Refrigerated compressed air dryers

Refrigerated compressed air dryers

COLDWAVE refrigerated compressed air dryers HHDplus Series, 381 to 10,800 m 3 /h The HHDp Series of HANKISON ColdWave TM refrigerated compressed air dryers is one of the world's most commonly installed generations of refrigerated compressed air dryers. HANKISON ColdWaveTM refrigerated compressed air dryers boast industry-leading technology. Since L.E. HANKISON patented the Condensifilter in 1943, HANKISON engineers have continually set the industry standard for refrigerated compressed air dryer technology. ColdWaveTM heralds the next generation of HANKISON refrigerated compressed air dryers. Versions HHDp 381 to 10800 with emm Energy Management Monitor HANKISON ColdWave TM heat exchanger technology HANKISON heat exchangers feature an industry-leading design with large flat surfaces to keep pressure differences to a minimum. Dirt, rust and scale are unable to become trapped and are swept through these heat exchangers by the compressed air. Unlike many competitive designs, these do not require pre-filtration, which reduces capital, installation and operating costs. The heat exchangers used are crafted from premium grade 316SS stainless steel and feature large and smooth sinusoidal air channels that provide a low pressure drop, unparalleled performance and superior reliability. Filtration technology The integrated filte HF 9 Series at the cold point effectively removes the water volumes that result from the condensed moisture. Consistently removing moisture at low flow rates can be particularly challenging, however the clever design of the HF Series Grade 9 separators effectively solves these challenges by using two stages of filtration inside the separator cartridges. All ColdWave TM refrigerated compressed air dryers can be optionally equipped with an HF Series Grade 5 oil removal filter. This stage reduces the residual oil content to 0.01 mg/m 3 at 20 C and users can save on space and assembly work by using this type of filter. This advanced 24 volt electronic control unit has a number of userfriendly displays which can save energy, automate service intervals, display information in ten languages and add functionality Energy-saving schedule mode allows compressed air users with one or two-shift operations to schedule the dryer to turn on and off in accordance with their work schedule Automatic service intervals can be set for preventative maintenance schedules to ensure that the condenser on air-cooled units is kept dust free, as well as to advise the replacement of both the standard HF Series Grade 9 Separator/Filter element and the optional HF Series Grade 5 cold coalescing, oil removal filter every 12 months Operator interface with read-outs in ten languages as standard: English, German, French, Spanish, Italian, Polish, Danish, Dutch, Norwegian and Finnish. Read-outs include the current time, operating status (e.g. manual or schedule running modes), hours to service and total operating hours. Functions include a push-to-test button for the condensate drain, poweron and compressor-on lights, an operator alert light to indicate a required service or a fault with the refrigeration system/drain, and a dew point temperature indicator Remote monitoring of the emm from your computer via the RS-232 interface Standard NO and NC voltage-free alarm contacts Fault condition diagnostics with user-friendly text display X-DRAIN Series electronic level-controlled condensate drain 2

How COLDWAVE refrigerated compressed air dryers work Air drying circuit - (Figure 1) Compressed air that is saturated with water vapour enters the air-to-air heat exchanger (A), is pre-cooled by the outgoing chilled air, and then directed to the air-to-refrigerant (evaporator) heat exchanger (B) where it is further cooled by the refrigeration system. As the air is cooled, water vapour condenses into liquid droplets that are removed by the separator/filter (C) and discharged from the dryer by an automatic drain (D). The air then passes through an optional oil removal filter (E) and dry, oil-free and chilled compressed air returns through the air-to-air heat exchanger (A) where it is reheated before exiting the dryer. Figure 1 - Refrigerant circuit (A) Air-to-air heat exchanger (B) (E) Optional Refrigerant-to-air grade 5 fine oil heat exchanger removal filter (C) Grade 9 separator/filterr (D) Automatic condensate drain Digital evaporator - Refrigeration control - HDS Series - (Figure 2) Digital evaporator technology monitors the incoming heat load to determine how much cooling energy is required to maintain stable dew point control. The digital emm control interprets the raw data from the digital evaporator and translates it into the amount of cooling energy that is needed. The digital emm control opens or closes the valve in precise time blocks that load or unload the Digital Scroll refrigeration compressor to match the varying heat loads. Dew point stability is achieved using the least possible amount of electrical energy. Hot gas bypass valve - Refrigeration control - HHDp Series - (Figure 3) Designed for rugged durability, the refrigeration compressors in HHDp dryers are the workhorses of the industry. The refrigeration circuit is hermetically sealed and vaporised refrigerant enters the refrigerant compressor where it is compressed to a higher pressure then passes to the refrigerant liquefier, where the compressed refrigerant is then liquefied by heat extraction. An injector reduces the pressure of the liquid refrigerant and injects it into the refrigerant-to-air heat exchanger. The vaporised refrigerant is sucked back in by the refrigerant compressor. The hot gas bypass valve automatically regulates the refrigerating capacity required in the partial load range. Figure 2 - Digital refrigeration circuit Digital control (B) Digital refrigerant-to-air heat exchanger Figure 3 - Bypass dryer (B) Refrigerant-to-air heat exchanger Thermal expansion valve Hot gas bypass valve Condenser 3

