Service Manual

for the

SRL Refrigerated Air Dryers

Models: SRL-250 to 6000 (60Hz)
SRL-120 to 1800 (50Hz)
Document PN#: 02250___-___
 SRL Service Manual
Revision 00
July 2007

Table of Contents
1. General Description 4
2. Specifications 5
2.1 Model Range 5
2.1.1 60 Hz Models 5
2.1.2 50 Hz Models 6

2.2 Operating Limits 6

2.3 Technical Specifications 7
2.3.1 60 Hz Air Cooled Models 7
2.3.2 60 Hz Water Cooled Models 8
2.3.3 50 Hz Air Cooled Models 9
2.3.4 50 Hz Water Cooled Models 10

2.4 Weight & Dimensions 11

2.4.1 60 Hz Models 11
2.4.2 50 Hz Models 12

3. System Design 13
3.1 The Air Circuit 14
3.1.1 Air-To-Air Heat Exchanger 15
3.1.2 Air-To-Refrigerant Heat Exchanger 15
3.1.3 Demister Separator 15
3.1.4 Condensate Chamber 15
3.1.5 Dew Point Temperature Sensor 16
3.1.6 Condensate Level Sensor 16

3.2 Refrigeration Circuit 16

3.2.1 The Thermal Mass Concept 17
3.2.2 Compressor 17
3.2.3 Condenser 18
3.2.4 Refrigerant Filter 18
3.2.5 Expansion Device 19
3.2.6 Refrigerant 19
3.2.7 High Pressure Switch 19
3.2.8 Low Pressure Switch 19
3.2.9 Fan Pressure Switch (Air Cooled Units) 20
3.2.10 Water Regulating Valve (Water Cooled Units) 20
3.2.11 Hot Gas Bypass Valve 20
3.2.12 Liquid Accumulator 21

(Continued on following page…)

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4. Control System 22
4.1 Power Supply 22
4.3 Microprocessor Controls 22
4.2.1 Inputs 23
4.2.2 Outputs 23
4.2.3 Electrical Specifications 24
4.2.4 User Interface 24
4.2.4.1 Lights 25
4.2.4.2 Buttons 26

5. Installation 27
6. Start Up 29
7. Operation & Control 30
7.1 Turning the Dryer On or Off 30
7.2 User Parameter List 31
7.3 Accessing & Modifying User Parameters 32
8. Dryer Operating Modes 33
8.1 Continuous Mode 33
8.2 Cycling Mode 34
9. Condensate Drain Operation 35
9.1 SRL-250 35
9.2 SRL-325 to 6000 35
9.3 Drain Operating Mode (Parameter D3) 37
9.4 Manual Drain Activation 37
10. Alarms & Warnings 38
10.1 Alarm & Warning List 38
10.2 Troubleshooting Alarms & Warnings 39
10.2.1 HP - High Pressure (Alarm) 39
10.2.2 LP - Low Pressure (Alarm) 40
10.2.3 Ld - Low Dewpoint (Alarm) 41
10.2.4 Ht – High (Discharge) Temperature (Alarm) 42
10.2.5 Lt - Low (Evaporator) Temperature (Alarm) 43
10.2.6 CP – Compressor Protection (Alarm) 44
10.2.7 PdE – Parameter Data Error (Alarm) 44
10.2.8 Hd - High Dewpoint (Warning) 45
10.2.9 drE - Drain Error (Warning) 46
10.2.10 dSE - Dewpoint Sensor Error (Warning) 47
10.2.11 rSE – Evaporator Temperature Sensor Error (Warning) 47
10.2.12 Sr - Service Required (Warning) 48
(Continued on following page…)

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10.3 Service Required Warning (Sr) 49

10.3.1 How to Reset the Service Required (Sr) Warning 49
10.3.2 How to Change the Service Required (Sr) Warning Interval 50

10.4 Alarm History Report 51

10.4.1 Viewing the Alarm History Report 51
10.3.2 Resetting the Alarm History Report 52

10.5 Remote Monitoring Option 53

11. Recommended Maintenance 54
11.1 Maintenance Schedule 54
11.2 Preventative Maintenance Kits 55
12. Maintenance Procedures 56
12.1 Replacing a Pressure Switch 56
12.2 Replacing the Drain Valve 56
12.3 Cleaning the Condensate Strainer 56
12.3 Replacing the Control Board 57
12.6 Adjusting the Hot Gas Bypass Valve 58
13. Confirming Dryer Sizing 59
13.1 Correction Factors 60
13.2 An Example 61

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1. General Description
The Sullair SRL Refrigerated Air Dryer reduces the dew point(1) of a compressed air stream by
reducing the temperature causing water and oil vapour (along with other evaporated contaminants) to
condense into liquids. These liquids are then separated from the air and discharged from the system.
The dry air is then re-heated before continuing downstream.
Air streams are measured in terms of their flow, temperature and
pressure. These variables fluctuate continuously throughout the
day and can change drastically throughout the year, depending on
the climate, conditions, and application. As they change, so does
the amount of heat in the air (called the “heat load”) and the
amount of moisture the air stream can carry.
Every refrigerated air dryer is designed to handle a maximum
incoming heat load. At any heat load below the maximum there is
the potential for energy savings as the dryer is absorbing less heat
than it is designed for.
The SRL is unique in that it can be operated either as a traditional
direct expansion dryer or a cycling dryer depending on the needs
and wishes of the end user.*
In direct expansion (a.k.a. “continuous”) mode the refrigerant compressor runs continuously, and the
dryer handles reduced heat loads by redirecting refrigerant away from the heat exchanger using a
bypass valve to maintain a constant outlet dewpoint. This is the simplest mode of operation, however
does not save any energy at part load.
In cycling mode the refrigerant compressor is cycled on and off depending on the temperature within
the heat exchanger. When there is less heat load, the heat exchanger absorbs less heat, and the
refrigerant system is cycled on and off only as necessary to keep the heat exchanger cold.*

* Cycling mode is not available on the SRL-250.

(1) Dew point – a measurement of the amount of moisture in a gas, indicated as the temperature at which
the air would be saturated (i.e. the relative humidity would be 100%) and liquid condensate would begin
o o
to form. It is commonly shown as F or C. It is important when discussing dew point to specify if you are
referring to the “pressure dew point” (the dew point at the pressure of the system) or “atmospheric dew
point” (the equivalent dew point at atmospheric pressure) as the two are significantly different. For the
purposes of this manual, “dew point” should be considered synonymous with “pressure dew point".

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2. Specifications
2.1 Model Range
2.1.1 60 Hz Models

Rated Pressure Absorbed Port

Sullair Voltage Condenser
Flow [1] Drop Power Size
Model Part # Volt Ph Hz AC/WC (scfm) (psid) (kW) (in)
02250169-434 1
230
02250169-435
SRL-250 60 AC 250 1.78 1.46 1 1/2"
02250169-436 460 3
02250169-805 575
02250169-437 230
SRL-325 02250169-438 460 3 60 AC 325 1.14 1.67 2"
02250169-806 575
02250169-439 230
SRL-400 02250169-440 460 3 60 AC 400 1.80 1.91 2"
02250169-807 575
02250169-441 230
SRL-500 02250169-442 460 3 60 AC 500 1.62 2.88 2"
02250169-808 575
02250169-443 230
02250169-444 460 AC 3.66
02250169-809 575
SRL-700 3 60 700 1.10 3"
02250169-457 230
02250169-458 460 WC 2.99
02250169-821 575
02250169-445 230
02250169-446 460 AC 1.51 3.82
02250169-810 575
SRL-800 3 60 800 3"
02250169-459 230
02250169-460 460 WC 1.53 2.99
02250169-822 575
02250169-447 460
AC 2.17 4.20
02250169-811 575
SRL-1000 3 60 1000 3"
02250169-461 460
WC 2.19 3.53
02250169-823 575
02250169-448 460
AC 0.92 5.46
02250169-812 575
SRL-1200 3 60 1200 3"
02250169-462 460
WC 0.93 4.52
02250169-824 575
02250169-449 460
AC 1.36 5.57
02250169-813 575
SRL-1400 3 60 1400 4"
02250169-463 460
WC 1.36 4.43
02250169-825 575
02250169-450 460
AC 1.75 6.03
02250169-814 575
SRL-1600 3 60 1600 4"
02250169-464 460
WC 1.75 5.10
02250169-826 575
02250169-451 460
AC 2.70 7.83
02250169-815 575
SRL-2000 3 60 2000 6"
02250169-466 460
WC 2.71 6.63
02250169-827 575
02250169-452 460
AC 1.62 10.26
02250169-816 575
SRL-2400 3 60 2400 6"
02250169-467 460
WC 1.64 8.14
02250169-828 575
02250169-453 460
AC 2.43 14.19
02250169-817 575
SRL-3000 3 60 3000 6"
02250169-468 460
WC 2.44 11.63
02250169-829 575
02250169-454 460
AC 2.33 17.73
02250169-818 575
SRL-3800 3 60 3800 6"
02250169-469 460
WC 2.31 13.26
02250169-830 575
02250169-455 460
AC 2.70 23.49
02250169-819 575
SRL-5000 3 60 5000 8"
02250169-470 460
WC 2.71 18.43
02250169-831 575
02250169-456 460
AC 3.05 31.31
02250169-820 575
SRL-6000 3 60 6000 8"
02250169-471 460
WC 3.09 22.54
02250169-832 575
(1) Maximum rated flow at CAGI conditions of 100 deg F & 100 psig inlet, 100 deg F ambient.

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2.1.2 50 Hz Models
Rated Pressure Absorbed Port
Sullair Voltage Condenser
Flow [1] Drop Power Size
Model Part # Volt Ph Hz AC/WC (m3/min) (mbar) (kW) (in)
SRL-120 02250169-405 400 3 50 AC 12 130 1.41 2"
SRL-140 02250169-406 400 3 50 AC 14 180 1.37 2"
SRL-180 02250169-407 400 3 50 AC 18 230 1.76 2"
02250169-408 AC 1.59
SRL-220 400 3 50 22 90 2 1/2"
02250169-421 WC 1.61
02250169-410 AC 2.29
SRL-260 400 3 50 26 130 2 1/2"
02250169-422 WC 2.28
02250169-411 AC 2.89
SRL-300 400 3 50 30 170 2 1/2"
02250169-423 WC 2.77
02250169-412 AC 3.60
SRL-350 400 3 50 35 240 2 1/2"
02250169-424 WC 3.49
02250169-413 AC 3.52
SRL-460 400 3 50 46 140 DN100
02250169-425 WC 3.39
02250169-414 AC 4.28
SRL-520 400 3 50 52 180 DN100
02250169-426 WC 3.87
02250169-415 AC 5.24
SRL-630 400 3 50 63 260 DN100
02250169-427 WC 5.05
02250169-416 AC 6.91
SRL-750 400 3 50 75 160 DN150
02250169-428 WC 6.20
02250169-417 AC 9.86
SRL-900 400 3 50 90 230 DN150
02250169-429 WC 8.87
02250169-418 AC 10.94
SRL-1210 400 3 50 120 190 DN150
02250169-430 WC 10.12
02250169-419 AC 15.25
SRL-1500 400 3 50 150 200 DN200
02250169-431 WC 14.09
02250169-420 AC 18.64
SRL-1800 400 3 50 180 260 DN200
02250169-432 WC 17.33
(1) Maximum rated flow at ISO conditions of 35 deg F & 7 bar g inlet, 25 deg F ambient.

