SERIES HC Heat-of-Compression Compressed Air Dryer

Transcription

1 SERIES HC Heat-of-Compression Compressed Air Dryer Models HC-3 HC-239 Information When making inquiries, please provide the following information: 1) Equipment Model Number 2) Equipment Serial Number 3) Equipment Operating Pressure 4) Equipment Operating Temperature 5) Approximate time in service 6) Nature of Problem IMPORTANT! BEFORE INSTALLING AND OPERATING THE DRYER, IT IS RECOMMENDED THAT THIS MANUAL BE STUDIED AND CLEARLY UNDERSTOOD. THIS DRYER IS DESIGNED TO BE USED ONLY WITH A NON- LUBRICATED COMPRESSOR. USE WITH A LUBRICATED COMPRESSOR WILL VOID ALL WARRANTIES AND MAY CAUSE SEVERE DAMAGE. For information, parts, or service, contact your local Ingersoll-Rand Service provider or reach us at

2 Reference No. 145 Final Rev 8 Page 2 October 2005

3 INDEX PREFACE SECTION 1: INTRODUCTION 1.1 General Information 1.2 Safety Instructions Identification of signs and symbols in this manual Safety tips for maintenance, inspection & assembly work 1.3 Personnel Qualification 1.4 Product Information Theory of Operation Pressure vessel regulations Airtightness test Overloading Technical data sheet Dryer Flow Capacities Transport Storage Use of an afterfilter SECTION 2: INSTALLATION 2.1 Set-up and installation Mechanical installation Filter installation Electrical installation SECTION 3: START UP AND OPERATION 3.1 Start-up / Shut down Pressurizing dryer Energizing dryer controls Reference No. 145 Final Rev 8 Page 3 October 2005

4 3.2 Operator interface Main screen Dryer status Settings Alarms 3.3 Program Steps SECTION 4: MAINTENANCE 4.1 Suggested preventive maintenance schedule 4.2 Replacement / Disposal of the desiccant 4.3 Dewpoint meter maintenance (DPDS Option only) 4.4 Filters General comments and use Function Assembly and installation Maintenance Changing of filter elements Accessories SECTION 5: SPARE PARTS LIST 5.1 Recommended spares for HC-3 TO HC-239 SECTION 6: TROUBLESHOOTING AND FAULTS 6.1 Introduction 6.2 High Dewpoint 6.3 Fail-to-shift 6.4 Primary Drain Failure 6.5 Secondary Drain Failure 6.6 Short-term shut-down 6.7 Shut-down in case of a fault or for maintenance Reference No. 145 Final Rev 8 Page 4 October 2005

5 SECTION 7: I-R ACTIVATED ALUMINA MSDS 7.1 Company Description 7.2 Material Description 7.3 Ingredients 7.4 Physical Data 7.5 Fire and Explosion Data 7.6 Reactivity Data 7.7 Health Hazard Information 7.8 Spill, Leak, and Disposal Procedures 7.9 Special Protection Information 7.10 Special Precautions and Comments 7.11 References SECTION 8: AUXILIARY MANUALS & DRAWINGS Reference No. 145 Final Rev 8 Page 5 October 2005

6 PREFACE: This technical manual from 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 in the particular location where the dryer is being used, the recognized special rules for safe and proper working procedures must also be followed. 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. Reference No. 145 Final Rev 8 Page 6 October 2005

7 SECTION 1: 1.1 GENERAL INFORMATION The adsorption dryer of the HC-3 HC-239 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 (gas) 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, 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 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. Reference No. 145 Final Rev 8 Page 7 October 2005

8 USER MANUAL SECTION 1: (Continued) 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! Warning against electrical voltage! Safety tips printed directly on the adsorption dryer must also be followed at all times and must be kept completely legible. Advice: 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: Reference No. 145 Final Rev 8 Page 8 October 2005

9 USER MANUAL SECTION 1: (Continued) Safety tips for maintenance, inspection and assembly work (Continued) Attention! Never make structural changes to the adsorption dryer that are not specifically authorized by Ingersoll-Rand! Only use original spare and accessory parts! Carry out maintenance work only when the adsorption dryer is switched off, depressurized, and disconnected from the electric power supply! Attention! Multiple power sources may exist in the electrical panel. All possible power sources must be disconnected before servicing dryer. Advice: Refer to the desiccant material safety data sheet (MSDS) when installing or disposing of desiccant, which can be found in Section 7 of this User Manual. Danger! Wear protective goggles and mask when working with the desiccant! Advice for protection: If desiccant comes into contact with the eyes, rinse eyes immediately with large amounts of clear water. If the desiccant is spilled, clean up with effort to minimize the formation of dust. In case of fire, there is no restriction on the use of fire extinguishing material. A small dust 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. Reference No. 145 Final Rev 8 Page 9 October 2005

10 SECTION 1: (Continued) 1.4 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, depending on certain conditions, provides pure, dry and oil-free compressed air or gases Theory of Operation The HC heat-of-compression dryer uses the hot air from the compressor to regenerate the desiccant. Each tower is sized for a minimum of 4 hours online, but may be extended by use of the optional DPDS which will allow the dryer to switch towers based on water load rather than time. The DPDS (Dewpoint Demand System) is optional equipment and may or may not be present on your particular air dryer. If your dryer is equipped with the DPDS, see the associated DPDS Installation and Operating Guide for more operational details. The regeneration cycle is split up into three functions. Reference No. 145 Final Rev 8 Page 10 October 2005

