INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR HEATLESS REGENERATIVE COMPRESSED AIR DRYER models HLS-55 through HLS-150

Transcription

1 SEPTEMBER 00 P/N C 950 MECHANIC STREET LAKE CITY, PA 63 PHONE: FAX: INSTALLATION, OPERATION & MAINTENANCE MANUAL FOR HEATLESS REGENERATIVE COMPRESSED AIR DRYER models through HLS-50 /80 HLS-0/50 READ ALL INFORMATION IN THIS MANUAL BEFORE BEGINNING INSTALLATION OR OPERATION OF THE DRYER. BEFORE STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES, TURN OFF THE MAIN POWER TO THE DRYER AND COMPLETELY DEPRESSURIZE THE UNIT TO PREVENT PERSONAL INJURY. DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS UNDER PRESSURE. NEVER OPERATE THIS DRYER ABOVE THE RATED OPERATING CONDITIONS. OPERATION ABOVE SPECI- FIED CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO THE UNIT AND/ OR PERSONAL INJURY. SEE BACK OF THIS MANUAL FOR ADDITIONAL SAFETY INSTRUCTIONS PRINTED IN THE U.S.A. PAGE

2 HANDLING THE DRYER SECTION. HANDLING INSTRUCTIONS DO NOT LIFT THE DRYER BY THE INLET PIPING OR CONTROL BOX. THESE COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF THE DRYER. PERSONAL INJURY AND/OR EQUIPMENT DAMAGE MAY RESULT. Lift the dryer by the outlet (top) piping or vessel center connector br. When lifting the unit mke sure tht the chins or cbles re cler of ll tubing nd frgile components.. STORAGE INSTRUCTIONS The idel plce to store the unit is indoors. The loction should be free from corrosive gsses nd extreme humidity. These conditions will cuse dmge to the unit. The unit should be covered with trpulin to keep the unit clen. If the unit is to be stored outdoors, it MUST BE covered completely. The cover must be dequte enough to prevent rin or snow from ccumulting on the dryer. The loction must be free of stnding wter nd mud. The preferred loction if outdoors, is on pved surfce..3 EQUIPMENT CHECK Inspect the dryer for ny dmge tht my hve occurred during shipment. Inspect ll fittings, piping connections, fsteners, etc. for loose connections. Also check guges for crcks or brekge. IF DRYER HAS BEEN DAMAGED DURING SHIPMENT: () NOTIFY CARRIER IMMEDIATELY AND FILE A CLAIM. () CONSULT FACTORY BEFORE OPERATING THE DRYER. SAFETY INSTRUCTIONS SECTION. HANDLING DO NOT LIFT THE DRYER BY INLET (BOTTOM) PIPING OR CONTROL BOX. THESE COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF THE DRYER. PERSONAL INJURY AND/ OR EQUIPMENT DAMAGE MAY RESULT. MAKE SURE THAT ALL EQUIPMENT BEING USED TO LIFT THE DRYER IS CAPABLE OF LIFTING THE WEIGHT OF THE DRYER..3 OPERATION DO NOT OPERATE DRYER IF THERE IS A LEAK IN EITHER VESSEL. IMMEDIATELY TAKE THE DRYER OUT OF SERVICE. ANY DAMAGE TO THE VESSELS CAN MAKE THEM UNSAFE TO USE. INSPECT OUTSIDE AND INSIDE OF VESSELS REGULARLY FOR CORROSION AND ANY DAMAGE (I.E., DENTS, GOUGES OR BULGES). IF DAMAGED, TAKE OUT OF SERVICE IMMEDIATELY. IF THE DRYER IS TO BE TRANSPORTED OVERHEAD, MAKE SURE THAT ALL PERSONNEL ARE ALERTED AND SAFETY PROCEDURES ARE FOLLOWED.. INSTALLATION BEFORE STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES, TURN OFF POWER AND DEPRESSURIZE UNIT TO PREVENT INJURY. SERIOUS PERSONAL INJURY MAY RESULT IF THESE SAFETY RULES ARE NOT FOLLOWED. DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON DRYER WHILE IT IS UNDER PRESSURE. TURN OFF MAIN POWER TO THE DRYER AND DEPRESSURIZE THE DRYER COMPLETELY BEFORE STARTING INSTALLATION AND/OR MAINTENANCE PROCEDURES. WHEN INSTALLING AND OPERATING THIS EQUIPMENT, COMPLY WITH