Energy-saving COLDWAVE refrigerated compressed air dryers HDS Series, 1,500 to 10,800 m 3 /h The HANKISON energy-saving (HDS) series is one of the world s most commonly installed series of refrigerated compressed air dryers for plants with varying levels of air demands. The HANKISON technology platforms of precision design, engineered heat exchangers, quality filtration, and energy-efficient digital evaporator refrigeration technology represent the best value solution available for variable heavy-duty air demand profiles. Digital evaporator technology The HDS Series features groundbreaking technologies for the refrigerated compressed air dryer industry. The digital evaporator continues the HAN- KISON tradition of stable dew point control while providing tremendous energy savings, which results in lower operating costs. Unlike most other products available in the industry, the HDS Series, with proprietary digital evaporator technology, offers clear energy saving advantages over traditional cycling and variable speed designs. Rapid return on investment The HDS Series is designed to provide a rapid return on investment by: Reducing the dryer s energy consumption down to 9% (91% savings) at 0% load Precisely matching average air flow (heat load) with the required input kw power no more, no less Maintaining stable class 4 and class 5 dew points with no dew point spikes which send water downstream and cause high maintenance and downtime costs The HDS refrigeration system HDS Series How the Potential Savings Pay Off Digital evaporator technology controls the actions of the three core components in the refrigeration system: digital evaporator, digital control board, digital scroll refrigeration compressor, providing true load-matching energy savings. Ø Air flow Energy Consumptions HDS series energy savings per year by type 1500 1800 2250 2700 3150 3600 4500 5400 100% 100% - - - - - - - - 75% 78% 435 1281 1083 520 826 924 1089 1210 50% 54% 774 1606 1587 1260 1652 1849 2252 2641 25% 33% 1114 1931 2073 2001 2477 2773 3415 4071 0% 9% 1453 2255 2567 2471 3303 3698 4578 5502 In comparison to flow-through dryers. Assumption: 37 C inlet and ambient temperature, 100 psig (6.9 bar) working pressure, 8.760 working hours per year, 0,10 / kwh energy costs. X-DRAIN HANKISON compressed air refrigerant dryers use an electronic level-controlled X-DRAIN to ensure that the condensate is drained off effectively. Further information can be found in our X-DRAIN data sheet. 4

H Series refrigerated compressed air dryers for flow rates from 7,200 12,000 m 3 /h Advantages of the H Series at a glance: When they require compressed air to be dried efficiently, production facilities around the world rely on HANKISON refrigerated compressed air dryers. This is also true of the H Series, which covers flow rates from 7,200 to 12,000 m 3 /h. Thanks to the amply dimensioned separating system and streamlined heat exchanger, H Series models exhibit very low differential pressure. The air-to-air and refrigerant-to-air stainless steel plate heat exchangers have been specially developed for use in refrigerated compressed air dryers. 50% - 100% or 33% - 66% - 100% controls are applied as standard for dryer outputs from 7,200 to 12,000 m 3 /h. The automatic level control of the HANKISON X-DRAIN Series condensate drain uses a level sensor to open a membrane valve when the drain collecting tank becomes full. The condensate drains off and the electronics maintain the maximum valve opening time required to ensure that the condensate is separated safely and without a pressure drop. X-DRAIN Series electronic level-controlled condensate drain Power regulation by switching off the cylinder as standard (50% - 100% or 33%/66%/100%) Effective energy savings, e.g., during the night or at weekends A wide range of customer requirements can be optimally satisfied Optional air-cooled or water-cooled version available 5