11 SECTION 1: (Continued) A. Regeneration Cycles 1. Heating. Hot air directly from the compressor enters the inlet of the HC and is directed by the inlet 2-way valves into the regenerating tower. This hot, thirsty air regenerates the bulk of the water from the desiccant. The air is then directed into the aftercooler where it is cooled, the coalescing separator where liquid water is removed through the drain trap system, then into the drying tower where the air is actually dried to its final low dewpoint. The heating cycle lasts 90 minutes. Reference No. 145 Final Rev 8 Page 11 October 2005

12 SECTION 1: (Continued) 2. Stripping. At the end of heating, the inlet valves shift position, directing the hot inlet air directly into the aftercooler, separator, and drying tower. We now begin stripping. The stripping phase of regeneration lasts 90 minutes. At the beginning of stripping, the regenerating tower is depressurized through a muffler. During stripping, a small adjustable flow of dry air is used to remove the last little bit of moisture from the regenerating tower. If dryer is equipped with optional trim heater, reference operational instructions in Addendum at back of manual. Reference No. 145 Final Rev 8 Page 12 October 2005

13 SECTION 1: (Continued) 3. Cooling. At the end of stripping, the regenerating tower is repressurized. The cooling cycle valves open and cooling begins. The cooling cycle lasts 60 minutes. During cooling, a portion of the dry outlet air is directed into the regenerating tower to reduce the temperature of the bed prior to tower shift. Reference No. 145 Final Rev 8 Page 13 October 2005

14 SECTION 1: (Continued) 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: Type Operating overpressure Operating Temperature Max. Max. Min. HC-3 HC PSIG 500 F 20 F Attention! Never weld on or alter a pressure vessel in any way! 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 inlet flow is too high, The temperature of the air at the discharge of the aftercooler is too high, The min. operating pressure is too low, The temperature of the air at the discharge of the compressor is too low. Reference No. 145 Final Rev 8 Page 14 October 2005

15 SECTION 1: (Continued) Technical data sheet MODEL HC-3 HC-6 HC-7 HC-9 Flow 100 PSIG 100 F Drying Temperature Vessel OD Inches Desiccant type IR Activated Alumina Lbs. Desiccant / Vessel Inlet connection 2 NPT 2 NPT 3 FLG 3 FLG Outlet connection 2 NPT 2 NPT 3 FLG 3 FLG FILTER Afterfilter AF-350 AF-550 AF-1000 AF-1000 Voltage 115/1/60 Standard - Consult Factory for other voltages Cooling Water GPM Stripping Flow SCFM Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control High Humidity Alarm Adjustable Adjustable Pressure Switch Setpoints 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105 F Low regeneration temperature alarm Process flow Adjustable Downward Regeneration / Upward Drying Reference No. 145 Final Rev 8 Page 15 October 2005

16 SECTION 1: (Continued) Technical data sheet MODEL HC-14 HC-21 HC-30 HC-41 Flow 100 PSIG 100 F Drying Temperature Vessel OD Inches Desiccant type IR Activated Alumina Lbs. Desiccant / Vessel Inlet connection 3 FLG 4 FLG 4 FLG 6 FLG Outlet connection 3 FLG 4 FLG 4 FLG 6 FLG FILTER Afterfilter AF-1400 AF-2400 AF-3600 AF-7200 Voltage 115/1/60 Standard - Consult Factory for other voltages Cooling Water GPM Stripping Flow SCFM Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control High Humidity Alarm Adjustable Adjustable Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105 F Low regeneration temperature alarm Process flow Adjustable Downward Regeneration / Upward Drying Reference No. 145 Final Rev 8 Page 16 October 2005

17 SECTION 1: (Continued) Technical data sheet MODEL HC-54 HC-69 HC-85 HC-103 Flow 100 PSIG 100 F Drying Temperature Vessel OD Inches Desiccant type IR Activated Alumina Lbs. Desiccant / Vessel Inlet connection 6 FLG 6 FLG 8 FLG 8 FLG Outlet connection 6 FLG 6 FLG 8 FLG 8 FLG FILTER Afterfilter AF-7200 AF-7200 AF-7200 AF Voltage 115/1/60 Standard - Consult Factory for other voltages Cooling Water GPM Stripping Flow SCFM Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control High Humidity Alarm Adjustable Adjustable Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105 F Low regeneration temperature alarm Process flow Adjustable Downward Regeneration / Upward Drying Reference No. 145 Final Rev 8 Page 17 October 2005

18 SECTION 1: (Continued) Technical data sheet MODEL HC-122 HC-143 HC-166 Flow 100 PSIG 100 F Drying Temperature Vessel OD Inches Desiccant type IR Activated Alumina Lbs. Desiccant / Vessel Inlet connection 8 FLG 8 FLG 10 FLG Outlet connection 8 FLG 8 FLG 10 FLG FILTER Afterfilter AF AF AF Voltage 115/1/60 Standard - Consult Factory for other voltages Cooling Water GPM Stripping Flow SCFM Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration Outlet Dewpoint Variable DPDS Control High Humidity Alarm Adjustable Adjustable Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105 F Low regeneration temperature alarm Process flow Adjustable Downward Regeneration / Upward Drying Reference No. 145 Final Rev 8 Page 18 October 2005

