hc3-hc239 usermanual rev5

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SERIES HC Heat-of-Compression Compressed Air Dryer Models HC-3 – HC-239 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. 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 For information, parts, or service, contact your local Ingersoll-Rand Service provider or reach us at www.air.irco.com

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  • SERIES HC Heat-of-Compression Compressed Air Dryer

    Models HC-3 HC-239

    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.

    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 For information, parts, or service, contact your local IInnggeerrssoollll--RRaanndd Service provider or reach us at www.air.irco.com

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 2 September 2004

    INDEX PREFACE SECTION 1: INTRODUCTION 1.1 General Information 1.2 Safety Instructions

    1.2.1 Identification of signs and symbols in this manual 1.2.2 Safety tips for maintenance, inspection & assembly work

    1.3 Personnel Qualification 1.4 Product Information

    1.4.1 Theory of Operation 1.4.2 Pressure vessel regulations 1.4.3 Airtightness test 1.4.4 Overloading 1.4.5 Technical data sheet 1.4.6 Dryer Flow Capacities 1.4.7 Transport 1.4.8 Storage 1.4.9 Use of an afterfilter

    SECTION 2: INSTALLATION 2.1 Set-up and installation

    2.1.1 Mechanical installation 2.1.2 Filter installation 2.1.3 Electrical installation

    SECTION 3: START UP AND OPERATION 3.1 Start-up / Shut down

    3.1.1 Pressurizing dryer 3.1.2 Energizing dryer controls

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 3 September 2004

    3.2 Operator interface

    3.2.1 Main screen 3.2.2 Dryer status 3.2.3 Settings 3.2.4 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

    4.4.1 General comments and use 4.4.2 Function 4.4.3 Assembly and installation 4.4.4 Maintenance 4.4.5 Changing of filter elements 4.4.6 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

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 4 September 2004

    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

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 5 September 2004

    PREFACE:

    This technical manual from IInnggeerrssoollll--RRaanndd 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 6 September 2004

    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. IInnggeerrssoollll--RRaanndd 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 IInnggeerrssoollll--RRaanndd and confirmed in writing.

    In the interest of further development, IInnggeerrssoollll--RRaanndd 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 7 September 2004

    SECTION 1: (Continued) 1.2.1 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.

    1.2.2 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:

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 8 September 2004

    SECTION 1: (Continued) 1.2.2 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 9 September 2004

    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.

    1.4.1 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 10 September 2004

    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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 11 September 2004

    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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 12 September 2004

    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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 13 September 2004

    SECTION 1: (Continued)

    1.4.2 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 HC-3 HC-239

    Operating overpressure Max. 150 PSIG

    Operating Temperature Max.Min.

    500F 20F

    Attention! Never weld on or alter a pressure vessel in any way!

    1.4.3 Airtightness test

    All adsorption dryers are subjected to an airtightness test prior to shipment using compressed air.

    1.4.4 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 14 September 2004

    SECTION 1: (Continued) 1.4.5 Technical data sheet

    MODEL HC-3 HC-6 HC-7 HC-9 Flow (SCFM) @ 100 PSIG 100F Drying Temperature

    301 535 677 836

    Vessel OD Inches 12 16 18 20

    Desiccant type IR Activated Alumina

    Lbs. Desiccant / Vessel 223 397 502 620

    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 9 16 20 25

    Stripping Flow SCFM 6 11 14 17

    Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration

    Outlet Dewpoint Variable

    DPDS Control Adjustable

    High Humidity Alarm Adjustable

    Pressure Switch Setpoints 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105F Low regeneration temperature alarm Adjustable

    Process flow Downward Regeneration / Upward Drying

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 15 September 2004

    SECTION 1: (Continued) 1.4.5 Technical data sheet

    MODEL HC-14 HC-21 HC-30 HC-41 Flow (SCFM) @ 100 PSIG 100F Drying Temperature

    1204 1880 2708 3686

    Vessel OD Inches 24 30 36 42

    Desiccant type IR Activated Alumina

    Lbs. Desiccant / Vessel 893 1395 2009 2735

    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 36 56 80 110

    Stripping Flow SCFM 24 38 54 74

    Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration

    Outlet Dewpoint Variable

    DPDS Control Adjustable

    High Humidity Alarm Adjustable

    Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105F Low regeneration temperature alarm Adjustable

