FLi -SERIES

INSTALLATION, OPERATING &

MAINTENANCE INSTRUCTION MANUAL

Please read carefully before installation

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 TABLE OF CONTENTS
FOREWORD 4

PRINCIPLE OF OPERATION ..................................................................................................... 5

INSTALLATION INSTRUCTIONS............................................................................................. 6

INSPECTION:.................................................................................................................................. 6
PACKING THE MACHINE ............................................................................................................. 6
ELECTRICALS ............................................................................................................................... 6
DUCT WORK .................................................................................................................................. 6
STEAM COIL INSTALLATION RECOMMENDATIONS……………………………………… 7

OPERATING INSTRUCTIONS ................................................................................................... 8

START-UP ........................................................................................................................................ 8
ELECTRIC REACTIVATION CONTROLS: .................................................................................. 8
AIRFLOWS...................................................................................................................................... 9
DESICCANT BED ROTATION ...................................................................................................... 9
PERFORMANCE TESTING ..................................................................................................... 9-10

MAINTENANCE INSTRUCTIONS .......................................................................................... 11

CABINET ....................................................................................................................................... 11
DESICCANT BED ......................................................................................................................... 11
SEALS ……………………………………………………………………………………………11
DRIVE MOTOR............................................................................................................................. 11
FILTERS......................................................................................................................................... 12

FAN AND MOTOR MAINTENANCE INSTRUCTIONS ....................................................... 13

GENERAL MAINTENANCE ....................................................................................................... 13

SERVICE INSTRUCTIONS ....................................................................................................... 14

REMOVING THE DESICCANT BED .......................................................................................... 14

CHANGING BED SEALS ............................................................................................................. 14
INSTALLING BED SEALS ........................................................................................................... 14

TROUBLE SHOOTING GUIDELINES .............................................................................. 15-16

PSYCHROMETRIC CHART 17

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 FOREWORD

Congratulations on your purchase of the Bry-Air FLi dehumidifier. The dehumidifier

offers the finest in air drying equipment; however, this machine can only provide its
maximum service if it is properly installed, operated, and maintained.

This manual is provided to acquaint you with the dehumidifier so that installation,
operation and maintenance can proceed successfully. Ultimate satisfaction depends on the
quality of installation and a thorough understanding of this equipment. The FLI
dehumidifier is built around tested engineering principles and has passed a thorough
inspection of quality of workmanship and function.

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 PRINCIPLE OF OPERATION
The function of the Bry-Air dehumidifier is to remove moisture (in the vapor state) from
an air stream. This is accomplished by exposing the air to an adsorbing media (desiccant)
in a sealed air stream (process). After the desiccant has adsorbed moisture, it is exposed
to a second air stream at an elevated temperature (reactivation). This causes the moisture
to be driven out of the desiccant preparing it for more moisture adsorption. This process
is done on a continuous basis, providing a constant drying process.

The two air streams (process and reactivation) are separated by seals which contact the
desiccant bed. Figure “A” illustrates the air flow relationship of the seals and air flow
pattern.

The FLI dehumidifier is designed with the two air streams flowing in opposite directions
(counter flow) thereby maximizing the energy efficiency of the equipment.
FIGURE –“A”

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 INSTALLATION INSTRUCTIONS
Proper installation of this dehumidifier is very important for best. service and
performance.
INSPECTION:
Thoroughly inspect the dehumidifier inside and out to insure that no damage has occurred
during shipping. (If any damage is found, a claim should be made to the shipping
company immediately!).

PACKING THE MACHINE

The dehumidifier should be carefully set in place and leveled. The equipment must be
supported adequately to prevent unnecessary flex in the structural base. Support below
the lifting lugs is the minimum required. Remove any external packing or crating before
connecting ductwork. Refer to Unit Outline at the back of this manual for minimum
clearance, servicing and duct work connections.

ELECTRICALS
All local and country codes must be strictly adhered to and good electrical practices
should be followed to achieve the best installation possible.

Power wiring to equipment must be adequately sized for minimum amperage as shown
on the unit nameplate. If a disconnect is furnished with your particular package, one
should be installed adjacent to the unit for both safety and servicing.

Equipment wiring diagram should be examined and thoroughly understood before field-
wiring connections are made. (See Electrical Schematic in the back of this manual).

The power supply should be checked to be certain that the supply voltage agrees with the
equipment nameplate. Serious damage to motors and controls can occur if improper
voltage is applied.