2.2 Operating Limits

Operating Limit Minimum Rated Maximum*
o
Ambient Temperature: 41 F 5oC 100 F o
38 C o
122 F o
50oC
o o o o o o
Inlet Temperature: 41 F 5C 100 F 38 C 140 F 60 C
Inlet Pressure: 60 psig 4 bar g 100 psig 7 bar g 203 psig 14 bar g
* Maximum allowable working pressures may vary with location depending on local pressure vessel design regulations.

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2.3 Technical Specifications

2.3.1 60 Hz Air Cooled Models

SRL-1000

SRL-1200
SRL-250

SRL-325

SRL-400

SRL-500

SRL-700

SRL-800
Type -- R407C
Refrigerant
Charge lb (kg) 3.26 (1.48) 5.07 (2.3) 5.29 (2.4) 5.95 (2.7) 9.92 (4.5) 13.23 (6) 14.33 (6.5)
Quantity Qty 1
Expansion Capillaries Internal Diameter mm 2.5 3.18 4
Length mm 2500 1500 900 1500 2800 2000
Min psig (barg) 62.4 (4.3)
Hot Gas Valve Setting
Max psig (barg) 66.7 (4.6)
Min °F (°C) 33.8 (1)
Suction Temperature
Max °F (°C) 48.2 (9)
Min °F (°C) 131 (55) 104 (40) 99 (37) 99 (37) 131 (55) 104 (40) 118 (48)
Discharge Temperature
Max °F (°C) 167 (75) 149 (65) 144 (62) 149 (65) 167 (75) 140 (60) 154 (68)
Min °F (°C) 35.6 (2)
Dew point temperature
Max °F (°C) 41 (5)
On psig (barg) 276 (19)
Fan Pressure Switch
Off psig (barg) 203 (14)
Number of Heat Exchangers Qty 1
High Pressure Switch Setting psig (barg) 406 (28)
Standard Supply Voltages Available -- (Note 1) 230 or 460V / 3ph / 60 Hz 460V / 3ph / 60 Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.
Note 1 - Available in 230/1/60, 230/3/60 or 460/3/60.

SRL-2400

SRL-3000

SRL-3800

SRL-5000

SRL-6000
SRL-1400

SRL-1600

SRL-2000

Type -- R407C
Refrigerant
Charge lb (kg) 19.84 (9) 22.05 (10) 27.12 (12.3) 25.35 (11.5) 40.79 (18.5) 42.99 (19.5) 61.73 (28) 68.34 (31)
Quantity Qty 2 3 4 5 6
Expansion Capillaries Internal Diameter mm 3.18 4
Length mm 2800 1000 2100 4000 2300 2500
Min psig (barg) 62.4 (4.3)
Hot Gas Valve Setting
Max psig (barg) 66.7 (4.6)
Min °F (°C) 33.8 (1)
Suction Temperature
Max °F (°C) 48.2 (9)
Min °F (°C) 131 (55) 113 (45) 131 (55)
Discharge Temperature
Max °F (°C) 167 (75) 158 (70) 167 (75) 158 (70) 167 (75)
Min °F (°C) 35.6 (2)
Dew point temperature
Max °F (°C) 41 (5)
On psig (barg) 276 (19)
Fan Pressure Switch
Off psig (barg) 203 (14)
Number of Heat Exchangers Qty 2 3 4 5 6
High Pressure Switch Setting psig (barg) 406 (28)
Standard Supply Voltages Available -- 460V / 3ph / 60 Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.

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2.3.2 60 Hz Water Cooled Models

SRL-1000

SRL-1200
SRL-250

SRL-325

SRL-400

SRL-500

SRL-700

SRL-800
Type -- R407C
Refrigerant
Charge lb (kg) 9.26 (4.2) 7.72 (3.5) 14.33 (6.5)
Quantity Qty 1
Expansion Capillaries Internal Diameter mm 3.18 4
Length mm 1200 2800 2000
Min psig (barg) 62.4 (4.3)
Hot Gas Valve Setting
Max psig (barg) 66.7 (4.6)
Min °F (°C) 33.8 (1)
Suction Temperature
Max °F (°C) NA 48.2 (9)
Min °F (°C) 140 (60)
Discharge Temperature
Max °F (°C) 185 (85)
Min °F (°C) 35.6 (2)
Dew point temperature
Max °F (°C) 41 (5)
Number of Heat Exchangers Qty 1
High Pressure Switch Setting psig (barg) 406 (28)
Supply Voltage -- 230 or 460V/3/60 460V / 3ph / 60 Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.

SRL-2400

SRL-3000

SRL-3800

SRL-5000

SRL-6000
SRL-1400

SRL-1600

Type -- SRL-2000 R407C

Refrigerant
Charge lb (kg) 15.43 (7) 13.23 (6) 18.52 (8.4) 21.38 (9.7) 19.4 (8.8) 25.35 (11.5) 37.48 (17) 45.19 (20.5)
Quantity Qty 2 3 4 5 6
Expansion Capillaries Internal Diameter mm 3.18 3.5 4
Length mm 2800 1800 2100 1300 1500 2000 2500
Min psig (barg) 62.4 (4.3)
Hot Gas Valve Setting
Max psig (barg) 66.7 (4.6)
Min °F (°C) 33.8 (1)
Suction Temperature
Max °F (°C) 48.2 (9)
Min °F (°C) 113 (45) 140 (60) 131 (55) 140 (60) 131 (55)
Discharge Temperature
Max °F (°C) 158 (70) 185 (85) 176 (80) 185 (85) 176 (80)
Min °F (°C) 35.6 (2)
Dew point temperature
Max °F (°C) 41 (5)
Number of Heat Exchangers Qty 2 3 4 5 6
High Pressure Switch Setting psig (barg) 406 (28)
Supply Voltage -- 460V / 3ph / 60 Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.

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2.3.3 50 Hz Air Cooled Models

SRL-120

SRL-140

SRL-180

SRL-220

SRL-260

SRL-300

SRL-350

SRL-460
Type -- R407C
Refrigerant
Charge kg 1.7 2.5 5.5 4.5 4.6 7.4 8.3
Quantity Qty 1 2
Expansion Capillaries Internal Diameter mm 2.5 3.18 4 3.18
Length mm 1500 4000 1500 1000 2800
Min barg 4.3
Hot Gas Valve Setting
Max barg 4.6
Min °C 1
Suction Temperature
Max °C 15
Min °C 45 60 45 60
Discharge Temperature
Max °C 70 85 70 85
Min °C 2
Dew point temperature
Max °C 5
On barg 19
Fan Pressure Switch
Off barg 14
Number of Heat Exchangers Qty 1 2
High Pressure Switch Setting barg 28
Standard Supply Voltages Available -- 400V / 3ph / 50Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.

SRL1200

SRL1500

SRL1800
SRL520

SRL630

SRL750

SRL900
Type -- R407C
Refrigerant
Charge kg 8.5 10.3 12 12.5 19.5 25.5 31
Quantity Qty 2 3 4 5 6
Expansion Capillaries Internal Diameter mm 3.18 3.5 4
Length mm 1800 1000 2100 1300 1500 2300 2500
Min barg 4.3
Hot Gas Valve Setting
Max barg 4.6
Min °C 1
Suction Temperature
Max °C 15
Min °C 50 60 50 60 50 45
Discharge Temperature
Max °C 75 85 75 85 75 70
Min °C 2
Dew point temperature
Max °C 5
On barg 19
Fan Pressure Switch
Off barg 14
Number of Heat Exchangers Qty 2 3 4 5 6
High Pressure Switch Setting barg 28
Standard Supply Voltages Available -- 400V / 3ph / 50Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.

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2.3.4 50 Hz Water Cooled Models

SRL-120

SRL-140

SRL-180

SRL-220

SRL-260

SRL-300

SRL-350

SRL-460
Type -- R407C
Refrigerant
Charge kg 3.4 4.2 3.3 7
Quantity Qty 1 2
Expansion Capillaries Internal Diameter mm 3.18 4 3.18
Length mm 4000 2000 1000 2800
Min barg 4.6
Hot Gas Valve Setting
Max barg 4.8
Min °C 1
Suction Temperature
Max °C NA 15
Min °C 60 45
Discharge Temperature
Max °C 85 70
Min °C 2
Dew point temperature
Max °C 5
Number of Heat Exchangers Qty 1 2
High Pressure Switch Setting barg 28
Standard Supply Voltages Available -- 400V / 3ph / 50Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.

SRL1200

SRL1500

SRL1800
SRL520

SRL630

SRL750

SRL900
Type -- R407C
Refrigerant
Charge kg 6 6.3 10.4 8.3 11.5 17 20.5
Quantity Qty 2 3 4 5 6
Expansion Capillaries Internal Diameter mm 3.18 3.5 4
Length mm 1800 1000 2100 1300 1500 2000 2500
Min barg 4.6
Hot Gas Valve Setting
Max barg 4.8
Min °C 1
Suction Temperature
Max °C 15
Min °C 45 60 55 60 55
Discharge Temperature
Max °C 70 85 80 85 80
Min °C 2
Dew point temperature
Max °C 5
Number of Heat Exchangers Qty 2 3 4 5 6
High Pressure Switch Setting barg 28
Standard Supply Voltages Available -- 400V / 3ph / 50Hz
Control Software Release Code dt.3
All parameters refer to operating conditions at zero air flow.

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2.4 Weight & Dimensions

2.4.1 60 Hz Models

Sullair Condenser Height Depth Width Weight

Model AC/WC in mm in mm in mm lbs kg
SRL-200 AC 37.2 945 22.1 561 27.7 704 183 83
SRL-250 AC 287 130
SRL-325 AC
41.9 1064 41.2 1046 27.8 706 320 145
SRL-400 AC
SRL-500 AC 342 155
SRL-700 AC 52.0 1321
WC 47.8 1214
529 240
AC 52.0 1321
SRL-800 45.2 1148 31.7 806
WC 47.8 1214
AC 52.0 1321
SRL-1000 551 250
WC 47.8 1214
AC 66.5 1689
SRL-1200 43.2 1097 816 370
WC 62.5 1588
AC 66.5 1689
SRL-1400 49.0 1245 1080 490
WC 62.5 1588
AC 67.8 1722
SRL-1600 1279 580
WC 62.5 1588
AC 67.8 1722
SRL-2000 71.6 1819 1477 670
WC 62.5 1588
AC 67.8 1722
SRL-2400 39.7 1008 1521 690
WC 62.5 1588
AC 81.0 2057
SRL-3000 1610 730
WC 62.5 1588
71.2 1808
AC 81.0 2057
SRL-3800 1830 830
WC 62.5 1588
AC 87.0 2210
SRL-5000 2425 1100
WC 63.6 1615
88.9 2258
AC 87.0 2210
SRL-6000 2624 1190
WC 63.6 1615

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2.4.2 50 Hz Models

Sullair Condenser Height Depth Width Weight

Model AC/WC mm in mm in mm in kg lbs
SRL-75 AC
945 37.2 562 22.1 703 27.7 83 183
SRL-95 AC
SRL-120 AC
145 320
SRL-140 AC 1064 41.9 1046 41.2 706 27.8
SRL-180 AC 155 342
AC 1316 51.8
SRL-220 230 507
WC 1214 47.8
AC 1316 51.8
SRL-260 240 529
WC 1214 47.8
1166 45.9 806 31.7
AC 1316 51.8
SRL-300 245 540
WC 1214 47.8
AC 1316 51.8
SRL-350 250 551
WC 1214 47.8
AC 1690 66.5
SRL-460 470 1036
WC 1586 62.4
1245 49.0 1007 39.6
AC 1690 66.5
SRL-520 490 1080
WC 1586 62.4
AC 1722 67.8
SRL-630 1657 65.2 1007 39.6 580 1279
WC 1586 62.4
AC 1722 67.8
SRL-750 670 1477
WC 1586 62.4
AC 1722 67.8
SRL-900 1807 71.1 690 1521
WC 1586 62.4
AC 2048 80.6
SRL-1210 1007 39.6 830 1830
WC 1586 62.4
AC 2208 86.9
SRL-1500 1100 2425
WC 1616 63.6
2257 88.9
AC 2208 86.9
SRL-1800 1190 2623
WC 1616 63.6