19 SECTION 1: (Continued) Dryer Flow Capacities Model Selection Chart: MODEL 85 PSI 90 PSI 95 PSI 100 PSI 105 PSI 110 PSI 115 PSI HC HC HC HC HC HC HC HC HC HC HC HC HC HC HC Note: Maximum operating pressure is 150 PSIG; higher pressures available as an option. Consult factory. Minimum Inlet Pressure (PSIG) Correction Factor CORRECTION FACTOR FOR COOLING WATER TEMPERATURE TEMPERATURE ºF Correction Factor To correct for a cooling water temperature other than 85 F, or an operating pressure other than 100 psig, multiply dryer capacity by the correction factors listed above. Example: To size for an inlet flow of Psig, using 90 F cooling water: Multiply 1300 * (1.1) * (1.2) = 1716 Use model HC-21 Reference No. 145 Final Rev 8 Page 19 October 2005

20 SECTION 1: (Continued) Transport After the adsorption dryer has been delivered, it must be checked for damage that may have occurred during transport. The Transport Company must be informed to register any damage. Shipping damage is not covered by any warranty Storage If the adsorption dryer is to be stored for a prolonged period of time, it should be stored in a dry place, preferably indoors; protected from the elements including freezing or extremely warm temperatures Use of a pre and afterfilter Use of a prefilter is not necessary with a heat-of-compression dryer. An afterfilter should be provided to prevent desiccant dust from migrating downstream. Reference No. 145 Final Rev 8 Page 20 October 2005

21 USER MANUAL SECTION 2: INSTALLATION 2.1 SET-UP AND INSTALLATION Once at the installation location, the adsorption dryers of the series HC-3 HC-239, which are supplied with a base frame, must be positioned so that all sides are easily accessible. Should vibrations occur on the installation location, the adsorption dryer is to be placed onto vibration dampeners. 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. Advice Should you still have questions regarding installation, you can request installation blueprints separately from Ingersoll-Rand Davidson NC. Warning! Use the appropriate, load-rated lifting equipment and observe safe lifting procedures during all operations of installation. The equipment should be unloaded as close as possible to the installation site to minimize any chances of equipment damage. Reference No. 145 Final Rev 8 Page 21 October 2005

22 SECTION 2: (Continued) Mechanical installation The equipment should be located in an area as practically possible with adequate clearances for service. An overhead clearance of not less than three feet above each adsorber tower is required for loading of the desiccant. Access clearance of three feet in front of the control panel should be provided. Insulate the pipe between the compressor and dryer to minimize heat loss. Remove all protective shipping crates, flange covers, etc. Utilizing the mounting holes provided on the skid, anchor the Ingersoll-Rand type HC Dryer to a solid, level foundation designed to support the dryer. Do not hydrostatically test the pressure vessels. All HC dryers pressure vessels are hydrostatically tested at one and one-half times the design pressure after fabrication and before assembly. Desiccant is shipped loose (HC-41 and above) and must be installed. Refer to section 4.2 for installation of desiccant. If the equipment is installed in a high traffic area, protective barriers may be required to prevent possible damage of equipment and to prevent contact with hot surfaces. Because of vibration during shipping, some tube fittings may have loosened; therefore, inspect all connections and tighten if required. Also, flange connections may have loosened; therefore tighten all flange bolts. Ensure that the inlet and outlet connections to and from the Ingersoll-Rand type HC Dryer are made using the correct rated fittings and piping to meet the design conditions. System isolation and by-pass valves should be installed. If not supplied as part of the equipment package by Ingersoll-Rand, they should be supplied and installed by others. It must be verified that these exist, so that future servicing of the Dryer System may take place. Full flow relief valves to protect the system from over-pressure must be provided by others in accordance with local regulations. The purge exhaust connection on the HC larger dryers may be connected to a vent header. To ensure satisfactory regeneration of the desiccant chambers is achieved, the purge exhaust piping should be sized as follows to prevent "back pressure" build up. Installed length of exhaust pipe Up to 10 Ft Up to 25 Ft Up to 50 Ft Up to 100 Ft Pipe size required Same size as the dryer exhaust One size larger than dryer exhaust Two sizes larger than dryer exhaust Three sizes larger than dryer exhaust Reference No. 145 Final Rev 8 Page 22 October 2005

23 SECTION 2: (Continued) Filter installation dryers are shipped with the afterfilter loose or with the filter skid mounted on a separate steel frame. The following installation applies to all models that are shipped with filters loose. Afterfilter Installation Mount afterfilter in such a way as to allow clearance for the element installation and removal. The filter must be piped so that the correct flow direction indicated on the filter is followed. Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection. Filter Skid with 3-Valve Bypass Installation Filters skid should be located as close to dryer as possible. Use the skid bolt holes to secure the assembly. Ensure that the skid is located such that the 3-valve bypass will bypass the dryer and filters when in use. Check the flow direction of each filter to ensure the after filter is connected to the outlet pipe of the dryer. Connect the filter skid piping and dryer skid piping using materials and fabrication procedures that are suitable for compressed air pressure piping. All flanges are ANSI B16.5 Class 150 Raised Face flanges. Reference No. 145 Final Rev 8 Page 23 October 2005

