HANKISON HBP, HBP500, HBP600, HBP750, HBP900 Instruction Manual

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3158050 Rev. E 1/08

XX-XXX-X

Internal Use Only

3158050e / 080102

INSTRUCTION MANUAL

HBP SERIES

MODELS

HBP500 HBP600 HBP750 HBP900 HBP1050

HBP1300 HBP1500 HBP1800 HBP2200 HBP2600

HBP3200 HBP3600 HBP4300

RATED

FLOW

500 SCFM 600 SCFM 750 SCFM 900 SCFM 1050 SCFM

1300 SCFM 1500 SCFM 1800 SCFM 2200 SCFM 2600 SCFM

3200 SCFM 3600 SCFM 4300 SCFM

MODEL

REFERENCE

500 600 750 900

1050

1300 1500 1800 2200 2600

3200 3600 4300

Contents

1.0 General Safety Information ........................... 2

2.0 Receiving, Storing, and Moving ..................... 2

3.0 Description .................................................... 3

4.0 Installation ..................................................... 3

5.0 Instrumentation .............................................. 8

6.0 Operation ....................................................... 12

7.0 Maintenance .................................................. 29

8.0 Troubleshooting ............................................. 31

BLOWER PURGE

DESICCANT

COMPRESSED

AIR DRYERS

Drawings

P&ID Schematic Models 500 through 600 ............ 34

P&ID Schematic Models 750 through 4300 .......... 36

Electrical Schematic – 460VAC, 3 phase .............. 38

Electrical Schematic – 575VAC, 3 phase .............. 39

Electrical Schematic – 380VAC, 3 phase .............. 40

Electrical Schematic – 415VAC, 3 phase .............. 41

Electrical Data – Fusing & Wire Sizing .................. 42

WARRANTY .......................................................... 44

SERVICE DEPARTMENT : (724) 746-1100

1.0 General Safety Information

DANGER—Immediate hazard which will result in severe injury or death.

This equipment is designed and built with safety as a prime consideration; industry-accepted safety factors have been used in the design. Each dryer is checked at the factory for safety and operation. All pressure vessels which fall under the scope of ASME Section VIII, are hydrostatically tested in accordance with the latest addenda. A factory-installed safety relief valve is standard on each dryer.

WARNING — The following safety rules must be observed to ensure safe dryer operation. Failure to follow these rules may void the warranty or result in dryer damage or personal injury.

1. Never install or try to repair any dryer that has been damaged in shipment. See the Receiving and Inspection instructions in this manual for appropriate action.

2. This equipment is a pressure-containing device. Never operate the dryer at pressures or temperatures above the maximum conditions shown on the data plate.

Never dismantle or work on any component of the

dryer or compressed air system under pressure. Vent internal air pressure to the atmosphere before servicing.

3. This equipment requires electricity to operate. Install equipment in compliance with national and local electrical codes. Standard equipment is supplied with NEMA 4, 4X electrical enclosures and is not intended for installation in hazardous environments.

Never perform electrical service on the dryer unless

the main power supply has been disconnected. Parts of the control circuit may remain energized when the power switch is turned off.

WARNING—Hazard or unsafe practice which could result in severe injury or death.

CAUTION—Hazard or unsafe practice which could result in minor injury or in product or property damage.

The dryer data plate, attached to the electrical control box, contains critical safety and identiﬁcation information. If the data plate is missing or defaced, immediately contact your local distributor for a replacement.

2.0 Receiving, Storing, and Moving

2.1 Receiving and Inspection

This shipment has been thoroughly checked, packed and inspected before leaving our plant. It was received in good condition by the carrier and was so acknowledged.

Immediately upon receipt, thoroughly inspect for visible loss or damage that may have occurred during shipping. If this shipment shows evidence of loss or damage at time of delivery to you, insist that a notation of this loss or damage be made on the delivery receipt by the carrier’s agent. Otherwise no claim can be enforced against the carrier.

Also check for concealed loss or damage. When a shipment has been delivered to you in apparent good order, but concealed damage is found upon unpacking, notify the carrier immediately and insist on his agent inspecting the shipment. The carrier will not consider any claim for loss or damage unless an inspection has been made. If you give the carrier a clear receipt for goods that have been damaged or lost in transit, you do so at your own risk and expense. Concealed damage claims are not our responsibility as our terms are F.O.B. point of shipment. Shipping damage is not covered by the dryer warranty.

4. Air treated by this equipment may not be suitable for breathing without further puriﬁcation. Refer to OSHA standard 1910.134 for the requirements for breathing quality air.

5. Certain parts of the dryer are not insulated and may become hot during normal operation of the dryer. Do not touch any of these areas without ﬁrst determining the surface temperature.

6. Use only genuine replacement parts from the manufacturer. The manufacturer bears no responsibility for hazards caused by the use of unauthorized parts.