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3. System Design
The SRL dryer consists of two circuits: the Air Circuit and the Refrigeration Circuit:
F
G
The A The
Refrigerant Air
Circuit E B Circuit
C
D
H I
The refrigerant The liquids condense
cools the air. & are drained away.
• The Air Circuit: Consisting primarily of:
A. Air-to-Air heat Exchanger,
B. Air-to-Refrigerant Heat Exchanger,
C. Slowflow Demister Separator, and
D. Condensate Chamber

The air enters the dryer and passes through the Air-to-Air Heat Exchanger (A) where it is
cooled by the outgoing air. The air then passes through the Air-to-Refrigerant Heat Exchanger
(B) where it is further cooled by the refrigerant. The air then passes through the Slowflow
Demister Separator (C) where the condensate is separated from the air. The condensate
collects in the Condensate Chamber (D), before being discharged from the system by a
condensate drain (not shown). The air passes back through the Air-to-Air Heat Exchanger
where it is reheated by the incoming air before leaving the dryer.
• The Refrigeration Circuit: Consisting primarily of:
B. Air-to-Refrigerant Heat Exchanger,
E. Refrigerant Compressor,
F. Hot Gas Bypass
G. Condenser,
H. Refrigerant Filter, and
I. Expansion Device.
The refrigerant passes through the Air-to-Refrigerant Heat Exchanger (B) where it absorbs
heat from the air and evaporates into a gas. It then passes through the Refrigerant
Compressor (E) where it is compressed, and then through the Condenser (G) where it is
cooled by either the ambient air (air cooled models) or with cooling water (water cooled
models). This causes it to condense back into a liquid. It then passes through the Refrigerant
Filter (H) where any impurities are removed, and then the Expansion Device (I) where it is
expanded causing it to cool before returning to the Air-to-Refrigerant Heat Exchanger.
In some conditions, a portion of the refrigerant is directed clockwise through the Hot Gas
Bypass (F) and recirculated back to the compressor to avoid excessive cooling.

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3.1 The Air Circuit

The SRL is unique in that it’s entire air circuit is combined into a single compact 4-in-1 unit, combining:
• the Air-to-Air Heat Exchanger,
• the Air-to-Refrigerant Heat Exchanger,
• a Slowflow Demister Separator, and
• a Condensate Chamber.
Air to Refrigerant
into a single component (patent pending). Heat Exchanger
This combined component performs the A
functions of cooling the incoming air to the
desired temperature (using first the cold
outgoing air, and then the refrigerant), as well
as separating the liquid form the air stream, and
C B
collecting the condensate to drain it from the
system*.
The Air-to-Air and Air-to-refrigerant heat exchangers are an aluminium fin design, which combine high
surface area (and therefore efficient heat transfer) with low pressure drop and minimum corrosion.
The air circuit is insulated with special TSI Thermal Shield Insulation (polystyrene based) offering a
very high thermal retention for even further improved efficiency. D
There are three control devices in the Air Circuit
• the Dew Point temperature Sensor,
• the Evaporation temperature Sensor, and
• the Condensate Level Sensor*.
* Not applicable to the SRL-250.
Please note that in models over 1000 cfm, multiple air side heat exchanger assemblies are used in
parallel. For the number of heat exchangers for a given model, refer to Section 2.3.

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3.1.1 Air-to-Air Heat Exchanger

The Air-to-Air Heat Exchanger is an aluminium fin, cross flow exchanger. The Air-to-Air Heat
Exchanger is also often called a “Pre-cooler / Re-heater” because the hot air entering the dryer is pre-
cooled by the cold air exiting the dryer; while at the same time the cold air exiting the dryer is re-
heated by the hot air entering. Then end result is that the pre-cooling offers a significantly reduced
heat load on the refrigerant circuit (which offers notable energy savings), and the re-heating offers
elimination of condensation accumulation on the downstream air piping, as well as increasing the
temperature of the air, keeping it well away from the dew point. The air leaving the dryer is
approximately 10 degrees cooler than the air coming in.

3.1.2 Air-to-Refrigerant Heat Exchanger

The Air-to-Refrigerant Heat Exchanger (a.k.a. Evaporator) is an

aluminium fin, counter flow exchanger. Here, the air, having been
already pre-cooled in the Air-to-Air Heat Exchanger, is further cooled
by the refrigerant. This Heat Exchanger is part of both the air and
refrigerant circuits.
The refrigerant tubes are connected to the Air-to-Refrigerant Heat
Exchanger using Rotalock connections to facilitate removal if needed
.
3.1.3 Demister Separator

All models are equipped with a Slowflow demister type moisture separator to remove the condensed
liquids from the compressed air. The liquid droplets impact the stainless steel fibers of the demister,
and coalesce into larger drops where they are pulled into the Condensate Chamber by gravity.
The demister combines a high efficiency with a low pressure drop. It is significantly larger than
standard demisters (typically at least four times as large) and as such the air velocity across it is much
slower. In addition, the Slowflow design provides increased contact time allowing high separation
efficiency. The Slowflow demister separator guarantees perfect operation at all air flows, unlike
centrifugal separators which quickly lose efficiency at lower air flows, and standard demisters which
lose efficiency at higher air flows.
Once separated the condensate is removed from the air circuit by the condensate drain. The dry, cold
air then passes through the “re-heating” side of the air-to-air exchanger.

3.1.4 Condensate Chamber

Condensate is collected in the condensate chamber before being discharged from the system through
the Condensate Drain. On the SRL-325 to 1200 (60Hz) or SRL-120 to 350 (50Hz) the condensate
chamber is integrated into the air side heat exchanger assembly. On the SRL-1400 to 6000 (60Hz) or
SRL-460 to 1800 (50Hz) the condensate chamber is external to the heat exchanger assembly.

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3.1.5 Dew Point Temperature Sensor

All models have a Dew Point Temperature Sensor that measures the temperature of the air leaving
the Air-to-Refrigerant Heat Exchanger. At this point in the dryer, the temperature of the air is
theoretically equivalent to what the outlet dew point will be. This is the dew point temperature which is
shown on the digital display during normal operation.

3.1.6 Condensate Level Sensor

All models except the SRL-250* have a Level Sensor in the Condensate Chamber. This sensor sends
a signal to the microprocessor when the level of condensate reaches it, which then opens the
Condensate Drain Valve. Details of condensate drain operation are covered in Section 9.
* There is not enough volume in the condensate chamber of the SRL-250 to allow efficient zero air loss drain
operation, so no level sensor is required.

3.2 Refrigeration Circuit

All models have the option of operating in continuous mode, or operating in cycling mode on a thermal
mass principal. For an overview of the thermal mass concept refer to 3.2.1 below. For full details on
both operation options, refer to Section 8.
The main components of the refrigeration circuit are the Compressor, the Condenser, the
Refrigerant Filter, the Expansion Device, the Hot Gas Bypass and the Air-to-Refrigerant Heat
Exchanger (as described in 3.1.2 above). In addition, there are several control components:
• High Pressure Switch - to shut down the dryer in the event of overpressure of the refrigerant system,
• Low Pressure Switch – to prevent freezing in the event of a system upset, and
• Fan Pressure Switch – to cycle the condenser fan on and off.
These components are connected in a closed
loop with pipes made entirely from high quality
copper, through which the refrigerant flows. All
models use R407C refrigerant.
The refrigeration circuit functions as a closed
loop.

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3.2.1 The Thermal Mass Concept

The combined air side heat exchanger assembly serves an additional purpose as a “Thermal Mass” –
that is a mass of material with high thermal retention – or the capacity to absorb a significant quantity
of heat without a rapid rise in temperature.
As the heat exchanger assembly absorbs heat from the air, it disperses this heat throughout its mass.
The controls of the SRL dryer monitor the temperature of the heat exchanger, and at reduced heat
loads (i.e. inlet air temperatures or flow rates below the rated maximum), it cycles the refrigerant
compressor on and off to keep the heat exchanger between upper and lower temperature limits.*
The less the heat load in the incoming air, the less heat is transferred to the heat exchanger, the
slower the temperature rises, the less the refrigerant compressor needs to come on, and the lower the
overall power consumption.
* This is a simplified explanation. For full details on cycling operation please refer to Section 8.

3.2.2 Compressor
All models (with the exception of the SRL-250*) are
equipped with compliant scroll refrigerant compressor
with a three phase motor. These compressors are
maintenance-free and installed on vibration damping
mountings.
The compressor reduces the pressure in the evaporator
ensuring the refrigerant evaporates at the correct
pressure (and therefore temperature). It compresses
the evaporated refrigerant and sends it to the
condenser.
Piston Compressor: Scroll Compressor:
The scroll compressor has two spirals (scrolls). One SRL-250 SRL-325 to 6000
stays stationary, while the other orbits within it. As this
motion occurs, the pockets between the two spirals are pushed to the centre while simultaneously
being reduced in volume. When the pocket reaches the center of the scroll form, the gas, now at a
high pressure, is discharged.

The SRL-325 to 1400 (60Hz) and SRL-120 to 520 (50Hz) are equipped with thermal overload
protection via a thermo amperometric internal switch. The SRL-1600 to 6000 (60Hz) and SRL-630 to
1800 (50Hz) are equipped with external electronic thermal protection.
Compliant scroll compressors are not damaged by liquid returns, and as such, they do not require pre-
heating upon start-up. They also offer significant advantages in terms of energy savings, reliability,
high efficiency and quiet operation.

* The SRL-250 uses a hermetically sealed piston compressor.

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3.2.3 Condenser

The condenser cools the refrigerant causing it to

condense back to a liquid.
The SRL-700 through 6000 (60Hz) and SRL-220 through
1800 (50Hz) can be purchased with either an air cooled
or water cooled condenser.
In an air cooled condenser, the refrigerant is fed through
finned coils (copper pipes, aluminium fins) across which
ambient air is blown by one or more axial fans.
In a water cooled condenser the refrigerant is fed through a brazed plate heat exchanger where it is
cooled by the water.
On all air cooled models the condensing coils are protected by a wire mesh pre-filter. This significantly
reduces dirt accumulation on the condenser, thereby reducing the need to shut the dryer down for
condenser cleaning, while at the same time reducing energy consumption.
In addition the condensing section is completely separated from the rest of the dryer, thereby allowing
maintenance even when the dryer is in operation.
The heat absorbed by the refrigerant in the Air-to-Refrigerant Heat Exchanger and produced during
compression, is rejected to the ambient in the condenser. If the condenser is unable to reject all the
heat absorbed (i.e. due to fouling), the refrigerant system will overheat and over pressure, resulting in
shutdown. For further information see Section 10.

3.2.4 Refrigerant Filter

The refrigerant filter is of a solid desiccant type construction that removes
solid and liquid contaminants from the refrigerant. Without it,
contaminants would re-circulate throughout the circuit continuously. Solid
contaminants could damage the compressor or block the flow of
refrigerant. Moisture could cause the compressor oil to become acidic.
The filter/dryer catches any solid contaminants in the system and absorbs
any moisture.
It is important to replace the filter if it becomes blocked, if the refrigerant system has been open to
atmosphere for an extended period of time, or if the compressor has been replaced.