    Process flow Downward Regeneration / Upward Drying

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 16 September 2004

    SECTION 1: (Continued) 1.4.5 Technical data sheet

    MODEL HC-54 HC-69 HC-85 HC-103 Flow (SCFM) @ 100 PSIG 100F Drying Temperature

    4814 6093 7522 9101

    Vessel OD Inches 48 54 60 66

    Desiccant type IR Activated Alumina

    Lbs. Desiccant / Vessel 3572 4521 5581 6753

    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-10000 Voltage 115/1/60 Standard -

    Consult Factory for other voltages

    Cooling Water GPM 143 138 172 208

    Stripping Flow SCFM 96 122 150 182

    Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration

    Outlet Dewpoint Variable

    DPDS Control Adjustable

    High Humidity Alarm Adjustable

    Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105F Low regeneration temperature alarm Adjustable

    Process flow Downward Regeneration / Upward Drying

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 17 September 2004

    SECTION 1: (Continued) 1.4.4 Technical data sheet

    MODEL HC-122 HC-143 HC-166 Flow (SCFM) @ 100 PSIG 100F Drying Temperature

    10832 12712 14742

    Vessel OD Inches 72 78 84

    Desiccant type IR Activated Alumina

    Lbs. Desiccant / Vessel 8037 9432 10939

    Inlet connection 8 FLG 8 FLG 10 FLG

    Outlet connection 8 FLG 8 FLG 10 FLG

    FILTER Afterfilter AF-16000 AF-16000 AF-16000 Voltage 115/1/60 Standard -

    Consult Factory for other voltages

    Cooling Water GPM 247 289 335

    Stripping Flow SCFM 217 254 295

    Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours Regeneration

    Outlet Dewpoint Variable

    DPDS Control Adjustable

    High Humidity Alarm Adjustable

    Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling Cooler outlet high temperature alarm 105F Low regeneration temperature alarm Adjustable

    Process flow Downward Regeneration / Upward Drying

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 18 September 2004

    SECTION 1: (Continued) 1.4.6 Dryer Flow Capacities

    Model Selection Chart:

    MODEL 85 PSI 90 PSI 95 PSI 100 PSI 105 PSI 110 PSI 115 PSI

    HC-3 262 274 287 301 313 327 342 HC-6 465 486 509 535 557 581 608 HC-7 588 615 645 677 705 735 769 HC-9 726 760 796 836 870 908 950 HC-14 1046 1094 1146 1204 1253 1308 1368 HC-21 1634 1709 1790 1880 1957 2042 2136 HC-30 2353 2462 2578 2708 2819 2941 3076 HC-41 3203 3351 3509 3686 3837 4003 4187 HC- 54 4183 4376 4583 4814 5011 5228 5469 HC-69 5295 5539 5801 6093 6343 6617 6922 HC-85 6537 6837 7161 7522 7830 8169 8545 HC-103 7909 8273 8664 9101 9474 9884 10339 HC-122 9413 9846 10312 10832 11276 11764 12305 HC-143 11047 11555 12102 12712 13233 13805 14441 HC-166 12812 13401 14035 14743 15347 16011 16748

    Note: Maximum operating pressure is 150 PSIG; higher pressures available as an option. Consult factory.

    Minimum Inlet Pressure (PSIG) 85 90 95 100 105 110 115 Correction Factor 1.15 1.1 1.05 1 .96 .92 .88

    CORRECTION FACTOR FOR COOLING WATER TEMPERATURE

    TEMPERATURE F 75 80 85 90 Correction Factor .85 .9 1.0 1.2

    To correct for a cooling water temperature other than 85F, 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 1300 SCFM @ 90 Psig, using 90F cooling water:

    Multiply 1300 * (1.1) * (1.2) = 1716 Use model HC-21

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 19 September 2004

    SECTION 1: (Continued) 1.4.7 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.

    1.4.8 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.