THE NATIONAL ELECTRICAL CODE AND ANY APPLICABLE FEDERAL, STATE, AND LOCAL CODES. WHEN INSTALLING THIS DRYER, MAKE SURE THAT THE NEMA RATING OF THE CONTROL BOX IS APPLICABLE TO THE INSTALLATION. MAKE SURE THAT ALL CUSTOMER SUPPLIED WIRING AND ELECTRICAL DEVICES ARE PROPERLY SIZED TO HANDLE THE ELECTRICAL REQUIREMENTS OF THE DRYER. DO NOT OPERATE THIS DRYER ABOVE THE MAXIMUM RATED WORKING PRESSURE. OPERATING CONDITIONS FOR PROPER PERFORMANCE OF THIS DRYER ARE DIFFERENT THAN MAXIMUM OPERATING CONDITIONS FOR THE VESSELS. BE SURE TO CHECK THE DRYER OPERATING CONDITIONS. SEE SECTION 3.. USE THIS DRYER FOR COMPRESSED AIR ONLY. AIR FROM THIS DRYER IS NOT SUITABLE FOR BREATHABLE AIR SYSTEMS WITHOUT FURTHER TREATMENT. DO NOT OPERATE THIS DRYER IF EITHER VESSEL HAS BEEN DAMAGED BY FIRE. TAKE OUT OF SERVICE IMMEDIATELY.. MAINTENANCE DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE DRYER WHILE IT IS UNDER PRESSURE. TURN OFF MAIN POWER TO THE DRYER AND DEPRESSURIZE THE DRYER COMPLETELY BEFORE STARTING MAINTENANCE PROCE- DURES. DO NOT WELD OR GRIND ON EITHER VESSEL. IT WILL NOT BE SAFE TO OPERATE. ALWAYS WEAR EYE PROTECTION, GLOVES AND A RESPIRATORY PROTECTIVE DEVICE WHEN HANDLING THE DESICCANT. THE DUST FROM THE DESICCANT MAY CAUSE EYE AND SKIN IRRITATION. AVOID BREATHING THE DUST AND PROLONGED CONTACT WITH THE SKIN. FIRST AID IN CASE OF EYE CONTACT WITH DESICCANT DUST; IMMEDIATELY FLUSH THE EYES WITH PLENTY OF WATER FOR AT LEAST 5 MINUTES. CONSULT A PHYSICIAN. PAGE PRINTED IN THE U.S.A.

3 DIMENSIONS AND SPECIFICATIONS SECTION 3 3. DRYER SPECIFICATIONS WEIGHT (with desiccnt instlled) lbs lbs HLS lbs HLS lbs DIMENSIONS See SECTION 3. IN/OUT CONNECTION.../"NPT..."NPT HLS-0..." NPT HLS-50..."NPT VESSELS (desiccnt towers) Design Pressure PSIG Design Temperture O F TO 00 O F PIPING Threded pipe fittings: ANSI B6.3 Threded union fittings: ANSI B6.39 Pipe: Crbon Steel, Schedule 0 VALVES Inlet... -Wy, solenoid piloted Outlet... Shuttle vlve Purge... 3-Wy Vlve (run s -Wy Vlve), solenoid piloted CONTROL AIR FILTER Construction... Zinc housing 3. DIMENSIONS Models through HLS-50 ELECTRICAL Nem Electricl enclosure Stndrd 5V... 5V/PH/50-60Hz Optionl 30V:... 30V/PH/50-60Hz DESICCANT Mteril... Activted Alumin, /8" (-5 MM) Bed type Quntity Per Tower (LBS) lbs lbs HLS lbs HLS lbs OPERATING CONDITIONS Inlet Air Pressure... MIN 60 PSIG... MAX 50 PSIG Inlet Air Temperture... MIN 0 O F... MAX 0 O F Ambient Air Temperture.. MIN 0 O F... MAX 0 O F RATED INLET CONDITIONS Inlet Air Pressure PSIG Inlet Air Temperture O F Reltive Humidity (sturtion)... 00% RH HLS-0 HLS-50 HLS-0 HLS-50 * (ROTATED TO BACK ON HLS-50) & HLS-0 & HLS-50 PRINTED IN THE U.S.A. PAGE 3

4 INSTALLING THE DRYER SECTION. LOCATION A colescing prefilter must be instlled before the dryer to remove lubricting oils, dust nd pipe scle contmintion. It is DO NOT INSTALL THIS DRYER IN AN ENVIRONMENT OF recommended tht high efficiency colescing filter with n CORROSIVE CHEMICALS, EXPLOSIVE GASSES, POISONOUS utomtic drin or electric drin vlve be instlled. The filter should GASSES, OR SATURATED STEAM HEAT. be equipped with pressure differentil indictor to monitor the condition of the element. Locte dryer in protected, well vented re where mbient tempertures re between 0 o F nd 0 o F. If this dryer must be instlled where mbient tempertures re below 0 o F, insultion nd het trcing must be properly instlled on the inlet piping, purge exhust line nd the desiccnt towers to