SERIES TZ TZ820 - TZ1710 EMS OPTION LDP OPTION 3V OPTION. TZ Heatless Desiccant Compressed Air Dryers

Transcription

1 SERIES TZ TZ820 - TZ1710 EMS OPTION LDP OPTION 3V OPTION TZ Heatless Desiccant Compressed Air Dryers More Than Air. Answers. Online answers: Phone : Form :APDD 789 CCN: July 2002

2 TABLE OF CONTENTS FOREWORD... 4 SECTION 1 INTRODUCTION GENERAL INFORMATION SAFETY INSTRUCTIONS Identification of signs and symbols in this technical manual Safety tips for maintenance, inspection and assembly work PERSONNEL QUALIFICATION PRODUCT INFORMATION Pressure vessel regulations... 8 Model Airtightness test Overloading Technical data sheet Transport Storage Use of a pre and after filter SECTION 2 INSTALLATION SET-UP AND INSTALLATION SECTION 3 START UP AND OPERATION START UP/ SHUT DOWN DESCRIPTION OF THE OPERATION Description of the operation Dryer operating sequence (No control or alarm option) Operating sequence (EMS Option) Alarms Electrical control SPECIAL EQUIPMENT EMS Controls EMS Controls Start-up and operation SECTION 4 MAINTENANCE REPLACEMENT OF THE DESICCANT DISPOSAL OF THE DESICCANT CHANGING OF THE REGENERATION ORIFICE FILTERS General comments and use Function Assembly and installation Maintenance Changing of filter elements Accessories SECTION 5 DRYER FLOW CAPACITY AND PURGE ADJUSTMENT DRYER FLOW CAPACITY CORRECTION FACTOR FOR INLET TEMPERATURE PURGE ADJUSTMENT

3 SECTION 6 SPARE PARTS LIST SPARE PARTS LIST FOR TZ820 TZ SERVICE BULLETIN SECTION 7 TROUBLE SHOOTING & FAULTS THE DEW POINT IS TOO HIGH THE ADSORPTION DRYER DOES NOT SWITCH OVER BACK PRESSURE IS TOO HIGH DURING REGENERATION PHASE SHORT-TERM SHUT-DOWN SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE RE-STARTING SECTION 8 APPENDIX A

4 FOREWORD This technical manual of Ingersoll-Rand is an aid in getting to know the adsorption dryer better and in utilizing its possibilities for application in accordance with its intended use. Furthermore, this manual contains important information for safe, proper and economic operation. All instructions must be followed as written in order to avoid danger and damages which could cause downtime and premature wear and tear on the adsorption dryer. In addition to the technical manual and the accident prevention regulations which are valid and compulsory in the country and in the particular workplace where the adsorption dryer is being used, the recognized special rules for safe and proper working procedures are also to be heeded. The technical manual must always be within reach wherever the adsorption dryer is being used. Each person involved with the set-up, start-up, operation, maintenance and repair of the adsorption dryer in the User Company must have first read and understood the technical manual and especially the safety tips. 4

5 SECTION 1 INTRODUCTION 1.1 GENERAL INFORMATION The adsorption dryer of the TZ820 TZ1710 series is built according to the latest technological developments and recognized safety rules. Its use however can endanger life and limb of the user or of third parties, and can lead to considerable damage to the adsorption dryer and other material assets if: it is operated by personnel not trained or instructed in its use, it is improperly used, it is improperly maintained or serviced. This can result in the loss of all damage claims. This adsorption dryer is designed for neutral media free of aggressive water, oil and solid elements. Ingersoll-Rand accepts no liability for corrosion damage and malfunctions caused by aggressive media. Applications other than those mentioned in this manual must be agreed to by Ingersoll-Rand and confirmed in writing. In the interest of further development, Ingersoll-Rand reserves the right to make changes at any time with or without notice, which, in keeping with the essential characteristics of the adsorption dryer described here, may be necessary for increasing efficiency or for reasons relating to safety or to normal business practice. 1.2 SAFETY INSTRUCTIONS This technical manual contains basic tips, which must be followed during set-up, operation and servicing. It is thus of utmost importance that it be read by the assembly technician before installation and start-up as well as by the specialist / operator in charge, and it must always be within reach at the place where the adsorption dryer is being used. 5

6 SECTION Identification of signs and symbols in this technical manual The safety tips contained in this technical manual, whose disregard could endanger people and machines, are indicated by a general danger sign and the additional markings Danger! or Attention! Danger! / Attention! Safety sign in accordance with DIN W9 Warning against electrical voltage! Safety sign in accordance with DIN W8 Safety tips printed directly on the adsorption dryer must be heeded at all times and must be kept completely legible. Recommendations This sign refers to a procedure or sequence of particular interest or importance. All tips must be followed to ensure proper use of this adsorption dryer. This dot refers to working or operational steps. The steps are to be carried out in the order of their appearance from top to bottom. The sign of a hyphen marks enumerations Safety tips for maintenance, inspection and assembly work The operator is to make sure that all maintenance, inspection and assembly work is carried out by special personnel who are authorized and qualified, and who are adequately informed through careful study of the technical manual. For this reason, special attention should be paid to the following attention and danger sign: 6

7 SECTION 1 Attention! Never make structural changes to the adsorption dryer! Only use original spare and accessory parts! Never weld on a pressure vessel or change it in any way! Carry out maintenance work only when the adsorption dryer is switched off, is depressurized and disconnected from the electric power supply. Recommendations Refer to the desiccant material safety data sheet (MSDS) when installing or disposing of desiccant (See Appendix A). Danger! Wear protective goggles when working with the desiccant! Recommendations for protection If desiccant comes into contact with the eyes, rinse eyes immediately with a lot of clear water. If the desiccant is spilled, clean up without causing swirls of dust. In case of fire, there is no restriction on the use of fire extinguishing material; the reaction with water and foam is defined as strong. A mask must be worn. 1.3 PERSONNEL QUALIFICATION The personnel involved in operation, maintenance, inspection and assembly must have the corresponding qualifications to do this work. Areas of responsibility and supervision of the personnel must be precisely established by the operator. Should the personnel not possess the necessary knowledge, then they must be trained and instructed. If need be, this training may be carried out by the manufacturer / supplier at the request of the operator of the adsorption dryer. Further, the operator is to make sure that the personnel completely understand the contents of the technical manual. 7