Safety instructions in this manual are boldfaced for emphasis. The signal words DANGER, WARNING and CAUTION are used to indicate hazard seriousness levels as follows:

2.2 Storing

Store the dryer indoors to prevent damage to any electrical or mechanical components. All packaging material should be left in place until the dryer is in position.

2.3 Handling

The dryer is designed to be moved by means of the shipping skid or the base channels. The dryer may also have lifting lugs for use with an overhead crane. Be sure to attach all of the lift points and use appropriate spreader bars to prevent damage to the dryer.

CAUTION — Never lift the dryer by attaching hooks or slings to the piping, or to any part other than the lifting lugs. Severe structural damage could occur.

3.0 Description

3.1 Function

Blower purge type regenerative dryers are an economical and reliable way to dry compressed air to dew points below the freezing point of water. Desiccant dryers lower the dew point of compressed air by adsorbing the water vapor present in the compressed air onto the surface of the desiccant. Adsorption continues until equilibrium is reached between the partial pressure of the water vapor in the air and that on the surface of the desiccant.

systems supplied by a lubricated air compressor, use a High Efﬁciency Oil Removal Filter. A coarser ﬁlter will be required upstream of the Oil Removal Filter if heavy liquid or solid loads are present.

To ensure downstream air purity (prevent desiccant dust from traveling downstream) adequate ﬁltration downstream of the dryer is required. A High Temperature Afterﬁlter, typically rated at 450°F (232°C) operating temperature and capable of removing all desiccant ﬁnes 1 micron and larger should be installed at the dryer outlet.

These dryers continuously dry compressed air by using two identical towers, each containing a desiccant bed. While one tower is on-stream drying, the other tower is off-stream being regenerated (reactivated, i.e. dried out). The towers are alternated on- and off-stream so that dry desiccant is always in contact with the wet compressed air. In this way a continuous supply of dry air downstream of the dryer is possible. The switching from one tower to the other is controlled by a solid-state controller on either a ﬁxed time basis (standard) or a demand basis (optional).

When a tower is placed off-line, it is slowly depressurized and the desiccant is regenerated. First, a blower draws in ambient air which is heated. The heated air ﬂows through the desiccant bed, desorbs the moisture from the desiccant, and carries the desorbed water out of the dryer. The blower and heater are turned off when the desiccant bed is fully heated. When conﬁgured for cooling, a portion of the dry compressed air is diverted from the main air ﬂow and throttled to near atmospheric pressure. This extremely dry, low pressure air passes through the hot off-line tower, partially cooling the desiccant bed and reducing the dew point spike after tower change over. At the end of the cooling stage, the tower is repressurized to full line pressure. This prevents desiccant bed movement and downstream pressure loss when the tower goes back on-line.

4.0 Installation

4.1 System Arrangement

Install the dryer downstream of an aftercooler, separator, receiver, and high-efﬁciency oil-removing ﬁlter(s) so that the dryer inlet air is between 40°F (4.4°C) and 120°F (49°C) and contains no liquid water or oil. Liquid water and/or inlet air temperatures above 100°F (37.8°C) can reduce drying capacity. Contact your local distributor for information on proper dryer sizing at elevated inlet air temperatures.

Adequate ﬁltration is required upstream of the dryer in order to protect the desiccant bed from liquid and solid contamination. Use an Air Line Filter in systems supplied by a non-lubricated (oil-free) air compressor. In

DANGER — This dryer must be ﬁtted with a high efﬁciency coalescing ﬁlter and liquid drainer that is maintained properly. Failure to do so could result in an in-line ﬁre.

WARNING — The afterﬁlter, if installed, must be rated for 450°F (232°C).

4.2 Ambient Air Temperature

Locate the dryer under cover in an area where the ambient air temperature will remain between 35°F (2°C) and 120°F (49°C).

NOTE: If dryer is installed in ambients below 35°F (2°C), low ambient protection requiring heat tracing and insulation of the preﬁlter bowls, auto drains and/ or sumps, and lower piping with inlet switching and purge/repressurization valves is necessary to prevent condensate from freezing. If installing heat tracing, observe electrical class code requirements for type of duty speciﬁed. Purge mufﬂers and their relief mechanisms must be kept clear from snow and ice buildup that could prevent proper discharge of compressed air.

4.3 Location and Clearance

Install the dryer on a level pad. Ensure the dryer is level by grouting or shimming as necessary. Holes are provided in the dryer base members for ﬂoor anchors. Securely anchor the dryer frame to the ﬂoor. Allow 24 inches clearance on all sides of the dryer for servicing. Provide adequate clearance for preﬁlter element, afterﬁlter element and heater element replacement. Provide protection for the dryer if it is installed where heavy vehicles or similar portable equipment is likely to cause damage.