DUCT WORK
The duct work requirements for this system are much more critical than conventional air
conditioning systems. ALL SUPPLY AND RETURN AIR DUCTWORK FOR THE
DEUMIDIFIER MUST BE AIRS AND VAPOR TIGHT. This is extremely important for
proper dehumidifier performance. Even though the dehumidifier is removing moisture, it
may not perform properly if moisture enters the dry air stream through leaks in the
ductwork. The air ducts must be properly sized to keep pressure losses at a minimum, and
prevent this loss from exceeding the designed fan static capability. It is important to
insure that the reactivation discharge air does not enter the process or reactivation inlets.
If the unit is installed indoor, the reactivation outlet can be connected by duct to the
outside of the building. See Unit Outline drawing for fan external static pressure.

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 STEAM COIL INSTALLATION RECOMMENDATIONS

• This section is applicable for unit having steam coil.

1. It is important that the steam coils operate at the design pressure. The amount of heat energy in the
steam is proportional to the steam pressure. If the steam pressure is allowed to drop, the dehumidifier
may not be able to deliver full performance.
2. Be certain that adequate piping flexibility is provided. Stresses resulting from expansion of closely
coupled piping and coil arrangement can cause serious damage.
3. Do not reduce pipe size at the coil return connection. Carry the return connection size through the dirt
pocket, making the reduction at the branch leading to the trap.
4. Vacuum breakers and air vents must be installed on all applications to prevent retaining condensate or
air in the coil. Generally the vacuum breaker is to be connected between the coil inlet and the trap.
For a system with a flooded return main, the vacuum breaker should be open to the atmosphere and
the trap design should allow venting of large quantities of air.
5. Do not drip steam mains through coils.
6. Insure stream pressure and condensate line pressure differential is sufficient to allow efficient
condensate removal from the steam coil, especially when using modulation steam control valves to
control the leaving air temperature of the coil.
7. Do not attempt to lift condensate without the assistance of a condensate pump. The pressure required
to lift condensate must also be considered for sufficient pressure differential. Check valves are also
required to prevent reverse flow of condensate back into the coil.
8. All coils in a system should be piped separately. It is not recommended to put multiple coils on a
common trap.
9. Multiple coil installations-
a.) Each coil or group of coils that is individually controlled must be individually trapped.
b.) Coils in series; separate traps are required for each coil, or bank of coils, in series.
c.) Coils in parallel; a single trap may be used but an individual trap for each coil is preferred.
10. Size traps in accordance with the manufacture’s recommendations. Be certain that the required
pressure differential will always be available. Do not undersize.
11. Float and thermostatic traps are recommended for high or low-pressure steam systems, but bucket
traps may be used. Float and thermostatic traps should be used when air venting is necessary. Bucket
traps are recommended for use with on- off control only. It is recommended that traps be located at
least 12 inches below the coil return connection. When traps without air venting capabilities are used,
air vents are required in the system.
12. Flash trap may be used if pressure differential between steam and condensate return exceeds 5 psi.

IMPORTANT NOTE:-

Steam reactivated systems – Bry-Air will only repair or replace leaking steam coils under warranty when

a.) Accompanied by a water quality report from an independent, qualified laboratory showing the chemical
analysis of the steam associated with these coils. These test must show pH values and sulphar content
within the ranges associated with proper steam operating ranges. Proper steam piping, per manufacturer’s
recommendations, must be applied to any steam coil installations to prevent contamination and possible
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water hammering that could lead to leaks.

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 OPERATING INSTRUCTIONS
START-UP
At this point it is assumed that the installation is complete and that the recommendations
and instructions have been followed. The following will outline the proper procedures for
starting and adjusting the FLI dehumidifier.
Note: Before starting the dehumidifier, check to insure that the outlet air
dampers are at least partially opened.

At this point, the dehumidifier can now be started using the ‘Auto Manual’ selection
switch. The Auto-Manual selector switch can be set on the Auto or Manual position
depending on automatic or manual humidity control. A humidity control device, such as
humidistat is required to be connected for ‘Auto’ operation.. This will start the
dehumidifier, energizing the fan motors, bed drive, and the reactivation heat source. The
fan rotations should be checked at this time, if not previously done, to insure they are
rotating in the proper direction.

ELECTRIC REACTIVATION CONTROLS:

Dehumidifiers with electric reactivation incorporate an air proving pressure switch and
two adjustable temperature-limiting devices. All three of these devices must be energized
to allow the reactivation heaters to be energized. One temperature limit automatically
resets and the second is manual reset. The manual reset limit may have to be reset open
start-up.

The reactivation temperature limits are safety limits only and are not operating
controls ! If on-off cycling of the heaters occur, the auto reset limit must be adjusted to a
higher setting until the heaters are continuously on (10-15° C higher than the reactivation
entering temperature after the heaters.) The manual reset limit is a fail-safe device and
should be set 20° C above the auto reset limit.