8 SECTION PRODUCT INFORMATION The adsorption dryer is used for the purpose of drying compressed air and other gases according to its respective design. As a "standard model" the adsorption dryer is equipped with two desiccant vessels and a pre- and after-filter, and depending on certain conditions at the outlet, provides pure, dry and oil-free compressed air or gases Pressure vessel regulations The pressure vessels are designed according to the standard technical requirements. They fulfill the test of the certifying procedure and carry the U, UM ASME Symbol. Range of application Model TZ820 TZ1710 Operating overpressure Max. 150 PSIG Temperature Max. Min. 500 F -20 F Airtightness test All adsorption dryers are subjected to an airtightness test prior to shipment using compressed air Overloading Attention! Protect the adsorption dryer from overloads! The adsorption dryer can become overloaded, if: The flow capacity of the medium to be dried increases, The temperature of the air at entry, and correspondingly its humidity increases, The min. operating pressure is under cut, The pre-filtration and separation of impurities are not sufficient. Introduction of oil into the air. 8

9 SECTION Technical data sheet Medium Model TZ820 TZ1050 TZ1200 TZ1450 TZ1710 Air, free of aggressive elements Connection FLG 150# Flow capacity (1) (STD) SCFM Flow capacity (1) (LDP) SCFM Standard LDP Dryers Quantity of desiccant Per vessel [Lbs.] Desiccant Input temp.: from 100 F and dew point (2) 40 C (-40 F) Filled with: activated alumina Input temp.: from 100 F and dew point (2) 74 C (-100 F) Filled with: activated alumina Filter size Control Operating voltage Standard Special voltage Drying time Standard LDP Dryers PLC Controller 120 V / 60 Hz (AC) Consult factory 5 min 2 min (1) (2) Flow capacity in SCFM at 100 PSIG according to DIN ISO 7183 Pressure dew point NOTE: Settings for EMS: Standard dryers EMS Control -40 F (-40 C) High humidity -35 F (-35 C) LDP Dryers EMS Control -100 F (-74 C) High humidity -95 F (-69 C) 9

10 SECTION Transport After the adsorption dryer has been delivered, it must be checked for damage that may have occurred during transport. If necessary, the Transport company must be informed to register the damage. Recommendations For transport within the company, only the skid of the adsorption dryers TZ820 TZ1710 may be used Storage If the adsorption dryer is to be stored for a longer period of time, its place of storage must be dry and free of dust. There has to be a min. ambient temp. of +1 C (33 F) Use of a pre and after filter In order to prevent droplets of condensate, oil and dirt from getting into the desiccant, a pre-filter is installed in front of the adsorption dryer, since an oil film on the desiccant reduces the drying capacity and the dewpoint. In order to prevent breakdowns in downstream consumers caused by material that has been abraded from the desiccant bed, an after-filter is mounted behind the adsorption dryer. Since no condensate accumulates in the after-filter, this filter is always equipped with a manual valve. Both filters are equipped with a differential pressure gauge (standard) as this ensures an indirect display of the degree of contamination of the filter elements. 10

11 SECTION 2 INSTALLATION 2.1 SET-UP AND INSTALLATION Once at the installation location, the adsorption dryers of the series TZ820 TZ1710, which are supplied with a base frame, must be positioned so that the side from which it is to be operated is easily accessible. The piping is to be connected to the adsorption dryer at a light slope. A shut-off valve is to be installed on the inlet and outlet sides of the adsorption dryer. Also, a by-pass pipe with an additional shutoff valve should be mounted onto the adsorption dryer, in order to be able to guarantee an uninterrupted supply of compressed air in case the adsorption dryer breaks down. Should vibrations occur on the installation location, the adsorption dryer is to be placed onto vibration dampers. Since the adsorption dryer has already been completely wired at our factory, the customer only has to connect the power supply cable to the terminal strip according to the supplied wiring diagrams. Recommendations Should you still have questions regarding installation, you can request installation blueprints separately from Ingersoll-Rand Davidson NC. NOTE: The dryer must be installed indoors in a heated environment (min. 33 F) to ensure proper operation and warranty protection. 11

12 SECTION 3 START UP AND OPERATION 3.1 START UP/ SHUT DOWN Attention! All pipes and wire connections are to be tightened! Furthermore, before start-up: The pipes must be checked for the presence of scale, abraded material from the threading, or other similar impurities. All shut off valves on the pre-filter, adsorption dryer, after-filter and on the bypass line should be closed. The ambient temperature must not be less than 33 F. Breakdowns resulting from faulty installation do not fall under Ingersoll-Rand's warranty obligation. Recommendations The following sequence is to be heeded for the initial start-up: Slowly open the inlet valve and observe the pressure build-up on the chamber pressure gauges of the adsorption dryer. An abrupt pressure build-up is to be avoided Turn the switch to the "POWER ON" position.. The adsorption dryer must be powered approx. 3-4 hours with the shutoff valve behind the after-filter closed; this regenerates the desiccant. After the regeneration phase, open the shut-off valve behind the afterfilter slowly while observing the chamber pressure gauge; if the shut-off valve is opened too abruptly, it could put a stress on the system. The adsorption dryer is now ready for operation and functions continuously and fully automatically. 3.2 DESCRIPTION OF THE OPERATION The Ingersoll-Rand adsorption dryer of the series TZ820 TZ1710 functions according to the pressure change principle, using dry air regeneration. Two adsorption vessels filled with desiccant are installed parallel to each other for this purpose. While the medium is being dried in one vessel, regeneration takes place in the other vessel. The changeover from one vessel to the other is performed in a fixed rhythm by means of a time-dependent control system. The adsorption dryer operates continuously and fully automatically. 12