24 SECTION 2: (Continued) Electrical installation Connect the dryer to a correctly sized power supply. The dryer requires a 115V 60 cycle connection. A disconnect switch is not provided with the dryer and must be supplied by end user in accordance with the recognized electrical codes. Ground the frame of the dryer in accordance with the recognized electrical codes. It is recommended that the common alarm relay, located in the dryer control panel, be connected to the control room or operator station so that an immediate response to the dryer alarm may be given when required. Reference No. 145 Final Rev 8 Page 24 October 2005

25 SECTION 3: START UP AND OPERATION 3.1 START UP 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 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 Pressurizing dryer Prior to pressurizing the Ingersoll-Rand Dryer system, verify the following: - Dryer On Off switch is in the off position. - System outlet block valve is closed. - Cooling water is turned on to the aftercooler. Slightly open the inlet isolation valve slowly admitting compressed air to the system. When full system operating pressure has been reached all connections should be soap bubble tested for leaks. Any leaks should be repaired and retested prior to placing the equipment in service. If some gas other than the process air will be used for leak testing, consult Ingersoll-Rand for its compatibility with system components before proceeding. Fully open the inlet isolation valve. When the system is filled with process air, is leak tight and start-up is completed, then slowly open the system outlet valve to pressurize the downstream piping. During the procedure, ensure that the dryer system pressure does not fall below 95% of its reading prior to opening the system outlet valve. This will protect the equipment internal components (i.e. filter elements, desiccant) from gas velocities above design conditions. Reference No. 145 Final Rev 8 Page 25 October 2005

26 SECTION 3: (Continued) Pressurizing dryer (Continued) When pressurizing is complete then fully open the system outlet valve to place the equipment in service. Verify the system inlet pressure and temperature are at the design operating levels Energizing dryer controls Turn ON-OFF switch to the ON position. A Micrologix programmable controller with individual input/output modules controls the dryer cycle. A copy of the program complete with a full listing of inputs, outputs, internal coils, timers and counters is included later in this manual. This should be used as a reference guide to ensure dryer is cycling. A manual mode is included in the dryer program to allow for fast cycling to verify the operation of the dryer. While dryer is in the stripping mode for either chamber, the regeneration flow setting should be checked. The stripping flow valve should be set at 1.5 turns open at start-up and adjusted as necessary to maintain the specified dewpoint. The pressure gauge on the regenerating tower should not exceed 10 psig. Warning! Failure to correctly set the stripping flow can lead to improper regeneration of the desiccant bed, resulting in a dewpoint failure when that chamber is returned to service. It is recommended that the operational program of the dryer and the wiring schematic be studied before operating the dryer. NOTE : If the DPDS (Dewpoint Demand System) option is purchased, reference the DPDS Installation and Operating Guide for instructions. Reference No. 145 Final Rev 8 Page 26 October 2005

27 SECTION 3: (Continued) 3.2 OPERATOR INTERFACE Function keys F1 through F4 perform the function displayed on the screen. ARROWS ALLOW USER TO SCROLL UP OR DOWN INSIDE OF THE SCREEN LIST SELECTOR. AN ARROW ON THE RIGHT SIDE OF THE SCREEN NAMES INDICATES WHICH SCREEN IS BEING SELECTED. ENTER=> SELECTS THE SCREEN IN WHICH THE ARROW IS POINTING AND DISPLAYS THAT SCREEN. Reference No. 145 Final Rev 8 Page 27 October 2005

28 SECTION 3: (Continued) Main Screen This is the main screen. This screen will be displayed upon initial startup or after an alarm has been cleared. Using the up or down arrow keys and the enter key you may select a screen to view Status This screen will give you the dryer s current status. The top line will tell you which tower is onstream. The second line is the regeneration cycle in which the opposite tower (regenerating) is in. This will toggle from HEATING to STRIPPING to REPRESSURIZATION to COOLING. If the optional dewpoint demand system (DPDS) is installed, you may also see STANDBY below the current tower status. The lower left hand corner gives the time remaining in the current regeneration cycle. This starts counting down from 240 minutes (four hours). Note: When the dryer is in DPDS Standby, the time remaining will read zero. The lower right hand corner is another screen selector list. This list is the same as the one on the MAIN screen, except it only displays one screen name at a time. Use the up or down arrow key to select the screen name you would like to go to then press the enter key. Reference No. 145 Final Rev 8 Page 28 October 2005

29 SECTION 3: (Continued) Settings The settings screen allows you to toggle between Dewpoint Demand and straight Time cycle. While in Time cycle, the dryer will shift towers every four hours. When utilizing the optional DPDS, the dryer will complete its four hour regeneration and go into a standby mode until the outlet dewpoint has reached the dewpoint monitor s set point. When dewpoint demand is not purchased, this screen will not be available Alarms The alarm screen will display any and all alarms. Alarms are displayed in the order in which they occur, for instance the top alarm is always the most recent one. When an alarm situation occurs, this screen will automatically be displayed. When an alarm clears, the operator interface will automatically return to the MAIN screen. The optional fail-to-shift alarm comes with an alarm horn. The F4 key will allow an operator to disable this horn while they are in the area to fix the alarm condition. When fail-to-shift is not purchased, this function will not be present. Using the other function keys, per the above designations, you may toggle to any other screen. When screen is switched with a pre-existing alarm, this alarm screen will not automatically pop back up until all alarms are cleared. Reference No. 145 Final Rev 8 Page 29 October 2005