prevent freezing of the equipment. Position the dryer in the upright position on solid, level, vibrtion free surfce cpble of supporting the dryer s weight. Allow sufficient clernce over nd round the dryer. Refer to SECTION 3. for dryer dimensions. The dryer should not be locted in extremely dirty res where irborne contminnts cn ccumulte on the dryer. If this cnnot be prevented, the dryer should be clened periodiclly.. PIPING AND ANCILLARY EQUIPMENT IMPORTANT Mke sure tht the inlet ir piping is connected to the bottom nd the outlet ir piping is connected to the top of the dryer. Mke sure tht the inlet nd outlet piping to nd from the dryer is properly supported. Excessive stress my cuse dmge nd/or dryer mlfunction. Remove protective cps or covers from ll vlves before instlling this dryer. If this dryer is to be instlled into n existing piping system, clen the existing inlet piping to remove ll ccumulted dirt, pipe scle, etc., before connecting the dryer. Mke sure tht the inlet nd outlet shutoff vlves re tightly closed before connecting to the existing piping system. When instlling the piping nd ny dditionl components, mke sure tht dequte pipe supports re used. Excessive stress on the dryer nd components my cuse dmge or premture filure. Use either overhed or stiff-leg type supports. Mke sure tht the piping is correctly connected to the dryer. The inlet is the bottom connection nd the outlet is the top connection. Reference SECTION 3. for dryer dimensions nd connection loctions. Once the loction hs been determined, plce the dryer into position. Reference SECTION for hndling instructions..- BYPASS PIPING (optionl) The instlltion of bypss piping is not required, but will llow the dryer nd filter(s) to be tken off strem without interrupting the ir system. A prticulte fterfilter should be instlled downstrem of the dryer. The fterfilter will remove ny desiccnt dust. The fterfilter should be equipped with pressure differentil indictor to monitor the condition of the element. Mke sure tht the filters re properly instlled ccording to the instructions provided with them..3 REMOTE PURGE EXHAUST PIPING To reduce the noise during purging nd tower depressuriztion, this dryer ws supplied with muffler for instlltion on the purge exhust vlve. If the sound or humidity dischrged from this dryer is uncceptble, the purge of this dryer cn be piped remotely wy. IMPORTANT Mke sure tht the piping is s short s possible nd does not crete bck pressure on the dryer. To prevent liquid ccumultion in the piping nd purge vlve, the piping must be t the sme level or lower thn the purge vlve. The purge line must be vented to tmospheric pressure. If the mbient temperture t the venting end of the piping is subject to tempertures below 3 o F, freeze protection must be instlled. The purge vlve hs threded pipe connections. Reference Section 3. for loction. Use dequte pipe supports on the piping to prevent stress on the vlve. The distnce will determine the size of piping tht is recommended. For distnces of 0 feet or less, use piping of the sme size s the purge vlve. For distnces up to 0 feet, use piping one size lrger thn the purge vlve.. INSTALLING PRESSURE RELIEF VALVES CAUTION THESE VESSELS MUST BE PROTECTED BY PRESSURE RELIEF VALVES. Refer to OSHA Pr. b, Sub. Pr (3) nd ASME Boiler nd Pressure Vessel Code, Section VIII, Division, UG-5 through UG-36. Also check government regultions, i.e., stte nd locl codes. Relief vlve connection ports were