13 SECTION Description of the operation TZ HEATLESS TYPE DRYER (TZ820 TZ1710) The Ingersoll-Rand TZ dryer has a NEMA cycle time of 10 minutes (STD) or 4 minutes (LDP) depending upon the air quality desired. In a 10 minute cycle, 5 minutes is dedicated to drying for each chamber (5 minutes half cycle). In a 4 minutes cycle, the half cycle is then 2 minutes. Through the inlet switching valve wet air enters either desiccant chamber at the inlet (bottom) and is dried as it flows upward through the desiccant bed. Dry air exits the dryer through the outlet check valve. At the outlet of each chamber, a portion of the dry air (purge air) is diverted to the regenerating chamber. The dry air, at near atmospheric pressure, will remove previously adsorbed moisture as it flows downward through the desiccant bed exiting through the purge exhaust muffler. The purge air is controlled by a purge adjusting valve and purge orifices located in the purge line. Purge pressure can be monitored on the purge pressure gauge. Refer to section on purge adjustment for instructions on setting the purge rate. Near the end of each half cycle, the chamber being regenerated will be repressurized. For this to occur, the exhaust valve of the chamber being regenerated closes while purge air continues to flow. Re-pressurizing the regenerated chamber to operating pressure before placing it into service minimizes fluidization of the desiccant and helps prevent desiccant abrasion which causes desiccant dust to prematurely block pilot and after-filter elements. Dryers operating at pressures greater than PSIG or in an accelerated NEMA cycle could be fitted with a re-pressurizing valve. This valve assists the regenerated chamber to reach dryer operating pressure before chamber switchover. Chamber switchover takes place when both towers are fully pressurized to minimize desiccant movement. When switchover is complete, the regenerated tower will be placed into service and the exhausted tower will begin a depressurization/regeneration cycle. 13

14 SECTION Dryer operating sequence (No control or alarm option) The Ingersoll-Rand TZ820 TZ1710 heatless air dryers use a SIEMENS PLC as its standard controller. In the event of a power failure, the exhaust valves will close and the dryer will pressurize both chambers. Since this control panel uses retentive programming the dryer will return to the same step in the cycle the dryer was in before power was lost. Energizing control panel : Power is turned ON electrical circuit energized. STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 SELECT LEFT CHAMBER DRYING. - De-energize solenoid EV-1R. - Energize solenoid EV-1L. - Inlet valve positioned for left chamber drying. - When 3 seconds have passed, go to STEP 2 RIGHT CHAMBER DEPRESSURIZATION. - Keep energized EV-1L - Energize EV-2R opening right chamber dump/exhaust valve. - When regeneration time has passed, go to STEP 3 RIGHT CHAMBER REPRESSURIZATION. - Keep energized EV-1L. - De energize EV-2R closing right chamber dump/exhaust valve. - The repressurization timer begins a countdown of 45 seconds. - Inlet valve remains in current position. - When repressurization time has passed, go to STEP 4 RIGHT CHAMBER DRYING. - De-energize solenoid EV-1L - Energize solenoid EV-1R. - Inlet valve positioned for right chamber drying. - When 3 seconds have passed, go to STEP 5 LEFT CHAMBER DEPRESSURIZATION. - Keep energized EV-1R - Energize EV-2L, opening right chamber dump/exhaust valve. - When regeneration time has passed, go to STEP 6 14

15 SECTION Dryer operating sequence (No control or alarm option) (Continued) STEP 6 RIGHT CHAMBER REPRESSURIZATION. - Keep energized EV-1R. - De energize EV-2L closing right chamber dump/exhaust valve. - The repressurization timer begins a countdown of 45 seconds. - Inlet valve remains in current position. The dryer has completed 1 full cycle and will repeat steps 1 through 6 until power is removed from the control panel Operating sequence (EMS Option) The Ingersoll-Rand TZ820-EMS TZ1710-EMS and all LDP heatless air dryer uses a Siemens PLC as its standard controller. In the event of a power failure, the exhaust valves will close and dryer will pressurize both chambers. Since this control panel uses retentive programming, the dryer will return to the same step in the cycle dryer was in before power was lost. (See NOTE 2) Energizing control panel: Power is turned ON electrical circuit energized. STEP 1 SELECT LEFT CHAMBER DRYING. - De-energize solenoid EV-1R. - Energize solenoid EV-1L. - Inlet valve positioned for left chamber drying. - When 3 seconds have passed, go to STEP 2 STEP 2 RIGHT CHAMBER DEPRESSURIZATION. - Keep energized EV-1L If not in EMS mode: - Energize EV-2R opening right chamber dump/exhaust valve. If in EMS mode and dewpoint is better than hygrometer setpoint: - EV-2R does not energize. When regeneration time has passed, go to STEP 3 STEP 3 RIGHT CHAMBER REPRESSURIZATION. - Keep energized EV-1L. - De energize EV-2R closing right chamber dump/exhaust valve. - The repress timer begins a countdown of 45 seconds (See Note 1) - Inlet valve remains in current position. - When repressurization time has passed, go to STEP 4 15

16 SECTION Operating sequence (EMS option) (Continued) STEP 4 STEP 5 STEP 6 NOTE 1: NOTE 2: NOTE 3: NOTE 4: RIGHT CHAMBER DRYING. - De-energize solenoid EV-1L - Energize solenoid EV-1R. - Inlet valve positioned for right chamber drying. - When 3 seconds have passed, go to STEP 5 LEFT CHAMBER DEPRESSURIZATION. - Keep energized EV-1R If not in EMS mode: - Energize EV-2L opening right chamber dump/exhaust valve. If in EMS mode and dewpoint is better than hygrometer setpoint: - EV-2R does not energize. When regeneration time has passed, go to STEP 6 LEFT CHAMBER REPRESSURIZATION. - Keep energized EV-1R. - De energize EV-2L closing left chamber dump/exhaust valve. - The repress timer begins a countdown of 45 seconds (See note 1) - Inlet valve remains in current position. EV-3 and repress valves could be used if dryer operating at pressure above 125 PSI (G) and / or dryer operating on a timing cycle other than 10 minute cycle. Refer to the specification sheet in this manual or to the flow schematic supplied with the dryer. If power failure occurs to the dryer or unit is turned off, both exhaust valves will close. The inlet valve will remain in its position. The actual timer setting may differ from the previously noted sequence. Example: A dryer requiring 30 seconds to re-pressurize the regenerating chamber will have a regeneration time of 4 minutes and 30 seconds. The half cycle time will remain at 5 minutes and full cycle at 10 minutes. The regeneration and repressurization times should be adjusted by Ingersoll-Rand trained personnel only. Changing the factory settings will result in loss of dew point and/or failure to repressurize before changeover. 16