    1.4.9 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 20 September 2004

    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 IInnggeerrssoollll--RRaanndd 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 21 September 2004

    SECTION 2: (Continued) 2.1.1 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 IInnggeerrssoollll--RRaanndd 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 IInnggeerrssoollll--RRaanndd 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 IInnggeerrssoollll--RRaanndd, 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 Pipe size required

    Up to 10 Ft Same size as the dryer exhaust Up to 25 Ft One size larger than dryer exhaust Up to 50 Ft Two sizes larger than dryer exhaust Up to 100 Ft Three sizes larger than dryer exhaust

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 22 September 2004

    SECTION 2: (Continued) 2.1.2 Filter installation

    Series HC 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 23 September 2004

    SECTION 2: (Continued) 2.1.3 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 24 September 2004

    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 33F.Breakdowns resulting from faulty installation do not fall under IInnggeerrssoollll--RRaanndd's warranty obligation.

    3.1.1 Pressurizing dryer

    Prior to pressurizing the IInnggeerrssoollll--RRaanndd Series HC 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 IInnggeerrssoollll--RRaanndd 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 25 September 2004

    SECTION 3: (Continued) 3.1.1 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. 3.1.2 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 26 September 2004

    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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 27 September 2004

    SECTION 3: (Continued)

    3.2.1 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.

    3.2.2 Status

    This screen will give you the dryers 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.

  • USER MANUAL Series HC

    Reference No. 145 Final Rev 5 Page 28 September 2004

    SECTION 3: (Continued) 3.2.3 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 monitors set point. When dewpoint demand is not purchased, this screen will not be available. 3.2.4 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.

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    Reference No. 145 Final Rev 5 Page 29 September 2004

    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

    4 180 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

    5 240 min. If dewpoint is below the analyzer set-point and the Dewpoint/Timer selector switch is on Dewpoint then; Begin standby Standby

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    Reference No. 145 Final Rev 5 Page 30 September 2004

    3.3 PROGRAM STEPS: (Continued)

    6 240 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

    7 242 min. De-energize SV2-2 Energize SV2-1; Opens V1 & 15 Closes V2 Heating Left Tower

    8 330 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

    9 420 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

    10 480 min. If dewpoint is below the analyzer set-point and the Dewpoint/Timer selector switch is on Dewpoint then; Begin standby Standby

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    Reference No. 145 Final Rev 5 Page 31 September 2004

    3.3 PROGRAM STEPS: (Continued)

    11 480 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 (240F) then; Low Regeneration Temperature Alarm 2.) At any time during the cycle, if the cooler outlet temperature (TS1) rises

    above the setpoint (105F) then; High Cooler Outlet Temperature Alarm 3.) At any time during the cycle, if the dewpoint (DPDS) rises above the setpoint

    (-20F) 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.

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    Reference No. 145 Final Rev 5 Page 32 September 2004

    SECTION 4: MAINTENANCE

    Advice: In order to ensure continuous and trouble-free operation, a maintenance contract with IInnggeerrssoollll--RRaanndd is recommended.

    4.1 SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE

    4.1.1 Introduction

    The Series HC 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, high-performance service.

    4.1.2 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 100F 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".

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    Reference No. 145 Final Rev 5 Page 33 September 2004

    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 38341285)

    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.

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    Reference No. 145 Final Rev 5 Page 34 September 2004

    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 Series HC 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.

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    Reference No. 145 Final Rev 5 Page 35 September 2004

    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 90F. 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.

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    Reference No. 145 Final Rev 5 Page 36 September 2004

    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 4.4.1 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.

    4.4.2 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.

    4.4.3 Assembly and installation

    Advice The piping system must be cleaned before assembling filter. The filter must always be installed vertically.

    4.4.4 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.

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    Reference No. 145 Final Rev 5 Page 37 September 2004

    SECTION 4: (Continued) 4.4.5 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.

    4.4.6 Accessories

    Advice Pressure differential gauge: Indicates the degree to which the elements are soiled.