4.4 Piping and Connections

All external piping must be supplied by the user unless otherwise speciﬁed. Refer to Figure 2 for connection sizes. Inlet and outlet isolation valves and a vent valve are recommended so the dryer can be isolated and depressurized for servicing. The connections and pipe ﬁttings must be rated for or exceed the maximum operating pressure given on the dryer nameplate and must be in accordance with industry-wide codes. Be sure all

Compressor Aftercooler Separator Receiver Prefilters Afterfilters ReceiverDesiccant Dryer

Figure 1

Typical System Conﬁguration

piping is supported. Do not allow the weight of any piping to bear on the dryer or ﬁlters. Piping should be the same size as or larger than the dryer connection. Piping smaller than the dryer connections will cause high pressure drop and reduce drying capacity.

If the purge exhaust piping must be extended outside the dryer area, choose a combination of diameters, lengths, and turns that limits the additional pressure drop to 1/4 psid or less. BACK PRESSURE WILL CAUSE DRYER MALFUNCTION. Consult the factory for piping details if required.

WARNING — Do not operate dryer without installed mufﬂers. Exhausting compressed air directly to atmosphere will result in noise levels above OSHA permissible levels and rapidly expanding gas could potentially cause harm to persons or property.

Dryer bypass piping may be installed to allow uninterrupted airﬂow during servicing. If the downstream application cannot tolerate unprocessed air for short periods, install a second dryer in the bypass line.

CAUTION — Do not hydrostatically test the piping with the dryer in the system. The desiccant will be damaged if saturated with water.

4.5 Electrical Connections

WARNING — These procedures require entering gaining access to the dryer’s electrical enclosure(s). All electrical work must be performed by a qualiﬁed electrical technician.

Connect the proper power supply to the dryer according to the electrical drawings in the back of this manual. Be sure to follow all applicable electrical codes.

NOTE: A disconnect switch is not provided as standard equipment and therefore, must be supplied by the customer.

Dry contacts (voltage free) are provided in the low tension electrical enclosure for a remote alarm. The contact ratings are shown on the electrical drawing.

Connections to voltage-free common alarm contacts with a minimum 5-amp rating can be made at terminals TB4-1 through 3.

• Terminal TB4-3 is the common alarm connection.

• Terminal TB4-1 is the N.O.. (normally open) contact connection.

• Terminal TB4-2 is the N.C. (normally closed) contact connection.

• The alarm relay coil is energized when power is supplied to the controller input terminals and there is no alarms.

• The coil is de-energized when power is removed or when an alarm condition exists.

NOTE: Before turning high voltage on to the dryer, an ohmic test should be performed on the heater elements to insure they are dry before proceeding with start-up. This should be done after extended shut downs and long delays between delivery and start-up. Connect one lead of a megger to an unpainted surface of the control panel or dryer frame. Connect the other lead to each phase on the load side of the contactor. Adjust the megger to the 1500 volt setting. Perform the ohmic test on each zone of the heaters. A minimum value of 500k ohms must be obtained.

CAUTION - Failure to ohmic test heaters after extended periods may cause heater failure.

4.5.1 RS-232 Connections

RS-232 connections can be made at the 3-pin connector labeled J3 and located at the upper left-handed corner of the control board. A cable for this connection can be purchased through your distributor.

4.6 Initial Desiccant Charge

Blower purge type regenerative dryers use activated alumina as the desiccant in the dryer towers.

Models 500 through 1050 are shipped with activated alumina (1/8” bead) in the dryer towers. Desiccant is shipped loose with all other standard models.

All desiccant shipped loose must be added to the dryer chambers before the dryer is put into service

Refer to TABLE 1, DESICCANT REQUIREMENTS for desiccant type and quantity per tower.

TO ADD DESICCANT

WARNING — The following procedure provides instructions for adding the initial desiccant to the towers. If replacing desiccant, refer to the “Procedure for Desiccant Charge Replacement” in Section 7.0.

1. Verify pressure gauges of both towers indicate 0 psig. If not, depressurize the towers according to the shutdown instructions in Section 6.

2. Remove the pipe plug or ﬁll port ﬂange cover (where applicable) from the desiccant ﬁll port at the top of each tower. Refer to Figure 3 for the ﬁll port location.

CAUTION – Pouring desiccant creates a ﬁne dust; safety goggles, gloves and a dust mask should be worn by personnel installing desiccant. Refer to the Material Safety Data Sheet that accompanies desiccant shipped loose for more complete information.

CAUTION – Do not tamp the desiccant in the towers. Tamping damages desiccant and causes dusting.

3. Refer to Table 1 for desiccant quantity per tower.

When using Table 1 you will ﬁnd the desiccant quan-

tities listed in layers. Each layer will vary in depth due to the type, quantity and purpose of the desiccant. Layer 1 must be installed ﬁrst at the bottom of the vessel followed by layer number 2 etc., until the complete charge of desiccant has been installed.