NOT provided on this dryer. It is recommended tht relief vlves be instlled to comply with ll pplicble codes. The relief vlves should be full flow type, rted for the dryer operting conditions. For recommended loction see Figure A..5 INSTALLING THE PURGE MUFFLER To reduce the sound level during purge nd tower depressuriztion, this dryer ws supplied with muffler for instlltion on the purge exhust vlve. For muffler loction Reference SECTION 3.. In Figure A, recommended bypss piping lyout nd dditionl components re shown. Bsic bypss piping should include n inlet isoltion vlve, bypss vlve, nd n outlet isoltion vlve. The isoltion nd bypss vlves must be bubble-tight..- FILTERS CAUTION A PROPERLY RATED COALESCING PREFILTER MUST BE INSTALLED BEFORE THE DRYER TO REMOVE LUBRICATING OILS, DUST AND PIPE SCALE CONTAMINATION. FAILURE TO USE A PREFILTER WILL RESULT IN DAMAGE TO THE DRYER AND VOIDS THE WARRANTY. Mke sure tht the elements re instlled in ll filter housings prior to strt up. PAGE The muffler ws shipped seprtely. It should NOT be instlled until the dryer hs been operted for severl hours. From desiccnt instlltion, some dust my be present in the desiccnt towers. Operting the dryer with the muffler instlled immeditely fter the towers hve been filled with desiccnt or t initil strt up my cuse the muffler to clog. IMPORTANT The dryer must be operted for severl hours without the muffler fter the towers hve been filled with desiccnt. This will prevent the muffler from becoming clogged. PRINTED IN THE U.S.A.

5 INSTALLING THE DRYER SECTION FIGURE A RECOMMENDED PIPING CONFIGURATION AND COMPONENTS MODEL HLS-0 HLS-50 DRYER IN/OUT /" NPT(F) " NPT(F) " NPT(F) " NPT(F) PREFILTER MODEL IN/OUT DEL-P INDICATOR MODEL AFTERFILTER MODEL IN/OUT DEL-P INDICATOR MODEL F /-C-AD F /-C-AD F C-AD F C-AD /" NPT(F) 3/" NPT(F) " NPT(F) " NPT(F) F /-RB-MD F /-RB-MD F RB-MD F RB-MD /" NPT(F) 3/" NPT(F) " NPT(F) " NPT(F).6 ELECTRICAL CONNECTIONS SERIOUS PERSONAL INJURY AND DAMAGE TO THE DRYER WILL OCCUR IF THE DRYER IS CONNECTED TO A POWER SOURCE OTHER THAN THE VOLTAGE LISTED ON THE DATA TAG. WHEN INSTALLING THE ELECTRICAL CONNECTIONS FOR THIS DRYER, COMPLY WITH NATIONAL ELECTRICAL CODE AND ALL APPLICABLE FEDERAL, STATE AND LOCAL CODES. Check the electricl rting of the dryer s listed on the dryer dt tg. Mke sure tht the power source is correct for the dryer rting. Remove the box cover to ccess the power supply nd lrm terminls. Wire the power supply s shown in Figure B. Connect the wiring nd necessry components to the dryer box. Comply with ll codes pplicble for this instlltion. The power supply to the dryer will be connected into the dryer control box. A 7/8" di hole ws provided in the bottom of the box for the connection of conduit or cord grip connector. FIGURE B ELECTRICAL CONNECTIONS PRINTED IN THE U.S.A. PAGE 5

6 START UP SECTION 5 5. START UP BEFORE STARTING THIS DRYER, FOLLOW THE INSTALLATION INSTRUCTIONS AND PROCEDURES COMPLETELY. SERIOUS PERSONAL INJURY CAN RESULT IF INSTRUCTIONS ARE NOT CAREFULLY AND COMPLETELY FOLLOWED. DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS UNDER PRESSURE. 