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SERVICE INSTRUCTIONS REMOVING THE DESICCANT BED Desiccant bed removal is accomplished by the following: 1. Remove unit access cover (drive side). 2. Swing chain idler sprocket away from bed to allow slack in the chain. 3. Remove chain from drive sprocket. Allow to hang from bed. 4. Remove the two bolts screws securing of the shaft on both sides of the desiccant bed. 5. In order to avoid any damage suitable soft rags and a rope can be inserted between chain and the rim before attempting to slide the bed out. 6. Pull on rope to slide bed straight toward access opening. Stop pulling when support shaft reaches perimeter of bed seal. 7. Generally lift the bed enough to remove the support shaft from the bed. 8. Remove the desiccant bed. To re-install bed, reverse the above procedure. CHANGING BED SEALS 1. 2.



Follow procedure for removing bed. Firmly grasp the bed seal and pull straight away from divider panel. Entire seal can be removed at this time. Repeat for both sides.



Note: Both perimeter and divider seals will be removed as one piece. INSTALLING BED SEALS Pre-Assembled 1. Fit seal over perimeter flange. Push seal straight toward vertical panel making sure that groove of seal seats firmly over flange. 2. Carefully cut seal length to 6mm longer than mark so that mating surfaces fit together. 3. Cut groove for intersection of perimeter / divider flange. 4. Re-install perimeter seal using a small amount of RTV at the mating surfaces. (this should bond and seal the joint). 5. Place length of seal over divider section flange and mark point of overlap at perimeter seal. 6. Carefully cut seal length to 6mm longer than mark so that mating surfaces fit together. 7. Re-install divider seal using a small amount of RTV at the mating surfaces. (This should bond and seal the joint). 8. Repeat the above steps for both sides.



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TROUBLE SHOOTING GUIDELINES FLI SERIES DEHUMIDIFIER Trouble Unit stopped (both Fans off)



Probable Fault Power and control failure



Probable Cause 1. Main Power off



Corrective Action 1. Check line and main power supply



2. Control Power off. a. Control circuit fuse blown. b. Faulty control transformer. c. Control switch open



2. Check per item. a. Replace Fuse b. Replace Transformer. c. Close or replace switch. d. Turn down to lower set point. e. Check and repair or replace as req’d. 1. Replace fuse or breaker. 2. Repair or replace 3. Reset or replace 4. Repair ore replace 5. Repair or replace as req’d.



d. Humidistat satisfied. e. Faulty control elements. Either fan off



Power failure



or



mechanical



1.



4.



Blower motor fuse(s) or tripped breaker. Bad motor starter contacts Motor over load(s). Burned out motor Failure of fan drive mechanism. (set screws, keys, etc. Executive unconditioned makeup air. Leaking ducts and/or air handling equipment outsides controlled space. Access openings opening to space not sealed. Space not vapor tight.



1. a. b. c.



Humidistat Improper adjustment. Out of calibration. Defective



1. a. b. c.



Excessive static pressure loss Dirty filters Damper closed Obstruction at inlet, outlet or ducting. Clogged desiccant beds (high pressure drop across beds.)



2. 3. 4. 5.



Unit running humidity rises.



but



Excessive infiltration of humit air into the controlled space.



1. 2.



3.



Faulty humidifier controls



Inadequate process reactivation air flow



or



d.



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1.



reduce make-up air.



2.



Seal leaks



3.



Close and /or seal.



4.



Seal with paint and / or vapor barrier.



a. b. c.



Readjust Recalibrate Replace



1. a. b. c.



Check per item Clean or replace Reset Remove construction Remove beds and replace desiccant.



d.



TROUBLE SHOOTING GUIDELINES FOR CHAIN DRIVE COMMON SYMPTOMS



PROBABLE CAUSE



CORRECTIVE ACTION



Non-symmetrical wear on sprockets or rollers



1. Shafts out of parallel or not in same plane



1. Realign shafts



Wear on inside of roller plates or side tooth form of sprocket teeth



1. Sprockets offset on shafts (misarranged), or out of parallel



1. Realign sprockets



Wear on tips of sprocket teeth



1. 2.



1. 2.



Worn or hooked sprocket teeth



1. Unhardened sprockets



1. replace with hardened sprockets



Wear on edges or sides of link plates



1. Chain contacting case or fixed object.



1. Increase case clearance or move fixed object



Excessive vibration



1.



1.



2.



Chain elongated excessively Improperly cut sprockets



Excessive eccentricity or face run out in sprocket Broken or missing roller



2.



Replace chain Replace with correct sprocket



Replace with properly machined sprocket Repair or replace chain



Premature elongation



1. Inadequate or contaminated lubrication, or under chaining



1. Increase oil flow or redesign



Brown-red oxide in chain joints and oil



1. Inadequate lubrication



1. Improve lubrication



Chain jumps sprocket teeth



1.



Wear to vertical limit or excess initial slack Wear to miasmic on large sprocket



1. 2.



Adjust centers or idler Replace chain



1. 2.



3. 4. 5. 6. 7.



Drive overloaded Excessive slack causing chain to jump teeth Foreign object Excess chain speed Poorly fitting sprockets Inadequate lubrication Corrosion



Redesign or avoid. Periodically adjust center distance Prevent entry Redesign or avoid Replace Proper lubrication Prevent or use non-corrosive chain



1. 2. 3. 4.



Chain contacting fixed objects Inadequate lubrication Broken or missing rollers Misalignment



1. 2. 3. 4.



5.



Chain jumping sprocket teeth



5.



2. Broken chain parts



Excessive noise



1. 2.



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3. 4. 5. 6. 7.



Remove objects Improve lubrication Repair or replace chain Check shaft and sprocket and realign Adjust center distance



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