17 SECTION Alarms ** If any alarms options are supplied with dryer then a PLC will control the timing of the dryer. COMMON ALARM RELAY Common alarm relay comes with any optional alarm. If any one of the alarms are activated, the common alarm relay will also be activated. SWITCHING FAILURE ALARM (OPTIONAL, INCLUDED WITH EMS OPTION) Two pressure switches, sensing desiccant chamber pressure, are provided. An alarm will be activated if both chambers remain at full pressure when regeneration is required. Furthermore, if pressure in both chambers remain below set pressure, after depressurization an alarm will be activated. NOTE: Dryers equipped with EMS and operating in the EMS mode do not depressurize during the purge cycle (and do not purge) when an acceptable dew point is maintained. During this condition the switching failure alarm is cancelled. The alarm has a 1-minute delay. HIGH HUMIDITY ALARM (OPTIONAL, INCLUDED WITH EMS OPTION) The hygrometer provided has been programmed to initiate an alarm if the dryer outlet dew point falls below the setting. An alarm light is provided. NOTE: The alarm has a 20-minute delay when the dryer is first powered up, then the alarm is instant if the condition exists. IF THE HYGROMETER PROBE CONNECTION FAILS, then a fault will be observed by the hygrometer. The high humidity alarm light will come on. The dryer will go into a fixed cycle mode. The digital display will indicate

18 SECTION Electrical control Danger! Work on electrical installations may only be done by a specialist or by other persons instructed in this type of work as long as they are under the instruction and supervision of a specialist; the general rules for working with electricity must be followed! You will find the corresponding operating and control voltage on the data sheet. The Ingersoll-Rand adsorption dryer of the TZ series is normally operated with a PLC controller. The set times are adjusted at the factory during the test run. Do not change these adjustments! 3.3 SPECIAL EQUIPMENT EMS Controls The EMS control option is an Energy Management System that monitors the dryer dewpoint performance and manages the requirement for regeneration of the dryer. The EMS controls major components are a digital dewpoint display hygrometer and a humidity sensor. The Ingersoll-Rand type TZ Air dryer is designed to provide a specific pressure dewpoint performance (generally 40 F (-40 C)) at the most severe operating conditions specified. (Maximum flow at lowest pressure and highest inlet temperature). The regeneration purge flow rate required for the dryer is calculated and adjusted to achieve this dewpoint and is based on these conditions. For example, for dryers operating at 100 PSIG (690 kpa) and 100 F (38 C) the purge flow rate is approximately 15% of the specified maximum inlet flow. Dryers operating under less severe inlet conditions will introduce a reduced humidity load. The EMS controls have been factory programmed to monitor the dryer outlet dewpoint performance and prevent initiation of a regeneration cycle under these conditions. The EMS controls system has the following standard features, refer to the enclosed technical bulletin for a complete overview of the digital hygrometer display. Programmable alarm relays (EMS and High Humidity Alarm). Digital display can be toggled to degrees F. Detection for cable fault between hygrometer and moisture probe. Stainless steel humidity probe sampling cell with service valves. 18

19 SECTION EMS Controls Start-up and operation The EMS controls system when supplied should be disabled for the initial 8 hours of dryer operation. A dryer fitted with the EMS control will have a 3-position selector switch on the electrical control panel. The 3 positions of this switch will perform the following actions: Position 1: DRYER OFF Position 2: DRYER ON Position 3: EMS ON The DRYER ON position will allow the hygrometer to be energized yet force the dryer to operate on a FIXED CYCLE mode. The dryer SHOULD BE OPERATED IN THIS POSITION AT TIME OF INITIAL STARTUP AND AT ALL TIMES WHEN THE HYGROMETER OR HUMIDITY PROBE ARE REMOVED FOR SERVICE OR CALIBRATION. The EMS ON position will control the dryer regeneration steps when the dewpoint of the dryer is better than the factory adjusted setpoint programmed into the digital hygrometer. The start-up procedure for the EMS system will be as follows. Refer to the assembly drawing in the following section. 1. Verify that the sample line is connected from the dryer outlet (see flow schematic enclosed) to the inlet valve on the humidity probe sample cell. 2. Verify that the humidity probe is installed into the sample cell 3. Connect the cable to the humidity probe 4. Fully open the inlet valve to the sample cell 5. Partially open the discharge valve of the sample cell to vent off a small amount of sample air. Do not fully open discharge valve 6. Perform a soap test to verify for leaks on all parts of the sample line connections and the humidity sample cell. 7. The digital display will now read the dewpoint of the dryer system. It will take a short period of time for a humidity probe to be purged of humidity. 19

20 SECTION EMS Controls Start up and operation (Continued) Humidity cell assembly 20

21 SECTION 4 MAINTENANCE Recommendations In order to ensure continuous and trouble-free operation, a maintenance contract with Ingersoll-Rand is recommended. Also, the following points should be checked regularly: Daily Carry out a general visual check and watch out for possible disturbances during operation. Check function by manually operating the automatic condensate drain on the pre-filter. Do an optical color test on the blue gel indicator for non-ems dryers: Indicator Color Approx. dew point [ F] Blue gel Blue Pink Transparent Weekly Check the differential pressure on the pre-filter, which should not exceed 10 PSID. Values greater than this indicate that the filter cartridge must be changed. Check the differential pressure on the after-filter, which should not exceed 10 PSID. Values greater than this indicate that the filter cartridge must be changed. Check the backpressure at the silencer placed behind the exhaust valve, it should not exceed 5 PSIG. Use the gauge of the vessel that is to be regenerated. Annually or after every 2500 hours of operation Check the desiccant for impurities and change it if necessary. A brownish / yellowish tone indicates that it has been soiled with oil. The desiccant has a normal lifetime of about 8000 operating hours. Check the seat o rings on the outlet check valves. Check the function of the 3-port inlet valve operation by sending electrical control signals. 21