5. PURGE FLOW ORIFICE DRYER MODEL HLS-0 HLS-50 ORIFICE SIZE 3/3" DIA 7/6" DIA 9/6" DIA 5/3" DIA FLOW AT 00 PSIG 9.5 SCFM.9 SCFM. SCFM 6. SCFM BLANK ORIFICE P/N IMPORTANT TO START THE DRYER YOU MUST PRESS THE RUN SWITCH WHICH WILL LIGHT THE RUN LED. If the dryer is being strted up for the first time or fter the desiccnt hs been chnged, the purge muffler must be removed. Operte the dryer until no desiccnt dust is visible t the purge vlve. Then the muffler cn be reinstlled. If bypss piping ws instlled on this dryer s outlined in SECTION., close the inlet nd outlet isoltion vlves. Open the bypss vlve. Pressurize the ir system. Once the ir system is pressurized, slowly open the inlet isoltion vlve. Check timing settings in control box. The dryer should be fctory set s shown in Figure B. Energize the power supply to the dryer. Both towers will pressurize. Severl seconds lter one tower will depressurize. Open the outlet isoltion vlve. The Purge Orifice is locted t the top of the outlet vlve. Purge cn be djusted by tking blnk orifice nd drilling new size hole. 5.3 CONDITIONING THE DESICCANT BED To condition the desiccnt bed, the dryer is operted without ny outlet flow, while the towers regenerte with purge ir. Close the outlet isoltion vlve nd pressurize the system. Energize the power supply nd strt the dryer. Observe the dryer for severl cycles. Mke sure tht it is operting properly. At initil strt up or fter extended shutdowns (over one month), the dryer my tke to 8 hours of continuous opertion for the bed to be conditioned. Moisture tht hs ccumulted on the desiccnt bed should be removed before the dryer is plced on strem. PRINCIPLE OF OPERATION SECTION 6 6. PRINCIPLE OF OPERATION HLS Series Hetless Regenertive Air Dryers utilize the pressure swing principle of opertion. The desiccnt bed in one tower dries the ir strem while the desiccnt bed in the other tower is regenerted. A purge of dry ir is used for tower regenertion. It is tken from the outlet of the dryer. To llow the correct mount of dry ir to flow into the regenerting tower, dryers re equipped with purge metering orifice. The het creted during dsorption of moisture in the drying tower is retined in the desiccnt bed nd increses the moisture removl cpcity of the purge ir. When the dryer is pressurized nd the power supply to the dryer is energized, the dryer will begin opertion. To chieve mximum performnce from this dryer, it should be operted continuously. Operting this dryer for single shift periods my result in vried outlet dew point performnce. The dryer opertion consists of four stges; REPRESSURIZATION, CHANGEOVER/DEPRESSURIZATION, DRYING nd REGENERATION. 6.- REPRESSURIZATION STAGE Repessuriztion occurs in the regenerting tower. Repessuriztion must occur before tower chngover. This reduces shock to the desiccnt nd the possibility of downstrem pressure spikes. The purge vlve is closed nd the purge ir, which ws vented to tomosphere erlier in the cycle, is now used to repressurize the regenerted tower. The regenertion stge of one tower occurs t the sme time s the drying stge in the opposite tower. During the regenertion stge, percentge of dry ir is directed through the desiccnt bed of the offstrem tower. The purge ir is vented through the purge vlve to the tmosphere. FIGURE 6A PNEUMATIC SCHEMATIC 6.- CHANGEOVER/DEPRESSURIZATION STAGE Tower chngeover occurs fter the previous regenerting tower is pressurized. The controller signls the inlet trnsfer vlve to switch. The tower tht ws on line nd drying the process ir will begin to depressurize DRYING AND REGENERATION STAGE During the drying stge, one tower is pressurized with process ir. This tower is in the drying stge. The process ir psses through the desiccnt bed, which dsorbs moisture from the ir. PAGE 6 PRINTED IN THE U.S.A.