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    Reference No. 145 Final Rev 5 Page 38 September 2004

    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-14

    38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745 Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle removal, miniature,

    inline, , for DPDS option 1 1 1 1

    38339370 SB350 filter element for AF-350 afterfilter

    1

    38335592 812-1B filter element 1 1 2 38335584 16D33 filter element, high efficiency,

    coalescing, for HEF-60 prefilter 1 1 1 1

    38339610 Fuse, 3 amp 1 1 1 1 38338836 Muffler, 2 MNPT 1 1 2 2 38338844 Relay, DPDT, 115/1/60 1 1 1 1 38338851 Gasket, grafoil, 3, 150#, ring, 1/16 6 6 38338869 Gasket, grafoil, 6, 150#, ring, 1/16 2 2 38342556 Gasket, grafoil, 3, 150#, FF, 1/16 4 4 38338893 Switch, pressure, 30-300 PSIG 1 1 1 1 38338901 Switch, pressure, 3-30#, SPDT, for

    Fail-to-shift Alarm option 1 1 1 1

    38339750 Repair kit, actuator, CTD&S-020 V11-13 1 1 38337937 Repair kit, actuator, CTD&S-030 V11-13 1 1 38339735 Repair kit, actuator, CTD&S-040 V1-10,15 2 2 38337960 Repair kit, actuator, CTS-050 V12 1 1 38339768 Repair kit, ball valve, 1 V11-13 2 2 38337929 Repair kit, ball valve, 1 V11-13 2 2 38338018 Repair kit, ball valve, 2 V1-10,15 1 1 38337986 Repair kit, butterfly valve, 3 V1-10,15 1 1 38335626 Repair kit, actuator, MX-60 V1-10,15 1 1 38341285 Repair kit, diaphragm valve, SD 1 1 1 1 38338943 Valve, solenoid single coil 4-way,

    aluminum SV3-5 1 1 1 1

    38338950 Valve, solenoid dual coil 4-way, aluminum

    SV1-2 1 1 1 1

    Part No. Description

    38004834 Alumina, 3/16" IR Activated 50 lbs bag

    38340642 Alumina, 3/16" IR Activated 100 lbs drum

    38340659 Alumina, 3/16" IR Activated 2000 lbs sack

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    Reference No. 145 Final Rev 5 Page 39 September 2004

    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-54

    38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745 Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle removal, miniature,

    inline, , for DPDS option 1 1 1 1

    38335592 812-1B filter element 2 3 6 6 38335584 16D33 filter element, high efficiency,

    coalescing, for HEF-60 prefilter 1 1 1 1

    38339610 Fuse, 3 amp 1 1 1 1 38341293 Seal, gasket, Manway, 11x15, PTFE 2 38342481 Seal, gasket, Manway, 12x16, PTFE 2 2 38338836 Muffler, 2 MNPT 4 4 8 8 38338844 Relay, DPDT, 115/1/60 1 1 1 1 38338851 Gasket, grafoil, 3, 150#, ring, 1/16 4 4 38342499 Gasket, grafoil, 4, 150#, ring, 1/16 6 6 38338869 Gasket, grafoil, 6, 150#, ring, 1/16 6 6 38342507 Gasket, grafoil, 8, 150#, ring, 1/16 2 38339222 Gasket, grafoil, 10, 150#, ring, 1/16 2 2 38338877 Gasket, grafoil, 12, 150#, ring, 1/16 2 38342564 Gasket, grafoil, 4, 150#, FF, 1/16 4 4 38338885 Gasket, grafoil, 6, 150#, FF, 1/16 4 4 38338893 Switch, pressure, 30-300 PSIG 1 1 1 1 38338901 Switch, pressure, 3-30#, SPDT, for

    Fail-to-shift Alarm option 1 1 1 1

    38339735 Repair kit, actuator, CTD&S-040 V11-13 1 1 38337960 Repair kit, actuator, CTS-050 V12 1 1 38335634 Repair kit, actuator, CTS-060 V12 1 1 38338018 Repair kit, ball valve, 2 V11-13 2 2 38337986 Repair kit, butterfly valve, 3 V11-13 2 2 38338927 Repair kit, actuator, MX-200 V1-10,15 1 1 38335626 Repair kit, actuator, MX-60 V1-10,15 1 1 38335626 Repair kit, actuator, MX-60 V11-13 1 1 38339271 Repair kit, butterfly valve, 4 V1-10,15 1 1 38338919 Repair kit, butterfly valve, 6 V1-10,15 1 1 38338935 Check valve, 3, CI, rebuilt CV1 1 1 38341285 Repair kit, diaphragm valve, SD 1 1 1 1 38338943 Valve, solenoid single coil 4-way,