Note : The dial indication on the thermostats is for reference only. The actual set-
point values may differ slightly. To check the calibration, turn the knob to
a lower setting until the heaters cut off, then increase the setting until the
heaters come on. Increase the setting 15° C above this point.
The Air Flows section of this manual will provide the information on adjusting airflows
through the dehumidifier. This is extremely important because the electric heaters are
sized for a temperature rise based on design air volume. Consult the dehumidifier set-up
sheet or system flow schematic included in this manual for the proper reactivation
temperature. This temperature is achieved through the proper air volume and is measured
at the dry-bulb temperature test ports in the reactivation inlet. The ideal temperature is
150°–160° C.

Note :It is important to insure the reactivation air flow is sufficient before
increasing the limit set points.

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AIRFLOWS

The FLI dehumidifier uses two distinct air streams positively sealed from each other. This
eliminates the requirement to “balance” the air streams. It is recommended to use the
pressure gauges or manometer to establish the proper air flows through the dehumidifier.
The pressure differential across the desiccant bed is a simple way of determining the
proper air volumes.

Adjust pressure values to that shown on the dehumidifier set-up sheet or flow schematic
provided with the unit.

DESICCANT BED ROTATION

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

PERFORMANCE TESTING

Note : Allow the dehumidifier to run for a minimum of one hour at proper reactivation
temperatures and airflows before beginning any performance tests. The
dehumidifier set-up sheet or flow schematic will provide the necessary
information on temperatures and pressure values.

The following procedures will outline the steps to performance test the dehumidifier :

1. Check the reactivation inlet temperature using a 300°C thermometer or

other sensible temperature sensor.
2. Check the reactivation outlet temperature using a 100°C thermometer
or other sensible temperature sensor.
3. Take the wet bulb* and dry-bulb temperature of the process inlet. Take
reading simultaneously using two 50° C calibrated thermometers.
4. Take the wet-bulb* and dry-bulb temperature of the process outlet
using the same thermometers as in step 3.

* The thermometers best suited for use in the field are a bimetallic dial type
with 200mm stem. The wet-bulb and dry-bulb thermometers should be a
matched pair with divisions no less than 0.5°C. The wet-bulb thermometer
requires a full length sock. The sock should fit tightly on the stem of the
thermometer. Distilled water, cooled to 5°C if possible should be used to
wet the sock. In taking the wet-bulb temperature, the wet-bulb
thermometer should be placed in an air stream (approximately 5 m/s
velocity) and observed until the lowest stabilized temperature is obtained.
It is necessary to take two or more readings to verify the correct wet-bulb.

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In cases of very low humidity (condition below 2°C WB) the above procedure may be
difficult to apply accurately. Other instruments may be used to take humidity readings for
this performance test. It is important to use an accurate device to obtain an accurate
evaluation of the dryer performance. Most relative humidity sensors are not accurate
below 10%-20% relative humidity. At these conditions, it is suggested that a laboratory
quality dew point sensor be used to obtain accurate humidity readings.

If there are any questions about the performance of the Bry-Air dehumidifier, completely
fill out the Dehumidifier Test Report Form included with this manual and contact the
Bry-Air factory or local sales representative. The system will be analyzed and proper
recommendations returned promptly.

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 MAINTENANCE INSTRUCTIONS
CABINET

Compression latch fasteners are used to seal front service panel as well as electrical
control panel. All rear panels, filter access use manual cap screw fasteners. All access
covers, hardware, and screws should be secured after any servicing activity. Care should
be taken not to over-tighten and deform panels.

The condition of the access panel gasket should be observed during inspection and
servicing to insure a good seal. Any leaks must be sealed for proper dehumidifier
operation.

DESICCANT BED

The state of the art desiccant bed supplied with the dehumidifier will last idenfinitely
under ideal conditions. Due to the nature of desiccants they make very good filters. The
life of the desiccant is directly related to the air born contaminates passed through it.
atmospheric contaminants, exposure to acidic gases / or air streams, and contact with
desiccant bed. Although the desiccant bed is considered a clean able / washable media,
the preferred method of cleaning is to blow dust out with low pressure compressed air
and to reactivate the bed at 170° C (max) for 15 minutes. Washing the rotor, although
possible, is not recommended as wash water impurities may contaminate the desiccant.
Proper filtration, and preventing contact with chemicals will greatly improve the life of
the desiccant. Inspect the face of the bed to see that no surface damage has occurred. The
bed should turn smoothly upon the shaft.