TABLE 1 DESICCANT REQUIREMENTS (Quantity per Tower)

Layer

Model

500

600

750

900

1050

1300

1500

1800

2200

2600

3200

3600

4300

* AA = Activated Alumina ** TS = Tabular Support

1 2 3

354#

1/8” bead AA

453#

1/8” bead AA*

590#

1/8” bead AA

590#

1/8” bead AA*

710#

1/8” bead AA

48#

1/4” bead AA*

92#

1/4” bead AA*

92#

1/4” bead AA*

161#

1/4” bead AA

161#

1/4” bead AA*

258#

1/4” bead AA*

258#

1/4” bead AA*

719#

1/2” bead TS**

1/8” bead AA*

1/4” bead AA*

— —

876#

1167#

1706#

2119#

2353#

146#

1/8” bead AA*

—

2679#

4. Utilizing an appropriate sized funnel, ﬁll each desiccant tower as follows:

a. Install the required quantity of tabular support or

activated alumina in layer 1 of each tower.

b. Level layer 1 and each subsequent layer of desic-

cant as added to each chamber.

c. Finish ﬁlling each tower with desiccant until all

desiccant has been installed. LIGHT tapping on the tower sides with a soft-face mallet should yield additional free space to allow installation of all desiccant required. DO NOT TAMP OR RAM DESICCANT.

5. Clean the ﬁll port closure. Replace the ﬁll plug using Teﬂon tape or another pipe thread sealant suitable for compressed air service. Reinstall ﬁll port ﬂange cover (where applicable) in each desiccant tower.

Dimensions and Connections

CENTERLINE OF

CUSTOMER DRY GAS

OUTLET CONNECTIO

TOP VIEW

SLOT

(TYP 4 PLACES

)

CENTERLINE OF

CUSTOMER WET GA

INLET CONNECTION

SIDE VIEW

(RIGHT CHAMBER REMOVED FOR CLARITY)

GAS OUTLET

(MAX)

GAS INLET

FACE OF CUSTOMER

WET GAS INLE

CONNECTION

FACE OF CUSTOMER

DRY GAS OUTLET

CONNECTION

SLOT

(TYP 4 PLACES)

TOP VIEW

SIDE VIE

(RIGHT CHAMBER REMOVED FOR CLARITY)

GAS INLET

GAS OUTLET

(MAX)

R SLOTS

YP 4 PLACES)

TOP VIEW

SIDE VIEW

(RIGHT CHAMBER REMOVED FOR CLARITY)

AIR INLET

AIR OUTLET

(MAX)

Figure 2 (continued on next page)

(Contact factory to request certiﬁed drawings)

VIEW III

3200 through 4300 scfm

VIEW II

750 through 2600 scfm

VIEW I

500 — 600 scfm

Dimensions and Connections

Figure 2 (continued from previous page)