    aluminum SV3-5 1 1 1 1

    38338950 Valve, solenoid dual coil 4-way, aluminum

    SV1-2 1 1 1 1

    Part No. Description

    38004834 Alumina, 3/16" IR Activated 50 lbs bag

    38340642 Alumina, 3/16" IR Activated 100 lbs drum

    38340659 Alumina, 3/16" IR Activated 2000 lbs sack

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    Reference No. 145 Final Rev 5 Page 40 September 2004

    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-122

    38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745 Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle removal, miniature,

    inline, , for DPDS option 1 1 1 1

    38335592 812-1B filter element 6 6 10 16 38335584 16D33 filter element, high efficiency,

    coalescing, for HEF-60 prefilter 1 1 1 1

    38339610 Fuse, 3 amp 1 1 1 1 38342481 Seal, gasket, Manway, 12x16, PTFE 2 2 2 2 38338836 Muffler, 2 MNPT 8 1 1 1 38338844 Relay, DPDT, 115/1/60 1 1 1 1 38338851 Gasket, grafoil, 3, 150#, ring, 1/16 4 38342499 Gasket, grafoil, 4, 150#, ring, 1/16 4 4 4 38338869 Gasket, grafoil, 6, 150#, ring, 1/16 6 38342507 Gasket, grafoil, 8, 150#, ring, 1/16 6 6 6 38338877 Gasket, grafoil, 12, 150#, ring,

    1/16 2

    38342515 Gasket, grafoil, 14, 150#, ring, 1/16

    2

    38342523 Gasket, grafoil, 16, 150#, ring, 1/16

    2 2

    38338885 Gasket, grafoil, 6, 150#, FF, 1/16 4 38342572 Gasket, grafoil, 8, 150#, FF, 1/16 4 4 4 38338893 Switch, pressure, 30-300 PSIG 1 1 1 1 38338901 Switch, pressure, 3-30#, SPDT, for

    Fail-to-shift Alarm option 1 1 1 1

    38337960 Repair kit, actuator, CTS-050 V12 1 1 1 1 38335634 Repair kit, actuator, CTS-060 V22 1 1 1 38337929 Repair kit, ball valve, 1 V12 1 1 1 38337986 Repair kit, butterfly valve, 3 V11-13 2 38338927 Repair kit, actuator, MX-200 V1-10,15 1 38335626 Repair kit, actuator, MX-60 V11-13 1 1 1 1 38339818 Repair kit, actuator, MX-450 V1-10,15 1 1 1 38339271 Repair kit, butterfly valve, 4 V11,13,22 2 2 2 38338919 Repair kit, butterfly valve, 6 V1-10,15 1 38339248 Repair kit, butterfly valve, 8 V1-10,15 1 1 1 38338935 Check valve, 3, CI, rebuilt CV1 1 38339545 Check valve, 4, CI, rebuilt CV1 1 1 1 38341285 Repair kit, diaphragm valve, SD 1 1 1 1 38338943 Valve, solenoid single coil 4-way,

    aluminum SV3-5 1 1 1 1

    38338950 Valve, solenoid dual coil 4-way, aluminum

    SV1-2 1 1 1 1

    Part No. Description

    38004834 Alumina, 3/16" IR Activated 50 lbs bag

    38340642 Alumina, 3/16" IR Activated 100 lbs drum

    38340659 Alumina, 3/16" IR Activated 2000 lbs sack

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    Reference No. 145 Final Rev 5 Page 41 September 2004