22 SECTION REPLACEMENT OF THE DESICCANT In order to ensure trouble-free operation, we recommend replacing the desiccant every 8000 Hours, or every 2 years on latest. Close dryer inlet/outlet isolation valves. Depressurize and switch off the adsorption dryer. Remove the drain plug and empty the old desiccant into a container. Screw the plug back in and fill new desiccant from above into the vessels. Pressurize the adsorption dryer and restore power to the dryer. NOTE : The dessicant life is determined by the quality of the inlet air. Proper filtering of the inlet air will extent the life of the dessicant. 4.2 DISPOSAL OF THE DESICCANT Danger! The desiccant can be disposed of at a suitable disposal site in accordance with local or official regulations. Don't forget: the desiccant may contain pollutants! 4.3 CHANGING OF THE REGENERATION ORIFICE Depressurize and remove power from the dryer. The regeneration orifice (Quantity = 2) are integrated into orifice unions that are threaded directly into the top purge manifold. The orifice union valves can be disassembled using standard hex. Pipe wrenches. The orifice disks are wedged between the two union parts. Remove regeneration orifice and re-install new orifice as required. Verify all previously disassembled piping joints are properly secured. NOTE: Consult Ingersoll-Rand for recommendations and or replacement of the purge regeneration orifice. Modification of the regeneration orifice can lead to performance deterioration of the dryer. Advice Should the need for spare parts arise during work on the Ingersoll-Rand adsorption dryer of the TZ820 TZ1710 series, then the dryer type and the construction of the adsorption dryer must always be indicated. This information is given on the nameplate mounted on the electric cabinet. 22

23 SECTION FILTERS General comments and use Filters of the series HE are suitable for filtering solids, oil and condensate out of compressed air and other neutral, compressed gases. This new filtration concept is characterized by high flows at low differential pressure Function The soiled medium flows through the filter element "Series HE" from the inside to the outside. Solids are filtered out by impact or by the effect of inertia, whereas oil particles and drops of humidity are filtered out by the effect of coalescence. By the force of gravity, the filtered-out droplets collect in the lower filter vessel and are drained automatically or manually Assembly and installation Recommendations Within the piping system, the filters should always be used where the air or gas temperature is lowest. The piping system must be cleaned before filters assembling. The filters must always be installed vertically. An arrow on the upper part of the housing marks the direction of the flow. Sufficient free space should be left at the bottom for the changing of filter elements Maintenance Recommendations The filter element should be replaced when a differential pressure of > 10 PSID has been reached, or on latest after 1 year of operation. The functioning of the automatic condensate drain is to be tested weekly by manual operation. Should there be no condensate drain, then, depending on the amount, the condensate on the pre-filter is to be removed several times a day by opening the hand drain. 23

24 SECTION FILTERS (Continued) Changing of filter elements Danger! The soiled filter elements are changed only when the housings are DEPRESSURIZED! Filter elements are to be changed according to the following steps: Separate the lower part of the housing from the upper part. Loosen and remove the element by hand. Install the new element and the O-ring and making sure that the element seats perfectly. Re-install filter bowl assembly. Elements of the HE or DP series can NOT be cleaned with compressed air Accessories Recommendations Pressure differential gauge: Indicates the degree to which the elements are soiled. Automatic condensate drain: Continuously draws off the condensate that has collected. Hand drain: Used when there is little or no condensate. 24

25 SECTION 5 DRYER FLOW CAPACITY AND PURGE ADJUSTMENT 5.1 DRYER FLOW CAPACITY MODEL Model Selection Chart Max. Inlet Air Pressure Average Inlet Air Flow (SCFM) Based upon 100 F Inlet Air Temperature Inlet Air Pressure (Psig) TZ TZ TZ TZ TZ Higher pressures available as an option. Consult factory 2. Based on 40 F PDP, 10 Minute NEMA cycle, activated alumina and average inlet air flow. 5.2 CORRECTION FACTOR FOR INLET TEMPERATURE TEMPERATURE DEGREES F Correction Factor To correct for an inlet temperature other than 100 F multiply dryer capacity by the temperature correction factor listed above. 25

26 SECTION CORRECTION FACTOR FOR INLET TEMPERATURE (Continued) Example: To size for an inlet flow of F and 110 Psig. 1. Select models that produce at least 950 SCFM at 110 Psig. This case would be the TZ1050 which can dry 1215 SCFM. 2. Multiply pressure corrected flow by the temperature correction factor to obtain the flow of the dryer corrected for pressure and temperature: 1215 X (0.83) = 1008 SCFM 3. Confirm model selection. Model TZ 1050 can flow 1008 SCFM at the inlet conditions specified. The requirements of 950 SCFM is less, so model TZ 1050 is correct. 5.3 PURGE ADJUSTMENT To adjust the purge pressure, the following steps are to be followed, refer to the flow schematics at the end of this manual: 1 The power is turned on, the dryer is operating. 2 When either chamber is depressurized and being regenerated, adjust the pressure on the pressure gauge using the purge adjusting valve supplied. 3 Refer to the table below to adjust purge based on operating/inlet pressure. TZ820 TZ1050 TZ1200 TZ1450 TZ1710 P1 P2 P2 P2 P2 P CF CF 98 CF CF CF CF = CONSULT FACTORY P1 = Dryer inlet pressure (PSIG) P2 = Dryer purge pressure (PSIG) based on dryer inlet temperature (100 F) 26