7 USING THE DRYER SECTION 7 7. CONTROLLER The Controller is compct NEMA control box. It hs the following fetures: Dryer Sttus LEDs - POWER ON LED - L/R TOWER DRYING LEDS - RUN LED - L/R TOWER REGENERATING LEDS - HOLD LED - DRYER PURGING LED - SWITCHING FAILURE LED The Dryer Sttus LEDs re locted on the front pnel of the control box. Figure 7A shows the loction of ech. FIGURE 7A When the Left tower is pressurized nd on line drying the process ir, the corresponding LEFT TOWER DRYING LED is illuminted. When the right tower is pressurized nd on line drying the process ir, the corresponding RIGHT TOWER DRYING LED is illuminted. POWER ON STOP RUN RUN The DRYER PURGING LED is illuminted when the purge exhust vlve is energized open. During repressuriztion this LED will not be illuminted. Repressuriztion occurs for pproximtely 0 seconds just before tower chngeover. The opertion sequence of the dryer is shown in FIGURE 7B TIMING CHART. SWITCHING FAILURE: When there is switching filure, the LED will be lit. This will energize the contcts shown in FIGURE B. The contcts cn be wired for remote nnuncition. To reset the Switching Filure Alrm press the run button on the control box front pnel. HOLD TOWER DRYING TOWER REGENERATING SWITCHING FAILURE HOLD FEATURE: For low lod or sttic pressure conditions, the hold contcts shown on Figure B cn be wired to n uxillry set of normlly closed contcts on the compressor strter. This will stop the cycling of the dryer nd repressurize both towers of the dryer, until there is demnd on the compressor. The Hold LED will light, if the dryer is wired s described nd the compressor is not running. 7. SETTING THE CYCLE TIME Reference Figure B: The setting for the time cycle is 5 min/hlf cycle. For the hlf cycle time setting, the switches indicted for DS (, 5, 7, & 8) s shown in the CYCLE TIME DETAIL hve been fctory set by pushing the switches up. The vlues for these switches re (56, 3, 8, & ) sec., so when dded together equl 300 sec or 5 min. WE DO NOT RECOMMEND time cycle setting below min/hlf cycle. For this hlf cycle time setting, the switches tht need to be pushed up re DS (, 5, 6, & 7) there vlues re (6, 3, 6, & 8) sec. so when dded together equl 0 sec or min. The setting for the pressuriztion time is 0 sec. For the pressuriztion time setting, the switches indicted for DS ( & ) s shown in the CYCLE TIME DETAIL hve been fctory set by pushing the switches up. The vlues for these switches re (6 & ) sec., so when dded together equl 0sec. WE DO NOT RECOMMEND CHANG- ING THIS SETTING. LEFT DRYER PURGING RIGHT The setting for the lrm time is 96 sec. For the lrm time setting, the switches indicted for DS (5 & 6) s shown in the CYCLE TIME DETAIL hve been fctory set by pushing the switches up. The vlues for these switches re (6 & 3) sec., so when dded together equl 96 sec. WE DO NOT RECOMMEND CHANGING THIS SETTING. NOTE: THE ALARM TIME SETTING NEEDS TO BE LESS THEN THE HALF CYCLE TIME SETTING OR THIS WILL NEGATE THE ALARM FUNCTION. IMPORTANT Operting this dryer on the minute cycle will more thn double the wer on the dryer components. To reduce wer on the dryer, operte the dryer on the 0 minute cycle if the -0 O F dew point is cceptble. FIGURE 7B CYCLE TIMING CHART PRINTED IN THE U.S.A. PAGE 7

8 SHUTDOWN SECTION 8 8. SHUTDOWN PROCEDURES Shutoff the ir supply to the dryer. If bypss piping nd vlves were instlled, close the inlet nd outlet isoltion vlves nd open the bypss vlve. Let the dryer cycle until it is totlly depressurized. MAINTENANCE & TROUBLESHOOTING SECTION 9 9. DAILY INSPECTION The following procedures should be performed dily: Check the dryer operting conditions, inlet temperture, mbient temperture, inlet pressure nd inlet flow. Monitor the dryer for one complete cycle. Mke sure tht it is operting properly. Visully check the dryer nd piping for dmge. Check the purge muffler. Purge ir should be exhusting from the vlve. If oil is present, the dryer nd ir system my be contminted with lubricnts. Inspect ll upstrem equipment, ftercoolers, seprtors, drins nd filters. Mke sure tht ll bypss vlves re tightly closed. Check the prefilter(s) for proper drining. If the prefilter is not equipped with n utomtic drin, it must be mnully drined. Check the pressure differentil indictor on ll prefilters nd fterfilters. If the differentil pressure is uncceptble, replce the elements. 