Model Capacity Max. operating pressure [bar.g] Weight Dimensions (LxWxH) Connection Refrigerant [ m³/h] [kg] [mm] [DN] HHDp 381 380 16 228 1230 x 820 x 820 R 3" R 134a HHDp 481 480 16 255 11370 x 820 x 820 R 3" R 134a HHDp 601 600 16 256 1370 x 820 x 820 R 3" R 134a HHDp 791 790 16 287 1370 x 820 x 820 R 3" R 134a HHDp 951 950 16 328 1510 x 820 x 1060 R 3" R 134a HHDp 1151 1150 16 328 1510 x 820 x 1060 R 3" R 134a HHDp 1451 1450 16 340 1510 x 820 x 1060 R 3" R 134a HHDp 1800 1800 16 535 2162 x 1270 x 1030 DN 80 R 404a HHDp 2250 2250 16 660 2162 x 1270 x 1287 DN 100 R 404a HHDp 2700 2700 16 679 2162 x 1270 x 1287 DN 100 R 404a HHDp 3150 3150 16 842 2162 x 1438 x 1510 DN 150 R 404a HHDp 3600 3600 16 849 2162 x 1438 x 1510 DN 150 R 404a HHDp 4500 4500 16 930 2162 x 1438 x 1510 DN 150 R 404a HHDp 5400 5400 16 938 2162 x 1438 x 1510 DN 150 R 404a HHDp 6300 6300 16 1850 2800 x 1438 x 2965 DN 200 R 404a HHDp 7200 7200 16 1950 2800 x 1438 x 2965 DN 200 R 404a HHDp 9000 9000 16 2080 2800 x 1438 x 2965 DN 200 R 404a HHDp 10800 10800 16 2090 2800 x 1438 x 2965 DN 200 R 404a Reference conditions based on DIN/ISO 7183 Flow rate in m 3 /h based on 20 C and 1 bar absolute Operating pressure:.............. 7 bar g Compressed air inlet temperature:... 35 C Ambient temperature:............ 25 C Operating conditions Max. inlet temperature: 49 C Min./max. ambient temperature: +2 C / +43 C Mains voltage/frequency: 380V-420V/3/50Hz 460V/3/60Hz (HHDp 381 - HHDp 1451) Mains voltage/frequency: 400V/3/50Hz 460V/3/60Hz (HHDp 1800 - HHDp 10800) Protection class: IP 44 (HHDp 381 - HHDp 10800) If the inlet conditions are different, consult our Technical Sales Department. HHDp 381 - HHDp 10800 Series incl. 3 µm filter, electronic condensate drain and Energy Management Monitor Special voltages and connections on request Technical changes reserved Correction factors for inlet temperature and inlet pressure Inlet temperature Inlet pressure 25 C 30 C 35 C 40 C 45 C 50 C 3 1,42 1,00 0,79 0,63 0,51 0,43 4 1,50 1,08 0,87 0,72 0,60 0,52 5 1,57 1,13 0,92 0,77 0,65 0,56 6 1,63 1,18 0,96 0,81 0,68 0,60 7 1,67 1,22 1 0,84 0,71 0,63 8 1,72 1,25 1,03 0,87 0,74 0,65 9 1,76 1,29 1,07 0,91 0,78 0,67 10 1,81 1,33 1,10 0,93 0,80 0,70 11 1,84 1,36 1,13 0,96 0,82 0,73 12 1,87 1,38 1,16 0,98 0,84 0,75 13 1,90 1,41 1,18 1,00 0,86 0,77 14 1,93 1,44 1,21 1,02 0,88 0,80 Correction factors for ambient temperature Ambient temperature +25 C +30 C +35 C +40 C +45 C Correction factor 1 0,94 0,89 0,83 0,78 6