27 SECTION 6 SPARE PARTS LIST 6.1 SPARE PARTS LIST FOR TZ820 TZ1710 DESCRIPTION Desiccant: Activated Alumina (LBS per dryer ) TZ820 Part no (920) TZ1050 Part no (1200) TZ1200 Part no (1400) TZ1450 Part no (1600) TZ1710 Part no (1904) Pressure Gauge Pressure regulator Muffler port inlet valve c/w actuator Repair kit for 3-port inlet Repair kit for 3-port inlet valve actuator Exhaust valve Exhaust valve kit Exhaust valve actuator kit Included w/exhaust valve kit Included w/exhaust valve kit Included w/exhaust valve kit Included w/exhaust valve kit Included w/exhaust valve kit Check valve Check valve, Seat o-ring Check valve, Spring Check valve, Teflon Blue gel filling Solenoid block Pilot light bulb Relief Valve Fuse Alarm Relay * Pressure Switch * Pilot Air Filter Element I/R-DP19 I/R-DP19 I/R-DP19 I/R-DP19 I/R-DP19 PLC * C/F C/F C/F C/F C/F EPROM * C/F C/F C/F C/F C/F HYGROMETER PROBE * C/F C/F C/F C/F C/F 27

28 SECTION SERVICE BULLETIN Vane Type Actuator Installation, Operation & Service Instructions Nylon bearings Bronze bushing Paddle postion indicator Shaft o-rings Paddle o-ring Paddle Stroke adjustment Vane type actuators are compact 90 rotary pneumatic devices to operate quarterturn valves. They are designed for pressures (supply and/or exhaust) up to 120 PSIG maximum. Explosion. DO NOT EXCEED PRESSURE RATINGS : excessive pressure may rupture the actuator and cause personal injury and/or property damage. INSTALLATION 1. Vane actuators are shipped from the factory with an indicator line stamped on the shaft ends which shows the position of the vane paddle. This indicator should be used in determining the mounting orientation of the actuator on the valve. 2. Before mounting, the actuator and the valve must be placed in the same position (fully counter-clockwise or fully clockwise). Check the valve and actuator mounting surfaces, bracket, stem adapter and valve stem for proper orientation and fit. WARNING! VALVE & ACTUATOR DAMAGE. Once installed, leave at least 1-16 inch axial clearance between the end of the actuator shaft and the drive coupling to prevent valve and actuator damage. 28

29 SECTION SERVICE BULLETIN (Continued) 3. Utilize all mounting holes provided on the actuator and assure a full bolt diameter of thread engagement into the actuator housing as a minimum. 4. Tighten all bolts and nuts uniformly, taking care to center the actuator on the valve stem. 5. Actuators are shipped from the factory with the travel stops adjusted for approximately 90 rotation. It is usually necessary to make slight adjustments to the stop adjusting screws alter the actuator s installed on the valve, Refer to the valve manufacturers recommendations for specific instructions. If valve manufacturer s instructions are not available, adjust the open position actuator stop to allow for full opening of the valve. 6. Actuate the valve closed and adjust the closed position actuator stop to ensure that the valve is completely seated in the closed position, 7. Cycle the valve back and forth to check for repeatability of seating, 8. Be sure that the actuator travel slops are what ends the rotation. This will prevent prolonged shaft loading and maximize the life of compensators. WARNING MASSIVE LEAKAGE. To reduce the possibility of inadvertent valve disassembly and line entry, replace or rework all valves using old style cover mounted brackets. Temporarily tag these valves until permanent corrective action is taken. See the Important Safety Bulletin (PN 831 I~O) for details. SPEED OF OPERATION The speed of operation is determined by a number of factors such as the distance from he pressure source, supply line and control valve sites, the torque requirement of the valve, pipeline flow conditions, and the size of the actuator. Cue to the interaction of those variables, it is difficult to specify a normal operating time. WARNING ACTUATOR DAMAGE. The 90 stroke for the MX3000 must exceed two seconds to prevent actuator damage. 29

30 SECTION SERVICE BULLETIN (Continued) The 90 stroke for other Matryx models must exceed one second to prevent actuator damage. Slower stroke times may be obtained by using smaller orifices. lower supply pressure. or flow control valves to meter the supply and exhaust. Clean, dry air or gas is essential for long service life and satisfactory operation. If instrument air of this type is not available, it s recommended that an in-line filter be installed to prevent foreign particles (above 40 microns) from entering the actuator New air lines often contain scare, metal chips and other debris which will damage control valves and actuator seats. MAINTENANCE Matryx Vane Actuators will give long, dependable service on dry instrument air before any maintenance is required. When leakage is detected, new seals should be installed as soon as possible to avoid irreparable damage to the actuator. See the following servicing instructions. SERVICE INSTRUCTIONS 1. Disconnect air and electrical supplies from actuator, Allow air in actuator to vent. 2. Remove actuator from valve and disconnect any accessories from the vane housing. 3. Remove cover screws from flange joint. 4. Carefully separate body halves by wedging them apart with a thin tool or by using a jackscrew. (Xomox does not supply the jackscrew.} WARNING. HAZARDOUS PROJECTILES DO NOT use compressed air to separate body halves. Compressed air will cause rapid separation and can result in personal injury SECTION 6 30

31 6.2 SERVICE BULLETIN (Continued) 5. Remove paddle and inspect bearing area for excessive wear. 6. Remove both stop adjusting screw assemblies (thread-seal, washer, locknut and stop adjusting screw). Discard thread-seals. 7. Clean paddle and inside surfaces of actuator with an environmentally safe solvent and inspect surfaces for wear. 8. Remove silicone sealant on paddle and joint surface of actuator with a fine grade abrasive and. if necessary, an environmentally safe solvent. 9. Lubricate internal surfaces with supplied or recommended grease WARNING 0-RING DAMAGE. In some situations oil mist lubricators may increase 0-ring wear. Oil dilutes the grease film and can increase 0-ring wear. 10. Replace shaft 0-rings and paddle 0- ring. Lubricate with supplied or recommended grease. 11. Place paddle in bottom half of actuator housing at mid-stroke position. 12. Coat housing joint surface with high quality silicone sealant and replace top housing. 13. With paddle rotated to right side, snug down screws on left side, shoulder bolt first. Rotate paddle to left side of actuator and snug down screws on right side, shoulder boll first. 14. Tighten all screws securely. WARNING SEAL DAMAGE. Sealant must set for at least four hours before the actuator is pressurized to maintain seal integrity. 15. Using a wrench, rotate shaft from one side to the other several times manually to wipe sealant from joint. SECTION 6 31