SEALS

All of the silicon ‘A’ seals which separate the process from the reactivation compartments
are manufactured specifically for Bry-Air. Normally, the seals will not require service or
replacement. However, should damage occur, or if air leakage is suspected of causing
poor performance, the seals should be replaced :

Seal inspection schedule: Upon installation

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

DRIVE MOTOR

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

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FILTERS

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

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 FAN AND MOTOR MAINTENANCE INSTRUCTIONS

GENERAL MAINTENANCE

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

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

1. Follow procedure for removing bed.

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

Note: Both perimeter and divider seals will be removed as one piece.
INSTALLING BED SEALS

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

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 TROUBLE SHOOTING GUIDELINES
FLI SERIES DEHUMIDIFIER
Trouble Probable Fault Probable Cause Corrective Action
Unit stopped (both Power and control failure 1. Main Power off 1. Check line and main
Fans off) power supply

2. Control Power off. 2. Check per item.

a. Control circuit fuse blown. a. Replace Fuse
b. Faulty control transformer. b. Replace Transformer.
c. Control switch open c. Close or replace
switch.
d. Humidistat satisfied. d. Turn down to lower set
point.
e. Faulty control elements. e. Check and repair or
replace as req’d.
Either fan off Power or mechanical 1. Blower motor fuse(s) or tripped 1. Replace fuse or
failure breaker. breaker.
2. Bad motor starter contacts 2. Repair or replace
3. Motor over load(s). 3. Reset or replace
4. Burned out motor 4. Repair ore replace
5. Failure of fan drive 5. Repair or replace as
mechanism. (set screws, keys, req’d.
etc.
Unit running but Excessive infiltration of 1. Executive unconditioned make- 1. reduce make-up air.
humidity rises. humit air into the up air.
controlled space. 2. Leaking ducts and/or air 2. Seal leaks
handling equipment outsides
controlled space.
3. Access openings opening to 3. Close and /or seal.
space not sealed.
4. Space not vapor tight. 4. Seal with paint and /
or vapor barrier.

Faulty humidifier controls 1. Humidistat

a. Improper adjustment. a. Readjust
b. Out of calibration. b. Recalibrate
c. Defective c. Replace

Inadequate process or 1. Excessive static pressure loss 1. Check per item

reactivation air flow a. Dirty filters a. Clean or replace
b. Damper closed b. Reset
c. Obstruction at inlet, outlet or c. Remove
ducting. construction
d. Clogged desiccant beds (high d. Remove beds and
pressure drop across beds.) replace desiccant.

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 TROUBLE SHOOTING GUIDELINES
FOR CHAIN DRIVE
COMMON SYMPTOMS PROBABLE CAUSE CORRECTIVE ACTION

Non-symmetrical wear on 1. Shafts out of parallel or not in 1. Realign shafts

sprockets or rollers same plane

Wear on inside of roller plates 1. Sprockets offset on shafts 1. Realign sprockets

or side tooth form of (misarranged), or out of
sprocket teeth parallel

Wear on tips of sprocket teeth 1. Chain elongated excessively 1. Replace chain

2. Improperly cut sprockets 2. Replace with correct sprocket
Worn or hooked sprocket 1. Unhardened sprockets 1. replace with hardened sprockets
teeth

Wear on edges or sides of 1. Chain contacting case or fixed 1. Increase case clearance or move
link plates object. fixed object

Excessive vibration 1. Excessive eccentricity or face 1. Replace with properly

run out in sprocket machined sprocket
2. Broken or missing roller 2. Repair or replace chain
Premature elongation 1. Inadequate or contaminated 1. Increase oil flow or redesign
lubrication, or under chaining

Brown-red oxide in chain 1. Inadequate lubrication 1. Improve lubrication

joints and oil

Chain jumps sprocket teeth 1. Wear to vertical limit or 1. Adjust centers or idler
excess initial slack 2. Replace chain
2. Wear to miasmic on large
sprocket
Broken chain parts 1. Drive overloaded 1. Redesign or avoid.
2. Excessive slack causing 2. Periodically adjust center
chain to jump teeth distance
3. Foreign object 3. Prevent entry
4. Excess chain speed 4. Redesign or avoid
5. Poorly fitting sprockets 5. Replace
6. Inadequate lubrication 6. Proper lubrication
7. Corrosion 7. Prevent or use non-corrosive
chain
Excessive noise 1. Chain contacting fixed objects 1. Remove objects
2. Inadequate lubrication 2. Improve lubrication
3. Broken or missing rollers 3. Repair or replace chain
4. Misalignment 4. Check shaft and sprocket and
realign
5. Chain jumping sprocket teeth 5. Adjust center distance

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