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3.2.5 Expansion Device

The expansion device reduces the pressure (and therefore temperature) of the
refrigerant and regulates it’s flow into the Air-to-Refrigerant Heat Exchanger.
All models use a capillary tube expansion device. The capillary tube is a copper
tube of precise length and diameter that provides a specific pressure drop and
choked flow rate. For details on each model, refer to Section. 2.3.

3.2.6 Refrigerant
The refrigerant is the medium used to transfer energy. By changing pressure and temperature and
changing from a liquid to a gaseous state it effectively transforms the input energy (i.e. compressor
electrical energy) to output energy (i.e. cooling of the air). All models feature R407C refrigerant.
R407C is classified as an environmentally friendly refrigerant, and offers an ODP (Ozone Depletion
Potential) of zero. As a consequence R407C has no planned phase-out date and can be used without
restrictions. It also offers a very low GWP (Global Warming Potential) level. R407C furthermore
features a high COP (Coefficient of Performance), thereby ensuring that the dryer’s power
consumption is kept to a minimum.

3.2.7 High Pressure Switch

Settings: On: 406 psig (28 barg), Off: 305 psig (21 barg).
Shuts down the dryer in the event of overpressure of the refrigerant system.
Installed at the compressor outlet. When it trips, the display will show the HP (High
Pressure) alarm, and the remote alarm contacts will be activated.
On all models the switch automatically resets when the pressure goes back below
305 psig (21 barg).
See Section 10 for details on troubleshooting an HP (High Pressure) alarm.

3.2.8 Low Pressure Switch

Settings: On: 21.7 psig (1.5 barg), Off: 36.2 psig (2.5 barg).
Al models have a Low Pressure Switch to shut down the dryer in the event of low
pressure at the compressor inlet, as this indicates a refrigerant temperature below
freezing. If the pressure goes below the set point for more than 2 minutes, the
microprocessor will shut down the dryer and go into alarm. The display will show the
LP (Low Pressure) alarm, and the remote alarm contacts will be activated.
The switch automatically resets when the pressure returns above 36.2 psig.
See Section 10 for details on troubleshooting an LP (Low Pressure) alarm.

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3.2.9 Fan Pressure Switch (Air Cooled Models)

Settings: On: 275 psig (19 barg), Off: 203 psig (14 barg).
Controls operation of the condenser fan which keeps the pressure (and therefore
temperature) of the refrigeration circuit within design limits. Turns the fan on
when the refrigerant pressure reaches 275 psig (19 barg) and off when it reaches
203 psig (14 barg).

3.2.10 Water Regulating Valve (Water Cooled Models)

Regulates the flow of water into the condenser to maintain a constant refrigerant
pressure (and therefore temperature). Adjustment at start up may be required
depending on the cooling water temperature.

3.2.11 Hot Gas Bypass Valve

Setting: Max: 66.7 psig (4.6 barg) Min: 62.4 psig (4.3 barg).
Maintains a constant refrigerant pressure in the compressor suction line to account for changes in the
heat load. As the heat load into the dryer decreases, less heat is transferred to the refrigerant in the
Air-to-Refrigerant Heat Exchanger, and so less refrigerant evaporates. This causes the pressure in
the compressor suction line to drop. The Hot Gas Bypass Valve injects hot high pressure refrigerant
from the compressor outlet into the suction line to keep it constant.
For details on adjusting the Hot Gas Bypass Valve, refer to Section 12.

SRL-250 to 1400 (60Hz) SRL-1600 to 6000 (60Hz)

SRL-220 to 520 (50Hz) SRL-630 to 1800 (50Hz)

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3.2.12 Liquid Accumulator

The SRL-700 to 6000 (60Hz) and SRL-220 to 1800 (50Hz) have a liquid
accumulator in the refrigerant suction line before the compressor. Even
though the compliant scroll compressor can handle some liquids, this
prevents large volumes of liquids from reaching the inlet.
The refrigerant mixture (in both gas and liquid form) enters the separator,
where the liquid falls to the bottom, and the gas moves to the top. By pulling
the refrigerant from the top, only refrigerant in gas form reaches the
compressor. In addition, to ensure proper lubrication of the compressor,
lubricant which collects in the accumulator is drawn through a capillary tube
into the suction line.

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4. Control System
The SRL-250 and larger dryers are fitted with microprocessor controls.

4.1 Power Supply

The following power supplies are offered on 60 Hz models:
• 230V/1ph/60Hz +/-10% on the SRL-250
• 230V/3ph/60Hz +/-10% on the SRL-250 through 800
• 460V/3ph/60Hz +/-10% on SRL-250 through 6000
• 575V/3ph/60Hz +/-10% on SRL-250 through 6000

All 50 Hz models are 400V/3ph/50Hz +/-10%.

4.2 Microprocessor Controls

The microprocessor controls on the Sullair SRL Dryers allow you to turn the dryer on and off, controls
the operation of the dryer, and continuously monitors the working parameters, informing the user of
possible problems through lights, alarms and a digital display.
In addition, the microprocessor also:
- Records and displays the last 8 warnings or alarms,
- Records the working hours of the dryer and of the refrigerant compressor,
- Provides a Service Required warning at a pre-set interval,
- Controls the cycling operation of the refrigerant compressor (SRL-325 & larger, when in Cycling
mode), and
- Controls operation of the condensate drain.
The microprocessor can also be connected to an external Modbus RTU protocol compatible system
by installing an (optional) RS-485 communication port. See Section 10.5 for further information.
The electrical panel is located inside the dryer and positioned for easy access. It is directly accessible
from the front via a hinged door, with a door lock integrated into the dryer’s main switch.
The power section comprises a main isolator switch, protection against motor over current, and a
series of contactors.

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4.2.1 Inputs

Consists of both analog inputs (J2) and digital inputs (J1 & J3).

Analog Inputs (J2)

J2 1 GND Ground for temperature sensors.
J2 2 B1 Dewpoint Temperature Sensor (B1)
J2 3 B2 Evaporator Temperature Sensor (B2)
J2 4 B3 Compressor Discharge Temperature Sensor (B3)
J2 5 B4 Optional Temperature Sensor

Digital Inputs (J1 & J3)

J1 1 ID5 Low Pressure Switch (LP Alarm)
J1 2 0V Power (Ground)
J1 3 24V Power (24Vac)
J1 5 ID1 High Pressure Switch (HP Alarm)
J1 8 ID2 Compressor Protection (CP Alarm)*
J1 11 ID3 Remote On-Off

J3 1 IDC2 Common (Ground)

J3 2 ID4 Drain Level Sensor**
J3 3 +5V Power Input to Drain Level Sensor**

* SRL-1600 to 6000 (60Hz) and SRL-630 to 1800 (50Hz) only.

** SRL-325 to 6000 (60Hz) and SRL-120 to 1800 (50Hz) only.

4.2.2 Outputs

All outputs are digital.

Digital Outputs (J1 & J3)

J1 4 NO1 Compressor Contactor (KM1) & Liquid Line Solenoid Valve (YV1)
J1 6 C4 Common Alarm
J1 7 NO2 Hot Gas Bypass Solenoid Valve (YV2)
J1 9 NO4 Alarm/Warning (N/O) Contact
J1 10 NO3 Drain Solenoid Valve (YV3)
J1 12 NC4 Alarm/Warning (N/C) Contact

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4.2.3 Electrical Specifications

Power Supply 24 Vac ± 20%

Temperature Sensors B1,B2 & B4: Reading Range -10oC to +90°C ± 1°C
Temperature Sensor B3: Reading Range 0°C to 150°C ± 5°C
Input for HP, LP, CP & Remote On-Off 24 Vac
Output for Drain Level Sensor 5Vc.c. - 15mA
Output to KM1, YV1, YV2, VY3 Vmax 30Va.c. - Imax 1A
Output for Alarm/Warning Signal Vmax 30Va.c. - Imax 1A

4.2.4 User Interface

Digital Display Energy Saving Indicator Synoptic Display

Control Buttons On / Off Switch Alarm & Warning List

The main control panel of the dryer consists of:

• On/Off Switch with door block,
• 7-segment, 3-digit digital display,
• 4 LED Lights, and
• 4 Buttons
• List of Alarms & Warnings
• Synoptic display

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4.2.4.1 Lights

Power LED
o Yellow: indicates the dryer is off, but connected to a power supply.
o Green: indicates the dryer is operating.

Warning LED
o Red: indicates the dryer has a warning or alarm.

Drain LED
o Green: indicates the drain valve is open.

Energy Saving LED

o Green: indicates that the parameters for cycling the refrigerant compressor
off have been met. The refrigerant compressor is currently off (and the dryer
is therefore saving energy). Not applicable to the SRL-250.

Alarm Reset Drain Test

Up Exit

Alarm LED Drain LED

Power LED

Alarm Report On / Off

Down Enter

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4.2.4.2 Buttons

Alarm Reset / Up
o Standard Function: Resets Alarm or Warning.
o In Alarm Menu: Scrolls up to previous alarm or item.
o In Parameter Menu: Scrolls up to previous parameter or increases a
value (when modifying a parameter).

Alarm Report / Down

o Standard Function: Displays recorded alarms & warnings.
o In Alarm Menu: Scrolls down to next alarm or item.
o In Parameter Menu: Scrolls down to previous parameter or decreases a
value (when modifying a parameter).

Drain / Exit
o Standard Function: Manually operates the drain valve according to
timed mode settings. (See Section 9)
o In Alarm Menu: Exits the current alarm, item or menu.
o In Parameter Menu: Exits the current parameter or menu.

On/Off / Enter
o Standard Function: Turns the dryer on and off.
o In Alarm Menu: Enters the current alarm or item.
o In Parameter Menu: Enters the current parameter or saves changes to
its value (when modifying a parameter).

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5. Installation

The SRL dryers have Nema 1 protection against the ingress of moisture and particles. They must be
installed indoors or provided adequate protection against wind, rain and direct sunlight. Faults
occurring from improper installation are not covered by warranty.
• Orient the unit so that there is adequate access to the control panel and drain compartment.
Verify that a minimum clearance of 5 ft (1.5 m) is left around the machine for maintenance access
and ventilation to the unit. For models with condenser fans in the top panel, leave at least 7 ft (2
m) above the dryer for adequate cooling air discharge.
• Refer to the Operating Limits in Section 2 for details on maximum and minimum ambient
temperatures.
• Verify that the power supply provided matches the the power supply indicated on the rating label
for the dryer.
• Connect the supply power cables and ground in accordance with all applicable regulations.
• Protect the dryer with an overcurrent and ground circuit breaker (0.3 Amps).
• Connect the inlet and outlet compressed air piping connections to the dryer using the correct ports
as indicated on the dryer.

SRL-250 through 1200 have BSP threaded inlet and outlet ports. BSP to NPT adapters
are provided (loose) and must be installed. Attempting to thread in NPT pipe into the
BSP ports will damage to the threads.

• Install a bypass line around the dryer, and inlet and outlet isolation valves, so that maintenance or
calibration operations can be carried out without interrupting the downstream compressed air
supply.

Do not flow air through the dryer when it is OFF. Open they bypass line and close the
inlet and outlet isolation valves at all times when the dryer is in the OFF position.