DIMENSIONS IN INCHES

A 53 55 60 60 64 66 80 80 85 85 85 85 109

B 46.3/4 47.9/16 52.11/16 52.11/16 56.7/16 57.5/16 69.13/16 69.13/16 73.3/8 73.3/8 82.7/8 82.7/8 93.3/8

MODEL 500 600 750 900 1050 1300 1500 1800 2200 2600 3200 3600 4300

VIEW REF. I I II II II II II II II II III III III

C 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4

E 59 60 68 68 62 73 79 79 86 89 107 116 123

D 23.3/8 23.13/16 26.5/8 26.5/8 29.9/16 30 34.7/8 34.7/8 38.9/16 38.9/16 36.9/16 36.9/16 41.13/16

F 45.1/2 45.1/2 53.1/2 53.1/2 53.1/2 53.1/2 53.1/2 53.1/2 59.1/2 59.1/2 59.1/2 59.1/2 63.1/2

G 22.3/4 22.3/4 26.3/4 26.3/4 26.3/4 26.3/4 26.3/4 26.3/4 29.3/4 29.3/4 29.3/4 29.3/4 31.3/4

DIMENSIONS IN MILLIMETERS

L 12.11/16 13.3/16 13.7/16 13.7/16 13.3/16 13.3/16 15.5/8 15.5/8 17.1/4 17.1/4 14.9/16 16.9/16 16.1/4

H — — 1.1/4 1.1/4 3.1/4 3.1/4 5.15/16 5.15/16 4.3/8 4.3/8 3/4 5 2

K 3 3 8 8 8 8 8 8 7.1/4 7.1/4 15.7/8 15.7/8 15.7/8

M 96.15/16 100.7/16 100.11/16 100.11/16 99.13/16 104.13/16 101.7/8 101.7/8 115.7/8 115.7/8 115.13/16 122.1/16 118.1/2

P 13.3/16 14.3/16 15.3/4 15.3/4 16.3/4 17.3/4 20.3/4 20.3/4 22.1/4 22.1/4 26.1/2 27.1/2 30.1/2

N 105 108 114 114 113 118 116 116 128 128 128 134 130

S 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE

R 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4

T 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE 6 FLANGE

WT/LBS 1,900 2,200 2,500 2,600 3,000 3,600 5,400 5,500 8,100 8,200 9,400 9,900 12,350

MODEL 500 600 750 900 1050 1300 1500 1800 2200 2600 3200 3600 4300

F 1156 1156 1359 1359 1359 1359 1359 1359 1511 1511 1511 1511 1613

A 1346 1397 1524 1524 1626 1676 2032 2032 2159 2159 2159 2159 2769

B 1187 1208 1338 1338 1434 1456 1773 1773 1864 1864 2106 2106 2372

VIEW REF. I I II II II II II II II II III III III

E 1491 1531 1734 1734 1580 1862 2009 2009 2186 2256 2708 2955 3132

C 32 32 32 32 32 32 32 32 32 32 32 32 32

D 594 604 677 677 750 761 886 886 980 980 929 929 1062

G 578 578 679 679 679 679 679 679 756 756 756 756 806

L 322 335 341 341 335 335 397 397 438 438 370 421 413

H — — 32 32 83 83 151 151 111 111 19 127 51

K 76 76 203 203 203 203 203 203 184 184 403 403 403

M 2462 2551 2557 2557 2535 2662 2588 2588 2943 2943 2942 3100 3010

N 2664 2753 2903 2903 2870 2997 2946 2946 3246 3246 3246 3404 3313

P 335 360 400 400 425 451 527 527 565 565 673 699 775

S 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE

R 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32

T 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE 6 FLANGE

WT/KGS 862 998 1,134 1,179 1,361 1,633 2,449 2,495 3,674 3,719 4,264 4,491 5,602

5.0 Instrumentation

The following instrumentation helps in monitoring dryer operation and performance. Instruments which are available as options are so noted.

Blower Purge Air dryers are rated NEMA 4 and include the following:

• Solid State Controls

• Chamber Pressure Gauges

• Purge Flow Pressure Gauge

• Energy Management (Option A)

• Energy Management System & Dew Point Transmitter (Option B)

5.1 Controls

The solid-st ate dr yer co ntro ls are locat ed in a polycarbonate, NEMA Class 4/4X, IP66 rated electrical enclosure mounted to a center panel located between the two desiccant towers. Control features include:

• 15 LED’s to indicate operating status and fault conditions.

5.5 Dew Point Transmitter

This option monitors and displays outlet pressure dew points and provides an alarm signal if the dew point exceeds user-specified set point. Recommen ded calibration interval is 12 months. Contact the service department for details.

Operation – The dew point is measured at the dryer operating pressure and is displayed in the operator interface. If the dew point is outside of the temperature range, the display will indicate an over-range (high dew point) or under-range (low dew point) condition. A defective sensor assembly or an electronics malfunction could also cause the transmitter to indicate underrange.

• Two line text display to provide status and diagnostic messages.

• Upon power loss, dryer “fails safe” (inlet valve remains in position). On power recovery, controller resumes where power was lost.

5.2 Chamber Pressure Gauges

A gauge mounted on the gauge panel indicates which chamber is on-stream and which is regenerating. The gauge for the onstream tower indicates operating pressure; the gauge for the regenerating tower indicates 0 psig.

5.3 Purge Flow Pressure Gauge

A gauge mounted on the gauge panel of the dryer indicates purge air pressure.

5.4 Energy Management System

Th e opt ional Energy Manag ement System (EMS) automatically adjusts dryer operation to compensate for changes in operating conditions. Air samples are continuou sly taken from the on-stream to wer and passed ov er a moisture probe which sense s both temperature and relative humidity. The moisture content of the air within the desiccant bed is then precisely determined. The on-stream tower will not depressurize and regenerate until a predetermined set point has been reached. This elimination of unnecessary regeneration reduce s energy cons ump tion and e xte nds d ryer desiccant and component life.

RS232

PURGE INLET CHECK VALVE

TOP VIEW

ASME RELIEF VALVE

OUTLET CHECK VALVE

DESICCANT

FILL PORT

LEFT TOWER

PRESSURE GAUGE

PRESSURE REGULATOR

& PILOT AIR FILTER

DEWPOINTER

(OPTIONAL)

TOWER PURG

EXHAUST VALVE

FRONT VIEW

TOWER DEPRESS VALV

DESICCANT DRAIN POR

WER INSULATION (OPTIONAL

)

CONTRO

ENCLOSURE

HIGH TENSIO

ENCLOSURE

RIGHT TOWER PRESSURE GA

UGE

PURGE PRESSURE GAUGE

REPRESS VALV

HEATER TEMP

THERMOCOUPLE

(CENTER END IN PIPE)

(OPPOSITE SIDE)

HEATER OVERTEMP RTD

PURGE

HEATER WITH

INSULATION

PURGE SUCTION FILTER SILENCER

PURGE BLOWER

AND MOTOR

REAR VIEW

TOWER INLET VALV

ASME CODE TAG

HOT PIPE INSULATION

P1P

TOWER BLOWDOWN VALVE

General Layout Drawing

Figure 3

(Models 500 through 600)