30 3.3 PROGRAM STEPS: (Continued) Part numbers for the instrument abbreviations listed in the program steps below (i.e. V1, V2, etc.) can be found in the Spare Parts List in Section 5 of this User Manual. STEP TIME DESCRIPTION OF ACTION 1 0 min. De-energize SV1-2 Energize SV1-1; Opens V3, 6, 8 & 9 Closes V4, 5, 7 & 10 Left Tower Onstream Start time delay of 60 seconds; When time delay times out if pressure switch PS2 is greater than 10 Fail to Shift alarm 2 2 min. De-energize SV2-2 Energize SV2-1; Opens V1 & 15 Closes V2 Heating Right Tower 3 90 min. De-energize SV2-1 Energize SV2-2; Opens V2 Closes V1 & 15 Energize SV4-1; Opens V12 Energize SV3-1; Opens V11 Stripping Right Tower min. De-energize SV4-1; Closes V12 Re-pressurizing Right Tower When PS3 reaches setpoint of 60 PSI then, Energize SV5-1; Opens V13 Cooling Right Tower min. If dewpoint is below the analyzer set-point and the Dewpoint/Timer selector switch is on Dewpoint then; Begin standby Standby Reference No. 145 Final Rev 8 Page 30 October 2005

31 3.3 PROGRAM STEPS: (Continued) min. If the dewpoint rises above the analyzer set-point or the Dewpoint/ +stdby Timer selector switch is on Timer then; De-energize SV5-1; Closes V13 De-energize SV1-1 Energize SV1-2 Opens V4, 5, 7 & 10 Closes V3, 6, 8 & 9 Right Tower Onstream Start time delay of 60 seconds; When time delay times out if pressure switch PS2 is greater than 10 Fail to Shift alarm min. De-energize SV2-2 Energize SV2-1; Opens V1 & 15 Closes V2 Heating Left Tower min. De-energize SV2-1 Energize SV2-2; Opens V2 Closes V1 & 15 Energize SV4-1; Opens V12 Energize SV3-1; Opens V11 Stripping Left Tower min. De-energize SV4-1; Closes V12 Re-pressurizing Left Tower When PS3 reaches setpoint of 60 PSI then, Energize SV5-1; Opens V13 Cooling Left Tower min. If dewpoint is below the analyzer set-point and the Dewpoint/Timer selector switch is on Dewpoint then; Begin standby Standby Reference No. 145 Final Rev 8 Page 31 October 2005

32 3.3 PROGRAM STEPS: (Continued) min. If the dewpoint rises above the analyzer set-point or the Dewpoint/ +stdby Timer selector switch is on Timer then; De-energize SV5-1; Closes V13 GOTO STEP 1 NOTES: 1.) At any time during the cycle, if Inlet temperature (TH1) drops below the setpoint (240 F) then; Low Regeneration Temperature Alarm 2.) At any time during the cycle, if the cooler outlet temperature (TS1) rises above the setpoint (105 F) then; High Cooler Outlet Temperature Alarm 3.) At any time during the cycle, if the dewpoint (DPDS) rises above the setpoint (-20 F) for more than five continuous minutes then; High Dewpoint Alarm 4.) At any time during the cycle, if the compressor goes unloaded (CR1) then stop the timing cycle of the dryer until the compressor is loaded. Reference No. 145 Final Rev 8 Page 32 October 2005

33 USER MANUAL SECTION 4: MAINTENANCE Advice: In order to ensure continuous and trouble-free operation, a maintenance contract with Ingersoll-Rand is recommended. 4.1 SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE Introduction The compressed air dryer requires a minimum of maintenance as most components are "maintenance-free". However, a certain amount of "preventive maintenance" is recommended to assure years of trouble-free, highperformance service Periodic Maintenance Schedule Whereas it is recommended that the dryer be observed and inspected as often as it is practical, the following is a minimum requirement: A. EVERY 2000 HOURS OR 3 MONTHS 1. Check the inlet air temperature; make adjustments, if necessary. 2. Check the air temperature at intercooler outlet; above 100 F means: a. Increase the cooling water flow. b. Lower the cooling water temperature. c. Back flush and thoroughly clean the intercooler, to restore efficiency. 3. "Blow off" the vessel relief valves to assure their integrity. 4. Test the drain trap assembly and drain the sump at the separator drain of sludge that may have accumulated by closing off the primary drain until the secondary valve actuates. All of the above can be accomplished while the dryer is operating. B. EVERY 4000 HOURS OR 6 MONTHS 1. Perform steps 1 through 4 as outlined in "Every 2000 Hours or 3 Months". Reference No. 145 Final Rev 8 Page 33 October 2005

34 SECTION 4: (Continued) 2. Isolate and depressurize the dryer. 3. Disconnect power to the dryer. 4. Replace afterfilter elements (the proper number and quantity is indicated on the filter and in the Spare Parts List in Section V of this manual). 5. Make certain all air and electrical connections are sound. 6. Repressurize the dryer and place "on stream". 7. Reconnect power to the dryer. C. EVERY 8000 HOURS OR 12 MONTHS 1. Perform steps 1 through 4 as outlined in "Every 4000 Hours or 6 Months". DO NOT REPRESSURIZE DRYER OR RECONNECT POWER TO THE DRYER YET! 2. Rebuild the actuators by installing repair kits in the major switching valves. (V1-V13 and V15) 3. Carefully disassemble and clean the solenoid valves in the control group; rebuild with new parts only if damage or serious wear is evident. 4. Carefully disassemble and clean the 3-way solenoid valve on the separator drain trap. 5. Rebuild the secondary drain valve by installing a valve repair kit. (SD - P/N ) 6. Disassemble and clean the primary drain. (FT) 7. It is recommended that the aftercooler be back-flushed and thoroughly cleaned, both tubeside and shellside, at 8,000 hours; but this interval should be adjusted shorter or longer, based on water quality and plant experience. Reference No. 145 Final Rev 8 Page 34 October 2005