Model Capacity Max. operating pressure [bar.g] Weight Dimensions (LxWxH) Connection [ m³/h] [kg] [mm] [DN] HDS 1500 1500 16 535 2162 x 1270 x 1030 DN 80 HDS 1800 1800 16 535 2162 x 1270 x 1030 DN 80 HDS 2250 2250 16 656 2162 x 1270 x 1287 DN 100 HDS 2700 2700 16 679 2162 x 1270 x 1287 DN 100 HDS 3150 3150 16 887 2162 x 1438 x 1510 DN 150 HDS 3600 3600 16 953 2162 x 1438 x 1510 DN 150 HDS 4500 4500 16 1015 2162 x 1438 x 1510 DN 150 HDS 5400 5400 16 1027 2162 x 1438 x 1510 DN 150 HDS 6300 6300 16 1850 2800 x 1438 x 2965 DN 200 HDS 7200 7200 16 1950 2800 x 1438 x 2965 DN 200 HDS 9000 9000 16 2080 2800 x 1438 x 2965 DN 200 HDS 10800 10800 16 2090 2800 x 1438 x 2965 DN 200 Reference conditions based on DIN/ISO 7183 Flow rate in m 3 /h based on 20 C and 1 bar absolute Operating pressure: 7 bar g Compressed air inlet temperature: 35 C Ambient temperature: 25 C Operating conditions Max. inlet temperature: 49 C Min./max. ambient temperature: +3 C / +45 C Mains voltage/frequency: 400V/3/50Hz 460V/3/60Hz Protection class: IP 44 Refrigerant: R 404a HDS Series incl. as standard 3 µm filter, electronic condensate drain emm (Energy Management Monitor) and Digital Scroll technology. Special voltages and connections on request Technical changes reserved Model Capacity Weight Dimensions (LxWxH) Connection [ m³/h] [kg] [mm] [DN] H-7200 7200 1850 2462 x 1590 x 3245 150 H-8400 8400 2000 2462 x 1590 x 3245 200 H-9600 9600 2200 2462 x 1590 x 3245 200 H-12000 12000 2600 2462 x 1590 x 3245 200 Correction factors for inlet temperature Te ( C) 30 35 40 45 50 k (Te) 1,14 1 0,83 0,67 0,55 Correction factors for operating overpressure p (bar) 3 4 5 6 7 8 10 12 14 16 k (p) 0,7 0,81 0,86 0,95 1 1,04 1,12 1,18 1,22 1,26 Correction factors for cooling water inlet temperature Te ( C) 25 30 35 K (Te) 1 0,95 0,9 Correction factors for differing voltage V 460V / 3 Ph / 60 Hz k (V) 1,2 Performance values @ 50 Hz and according to DIN/ISO 7183 Ambient temperature............. +25 C Compressed air inlet temperature... +35 C Pressure dew point. v............ +3 C Operating conditions Pressure dew point............ +3 C Min./max. inlet temperature....... +4 C / +55 C Min./max. ambient temperature.... +7 C / + 45 C Netzspannung/Frequenz: 400V/3/50 Hz Mains voltage/frequency:......... 2 bar ü - 16 bar ü Refrigerant: : R 404a Protection class:................ IP 44 Different voltages and connections on request Technical changes reserved 7

Intelligent HANKISON solutions! At HANKISON, we have been providing our customers with consistently clean and dry compressed air for seamless operation of their plants since 1948. Today, working together with other market leaders in the compressed air preparation industry under the SPX brand name, HANKISON provides you with the highest quality compressed air systems available on the market. We have earned our excellent reputation through the development and manufacture of products that meet the challenging expectations of our customers in terms of innovation, reliability, availability and an optimum price/performance ratio. Customer satisfaction is the focus of all our endeavours. Our service and advice, innovations, competence, efficiency and the technical dependability of our solutions all guarantee both your and our success. Place your trust in our global experience and reap the benefits. With kind regards SPX Dehydration & Process Filtration GmbH Konrad-Zuse-Straße 25 D-47445 Moers Germany Telefon: + 49 (0) 28 41 / 8 19-0 Fax: + 49 (0) 28 41 / 8 19 83 email: csc@dehydration.spx.com For further information on our worldwide locations, licences, certifications and our local representatives, please visit our website: / www.spx.com. The SPX Corporation reserves the right to include the latest design and material changes without prior notice and without obligation. Design configurations, materials and dimensions as specified in this document are for information only. All data is non-binding, unless confirmed in writing. Edition: 06.2010 Copyright 2010 SPX Corporation