32 6.2 SERVICE BULLETIN (Continued) 16. Lightly oil stop adjusting screws. 17. Turn new thread seal into place on stop adjusting screw. DO NOT SLIDE IT OVER THE THREADS. Reinstall stop adjusting screw in actuator. 18. Reinstall flat washers and jam nuts on stop adjusting screws. 19. Readjust stop adjusting screws to approximate the 90 position. Replacement parts. Replacement parts for Matryx Actuators may be obtained by ordering the appropriate seal kit as listed below. Valve Part Number Actuator Kit Part Number Note : the above kits contain only the O-rings. 32

33 SECTION SERVICE BULLETIN (Continued) MAINTENANCE INSTRUCTIONS- SLEEVED PLUG VALVES Replacement parts. Replacement parts are designed for maximum interchangeability between valve sizes, types and models. However, some are not interchangeable; and, to ensure receiving correct parts, the following information must be supplied when ordering replacement parts. 1. Specify if repair is in-line or out-of-line on all 1/2 and 3/4 inch valves as well as 1 inch ductile iron valves. 2. Specify valve identification number (six digit number found on hub washer or flow indicator). If you cannot supply the l.d. number, provide the following information: a. Size. b. Body and plug material. c. Class (150, 300, 600). d. Is valve for use on a toxic service such as Chlorine or HF? If yes, specify. e. Does valve have hex head bolts or allen head adjustment screws? If allen head, advise if a T is stamped on the cover. f. Is valve manual or actuated? If actuated, specify type of actuator. Tufline valves are designed and built to give long, trouble-free service. Properly applied, adjusted and operated, these valves should require minimum attention. The following procedures and illustrations have been prepared to assist you in the maintenance and repair of your Tufline valves. Please read instructions carefully. If there are any questions, consult your Tufline valve representative or the factory at SECTION 6 33

34 6.2 SERVICE BULLETIN (Continued) Adjustments. Loss of seal. All Tufline valves are factory adjusted and normally further adjustment is not required. However, if seepage does occur at the plug stem or downstream, the following adjustments can be made. Tighten each of the three adjustments bolts (or screws) 1/4 turn. Operate valve and check for leakage. Repeat as necessary to stop the seepage. The need for frequent adjustment of the bolts, and/or many adjustments turns indicates the seals are worn to the point of needing replacement (see page 4). Excessive tightening of the adjustment bolts will cause an increase in the valve stem torque. Valve torque. Valves should be operated under service conditions for at least twelve hours before any torque adjustments are made, since the initial breakaway torque normally reduces with usage and temperature. Running torques. Normal running torques may be less than the values shown in the tables below. Valve torque may be greater if the valve is used to control a highly viscous or abrasive medium. Size (inches) PTFE sleevefoot-pounds at stem UHNMWPE Sleeve foot-pounds at stem 1/ ¾ / Size (inches) PTFE sleevefoot-pounds at stem EG Wormgear UHNMWPE Sleeve foot-pounds at stem EG Wormgear * Values at the plug can be greater **Torque at the input shaft less hand wheel or crank. 34

35 SECTION SERVICE BULLETIN (Continued) TOP SEAL REPLACEMENT INSTRUCTIONS WARNING!! MEDIA EXPOSURE. Depressurize, clean, and neutralize any media that may remain in the valve and pipeline. If the valve is in the pipeline, you must follow your line entry procedures. WARNING!! MASSIVE LEAKAGE. DO NOT attempt to repair a valve or its accessories while pressurized! Death or serious injury could result. Loosen the cover bolts (or nuts) approximately 4 turns each, being careful not to allow the release of the valve cover. Rotate the plug 1/4 turn to release any trapped pressure within the valve. Remove the hub (or E.G. actuator and bracket). Remove the valve cover Using a wrench to turn the plug, remove the plug and top seal parts. Top seal parts must be discarded INSPECTION For best sealing results inspect the following components: 1. The seal surface on the plug stem. 2. The plug surface. 3. The seal surface on the cover. 4. The body seal surface that mates with the cover. 5. The sleeve. 35

36 SECTION SERVICE BULLETIN (Continued) These surfaces should be free from defects, which are typically caused by corrosion, erosion, improper handling, or improper storage of a disassembled valve. If defects are found on any of these parts, the valve must not be repaired. Reassembly. 18. Replace the plug in the valve body with the ports in the open position. 19. Install wedge ring onto plug stem. The small diameter end must be upward. 20. Place assembly cone tool with formed PTFE diaphragm over plug stem. (In valves that have a threaded stud atop the plug stem it will be necessary to make a 5/16-inch diameter hole through the crown of the assembly cone tool to allow the cone to rest on the top of the plug stem.) 21. Push the formed PTFE diaphragm over taper on assembly cone tool and onto plug stem, being sure to evenly distribute the pushing force on the crown of the diaphragm to prevent back rolling and damage to the sealing lip. When installing the formed PTFE diaphragm, the thrust collar may be used as a pushing tool to push the diaphragm over the taper and onto the largest diameter of the assembly cone tool. The thrust collar can now be set aside. Continue pushing the diaphragm over assembly cone tool and onto plug stem. 22. Check to see that the wedge ring has seated properly inside the crown of the formed PTFE diaphragm. 23. Remove and discard assembly cone tool. 24. Install metal diaphragm 25. Install the trust collar with that side facing up. 26. On 1/2 through 4 inch valves, install the static eliminator with thin lip facing down. (Not required on actuated valves.) 27. Back out adjustment screws to within one thread of bottom of cover bore. 28. Install the cover. To facilitate tightening of the cover bolts, press the plug into the body with an arbor press until the bottom of the plug port opening is 1/16 inch above the bottom of the valve body port opening. Do not apply force to the cover as this may damage the formed PTFE diaphragm. 36