35 SECTION 4: (Continued) 8. If the DPDS option is purchased, refer to the DPDS Installation and Operating Guide for instructions. 9. Make certain all air, electric, and water connections are sound. 10. Open the cooling water supply valve and adjust as required. 11. Repressurize the dryer and place "on-stream". 12. Reconnect power to the dryer. D. EVERY 16,000 HOURS OR 24 MONTHS 1. Perform steps 1 through 9 as outlined in "Every 8000 Hours or 12 Months. DO NOT REPRESSURIZE DRYER OR RECONNECT POWER TO THE DRYER YET! 2. Drain all the desiccant from both vessels through the drain at the bottom of each vessel. 3. Refill both vessels with the proper amount of desiccant as noted in the specifications at the front of this manual. NOTE: Desiccant can be purchased only through Ingersoll-Rand distributors authorized to sell dryers and related products. 4. Make certain all air, electric, and water connections are sound. 5. Open the cooling water supply valve and adjust as required. 6. Repressurize the dryer and place "on-stream". 7. Reconnect power to the dryer. Reference No. 145 Final Rev 8 Page 35 October 2005

36 SECTION 4: (Continued) D. ADJUSTMENTS The inlet air temperature (as indicated on the Instrument Panel) should be adjusted to obtain the desired temperature/dewpoint performance (reference the Regenerative Dryer Specification Sheet in Section I). This can be accomplished through manipulation of the inlet piping insulation and/or the compressor intercooling. The temperature of the air leaving the dryer aftercooler should be maintained at or below 90 F. Adjust the cooling water supply as required. 4.2 REPLACEMENT / DISPOSAL OF THE DESICCANT NOTE : Refer to the desiccant MSDS in the appendix of this manual for detailed information regarding material description and ingredients. The dryer is filled from the top and emptied from the bottom. Refer to the General Arrangement drawing for location of fill and drain ports. To drain the desiccant, remove the drain plug/cover and catch the old desiccant in a suitable container. Replace the desiccant drain plug/cover. Remove the fill cap and refill the chamber with the specified desiccant. Refer to the spare parts section for desiccant quantity. Do not tamp the desiccant. Replace the fill cap. Soap test both fill and drain ports for leaks before returning the dryer to service. Reference No. 145 Final Rev 8 Page 36 October 2005

37 SECTION 4: (Continued) 4.3 DEWPOINT METER MAINTENANCE (DPDS Option only) NOTE: Refer to the Dewpoint Demand Installation & Operating Guide included with this User Manual for information on dewpoint meter maintenance and operation. 4.4 FILTERS General comments and use Filters of the series AF are suitable for filtering solids 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 AF" from the outside to the inside. Solids are filtered out by impact or by the effect of inertia Assembly and installation Advice The piping system must be cleaned before assembling filter. The filter must always be installed vertically Maintenance Advice The filter element should be replaced when a differential pressure of > 10 PSID has been reached or, at latest, after 6 months of operation. Reference No. 145 Final Rev 8 Page 37 October 2005

38 SECTION 4: (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: Open the hand hole. Loosen and remove the element by hand. Install the new element and make sure that the element seats perfectly. Re-install hand hole cover. Elements of the AF series can NOT be cleaned with compressed air Accessories Advice Pressure differential gauge: Indicates the degree to which the elements are soiled. Reference No. 145 Final Rev 8 Page 38 October 2005

39 SECTION 5: RECOMMENDED SPARE PARTS LIST 5.1 RECOMMENDED SPARE PARTS FOR HC-3 TO HC-14 Part No. Description ID HC-3 HC-6 HC-7 HC-9 HC Probe, for Dewpoint Demand option Thermocouple, armoured, Filter, particle removal, miniature, inline, ¼, for DPDS option SB350 filter element for AF afterfilter B filter element D33 filter element, high efficiency, coalescing, for HEF-60 prefilter Fuse, 3 amp Muffler, 2 MNPT Relay, DPDT, 115/1/ Gasket, grafoil, 3, 150#, ring, 1/ Gasket, grafoil, 6, 150#, ring, 1/ Gasket, grafoil, 3, 150#, FF, 1/ Switch, pressure, PSIG Switch, pressure, 3-30#, SPDT, for Fail-to-shift Alarm option Repair kit, actuator, CTD&S-020 V Repair kit, actuator, CTD&S-030 V Repair kit, actuator, CTD&S-040 V1-10, Repair kit, actuator, CTS-050 V Repair kit, ball valve, 1 V Repair kit, ball valve, 1½ V Repair kit, ball valve, 2 V1-10, Repair kit, butterfly valve, 3 V1-10, Repair kit, actuator, MX-60 V1-10, Repair kit, diaphragm valve, ¾ SD Valve, ¼ solenoid single coil 4-way, SV aluminum Valve, ¼ solenoid dual coil 4-way, aluminum SV Part No. Description Alumina, 3/16" IR Activated 50 lbs bag Alumina, 3/16" IR Activated 2000 lbs sack Reference No. 145 Final Rev 8 Page 39 October 2005