LEFT TOWER PURGE

EXHAUST VALVE

DEWPOINTE

(OPTIONAL)

PRESSURE REGULATOR

& PILOT AIR FILTER

LEFT TOWER

PRESSURE GAUGE

DESICCANT

FILL PORT

LEFT OUTLET

CHECK VALV

PURG

PRESSURE GAUGE

RIGHT TOWER PRESSURE GAUGE

CONTROL ENCLOSURE

HIGH TENSION ENCLOSUR

TOWER INSULATION (OPTIONAL)

DESICCANT DRAIN PORT

RIGHT TOWE

DEPRESS VALV

ASME RELIEF VALV

REPRESS VALV

TOP VIEW

FRONT VIEW

PURGE

HEATER WITH

INSULATIO

PURGE SUCTION FILTER SILENCER

PURGE BLOWER

AND MOTO

REAR VIEW

LEFT TOWER INLET VALV

ASME CO

DE TAG

LEFT PURGE INLE

CHECK VALV

HOT PIPE INSULATION

AIR

OUTLET

AIR

INLET

LEFT TOWER

DEPRESS VALV

RIGHT TOWER PURGE EXHAUST VALV

RIGHT OUTLET CHECK VALV

AIR

OUTLET

AIR

INLET

LEFT TOWER

PURGE EXHAUST

VALV

PURGE EXHAUST

RIGHT TOWE

R PURGE EXHAUST VALV

PURGE EXHAUST

TOWER BLOW

DOWN VALV

HEATER TEMP

THERMOCOUPLE

(CENTER END IN PIPE)

(OPPOSITE SIDE)

HEATER OVERTEMP RT

General Layout Drawing

(Models 750 through 2600)

Figure 3a

TOP VIEW

OUTLET CHECK VALV

ASME RELIEF VALV

DESICCANT

FILL PORT

LEFT TOWER

PRESSURE GAUGE

PRESSURE REGULATOR

& PILOT AIR FILTER

DEWPOINTE

(OPTIONAL)

TOWER PURGE

EXHAUST VALV

FRONT VIEW

TOWER DEPRESS VALVE

DESICCANT DRAIN PORT

TOWER INSULATION (OPTIONAL)

HIGH TENSION ENCLOSUR

CONTROL ENCLOSUR

RIGHT TOWER PRESSURE GAUGE

PURGE PRESSUR

GAUGE

REPRESS VALV

PURGE BLOWER

AND MOTO

PURGE BLOWER

THROTTLING VALV

PURGE SUCTION FILTER SILENCER

PURGE HEATER

WITH INSULATION

HEATER

OVERTEMP RT

HOT PIPE INSULATIO

PURGE INLET CHECK VALV

TOWE

INLET VALV

REAR VIEW

HEATER TEMP

THERMOCOUPLE

(CENTER END IN PIPE

)

(OPPOSITE SIDE

)

CHAMBER

BLOW-DOWN

VALV

Figure 3b

General Layout Drawing

(Models 3200 through 4300)

6.0 Operation

6.1 Controls

A solid-state controller controls valve and heater operation, monitors all critical operating conditions, and indicates operating status on a 2-line LCD display operator interface. The controller receives input data from pressure switches, temperature sensors and the operator interface. The operator interface displays information about the dryer operating status and is used to change the dryer operating mode.

6.2 Operating Modes

6.2.1 Automatic and Manual Advance

The drying and regeneration cycles are divided into discrete steps. The operator selects either one of the automatic advance modes (Energy Management, Dew Point Control, or Fixed Cycle) or manual advance mode (Test Cycle) through the operator interface.

Selecting any of the automatic advance modes enables a timer in the controller to advance the program step-bystep according to the programmed schedule.

Setting up the controller for manual advance disables the timer and the operator can advance the program one step at a time. This mode is used for diagnostic purposes.

6.2.2 Fixed, Energy Management or Dew Point Control Operation

The operator interface is used to select either Fixed, Energy Management or Dew Point Control operation. In Fixed Cycle operation, each tower is on-line (drying) for a ﬁxed time period regardless of the operating conditions. In Energy Management or Dew Point Control operation, a tower remains on-line until the desiccant bed has been fully utilized. For lower than designed moisture loads, this results in longer drying cycles, longer time between regenerations and, therefore lower energy consumption. Energy Management or Dew Point Control operation are optional features.

6.3 Operating Sequence Description

1. Left Tower Drying – Right Tower Regenerating

At the start of the Left Tower Drying cycle, Left Inlet

Valve V1 opens, Right Inlet Valve V2 closes to isolate the two towers. Wet, compressed air ﬂows up through the left tower where it is dried. The dry air exits the dryer through the Left Outlet Check Valve V7.