    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-239

    38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745 Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle removal, miniature,

    inline, , for DPDS option 1 1 1 1

    38335592 812-1B filter element 16 16 20 30 38335584 16D33 filter element, high efficiency,

    coalescing, for HEF-60 prefilter 1 1 1 1

    38339610 Fuse, 3 amp 1 1 1 1 38342481 Seal, gasket, Manway, 12x16, PTFE 2 2 2 2 38338836 Muffler, 2 MNPT 1 1 1 1 38338844 Relay, DPDT, 115/1/60 1 1 1 1 38342499 Gasket, grafoil, 4, 150#, ring, 1/16 4 38338869 Gasket, grafoil, 6, 150#, ring, 1/16 4 4 4 38342507 Gasket, grafoil, 8, 150#, ring, 1/16 6 38339222 Gasket, grafoil, 10, 150#, ring, 1/16 6 6 6 38342531 Gasket, grafoil, 18, 150#, ring, 1/16 2 38342549 Gasket, grafoil, 20, 150#, ring, 1/16 2 38342572 Gasket, grafoil, 8, 150#, FF, 1/16 4 38342580 Gasket, grafoil, 10, 150#, FF, 1/16 4 4 4 38338893 Switch, pressure, 30-300 PSIG 1 1 1 1 38338901 Switch, pressure, 3-30#, SPDT, for

    Fail-to-shift Alarm option 1 1 1 1

    38337960 Repair kit, actuator, CTS-050 V12 1 38335634 Repair kit, actuator, CTS-060 V22 1 38335634 Repair kit, actuator, CTS-060 V12 1 1 1 38339693 Repair kit, actuator, CTS-065 V22 1 1 1 38337929 Repair kit, ball valve, 1 V12 1 38338018 Repair kit, ball valve, 2 V12 1 1 1 38338927 Repair kit, actuator, MX-200 V11-13 1 1 1 38335626 Repair kit, actuator, MX-60 V11-13 1 38335618 Repair kit, actuator, MX-750 V1-10,15 1 1 1 38339818 Repair kit, actuator, MX-450 V1-10,15 1 38339271 Repair kit, butterfly valve, 4 V11,13,22 2 38338919 Repair kit, butterfly valve, 6 V11,13,22 2 2 2 38339248 Repair kit, butterfly valve, 8 V1-10,15 1 38338000 Repair kit, butterfly valve, 10 V1-10,15 1 1 1 38339545 Check valve, 4, CI, rebuilt CV1 1 38339719 Check valve, 6, CI, rebuilt CV1 1 1 1 38341285 Repair kit, diaphragm valve, SD 1 1 1 1 38338943 Valve, solenoid single coil 4-way,

    aluminum SV3-5 1 1 1 1

    38338950 Valve, solenoid dual coil 4-way, aluminum

    SV1-2 1 1 1 1

    Part No. Description

    38004834 Alumina, 3/16" IR Activated 50 lbs bag

    38340642 Alumina, 3/16" IR Activated 100 lbs drum

    38340659 Alumina, 3/16" IR Activated 2000 lbs sack

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    Reference No. 145 Final Rev 5 Page 42 September 2004

    SECTION 5: (Continued)

    I-R Series HC 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

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    Reference No. 145 Final Rev 5 Page 43 September 2004

    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 6.2.1 Changed Operating Conditions

    Check to see that flow rate, pressure, and temperature are still within specification.

    6.2.2 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.

    6.2.3 Towers Not Reversing

    Check PLC, solenoid valve, inlet switching valves, and, if supplied, Dewpoint Demand System meter.

    6.2.4 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.

    6.2.5 Dewpoint Indication In Error

    Check calibration/operation of dewpoint measuring instrument.

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    Reference No. 145 Final Rev 5 Page 44 September 2004

    SECTION 6: (Continued) 6.2.6 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 6.3.1 Solenoid Valve Failed To Operate

    Check electrical connection, coil, and valve seat.

    6.3.2 Pilot Air Tubing Leakage

    Check tubing fittings for leakage.

    6.3.3 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 6.4.1 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.

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    Reference No. 145 Final Rev 5 Page 45 September 2004

    SECTION 6: (Continued) 6.5 SECONDARY DRAIN FAILURE 6.5.1 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.

    6.5.2 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!