• Install a Sullair 1 micron coalescing pre-filter (SCF or PF) immediately upstream of the dryer to
prevent rust, pipe scale, bulk water, oil or other pollutants from entering the system and clogging
the heat exchangers, separator, or condensate drain. This can cause pressure drop, condensate
carry over, loss of efficiency, and or damage to the dryer.

Adequate Sullair pre-filtration is a requirement for extended warranty coverage. Contact

Sullair for further details.

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• If necessary, protect the dryer from vibration using vibration dampeners and/or flexible hoses on
the inlet and outlet.
• Also if necessary, protect the dryer from pulsation in the air stream by installing a upstream wet air
receiver.
• Pressure safety relief valves must be installed in the compressed air system in accordance with
local regulations. Verify that these valves will protect the dryer from any pressure above 203 psig
at all times.
• Ensure that the inlet compressed air and ambient air in and around the dryer do not contain solid
or gaseous contaminants. All compressed and condensed gases can generate acids or chemical
products which may be aggressive against the aluminium heat exchanger or the other components
inside the dryer. Take particular care with sulphur, ammonia, chlorine, and installations in marine
environments.
• Protect the dryer from instantaneous or continuous flows in excess of the dryers’ maximum rated
capacity. This may require installation of a down stream air receiver.
• Ensure the drain outlet is free from restriction and back pressure. Do not connect drain outlets into
a common header if there is any chance that any condition (i.e. multiple drains discharging at the
same time could cause a restriction or back flow.)

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6. Start-up
Before starting up the dryer, make sure that the air inlet and outlet isolation valves are closed, and the
bypass valve is open. This will ensure there is no air flow through the dryer.

For water cooled units do not open the isolation valves to allow cooling water to flow of
water through the condenser until immediately before start up, otherwise, the HP (high
pressure) alarm may occur. In this case, reset the alarm on the control panel, wait few
minutes and restart the dryer. You may have to restart the unit repeatedly to get this
alarm to disappear.

Turn the ON/OFF switch to the “I/On” position.

The Power LED (4.2.4.1) comes on (yellow).
Press the ON/OFF Button (4.2.4.2).
The Power LED light turns from yellow to green, the Refrigerant Compressor (3.2.2) starts and
the digital display shows the B1 temperature reading (dew point temperature).

On three-phase units if the phases are inverted, the compressor and the fan will rotate
in the wrong direction. In this case:
a) The scroll compressor is not displacing any refrigerant. It will be noisy
and the dryer will vibrate. Since the dryer is not producing any cooling
effect, after 15 minutes, the “Hd” (High dew point) warning will come on.
b) The fan is moving air in the wrong direction. This can be verified by
comparing the air flow to the air flow indicated in the User Guide and on
the name plate inside the electrical panel.
Shut down the dryer, isolate the power supply, and swap the two phases.

Let the dryer operate without air flow until the dew point drops to operating levels and the dryer
begins to cycle.
Slowly open the inlet isolation valve to pressurise the dryer, then open slowly the outlet isolation valve.
Close the bypass valve.
The dryer is now on line and operating.

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7. Operation & Control

7.1 Turning the Dryer On or Off

Turn the main switch to the “I/ON” position.
For the first few seconds, the controller does an internal check, during which time the
display shows “d.t.3”, indicating the version of the software installed.
The dryer then can be in one of three operating modes:
• OFF: The display is off. The “Power” light is yellow. Al other lights are off.
• ON: The display shows the reading of dew point sensor (B1). The “power” light is green.
All other lights are off, lighting up only when: a) an alarm or warning occurs, b) the drain
valve is activated, or c) the refrigerant compressor cycls off.
• Remote OFF: In this case the dryer has been turned off remotely. The
display shows “r.OF”. The “Power” light is yellow. Al other lights are off.
Note: The Remote OFF function can be activated by replacing the bridge between
terminals X4.0 and X4.10 in the electrical cabinet with a switch. With the contact open, the
remote OFF is activated (dryer is turned off), with the contact closed, it is not activated
(dryer is turned on).
To turn the dryer ON, press the ON/OFF button (or provide the command via an external control
system as described above). The display will show the B1 (dewpoint temperature) sensor reading and
the refrigerant compressor will turn on*.
To turn the dryer OFF, press the ON/OFF button or provide the command via an external control
system. The display goes off, and the refrigerant compressor stops.
The dryer can also be turned OFF remotely by opening the Remote OFF Contacts as described
previously. In this case the compressor stops and “r.OF” is displayed. Note that the On/OFF switch
must be in the On position in order to activate the Remote Off Mode.
When in remote OFF, closing the Remote Off Contacts turns the dryer on. The
compressor comes on* and the display blinks “on” for 5 seconds and then displays the
B1 dewpoint temperature reading.
The dryer status is recorded in the flash memory of the controller, so disconnecting power to the unit
while it is on will cause the dryer to automatically come back on 5 seconds after the power is restored.
If during these 5 seconds the ON/OFF button is pressed or an off command is coming through the
external control system, the controller stays off.
* If the evaporator temperature is below the cycling set point, the refrigerant compressor will remain off
and the “Energy Saving” light will come on.

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7.2 User Parameter List

Parameter Description Units Min Max Default
A1 Temperature Unit of Measure - 0 (oC) 1 (oF) 1 (oF)
A2 Dryer Working Hours hrs 0 999 0
A3 Dryer Working Hours x 1000 hr x 103 0 999 0
A4 Compressor Working Hours hrs 0 999 0
A5 Compressor Working Hours x 1000 hr x 103 0 999 0
A6 High Dewpoint (Hd) Warning Setting oC / oF 0 / 32 70 / 158 15 / 59
A7 Disable Remote Off - 0 (no) 1 (yes) 0 (no)
B1 ID Number in Modbus Network - 1 200 1
B2 Serial Communication Speed kbaud 1.2 19.2 9.6
(1)
B3 Reset Service Required Warning (1) - no YES no
(1)
B7 Reset Alarm History Report (1) - no YES no
B8 (2) Refrigerant Compressor Outlet Temperature (2) oC - - -
(1)
B9 Service Required Warning Interval (1) hrs x 103 1 999 6
(3)
C7 Dryer Operating Mode (3) (5) - CYC Con CYC
D1 Drain Duration (Time open) sec 1 60 5
D2 Drain Interval (Time closed) sec 1 900 120
(4)
D3 Drain Operation Mode (4) (5) - 0 (CAP) 2 (Con) 0 (CAP)

(1) Parameters B3, B7 & B9 are passcode protected and cannot be changed or reset without the
proper code. Refer to Section 10.3 & 10.4 for further information.
(2) Parameter B8 only displays the temperature being read by the sensor. It cannot be modified.
(3) Parameter C7 changes the dryer operating mode. CYC = Cycling Operation Mode.
Con = Continuous (Non-Cycling) Mode. Refer to Section 8 for further information.
(4) Parameter D3 changes the drain operating mode. CAP = Capacitive (Zero Air Loss) Mode,
tiM = Timed Mode, Con =Continuous (Deactivated) Mode. Refer to Section 9 for further
information.
(5) Cycling Operation Mode and Capacitive Drain Mode are not applicable to the SRL-250.

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7.3 Accessing & Modifying User Parameters

To access the User Parameters:

• Press the Alarm Reset & Alarm Report buttons simultaneously. &

The display will show you are at Parameter “A1”.

To view and modify the User Parameters:

• Press the Up or Down buttons to scroll through the parameters. or

• When you get to the parameter you want, press Enter to see it’s value.
or
(1)
• Press the Up or Down buttons to modify it’s value . or

• Press Enter to save your changes (2).

• Press Exit to leave the parameter (2).

(1) Parameters B3, B7 & B9 are passcode protected and cannot be changed or reset without the proper
code. Contact Sullair for further information.
(2) If you press Exit without first pressing Enter to save your changes, you will exit without saving and the
parameter will revert to it’s previous value.

Note that once inside the parameters menu, the meaning of the buttons is different from the standard
operation. (See section 3.2) It is not possible to:
• Turn the dryer On or Off
• Reset a warning or alarm
• Display the alarm report
• Activate the drain valve

Once in the parameters menu, if the user does not press any button for 5 minutes, the controller will
exit the menu and return to standard operating mode.

To exit the parameter menu and return to the standard operating mode, press Exit.

When in standard operating model the display will show either:

• “OFF” when the dryer is OFF,
• “r.OF” with dryer is in Remote OFF mode,
• the dew-point temperature when the dryer is ON and has no alarm, or
• the alarm or warning code if the dryer is ON and has an alarm or warning.

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8. Dryer Operating Modes

In most applications, the air stream passing through the refrigerated dryer changes in pressure,
temperature and flow rate throughout the day and throughout the year. This is due to external
influences such as ambient temperature, and the pattern of usage of the air in the application.

As the temperature, pressure and flow of the incoming air flow varies, so does the amount of heat the
refrigerant absorbs. If the flow of refrigerant did not constantly adjust to match this incoming heat
load, the temperature of the evaporator (and therefore the outlet dewpoint of the air) would increase
as the heat load increased, and decrease as the heat load decreased. If the temperature in the
evaporator dropped below freezing, the forming condensate would freeze, and the evaporator would
quickly block with ice.

Therefore it is vital that the refrigerant circuit be constantly controlled to maintain a steady temperature
(and therefore pressure) in the evaporator. Ultimately the temperature in the evaporator is maintained
at about 35 to 39 degrees Fahrenheit – just above freezing. In this way, the dryer provides the lowest
possible dewpoint, while keeping the condensate in liquid form so it can be removed.

8.1 Continuous Mode

When Parameter C7 is set to “Con” the dryer operates in continuous mode. This can also be called
direct expansion, or non-cycling mode. The refrigerant compressor runs continuously and variations
in the thermal load are handled by means of the hot gas bypass valve. The hot gas bypass valve
monitors the pressure in the suction line between the evaporator and the compressor. As the
pressure decreases – signaling a lower heat load, and therefore less evaporation is taking place in the
evaporator - it begins injecting hot high pressure gas from the compressor discharge to keep the
pressure (and therefore temperature) steady.

Note that in this arrangement the solenoid upstream of the Hot Gas Bypass valve is constantly open.

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8.2 Cycling Mode

When Parameter C7 is set to “CYC” the dryer operates in cycling mode. In this mode the
microprocessor reads the dew point, the temperature of the evaporator, and the time since the
compressor was last turned off, and cycles the refrigerant compressor on and off as required to keep
the temperature of evaporator between preset upper and lower temperature limits.

As the temperature in the evaporator decreases, these three values are fed into an algorithm which
calculates whether or not to turn the refrigerant compressor off. This algorithm is designed to maintain
a minimum dewpoint, while ensuring maximum energy savings, and protecting the compressor from
excessive starts and stops.
When these three goals have been met, the compressor is turned off and the “Energy Saving” light
turns on indicating the compressor is stopped and the dryer is saving energy.

It should be noted that there is no specific temperature at which the compressor will turn off. The
microprocessor must also consider other factors such as the amount of time since the compressor
was last turned off, and therefore may delay turning the compressor off regardless of the temperature
of the evaporator. In these cases, the Hot Gas Bypass Valve will ensure the temperature in the
evaporator is maintained to avoid freezing.

While the compressor is off, the temperature in the evaporator will begin to rise. This is due to heat in
the air flow (or, if there is no airflow, due to the ambient). When the evaporator reaches a preset
temperature value, the compressor is turned back on.

The purpose of the “cycling” mode is solely to save energy. Dewpoint will fluctuate moreso in Cycling
mode than in Continuous mode so it is suggested that if energy costs are not a concern, the dryer is
operated in continuous mode for optimum performance and reliability.