Next, the Right Depressurization Valve V10 is

opened and the right tower is slowly depressurized. Air exits through exhaust mufﬂer M2.

After the right tower has depressurized, the Right

Purge Valve V4 is opened and the Blower M and Heater H1 are energized. The heated air ﬂows through the Right Purge Check Valve V6, down through the right tower, and exits through the Right Purge Valve V4. The Blower intake air is ﬁltered to keep dust and dirt from entering the dryer. The Blower M and Heater H1 are de-energized when the temperature at the bottom of the right tower, as sensed by the Right Tower Temperature Sensor RTD2, reaches the Heat Termination set point. This indicates that the bed has been fully heated.

Note: Blower will continue to run brieﬂy at the end

of the Heating Step to sweep residual heat from the heater.

The Repressurization Valve V11 is opened. A portion

of the dry air from the left tower now ﬂows through Repressurization Valve V11. This air is throttled to near atmospheric pressure by Repressurization/ Sweep Oriﬁce O2. The dry, low pressure air ﬂows down through the right tower cooling the desiccant bed, and exits through the Right Tower Purge Exhaust Valve V4.

The Cooling Step continues until:

a) the right tower bed temperature falls to 150°F

or,

b) it is time to repressurize the right tower,

whichever occurs ﬁrst.

Note: In ﬁxed cycle, the bed will normally be partially

cooled because the repressurization step will occur before the bed temperature can fall to 150°F.

Note: In Energy Management or Dew Point Control,

as the drying time extends beyond 4 hours, additional cooling time becomes available thus the cooling step will frequently terminate based on temperature providing complete bed cooling.

At the end of the Cooling Step, the Right Tower Purge

Exhaust Valve V4 is closed. The right tower slowly repressurizes to full line pressure and is ready to go back on-line.

Note: Bed cooling can be disabled by moving JP4

to the “ON” position.

2. Right Tower Drying – Left Tower Regenerating At the start of the Right Tower Drying cycle, Right

Inlet Valve V2 opens, Left Inlet Valve V1 closes to isolate the two towers. Wet, compressed air ﬂows up through the right tower where it is dried. The dry air exits the dryer through the Right Outlet Check Valve V8.

Next, the Left Depressurization Valve V9 is opened

and the left tower is slowly depressurized. Air exits through exhaust mufﬂer M1.

WET GAS INLET

DRY GA

OUTLET

SOL 'D'

SOL 'F'

RTD

SOL 'B

SOL 'A

SOL 'G'

RTD

1PS

(RTD4/HS1)

ENERGY MGMT OPTION

SET @ 176°F

DRYING

EXH.

3PS

SET

5 PSIG

SOL 'C'

LEFT

TOWER

SET

45 PSI

RTD

SET @ 650°F

SET @ 370°F

SET @ 176°F

SET

5 PSI

REGE

SET

45 PSIG

SET AT 100 PSIG

RIGH

TOWE

V12 V13

SOL 'E'

V7 V11

SET @ 165 PSI

DEWPOINTER OPTION

SOLENOID VA

LVES 'B', 'D', & 'G' ARE SHOWN ENERGIZED,

SYMBOLS ARE PER ANSI Y32.10 "GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS."

SOLENOID VA

LVES 'A', 'C', 'E', & 'F' ARE SHOWN DE-ENERGIZED.

AS SHOWN FLOW DIRECTION IS:

INDICATES OPTION

PILOT GAS LINE

RIGHT CHAMBER REGEN

LEFT CHAMBER DRYING

NOTES

BD2BD1

PI3

PI1

PI2

PR&G

Figure 4

Sequence of Operation — Fixed Cycle Operation

Left Chamber Drying – Right Chamber Regenerating (shown)

(continued on next page)

After the left tower has depressurized, the Left Purge

LEFT

TOWER

RIGHT

TOWER

Valve V3 is opened and the Blower M and Heater H1 are energized. The heated air ﬂows through the

Left Purge Check Valve V5, down through the left tower, and exits through the Left Purge Valve V3. The Blower intake air is ﬁltered to keep dust and dirt from entering the dryer. The Blower M and Heater H1 are de-energized when the temperature at the bottom of the left tower, as sensed by the Left Tower Temperature Sensor RTD1, reaches the Heat Termination set point. This indicates that the bed has been fully heated.

The Repressurization Valve V11 is opened. A portion

of the dry air from the right tower now ﬂows through Repressurization Valve V11. This air is throttled to near atmospheric pressure by Repressurization/ Sweep Oriﬁce O1. The dry, low pressure air ﬂows down through the left tower cooling the desiccant bed, and exits through the Left Tower Purge Exhaust Valve V3.

The Cooling Step continues until:

a) the left tower bed temperature falls to 150°F

or,

b) it is time to repressurize the left tower,

whichever occurs ﬁrst.