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    Reference No. 145 Final Rev 5 Page 46 September 2004

    SECTION 7:

    IR ACTIVATED ALUMINA MSDS 7.1 COMPANY DESCRIPTION

    Ingersoll-Rand Company Heavy Industrial Air Solutions 800-B Beaty Street, Davidson, NC 28036 For Product Information: Tel: (800) 247-8640

    7.2 MATERIAL DESCRIPTION Chemical Name & Formula: Aluminum Oxide; A1203 xH20 Other Designation: Activated Alumina F-1, F-20, F-200, HF-200, S-100, F-1(E), S-100, CG-20, OF-2000, Active bed supports, SRU Product Use: Absorbent; dehydration agent; catalyst support

    7.3 INGREDIENTS

    Component & by weight typical Occupational Exposure Limits A1203 90.0 95.0 TWA I mg/m3 *Na20 0.3 0.6 ACGIH TLV *Si02 0.01 0.2 Alumina Dust: *Fe203 0.03 0.1 Total fraction - 10 Loss on ignition (water) 4.0 7.0 PEL Respirable fraction - 5 * Expressed as oxide equivalent No LD50 or LC50 found for oral, dermal, or inhalation routes of administration.

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    Reference No. 145 Final Rev 5 Page 47 September 2004

    7.4 PHYSICAL DATA Physical Form: Crystalline or gelatinous granules, pellets, or powder Boiling Temperature: NA Freeze-Melt Temperature: 3700F (2038C) Vapor Pressure (mm): NA Vapor Density (air = 1): NA Evaporation Rate: NA Specific Gravity: 3.2 Density: Loose bulk: 39 52 lb./ft.3 (0.62 0.83 g/CM3) Water Solubility: Insoluble; soluble in concentrated acids and alkalies pH: -10 (20% slurry solution) Color: Off-white Odor: None; Odor Threshold (ppm): NA Coefficient of water/oil distribution: NA

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    7.5 FIRE AND EXPLOSION DATA

    Flashpoint: NA Auto-Ignition Temp.: NA Flammability Limits in Air: Upper/Lower: NA Product is non-flammable; not an explosion hazard.

    7.6 REACTIVITY DATA

    With water: Generates heat With air: None With heat: None With strong oxidizers: None Non-corrosive

    7.7 HEALTH HAZARD INFORMATION

    The desiccant properties of Activated Alumina may cause irritation to the eyes and upper respiratory tract. Alumina is a low health risk by inhalation. Alumina should be treated as a nuisance dust, as specified by the American Conference of Governmental Industrial Hygienists (ACGIH). According to AIHA Hygienic Guide, Alumina:

    Toxicity by ingestion: None expected Skin and eyes: Not an irritant

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    7.8 SPILL, LEAK, & DISPOSAL PROCEDURES

    Clean up using dry procedures; avoid dusting. Waste may be considered as inert material, suitable for landfill. RCRA Hazardous Waste No.: Not federally regulated

    7.9 SPECIAL PROTECTION INFORMATION

    Use with adequate ventilation to meet the exposure limits as listed in Section 7.3. Where the exposure limit is or may be exceeded, use NIOSH approved respiratory protection. Select the appropriate respirator (dust respirator, etc.) based on the actual or potential airborne contaminants and their concentrations present.

    7.10 SPECIAL PRECAUTIONS & COMMENTS

    Chemical substance components have been reported to the EPA Office of Toxic Substances in accordance with the requirements of the Toxic Substances Control Act (Title 40 CFR 710). None of the materials in this mixture are on the EPA list of extremely hazardous substances (Section 302 of SARA). Aluminum oxide is on the toxic chemical list (Section 313 of SARA). The reportable chemical substances in this product are regulated by the OSHA Hazard Communication Standard (29 CFR 1910.1200) solely because they are listed by ACGIH. However, they do not fit any of the five proposed hazard categories under Section 311 and 312 of SARA. D.O.T. Shipping Name, Hazard Class, I.D. No. (if applicable): Not regulated Canadian TDG Hazard Class & PIN: Not regulated

    7.11 REFERENCES

    American Industrial Hygiene Association (AIHA) Hygienic Guide Series (Revised June 1978). U.S. Dept. of Health and Human Services, NIOSH: Registry of Toxic Effects of Chemical Substances. 1985-86 Edition. Sax, N. Irving: Dangerous Properties of Industrial Materials. Van Nostrand Reinhold Co., Inc., 1984. Information herein is given in good faith as authoritative and valid; however, no warranty, express or implied, can be made.

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    SECTION 8:

    AUXILIARY MANUALS & DRAWINGS