9. SCHEDULED MAINTENANCE MONTHS Replce purge muffler element Replce the control ir filter element -60 MONTHS The desiccnt in the towers should be replced every two to five yers. The life of the desiccnt will vry depending on the inlet ir conditions. Systems with excessive contminnts nd/or indequte filtrtion will decrese the life spn of the desiccnt drsticlly. Once the desiccnt is contminted with lubricnts, it must be replced. 9.3 DESICCANT REPLACEMENT DO NOT ATTEMPT TO REMOVE ANY ITEM UNTIL ALL AIR PRESSURE IS OUT OF THE VESSEL. CHECK ALL TOWER PRESSURE GAUGES, MAKING SURE THAT THEY ARE AT 0 PSIG AND THAT INCOMING PRESSURE HAS BEEN TURNED OFF. ALWAYS WEAR EYE PROTECTION AND GLOVES WHEN HANDLING THE DESICCANT. DUST FROM THE DESICCANT MAY CAUSE EYE AND SKIN IRRITATION. AVOID BREATHING THE DUST AND PROLONGED CONTACT WITH THE SKIN. Remove ny oil, dirt, or scle from the towers nd piping. Do NOT weld, grind or sndblst the vessels. The vessels my be stem clened internlly nd externlly to remove dirt nd oil. CAUTION Mke sure tht the towers re clen to prevent contmintion of new desiccnt. Reinstll the bushing/diffusers in the bottom of the vessels. Instll the inlet piping ssembly. Apply pipe thred selnt s necessry. Remove the bushing/diffusers from the top of the vessels. Lod desiccnt through these ports. REFER TO SECTION 3. FOR PROPER DESICCANT AMOUNTS. Reinstll the bushing/diffusers in the top of the vessels. Instll the outlet piping ssembly. Reconnect the dryer to the process piping. Apply pipe thred selnt s necessry. Follow START UP PROCEDURES IN SECTION 5. to strt up nd plce dryer in opertion. For HLS-0 nd HLS-50 fill nd drin ports re provided, so piping disssembly is not required. 9. CONTROL AIR FILTER REPLACEMENT Close the dryer inlet nd outlet isoltion vlves (nd open bypss vlve if provided). Turn off the power nd completely depressurize the dryer. DO NOT REMOVE THE FILTER BOWL FROM HEAD UNTIL HOUSING IS COMPLETELY DEPRESSURIZED. After ll pressure is out of the dryer, grsp the filter bowl firmly. While pushing the bowl upwrd, turn it clockwise to remove it from the filter hed. Unthred the used element from the hed. Discrd the used element properly. FIRST AID IN CASE OF EYE CONTACT, IMMEDIATELY FLUSH EYES WITH PLENTY OF WATER FOR AT LEAST 5 MINUTES. CONSULT A PHYSICIAN. Tke dryer off strem following the SHUTDOWN PROCEDURES IN SECTION 8. For nd : Crefully disconnect the inlet nd outlet piping ssemblies from the dryer nd process piping. Disconnect the piping ssemblies t the union connections. Unthred the bushing/diffusers from the bottom of ech vessel to drin the old desiccnt. Remove new element from the shipping pckge. Thred the new element into the filter hed. Position the bowl in the filter hed. While pushing the bowl upwrd into the hed, turn the bowl counterclockwise to lock it in plce. Following the strt up procedures for the dryer, plce the dryer on strem. PAGE 8 PRINTED IN THE U.S.A.

9 MAINTENANCE & TROUBLESHOOTING SECTION TROUBLESHOOTING The following check list should be used s guideline for troubleshooting problems. IS THE POWER ON AND RUN SWITCH PRESSED? Check the min power source nd check tht the Power LED is lit. Mke sure tht the dryer Run switch hs been pressed nd tht the Run LED is lit IS THE SYSTEM PRESSURIZED? The dryer is designed to operte t 60 to 50 psig. Check the upstrem equipment nd ny isoltion or bypss vlves. IS THE DRYER CYCLING? IS THE CONTROL SYSTEM WORKING? Is there incoming power to the control box. IS THERE CONTROL AIR PRESSURE, 60 PSIG MINIMUM. Mke sure tht the dryer inlet pressure is bove 60 PSIG. Check the control ir filter element nd replce it with new