Note: Cycling mode is not available on the SRL-250.

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9. Condensate Drain Operation

9.1 SRL-250
The SRL-250 has a solenoid valve (coil YV3) that is controlled as a timed drain by the microprocessor
on the dryer. The user can adjust the operation of the drain by changing User Parameters D1
(Duration) and D2 (Interval) on the dryers control panel. See Section 7.3 for further information on
accessing and adjusting User Parameters.
Parameters Units Min Max Default
D1 Drain Duration (Time open) sec 1 60 5
D2 Drain Interval (Time closed) sec 1 900 120

9.2 SRL-325 to 6000

On dryers SRL-325 through 6000 the solenoid valve can be also
controlled as a zero air loss drain by the microprocessor. Factory
Parameters D4 through D8 control the operation to ensure zero air loss
operation. These parameters are locked and cannot be viewed or
adjusted.
Parameters Units Min Max Default
D4 Drain Open Delay* sec 0 900 60
D5 Drain Close Delay (Normal Cycle)* sec 0 120 5
D6 Drain Close Delay (Extended Cycle)* sec 0 300 10
D7 Extended Cycle Interval* - 0 900 100
D8 Drain Alarm Setting* sec 10 900 30

Condensate collects in the Condensate Chamber (3.1.4). The Level Sensor (3.1.6) continuously
monitors the level of condensate, closing the contacts and sending a signal to the microprocessor
(digital input ID4) when it senses liquid.
The microprocessor opens the solenoid drain valve (coil YV3) when it gets a signal from the Level
Sensor continuously for 30 seconds (Parameter D4 – Drain Open Delay).
The condensate is then discharged from the Condensate Chamber through the solenoid drain valve
under pressure.
The microprocessor closes the solenoid drain valve when it stops getting a signal from the level
Sensor continuously for 5 seconds (Parameter D5 – Drain Close Delay).

(Continued on following page…)

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Every 100 cycles (Parameter D7 – Extended Cycle Interval), the microprocessor goes through an
extended cycle, keeping the drain open for 10 seconds (Parameter D6 –Drain Close Delay [Extended
Cycle]) after the level Sensor stops sending a signal. This allows the drain to periodically clean itself.

If the drain has been open for 30 seconds and the Level Sensor still senses liquid (Parameter D8 –
Drain Alarm Setting), the dryer goes into alarm. “drE” flashes on the display, and the microprocessor
automatically changes to timed operation in accordance with the interval and duration settings in User
Parameters D1 & D2. When the Level Sensor stops sensing liquid, the microprocessor will
automatically change back to zero air loss operation.

If desired the user can force the drain on the SRL-325 through 6000 to always operate in timed mode
or they can deactivate drain control completely*. This is achieved by adjusting Parameter D3 – Drain
Operating Mode. See Section 9.4 for details on this parameter.

* In this case, the solenoid valve must be removed and a separate self controlling condensate drain installed.

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9.3 Drain Operating Mode (Parameter D3)

Parameter D3 changes the operating mode of the condensate drain. There are 3 settings available for
this parameter:

Capacitive (Zero Air Loss): The drain solenoid valve (output YV3) is controlled by the
level sensor (input ID4) found inside the integrated or external condensate chamber.
This option is on the SRL-325 to 6000 (60hz) or SRL-120 to 1800 (50Hz) ONLY)

Timed: The drain solenoid valve (output YV3) is controlled by the duration and interval
settings in Parameters D1 & D2.

Continuous (Deactivated): For use when customer prefers to install a separate self
controlled external drain. (Signal to open N03 is always activated - even if the dryer is
off.)

Note: Since the SRL-250 has no level sensor, if the “Capacitive” mode was set on this
model, the microprocessor would get no signal to open, and would keep the valve
closed permanently.

Note that when the drain is set to Continuous (Deactivated) Mode, the drain solenoid
valve must be removed and an external self controlled condensate drain must be
installed. The external drain can be powered through the board output NO3 (24V) or
directly from the electrical cabinet.

9.4 Manual Drain Activation

When set in either Capacitive or Timed mode, the drain valve can be manually activated by
pressing the Drain Button. When the button is pressed the solenoid valve coil is energized
for the duration time set in parameter D1. The manual drain activation is always possible no
matter what the dryer status or signal coming from the level sensor.

If you press the Drain Button while the drain is activated by the controller, it will cause the drain valve
to close.

For further information on the Drain LED and Drain Button, please refer to Sections 4.2.4.1 & 4.2.4.2.

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10. Alarms & Warnings

10.1 Alarm & Warning List

Code # Description Type Delay Action

HP 1 High Pressure Alarm None Stops Dryer.
LP 2 Low Pressure Alarm 2 min Stops Dryer.
Ld 4 Low Dewpoint (B1) Alarm 3 min Stops Dryer.
Ht 9 High Discharge Temperature (B3) Alarm None Stops Dryer.
Lt 10 Low Evaporation Temperature (B2) Alarm 1 min Stops Dryer.
CP 11 Compressor Protection Alarm None Stops Dryer.
PdE 12 Parameter Data Error Alarm None Stops Dryer.
Hd 3 High Dewpoint Temperature (B1) Warning Note 1 Trips common alarm.
drE 5 Drain Error Warning None Changes to Timed Mode
dSE 7 Dewpoint Sensor Error (B1) Warning None Trips common alarm.
rSE 8 Evaporator Temp Sensor Error (B2) Warning None Trips common alarm.
Sr 6 Service Required Warning None Trips common alarm.

The control board is provided with an alarm relay with NO/NC contacts. The relay is normally
energized once the controller is powered in order to provide an alarm indication when a fault happens
or when power is disconnected.

When the controller gets a signal to indicate an alarm or warning, it cuts power to the alarm relays,
turns on the “Warning” light, and displaying the alarm code on the digital display. Each alarm/warning
is identified with a number which is used to pass the information through the serial port.

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10.2 Troubleshooting Alarms & Warnings

10.2.1 High Pressure (Alarm)

What it means: High pressure switch registers a refrigerant pressure above 406 psig (28 barg).
What it does: Cuts power to compressor contactor & alarm contacts. Turns the dryer OFF. Turns
on Warning Light & blinks “HP” on the digital display.
Possible Causes & Remedies:
1) High ambient temperature in the compressor room due to:
a. Warm weather,
b. Poor compressor room ventilation,
c. Poorly located dryer (restricted air flow through the condenser),
d. Compressor aftercooler is exhausting warm air near the dryer.
Remedy - increase ventilation to the compressor room, duct the compressor after-cooler
out of the room, or move the dryer to a cooler location.
2) The condenser is dirty causing a reduction of air flow and/or cooling if the refrigerant.
Remedy - Clean the condenser coils and condenser pre-filter (if applicable) by blowing
compressed air backwards through them. Be careful not to bend the fins.
3) The condenser fan is not coming on because of a failure of the fan motor, contacts, or
pressure switch. (Can be confirmed by checking the condensing pressure with a gauge.)
Remedy - Replace the detective component.
4) Excessive thermal load on the dryer due to excessive air flow rate and/or air inlet
temperature. (Can be confirmed using the instructions in Section 13.)
Remedy – Improve the efficiency of the aftercooler on the compressor, install an additional
or larger air or water cooled aftercooler upstream the dryer, or install a larger dryer. If the
overload is limited to a very short period of time, this alarm can be avoided by partially
opening the air by pass line to reduce the load to the dryer. Please note that this will
significantly increase the downstream dew point.
5) Defective high pressure switch. (Can be confirmed by checking the condensing pressure
with a gauge.)
Remedy - Replace the detective component.
6) Incorrect start-up procedure. Compressed air was allowed to flow through the dryer
before it was started, causing an immediate HP alarm on start up.
Remedy – Isolate the dryer from the air flow by closing the inlet and outlet isolation valves
and opening the bypass line. Start the dryer with no air flow. You may need to start the
dryer repeatedly before the alarm clears.
To Reset: Press ALARM RESET. Power restored to alarm relay, Warning Light goes off.
Dryer remains OFF. Display clears.
Press ON/OFF to restart dryer.
Notes: Alarm can only be cleared if the pressure is below 304 psig (21 barg).

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10.2.2 Low (Evaporator) Pressure (Alarm)

What it means: Low pressure switch registers a refrigerant pressure below 22 psig (1.5 barg) for 2
minutes or more.
What it does: Cuts power to compressor compressor contactor & alarm contacts. Turns dryer
OFF. Turns on Warning Light & blinks “LP” on the digital display.
Possible Causes & Remedies:
1) A low refrigerant charge is causing the compressor to pull the suction pressure
below 22 psig.
Remedy – Check or leaks at welds, threaded connections, schrader valve caps,
and joints of the condenser and evaporator. Repair the leak, pull the system to deep
vacuum and charge the dryer with the correct amount of refrigerant as specified in
the Section 2.3.
2) A defective low pressure switch is giving a wrong signal to the controller. Can be
confirmed by checking the evaporator pressure with a gauge.
Remedy - Replace the detective component.
To Reset: Press ALARM RESET. Power restored to alarm relay, Warning Light goes off.
Dryer remains OFF. Display clears.
Press ON/OFF to restart dryer.
Notes: Alarm can only be cleared if the pressure is above 36 psig (2.5 barg).

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10.2.3 Low dewpoint (Alarm)

What it means: Temperature sensor B1 (dew point temperature) registers a temperature below
28.4oF (-2oC) for 3 minutes or more.
What it does: Cuts power to compressor contactor & alarm contacts. Turns dryer OFF. Turns on
Warning Light & blinks “Ld” on the digital display.
Possible Causes & Remedies:
1) Hot Gas Bypass Valve is miscalibrated, causing it to allow pressure in the
evaporator to go too low, causing the temperature to go below 28.4oF (-2oC).
Remedy – Adjust the Hot Gas Bypass Valve as outlined in Section 12.
2) Low ambient temperature is causing excessive cooling of the refrigerant in the
condenser. The dryer may be installed outdoors, in an unheated room, or near a
vent. This cause can be confirmed by checking the condensation pressure with a
gauge. It will stay below 261 psig and the fan never comes on.
Remedy – Increase the ambient temperature in the room or duct the air for the
condenser from a warmer source. Alternately, you can partially cover the
condenser coils in order to reduce the air flow across them, thereby reducing the
cooling effect.
3) A defective fan pressure switch is causing the condenser fan to stay on all the
time causing excessive cooling of the refrigerant.
Remedy – Replace the defective component.
4) The dewpoint temperature sensor (B1) is miscalibrated, causing a low reading.
This can be confirmed by using a temperature gun to check the temperature at the
location of the dew point probe, and comparing it to what the probe is reading.
Remedy – Replace the defective component.
To Reset: Find the cause of the alarm and fix the problem.
Press ALARM RESET to clear alarm. Power restored to alarm relay, Warning Light
goes off. Dryer remains OFF. Display clears.
Press ON/OFF to restart dryer.
Notes: Alarm can only be cleared if the dew point temperature is above 28.4oF (-2oC).
The low dew point alarm is possible whether the dryer is ON, or in Remote Off
Mode – as long as there is power to the controller.