40 SECTION 5: (Continued) RECOMMENDED SPARE PARTS LIST 5.1 RECOMMENDED SPARE PARTS FOR HC-21 TO HC-54 Part No. Description ID HC-21 HC-30 HC-41 HC Probe, for Dewpoint Demand option Thermocouple, armoured, Filter, particle removal, miniature, inline, ¼, for DPDS option B filter element D33 filter element, high efficiency, coalescing, for HEF-60 prefilter Fuse, 3 amp Seal, gasket, Manway, 11x15, PTFE Seal, gasket, Manway, 12x16, PTFE Muffler, 2 MNPT Relay, DPDT, 115/1/ Gasket, grafoil, 3, 150#, ring, 1/ Gasket, grafoil, 4, 150#, ring, 1/ Gasket, grafoil, 6, 150#, ring, 1/ Gasket, grafoil, 8, 150#, ring, 1/ Gasket, grafoil, 10, 150#, ring, 1/ Gasket, grafoil, 12, 150#, ring, 1/ Gasket, grafoil, 4, 150#, FF, 1/ Gasket, grafoil, 6, 150#, FF, 1/ Switch, pressure, PSIG Switch, pressure, 3-30#, SPDT, for Fail-to-shift Alarm option Repair kit, actuator, CTD&S-040 V Repair kit, actuator, CTS-050 V Repair kit, actuator, CTS-060 V Repair kit, ball valve, 2 V Repair kit, butterfly valve, 3 V Repair kit, actuator, MX-200 V1-10, Repair kit, actuator, MX-60 V1-10, Repair kit, actuator, MX-60 V Repair kit, butterfly valve, 4 V1-10, Repair kit, butterfly valve, 6 V1-10, Check valve, 3, CI, rebuilt CV Repair kit, diaphragm valve, ¾ SD Valve, ¼ solenoid single coil 4-way, SV aluminum Valve, ¼ solenoid dual coil 4-way, aluminum SV Part No. Description Alumina, 3/16" IR Activated 50 lbs bag Alumina, 3/16" IR Activated 2000 lbs sack Reference No. 145 Final Rev 8 Page 40 October 2005

41 SECTION 5: (Continued) RECOMMENDED SPARE PARTS LIST 5.1 RECOMMENDED SPARE PARTS FOR HC-69 TO HC-122 Part No. Description ID HC-69 HC-85 HC-103 HC Probe, for Dewpoint Demand option Thermocouple, armoured, Filter, particle removal, miniature, inline, ¼, for DPDS option B filter element D33 filter element, high efficiency, coalescing, for HEF-60 prefilter Fuse, 3 amp Seal, gasket, Manway, 12x16, PTFE Muffler, 2 MNPT Relay, DPDT, 115/1/ Gasket, grafoil, 3, 150#, ring, 1/ Gasket, grafoil, 4, 150#, ring, 1/ Gasket, grafoil, 6, 150#, ring, 1/ Gasket, grafoil, 8, 150#, ring, 1/ Gasket, grafoil, 12, 150#, ring, 2 1/ Gasket, grafoil, 14, 150#, ring, 2 1/ Gasket, grafoil, 16, 150#, ring, 2 2 1/ Gasket, grafoil, 6, 150#, FF, 1/ Gasket, grafoil, 8, 150#, FF, 1/ Switch, pressure, PSIG Switch, pressure, 3-30#, SPDT, for Fail-to-shift Alarm option Repair kit, actuator, CTS-050 V Repair kit, actuator, CTS-060 V Repair kit, ball valve, 1 ½ V Repair kit, butterfly valve, 3 V Repair kit, actuator, MX-200 V1-10, Repair kit, actuator, MX-60 V Repair kit, actuator, MX-450 V1-10, Repair kit, butterfly valve, 4 V11,13, Repair kit, butterfly valve, 6 V1-10, Repair kit, butterfly valve, 8 V1-10, Check valve, 3, CI, rebuilt CV Check valve, 4, CI, rebuilt CV Repair kit, diaphragm valve, ¾ SD Valve, ¼ solenoid single coil 4-way, SV aluminum Valve, ¼ solenoid dual coil 4-way, aluminum SV Part No. Description Alumina, 3/16" IR Activated 50 lbs bag Alumina, 3/16" IR Activated 2000 lbs sack Reference No. 145 Final Rev 8 Page 41 October 2005