element. Reference Section 9. for element replcement instructions. IS THE INLET VALVE FAULTY? Rebuild or replce the inlet vlve s necessry. Use mnul override to check. IS THE PURGE EXHAUST VALVE FAULTY? Rebuild or replce the fulty purge exhust vlve. Use mnul override to check. IS THE OUTLET VALVE FAULTY? Check the outlet shuttle vlve. ARE THE TOWERS DEPRESSURIZING? Check the purge vlve for proper opertion. Check the purge muffler. It might be clogged. If clogged or dmged, replce it. Use mnul overide to check. (This should cuse depressuriztion.) IS THE DEW POINT ACCEPTABLE? ARE THE INLET CONDITIONS WITHIN THE SPECIFICATIONS? Reference Section 3. for the inlet conditions of the dryer. Correct the inlet conditions if necessry. Excessive inlet flow will gretly reduce the performnce of the dryer. WAS THE DESICCANT INSTALLED? Mke sure tht the desiccnt ws instlled. Reference Section 9.3 for desiccnt instlltion procedures. IS THE DESICCANT CONTAMINATED WITH LUBRICANTS? Check the condition of the desiccnt bed. If the bed is contminted with lubricnts, replce the desiccnt following the procedures in Section 9.3. IS THE DESICCANT CONTAMINATED WITH MOISTURE? If the dryer ws operted under excessive inlet conditions, the desiccnt bed my be sturted with liquid moisture. Check upstrem equipment such s ftercoolers. Check the ctul inlet conditions, correct them nd condition the bed following the procedures in Section 5.3. ARE THE BYPASS VALVES OPEN OR LEAKING? Check the vlves (if instlled). Repir or replce if fulty. 9.6 WIRING DIAGRAMS CAUTION THE DRYER CONTROL CIRCUIT IS DUAL VOLTAGE RATED. NEVER SET THE BOARD TO A VOLTAGE OTHER THAN THE VOLTAGE RATING OF THE DRYER LISTED ON THE DRYER DATA TAG. SETTING THE BOARD INCORRECTLY WILL CAUSE DAMAGE TO THE INLET AND PURGE VALVES AND POSSIBLE PERSONAL INJURY OR FIRE. PRINTED IN THE U.S.A. PAGE 9

10 REPLACEMENT PARTS SECTION 0 ITEM b c 3 b b c DESCRIPTION Inlet Trnsfer Vlve, -wy Repir kit for -wy vlve Vlve pilot for -wy vlve -wy vlve without bse Outlet Shuttle Vlve Purge Vlve, 3-wy Repir Kit for 3-wy vlve Vlve pilot for 3-wy vlve Pressure Guge Diffuser/Desiccnt Retiner Purge Exhust Muffler Element, purge exhust muffler Control Air Filter Element, control ir filter Desiccnt Activted Alumin, /8" di, 5# pil Control Box (complete) Circuit Bord only Membrne Pnel Pressure Switch (5V) (30V) (5V) (30V) PAGE 0 PRINTED IN THE U.S.A.

11 REPLACEMENT PARTS SECTION 0 ITEM b c 3 b b c DESCRIPTION Inlet Trnsfer Vlve, -wy Repir kit for -wy vlve Vlve pilot for -wy vlve -wy vlve without bse Outlet Shuttle Vlve Purge Vlve, 3-wy Repir Kit for 3-wy vlve Vlve pilot for 3-wy vlve Pressure Guge Diffuser/Desiccnt Retiner Purge Exhust Muffler Element, purge exhust muffler Control Air Filter Element, control ir filter Desiccnt Activted Alumin, /8" di, 5# pil Control Box (complete) Circuit Bord only Membrne Pnel Pressure Switch HLS-0 (5V) HLS-0 (30V) HLS-50 (5V) HLS-50 (30V) PRINTED IN THE U.S.A. PAGE

12 SAFETY PRECAUTIONS Sfety is everybody s business nd is bsed on your use of good common sense. All situtions or circumstnces cnnot lwys be predicted nd covered by estblished rules. Therefore, use your pst experience, wtch out for sfety hzrds nd be cutious. DANGER DANGER DISCHARGE AIR USED FOR BREATHING WILL CAUSE SEVERE INJURY OR DEATH. CONSULT FILTRATION SPECIALIST FOR ADDITIONAL FILTRATIONS AND TREATMENT EQUIPMENT TO MEET HEALTH AND SAFETY REGULATIONS. AIR AND OIL UNDER PRESSURE WILL CAUSE SEVERE PERSONAL INJURY OR DEATH. SHUT DOWN COMPRESSOR AND RELIEVE SYSTEM OF ALL PRESSURE BEFORE REMOVING VALVES, CAPS, PLUGS, FITTINGS, BOLTS AND FILTER. ELECTRICAL SHOCK FROM IMPROPER GROUNDING CAN CAUSE INJURY OR DEATH. GROUND UNIT AND RELATED EQUIPMENT ACCORDING TO NATIONAL ELECTRICAL CODE AND LOCAL REGULATIONS. READ THE OPERATOR S MANUAL BEFORE STARTING THIS UNIT. FAILURE TO ADHERE TO INSTRUCTIONS CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH. REPLACEMENT MANUALS CAN BE PURCHASHED BY CONTACTING THE MANUFACTURER. PAGE PRINTED IN THE U.S.A.