37 SECTION SERVICE BULLETIN (Continued) 12. Check to see that the metal diaphragm is centered in the valve body counterbore. 13. Tighten the cover bolts alternately (criss-cross pattern) and incrementally until the following torque values are reached: Bolt Size (inches) Foot-Pounds 3/8 20 7/ /2 45 5/ Tighten the adjusting bolts uniformly in 1/4 turn increments until contact is made, then tighten an additional 1/4 turn. 15. Replace the hub and wrench (or bracket and E.G.actuator) and rotate the plug. 16. Compare the valve torque against the values listed under Running Torque on page 38. If satisfactory results have not been obtained, consult the nearest Tufline Service Center. WARNING!!! VALVE DAMAGE. DO NOT exceed maximum torque values. Personal injury and property damage may result 37

38 SECTION SERVICE BULLETIN (Continued) REPAIR INSTRUCTIONS FOR 1 THROUGH 8 INCH VALVES, OUT-OF-LINE WARNING!! MEDIA EXPOSURE. Depressurize, clean, and neutralize any media that may remain in the valve and pipe-line. If the valve is in the pipeline, you must follow your line entry procedures. Always wear appropriate safety attire. Failure to follow this warning- could result in death, personal-injury, or property damage. WARNING!! MASSIVE LEAKAGE. DO NOT attempt to repair a valve or its accessories while pressurized 1 Death or serious injury could result. WARNING!! MEDIA LEAKAGE. Discard and replace valve body if scored. With a scored body, in-line leakage may occur. 1. Loosen the cover bolts (or nuts) four turns each. Rotate the plug approximately 1/4 turn to release any trapped pressure within the valve. Remove the hub (or EG actuator and bracket). Remove the cover bolts. Remove cover Remove plug and top seal parts by turning plug with a wrench. Remove and discard the old top. 2. To remove the sleeve, cut through the sleeve with a sharp knife at top and bottom side of the ports. Care must be taken not to score the valve body during sleeve removal. 38

39 SECTION SERVICE BULLETIN (Continued) 3. After the sleeve has been cut, insert a screwdriver behind the sleeve and curl the sleeve away from the valve body. Remove the sleeve by prying it out of the body. Discard old sleeve. Clean the body and plug. Check pads for erosion and replace if necessary. Check the finish of the sealing surfaces on the plug. Replace the plug if not smooth. 4. The replacement sleeve has been sized and taped at the factory. Do not remove the tape until ready for use. Place the loading ring in the counterbore of the valve body. Remove the tape from the sleeve. Insert the sleeve so that its pods are 90 from being aligned with the waterway of the valve body. Press the sleeve through the loading ring until the bottom of the sleeve is past the top of the retaining lips of the valve body (1/16 inch wide protruding metal rib that surrounds the valve port). 5. Place the large end of the plunger on top of the sleeve. Press the sleeve into the valve body with an arbor press. Reverse the plunger and use the small end of the plunger to press through the loading ring. Remove the ring plunger and loading 6. When the sleeve is in the body, use a screwdriver (or prybar) through the pod of the valve to tuck the edge of the sleeve port behind the retaining lip of the valve body. Repeat on the other port opening. Manually rotate the sleeve until the pods of the sleeve are aligned with the pods of the body. 7. Tuck the bottom and top edges of the sleeve pod opening into position behind the retaining lip of the valve body. If properly installed, the edges of the sleeve pods should now be in perfect alignment and locked behind the retaining lips of the body. Also the bottom of the sleeve should be resting on the lower ledge of the body and the top of the sleeve should be tucked under the upper ledge of the body. 39

40 SECTION SERVICE BULLETIN (Continued) 8. Insert the spreading tool into the sleeve and press to the bottom of the valve. This presses the sleeve to the valve body around the pods to prevent tearing of the sleeve during sizing. 9. Place the sizing plug into the valve body and press the sizing plug to the bottom of the valve. Remove the sizing plug, using a jackscrew if necessary. There may be a small excess of sleeve material around the ports which should be trimmed with a sharp knife. Do not mar the sealing areas of the sleeve or leakage may result. 10. Insert the standard plug with the ports in the open position. The top of the plug should drop within approximately 1/4 inch of the body counterbore. If it does not, resize with the sizing plug. 11. Install the wedge ring onto plug stem. The small diameter end should be upward. Place assembly cone tool with formed PTFE diaphragm over plug stem. 12. Push the formed PTFE diaphragm over taper on cone and onto plug stem, being sure to evenly distribute the pushing force on the crown of the diaphragm to prevent back rolling and damage to the sealing lip When installing the formed PTFE diaphragm, the thrust collar may be used as a pushing tool to push the diaphragm over the taper and onto the largest diameter of the assembly cone tool. 12. The thrust collar can now be set aside. Continue pushing the diaphragm over assembly cone tool and onto plug stem. Check to see that the wedge ring has seated properly inside the crown of the formed PTFE diaphragm. Remove and discard assembly cone tool. Install metal diaphragm. 14. Install the thrust collar with flat side facing up. On 1 inch through 4 inch valves, install the static eliminator with thin lip facing down. (Not required on actuated valves 40

41 SECTION SERVICE BULLETIN (Continued) 15. On the valve cover, back adjusting bolts out to within one thread of bottom of cover bore. 16. Install the cover. To facilitate tightening of the cover bolts, press the plug into the body with an arbor press until the bottom of the plug port opening is 1/16 inch above the bottom of the valve body port opening. Do not apply force to the cover, as this may damage the formed PTFE diaphragm 17. Check to see that the metal diaphragm is centered in the valve body counterbore. Tighten the cover bolts alternately (criss-cross pattern) and incrementally until the following torque values are reached: Bolt Size (inches) Foot-Pounds 3/8 20 7/ /2 45 5/8 95 WARNING VALVE DAMAGE. DO NOT exceed torque values. Personal injury and property damage may result. 18. Tighten the adjustment bolts uniformly in 1/4 turn increments until contact is made; then tighten an additional 1/4 turn. Replace hub (or E.G. actuator and bracket). Rotate the plug and compare the valve torque against the values listed under Running Torque on page 3. If satisfactory results have not been obtained, consult your nearest Tufline Service Center. 41

42 SECTION SERVICE BULLETIN (Continued) CHECK VALVE Bushing Seat o ring Bushing Guide Spring 42

43 SECTION SERVICE BULLETIN (Continued) DEPRESS / EXHAUST VALVE Valve actuator Valve body Valve body gasket Valve seat disk 43