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10.2.4 High (Discharge) temperature (Alarm)

What it means: Temperature sensor B3 (compressor discharge temperature) registers a

temperature above 248oF (120oC).
What it does: Cuts power to compressor contactor & alarm contacts. Turns dryer OFF. Turns on
Warning Light & blinks “Ht” on the digital display.
Possible Causes & Remedies:
1) A low refrigerant charge is causing the refrigerant to absorb too much heat in the
evaporator causing a compressor discharge temperature in excess of 248oF.
Remedy – Check or leaks at welds, threaded connections, schrader valve caps,
and joints of the condenser and evaporator. Repair the leak, pull the system to deep
vacuum and charge the dryer with the correct amount of refrigerant as specified in
the Section 2.3.
2) A clogged refrigerant filter is restricting the amount of refrigerant getting to the
evaporator, causing it to absorb too much heat, which causes a compressor
discharge temperature in excess of 248oF. This can be confirmed by measuring the
temperature drop across the filter, which should not exceed a few degrees.
Remedy – Replace the clogged component.
3) A clogged capillary tube is restricting the amount of refrigerant getting to the
evaporator, causing it to absorb too much heat, which causes a compressor
discharge temperature in excess of 248oF.
Remedy – Replace the clogged component. Pay attention when welding the tube,
not to restrict it or block it with the brazing alloy.
To Reset: Find the cause of the alarm and fix the problem.
Press ALARM RESET to clear alarm. Power restored to alarm relay, Warning Light
goes off. Dryer remains OFF. Display clears.
Press ON/OFF to restart dryer.
Notes: Alarm can only be cleared if the discharge temperature is below 248oF (120oC).

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10.2.5 Low (Evaporation) temperaure (Alarm)

What it means: Temperature sensor B2 (evaporation temperature) registers a temperature below

27.5oF (-2.5oC) for 1 minute or more.
What it does: Cuts power to compressor contactor & alarm contacts. Turns dryer OFF. Turns on
Warning Light & blinks “Lt” on the digital display.
Possible Causes & Remedies:
1) Hot Gas Bypass Valve is miscalibrated, causing it to allow pressure in the
evaporator to go too low, causing the temperature to go below 28.4oF (-2oC).
Remedy – Adjust the Hot Gas Bypass Valve as outlined in Section 12.
2) Low ambient temperature is causing excessive cooling of the refrigerant in the
condenser. The dryer may be installed outdoors, in an unheated room, or near a
vent. This cause can be confirmed by checking the condensation pressure with a
gauge. It will stay below 261 psig and the fan never comes on.
Remedy – Increase the ambient temperature in the room or duct the air for the
condenser from a warmer source. Alternately, you can partially cover the
condenser coils in order to reduce the air flow across them, thereby reducing the
cooling effect.
2) A defective fan pressure switch is causing the condenser fan to stay on all the
time causing excessive cooling of the refrigerant.
Remedy – Replace the defective component.
3) The dewpoint temperature sensor (B1) is miscalibrated, causing a low reading.
This can be confirmed by using a temperature gun to check the temperature at the
location of the dew point probe, and comparing it to what the probe is reading.
Remedy – Replace the defective component.
To Reset: Find the cause of the alarm and fix the problem.
Press ALARM RESET to clear alarm. Power restored to alarm relay, Warning Light
goes off. Dryer remains OFF. Display clears.
Press ON/OFF to restart dryer.
Notes: Alarm can only be cleared if the dew point temperature is above 27.5oF (-2.5oC).
The low evaporation temperature alarm is possible whether the dryer is ON, or in
Remote Off Mode – as long as there is power to the controller.

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10.2.6 Compressor Protection (Alarm)

What it means: The compressor protection module registers a motor winding temperature above
the allowable limit.
What it does: Cuts power to compressor contactor & alarm contacts. Turns dryer OFF. Turns on
Warning Light & blinks “CP” on the digital display.
Possible Causes & Remedies:
1) Scroll compressor is rotating backwards because the phases are inverted. The
compressor is not displacing any refrigerant, so there is no cooling of the
compressor causing it to overheat. The compressor will generally be noisy, and
there will be no cooling in the refrigerant circuit.
Remedy - Swap two phases on the power supply.
2) One phase of the power supply is disconnected. Because of the missing phase,
the compressor is pulling high Amps, causing overheating of the windings.
Remedy – Ensure that the electrical connections at the compressor terminal and
the contactor are correctly attached and tight.

To Reset: Find the cause of the alarm and fix the problem.
Press ALARM RESET to clear alarm. Power restored to alarm relay, Warning Light
goes off. Dryer remains OFF. Display clears.
Press ON/OFF to restart dryer.
Notes: Alarm can only be cleared if the compressor protection module registers a winding
temperature within allowable limits.

10.2.7 Parameter data Error (Alarm)

What it means: The microprocessor found an anomaly during a periodic check of the flash memory
and the stored parameters.
What it does: Resets all parameters to their default settings. Cuts power to compressor contactor
& alarm contacts. Turns dryer OFF. Turns on Warning Light & blinks “PdE” on the
digital display.
To Reset: Press ALARM RESET to clear alarm. Power restored to alarm relay, Warning Light
goes off. Dryer remains OFF. Display clears.
Press ON/OFF to restart dryer.

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10.2.8 High Dewpoint (Warning)

Cause: Temperature sensor B1 (dewpoint temperature) is registering a temperature above

the High Dewpoint Warning Setting (parameter A6: Default 15oC [59oF]) for more
than 3 minutes.
Result: Cuts power to the alarm contacts. Turns on Warning Light & alternates between
“Hd” and the dewpoint reading on the digital display.
Possible Causes & Remedies:
1) High ambient temperature in the compressor room due to:
a. Warm weather,
b. Poor compressor room ventilation,
c. Poorly located dryer (restricted air flow through the condenser),
d. Compressor aftercooler is exhausting warm air near the dryer.
Remedy - increase ventilation to the compressor room, duct the compressor after-
cooler out of the room, or move the dryer to a cooler location.
2) Excessive thermal load on the dryer due to excessive air flow rate and/or air inlet
temperature. (Can be confirmed using the instructions in Section 13.)
Remedy – Improve the efficiency of the aftercooler on the compressor, install an
additional or larger air or water cooled aftercooler upstream the dryer, or install a larger
dryer. If the overload is limited to a very short period of time, this alarm can be
avoided by partially opening the air by pass line to reduce the load to the dryer. Please
note that this will significantly increase the downstream dew point.
3) The dewpoint temperature sensor (B1) is out of calibration, causing a high reading.
This can be confirmed by using a temperature gun to check the temperature at the
location of the dew point probe, and comparing it to what the probe is reading.
Remedy – Replace the defective component.
4) A low refrigerant charge is keeping the air from being adequately cooled.
Remedy – Check or leaks at welds, threaded connections, schrader valve caps, and
joints of the condenser and evaporator. Repair the leak, pull the system to deep
vacuum and charge the dryer with the correct amount of refrigerant as specified in the
Section 2.3.
5) Scroll compressor is rotating backwards because the phases are inverted. In this
case the compressor does not compress the refrigerant so there is no cooling of the air.
Remedy - Swap two phases on the power supply.
To Reset: Alarm will reset automatically when the dewpoint goes at least 2oC below the High
Dewpoint Alarm Setting (A6). Warning Light goes off, power is restored to the alarm
contacts and “Hd” disappears from the display.
Notes: This warning is on a 15 minute delay at startup to allow the dryer to get down to
operating temperature without triggering a false alarm.

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10.2.9 drain Error (Warning)

What it means: Drain Operating Mode (Parameter D3) is set to Capacitive (Zero Air Loss) Mode,
and although the drain valve has been open for 30 seconds, the condensate level
sensor is still registering condensate in the chamber.
What it does: Cuts power to the alarm contacts. Turns on Warning Light & alternates between
“drE” and the dewpoint reading on the digital display. The drain is operated in
Timed Mode according to the interval and duration settings (parameters D1 & D2).
Possible Causes & Remedies:
1) Blockage, restriction or back pressure in the condensate discharge line.
Condensate is not being evacuated efficiently and is backing up in the heat
exchanger.
Remedy – Find the cause of the blockage, restriction or back pressure and fix it.
2) Defective condensate level sensor gives a signal indicating condensate is
present even if there is none.
Remedy - Replace the defective component.
3) Defective condensate drain valve.
Remedy – Replace the defective component.
To Reset: The drain will automatically return to Capacitive (Aero Air Loss) Mode operation
when the level sensor stops sensing liquid for at least 5 seconds, but alarm will not
automatically clear.
Push Alarm Reset to clear the alarm. The alarm will also clear if the drain operating
mode (Parameter D3) is changed to Timed or Continuous (Deactivated) Modes.
Notes: The drain alarm is possible whether the dryer is ON or in Remote Off Mode – as
long as there is power to the controller, and Parameter D3 is set to “Capacitive”
mode.
Even though the drain automatically operates in Timed Mode during this alarm,
Parameter D3 will continue to show that Capacitive Mode is the set mode of
operation.

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10.2.10 Dewpoint Sensor Error (Warning)

What it means: Temperature sensor B1 (dewpoint temperature) is short circuited, open, or a

signal outside it’s range (-10oC to +90°C).
What it does: Cuts power to the alarm contacts. Turns on Warning Light & alternates between
“dSE” and the dewpoint reading on the digital display.
To Reset: Find the cause of the alarm and fix the problem.
Press ALARM RESET to clear alarm. . Power restored to alarm relay, Warning
Light goes off.
Notes: Alarm can only be cleared if sensor reading is within limits.

10.2.11 Evaparator Temperature Sensor Error (Warning)

What it means: Temperature sensor B2 (evaporation temperature) is short circuited, open, or a

signal outside it’s range (-10oC to +90°C).
What it does: If dryer was in Cycling Operating Mode, it is automatically switched to
Continuous Mode. Cuts power to the alarm contacts. Turns on Warning Light &
alternates between “rSE” and the dewpoint reading on the digital display.
To Reset: Find the cause of the alarm and fix the problem.
Press ALARM RESET to clear alarm. . Power restored to alarm relay, Warning
Light goes off.
Notes: Alarm can only be cleared if sensor reading is within limits.

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10.2.12 Service required (Warning)

What it means: Dryer has on for longer than the Service Required Warning Interval (Parameter
B9: Default 6000 hours) without service or inspection.
What it does: Cuts power to the alarm contacts. Turns on Warning Light & alternates between
“Sr” and the dewpoint reading on the digital display.
To Reset: Press ALARM RESET. Power restored to alarm relay & Warning Light goes off
for 24 hours.
To reset the alarm for another 6000 hours, contact Sullair or your authorized
Sullair distributor and ensure the dryer & filters are inspected and maintained in
accordance with the schedules in their respective user guides.
The alarm reset (Parameter B3) and it’s interval (Parameter B9) are locked and
can only be modified after entering a special pass code. See Section 10.3 for
further information.
Notes: Unlike the other alarms, the “Sr” warning is not recorded in the alarm history.

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10.3 Resetting or Modifying the Service Required Warning (Sr)

Every 6000 hours the dryer will display the “Sr” (Service Required) warning. The dryer will continue to
function normally while this warning is displayed. The purpose of this warning is to ensure that the
dryer is maintained in accordance with the maintenance schedule outlined in Section 10.1.

Please Note:
The purpose of the “Service Required” warning is to ensure proper maintenance
in accordance with the recommendations of the User Guide.

For this reason, pressing Alarm Reset will only reset the warning for 24 hours,
and parameters B3 (Reset Service Required Warning) and B9 (Service Required Warning Interval)
are locked - their values cannot be changed by pushing the Up and Down buttons.

Changing these parameters is a choice to ignore the supplier’s preventative maintenance

recommendations. This may lead to compromised performance, higher operating costs,
and eventual failure of the equipment.

For this reason, the procedures presented below are intended

ONLY for authorized factory and distributor service technicians.