42 SECTION 5: (Continued) RECOMMENDED SPARE PARTS LIST 5.1 RECOMMENDED SPARE PARTS FOR HC-143 TO HC-239 Part No. Description ID HC-143 HC-166 HC-186 HC-211 HC Probe, for Dewpoint Demand option Thermocouple, armoured, Filter, particle removal, miniature, inline, ¼, for DPDS option B filter element D33 filter element, high efficiency, coalescing, for HEF-60 prefilter Fuse, 3 amp Seal, gasket, Manway, 12x16, PTFE Muffler, 2 MNPT Relay, DPDT, 115/1/ Gasket, grafoil, 4, 150#, ring, 1/ Gasket, grafoil, 6, 150#, ring, 1/ Gasket, grafoil, 8, 150#, ring, 1/ Gasket, grafoil, 10, 150#, ring, 1/ Gasket, grafoil, 18, 150#, ring, 1/ Gasket, grafoil, 20, 150#, ring, 1/ Gasket, grafoil, 8, 150#, FF, 1/ Gasket, grafoil, 10, 150#, FF, 1/ Switch, pressure, PSIG Switch, pressure, 3-30#, SPDT, for Fail-to-shift Alarm option Repair kit, actuator, CTS-050 V Repair kit, actuator, CTS-060 V Repair kit, actuator, CTS-060 V Repair kit, actuator, CTS-065 V Repair kit, ball valve, 1 ½ V Repair kit, ball valve, 2 V Repair kit, actuator, MX-200 V Repair kit, actuator, MX-60 V Repair kit, actuator, MX-750 V1-10, Repair kit, actuator, MX-450 V1-10, Repair kit, butterfly valve, 4 V11,13, Repair kit, butterfly valve, 6 V11,13, Repair kit, butterfly valve, 8 V1-10, Repair kit, butterfly valve, 10 V1-10, Check valve, 4, CI, rebuilt CV Check valve, 6, CI, rebuilt CV Repair kit, diaphragm valve, ¾ SD Valve, ¼ solenoid single coil 4-way, SV aluminum Valve, ¼ solenoid dual coil 4-way, aluminum SV Part No. Description Alumina, 3/16" IR Activated 50 lbs bag Alumina, 3/16" IR Activated 2000 lbs sack Reference No. 145 Final Rev 8 Page 42 October 2005

43 SECTION 5: (Continued) I-R Theory of Operation Illustration Legend: BE = visual moisture indicator CS = separator F = filter FS = float switch FT = primary float trap P = pressure gauge PRV = pressure relief valve SD = secondary drain SV = solenoid valve T = temperature gauge TW = thermowell V = valve Reference No. 145 Final Rev 8 Page 43 October 2005

44 SECTION 6: TROUBLESHOOTING & FAULTS 6.1 INTRODUCTION Following proper preventive maintenance procedures will go far toward assuring trouble-free dryer performance; however, failures will still occur. This troubleshooting part will help to identify the source of the problem and to effect a remedy. 6.2 HIGH DEWPOINT Changed Operating Conditions Check to see that flow rate, pressure, and temperature are still within specification Old Desiccant If the dryer is not able to maintain dewpoint for a sufficiently long period, the desiccant may have aged to the point where its capacity is inadequate. Replace the desiccant with the appropriate quantity and type of desiccant Towers Not Reversing Check PLC, solenoid valve, inlet switching valves, and, if supplied, Dewpoint Demand System meter Cooler Discharge Air Temperature Too High Check cooling water flow rate and temperature. Fouled or dirty cooler may require cleaning on air and/or water side Dewpoint Indication In Error Check calibration/operation of dewpoint measuring instrument. Reference No. 145 Final Rev 8 Page 44 October 2005

45 SECTION 6: (Continued) Two-way Valve Leakage Valve leakage here will allow relatively wet inlet air to leak into the dry outlet air stream, thereby raising the dewpoint of the composite air. Compare the dewpoint of the air at the dryer outlet to the dewpoint measured at the top (outlet) of the drying tower (i.e., at the relief valve location). If there is a significant difference in dewpoint, one or both closed 2-way valves is leaking. Check actuator operation and check for seat wear. 6.3 FAIL-TO-SHIFT Solenoid Valve Failed To Operate Check electrical connection, coil, and valve seat Pilot Air Tubing Leakage Check tubing fittings for leakage Two-way Switching Valve Actuator Leakage A leaking actuator can cause the switching valve to malfunction; low pilot pressure due to leakage (or solenoid valve failure) will cause the FAIL-TO- SHIFT ALARM to activate. Check for leakage. 6.4 PRIMARY DRAIN FAILURE Plugging Or Sticking Due To Foreign Matter If the PRIMARY DRAIN FAILURE ALARM activates, the probable cause is sediment plugging the orifice or impeding the proper operation of the float. Disassemble, inspect, and clean as necessary. Reference No. 145 Final Rev 8 Page 45 October 2005

46 SECTION 6: (Continued) 6.5 SECONDARY DRAIN FAILURE Solenoid Valve Failure When the liquid level rises above the primary float valve elevation and contacts the liquid level probe, a circuit is completed energizing the 3-way normally open solenoid valve depressurizing the secondary drain valve actuator. The system pressure should open the secondary drain valve. If the PRIMARY DRAIN FAILURE ALARM activates, but the secondary drain valve fails to open, check the 3-way normally open solenoid valve. Clean, repair, or replace as necessary Liquid Level Probe Failure If the PRIMARY DRAIN FAILURE ALARM does not activate after or during failure of the float operated drain, check the liquid level probe for proper operation. 6.6 SHORT-TERM SHUT-DOWN Advice The following sequence is to be heeded when switching off the adsorption dryer: First close all the shut off valves up and downstream of dryer Then immediately switch off the adsorption dryer. Attention! Dryer will remain pressurized. 6.7 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE Danger! Before any kind of maintenance or repair work is done, the adsorption dryer must be depressurized and disconnected from the power source. Apply the general safety regulations! Reference No. 145 Final Rev 8 Page 46 October 2005