10.3.1 How to Reset the Service Required (Sr) Warning:

1) Press the Alarm Reset & Alarm Report buttons simultaneously to access the User Parameter
&
Menu. The display will show you are at Parameter “A1”.
2) Press the Down button repeatedly to scroll down to Parameter “B3”.

3) Press Enter to access this parameter. The display will show you it’s value is “no”.
(The value cannot be changed by pressing the Up or Down buttons.)
4) Press the Up & Enter buttons simultaneously for 5 seconds. The value will change to “Yes” for &
a moment and then change back to “no”. The alarm has now been reset.
5) Press Exit to exit the parameter. The display will show you are at Parameter “B3”.

6) Press Exit again to exit the User Parameter Menu. The display will show the dewpoint if the dryer
is on, “OFF” if the dryer is off, or “rOF” if the dryer is in Remote Off Mode.

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10.3.2 How to Change the Service Required (Sr) Warning Interval:

1) Press the Alarm Reset & Alarm Report buttons simultaneously to access the User Parameter
&
Menu. The display will show you are at Parameter “A1”.
2) Press the Down button repeatedly to scroll down to Parameter “B9”.

3) Press Enter to access this parameter. The display will show you it’s value is “6” (6000 hours).
(The value cannot be changed by pressing the Up or Down buttons.)

4) Press the Up & Enter buttons simultaneously for 5 seconds. This unlocks the parameter &
so it can be modified).

5) Press the Up or Down buttons to change it’s value (min = 1000 hours, max = 999,000 hours) or

6) Press Enter to save your changes and exit the parameter. The display will show you are at Parameter “B8”.

Press Exit to exit the User Parameter Menu. The display will show the dewpoint if the dryer is on,
“OFF” if the dryer is off, or “rOF” if the dryer is in Remote Off Mode.

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10.4 Alarm History Report

10.4.1 Viewing the Alarm History
Each alarm or warning (with the exception of the Service Required Warning “Sr”) is recorded in the
alarm report. The controller stores the last 8 alarms or warnings. New alarms will overwrite the oldest.
For each alarm or warning, the controller stores the following data:
• The alarm or warning code
• Dryer working hours at the time of the alarm or warning
• Dew point temperature (Sensor B1) at the time of the alarm or warning
• Evaporation temperature (Sensor B2) at the time of the alarm or warning
• Discharge temperature (Sensor B3) at the time of the alarm or warning
To view the Alarm History Report, press the Alarm Report Button for 5 seconds. The
alarm records are displayed starting from the oldest.
If there are alarms or warnings recorded the display will shows “ALx”, where x
is the number of alarms recorded (up to a maximum of 8).
If there are no alarms or warning recorded, the display temporarily shows three
dashes.
To scroll through the alarms and warnings press the Up or Down Buttons. “AL1” or
indicates the most recent alarm, “AL8” the oldest.
When you get to the alarm you want to see, press Enter to display the data recorded at
the time of the alarm.
Scroll through the recorded data using the UP & DOWN buttons: or
• Alarm Code (HP, LT, Ld, etc...)
• Working Hours x 1000
• Working Hours
• Dewpoint Temperature (B1)
• Evaporation Temperature (B2)
• Discharge Temperature (B3)
Press Exit to go back to the list of alarms.
Press Exit again to leave the Alarm History Report.

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10.4.2 Resetting the Alarm History

Please Note:
The purpose of the Alarm History Report warning is to provide critical information to service personnel
when troubleshooting the unit.

For this reason, the procedure presented below is intended

ONLY for authorized factory and distributor service technicians.

1) Press the Alarm Reset & Alarm Report buttons simultaneously to access the User Parameter
&
Menu. The display will show you are at Parameter “A1”.
2) Press the Down button repeatedly to scroll down to Parameter “B7”.

3) Press Enter to access this parameter. The display will show you it’s value is “no”.
(The value cannot be changed by pressing the Up or Down buttons.)
4) Press the Up & Enter buttons simultaneously for 5 seconds. The value will change to “Yes” for &
a moment and then change back to “no”. The alarm has now been reset.
5) Press Exit to exit the parameter. The display will show you are at Parameter “B7”.

6) Press Exit again to exit the User Parameter Menu. The display will show the dewpoint if the dryer
is on, “OFF” if the dryer is off, or “rOF” if the dryer is in Remote Off Mode.

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10.5 Remote Monitoring Option

The SRL-250 to 6000 can be simply connected to an external supervisor system (otherwise known as
BMS or Building Management System).
To do so an (optional) RS485 serial card is fitted to the back of the microprocessor.
This allows direct connection to a BMS using the MODBUS RTU protocol, without the need for any
intermediate Gateway.

Once connected to the BMS it is possible to achieve:

Visualization of:
• Dew point & other temperatures
• Alarms
• Working hour counters

Control of:
• Dryer on/off
• Alarm reset (if allowed)

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11. Recommended Maintenance

11.1 Maintenance Schedule

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11.2 Preventative Maintenance Kits

In addition to the service requirements outlined above, proactive preventative maintenance can
ensure continuous trouble free operation without unexpected alarms or failures. Three year
preventative maintenance kits are available which include:

• Pressure switches (HP, LP & fan)

• Temperatures probes (B1, B2 & B3)
• Fan/compressor contactors
• Solenoid Valve Coils (YV1 & YV2)

Refer to the User Guide supplied with the dryer for further details.

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12. Maintenance Procedures

12.1 Replacing a Pressure Switch
• When removing any pressure switch (High Pressure Switch [3.3.7],
Low Pressure Switch [3.3.8] or Fan Pressure Switch [3.3.9]) use
two spanners to avoid cracking the weld on the T joint.
• Use a copper gasket to guarantee a seal.
Place the gasket inside the switch connection
with a drop of oil or grease to keep it in
position while screwing the switch onto the
valve.

12.2 Replacing the Drain Valve

• Loosen the 3 piece union.
• Unscrew the electrical connector.
• Remove the fixing nut.
• Remove the old coil and install the new one.
• Replace the fixing nut.
• Reattach the electrical connector.
• Tighten the 3 piece union.

12.3 Cleaning the Condensate Strainer

The internal strainer of the drain valve should be cleaned at

least every four to six months.

• Unscrew the cap at the bottom side of the drain valve.

• Remove the strainer.
• Clean the strainer with compressed air.
• Replace the strainer.
• Tighten the cap firmly, but do not over-tighten.

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12.4 Replacing the Control Board

• Open the electrical box.
• Remove the white connector containing the electrical supply & digital inputs & outputs.
• Disconnect the temperature sensor wires.
• Disconnect the level sensor (SRL-325 to 6000 ONLY) Pull firmly on the connector, being
careful not to damage it.

Level sensor
Electrical supply &
connection
digital input & output
connections

Temperature sensor connections

• Unscrew the six screws holding the board in place.

• Replace the old board with the new one.
• Reinstall the temperature sensors, wires in the same locations.

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12.4 Adjusting the Hot Gas Bypass Valve

The adjustment of the hot gas by-pass valve must be done without air flowing through the dryer. The
pressure should be set between 62.4 and 66.7 psig (4.3 to 4.6 barg) for all models.

• Mount a precision pressure gauge on the ¼” schrader valve on the refrigerant tube at the outlet of
the evaporator. Make sure to use as short a hose as possible on the gauge to avoid refrigerant
losses which may affect the dryer performance, especially on smaller models.
• Remove the cap on the Hot Gas Bypass Valve.
• To increase the evaporation pressure, turn the regulating screw clockwise (loading the internal
spring)
• To decrease the evaporation pressure, turn the regulating screw anti-clockwise (unloading the
internal spring).
• After adjusting, wait a few minutes to allow the pressures to stabilise. Re-adjust as necessary.

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13. Confirming Dryer Sizing

The first step to troubleshooting any problem with a refrigerated air dryer is to confirm the dryer is
sized correctly for the operating conditions it is experiencing. Many problems, especially High Dew
Point (Hd) or High Pressure (HP) alarms can be directly attributed to operating conditions that exceed
the dryers maximum capacity.
In order to confirm the dryers maximum capacity at any given set of conditions, the following data is
required:
• Air Flow (maximum),
• Inlet Air Pressure (minimum),
• Inlet Air Temperature (maximum), and
• Ambient Temperature (maximum).
Additional information will allow an even more accurate determination of the dryer’s capability,
however the above is to be considered the absolute minimum information required to confirm a dryer
is sized properly.
In most applications, temperatures, pressures, and air flow will fluctuate considerably with time.
Please ensure that the maximum temperatures and air flow and the minimum pressure is used, as
these will correctly reflect the worst case scenario. Do not use simply the instantaneous or average
values.
If the operating parameters only exceed the maximum capacity of the dryer by a relatively small
amount, often the dryer will continue to operate, however the outlet dewpoint will rise. However, if
conditions greatly exceed the dryer’s maximum capacity, it will eventually reach a point where the
dryer cannot reject all the heat it is absorbing, and the refrigerant circuit will rapidly rise in temperature
and pressure until the unit shuts down.
The correction factors given below make several assumptions and approximations, and as such,
provide only a rough method of determining a dryer’s maximum capacity. If possible, the SRL
selection software should be used, as this will provide more accurate sizing data. In addition the
sizing software can provide actual performance criteria of the dryer at the input operating conditions.
Contact Sullair for further information.

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13.1 Correction Factors

Ambient Temperature Correction Factor (A)
Ambient Temperature (oF) 60 70 80 90 100 110 113
Correction Factor “A” 1.30 1.23 1.16 1.08 1 0.92 0.89

Air Inlet Temperature Correction Factor (B)

o
Air Inlet Temperature ( F) 90 100 110 120 130 140
Correction Factor “B” 1.26 1 0.80 0.63 0.50 0.38

Air Inlet Pressure Correction Factor (C)

Ambient temperature (oF) 50 80 100 125 150 170 190 200
Correction Factor “C” 0.76 0.93 1 1.03 1.11 1.14 1.16 1.17

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13.2 An Example

To determine the maximum air flow capacity of a given dryer at any set of given conditions, apply the
correction factors given above, using the following equation:

Rated Inlet Air Flow x A x B x C

Where:
• A = the correction factor for the maximum ambient temperature,
• B = the correction factor for the maximum inlet air temperature, and
• C: the correction factor for the minimum inlet air pressure.

This will give the maximum amount of flow the dryer can handle at those conditions. You can then
compare that to the actual air flow to determine if the dryer is undersized for the application.

Example: A customer complains that every day around noon, his SRL-400 shows an “Hd” (High
Dewpoint) alarm. You ask him to confirm the actual operating conditions when the alarm occurs,, and
after consulting with his plant manager, he tells you the following:

Air Flow (cfm) = 300 cfm

Ambient Temperature (oF) = 100 oF
Inlet Air Temperature (oF) = 120 oF
Inlet Air Pressure (psig) = 125 psig

Using the above correction factor tables you quickly find the three Correction Factors are:
A = 1, B = 0.63, C = 1.03
Using your calculator, and knowing that an SRL-400 is rated for 400 cfm at standard conditions, you
plug these values into the formula and find out that the maximum capacity of the SRL-400 at those
conditions is:
400 cfm x 1 x 0.63 x 1.03 = 260 cfm

So, the customer is putting more air flow through this dryer than it is designed to handle. This is what
is causing the High Dew point alarm.

You can tell him that he needs to call his local Sullair distributor and order an SRL-500, which would
adequately handle his 300 cfm at these warm conditions (since 500 cfm x 1 x 0.63 x 1.03 = 324 cfm).

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