6.3.1 Energy Management Control (optional)

Operation of the Energy Management Control cycle is identical to the ﬁxed cycle except the cycle is extended until the desiccant bed in the on-line tower has been fully utilized. The off-line tower is regenerated and remains in a stand-by mode after being repressurized.

Figure 5 shows the air sampling system for the Energy Management System – EMS option. A 3-way pilot valve directs an air sample from the drying tower to the EMS sensor. The EMS sensor detects the relative humidity and temperature of the air sample. The air sample then exhausts to atmosphere. The drying tower remains online until the moisture front arrives at the sensor.

Note: In ﬁxed cycle, the bed will normally be partially

cooled because the repressurization step will occur before the bed temperature can fall to 150°F.

Note: In Energy Management or Dew Point Control,

as the drying time extends beyond 4 hours, additional cooling time becomes available thus the cooling step will frequently terminate based on temperature providing complete bed cooling.

At the end of the Cooling Step, the Left Tower Purge

Exhaust Valve V3 is closed. The left tower slowly repressurizes to full line pressure and is ready to go back on-line.

Note: Bed cooling can be disabled by moving JP4

to the “ON” position.

Figure 5

Optional Moisture Sensing

Energy Management System (EMS)

6.4 Control Board Jumpers

In the upper left hand corner of the control board there are eight two-pin jumpers labeled JP1 through JP8. Only ﬁve of the eight jumper pairs are utilized. Pairs JP6-JP8 are used for factory settings and testing. NOTE: Do

not install jumpers in the ON position on pairs JP6 through JP8. The jumper is a removable bridge that is

used to make or break continuity between two pins that form a pair. When installed in the ON position, the jumper is place on both pins of the pair and continuity between the pins is established. When installed in the OFF position, the jumper is removed or stored on a single pin and continuity is broken. Jumper functions are as follows:

1. JP1 – Dryer Type Jumper JP1 is used to select the dryer type conﬁgu-

ration. It is installed in the ON position for Blower Purge dryer conﬁguration.

2. JP2 – Energy Management Jumper JP2 is installed in the ON position when an

Energy Management sensor is installed. The jumper is installed in the OFF position when no Energy Management sensor is installed.

3. JP3 – Dew Point Transmitter Jumper JP3 is installed in the ON position when a

Dew Point Transmitter is installed. The jumper is installed in the OFF position when no Dew Point Transmitter is installed.

NOTE: “Energy Management” can co-exist with the

dew point transmitter option. Dryer control based on the ENERGY MANAGEMENT or DEWPOINT CONTROL is selected on Screen 1 of the Set Up Mode.

If DEWPOINT CONTROL is not selected then the

dew point signal does not control the dryer cycle but still serves a monitoring and alarm function.

8. JP8 – Set Up Jumper JP8 is factory installed in the OFF position

to disable access to “factory” set up screens. The jumper is installed in the ON position during ﬁnal inspection at the factory to set controller to match customer requirements.

6.5 Operator Interface

Refer to Figure 6 , Front Panel Overlay for information regarding the location and function of the LEDs, switches, and text display.

6.5.1 Front Panel LED’s

• Power On - green

• Alarm - red

• Service / Maintenance reminder - amber

• Filters (pre, after, and pilot) service / maintenance reminders - amber

• Inlet switching and purge / repressurization valve status (On = valve open; Off = valve closed) - green

• Left and right tower status (heating) - amber

• Left and right tower status (drying) - green

• Left and right tower pressure switch status (On = switch closed; Off = switch open) - green

6.5.2 Front Panel Switches

The front panel contains four momentary-contact pushbutton switches. Refer to Figure 6, Front Panel Overlay for the appropriate icon associated with each switch. Pushing on the overlay icon actuates the switch.

Data Display Switch

Th is switch is used to step th rough the display screens.

Select Switch

This button is located to the left of the text display window. Refer to the Front Panel Operation Section for additional information.

4. JP4 – Cooling Cycle Jumper JP4 is installed in the ON position to disable

the Cooling Cycle. The jumper is installed in the OFF position to enable a Cooling Cycle.

5. JP5 – Switching Failure Jumper JP5 is installed in the ON position to enable

Switching Failure. The jumper is installed in the OFF position if Switching Failure is disabled.

6. JP6 – Not Used

NOTE: Jumpers JP7 and JP8 are used by the factory during ﬁnal inspection to download language text and to enable ‘factory’ set-up screens.

7. JP7 – Download Language Text Jumper JP7 is factory installed in the OFF position

to disable Language Text download. The jumper is installed in the ON position to allow for language text download due to either language corrections or new language installation.

ENTER Switch

This button is located to the right of the text display window. Refer to the Front Panel Operation Section for additional information.

Alarm Reset Switch

This button is normally used to reset an alarm or service reminder. Refer to the Front Panel Operation Section for additional information.

Left Tower Drying LED

Left Purge Valve LED On=valve open Off=valve closed

Left Inlet Valve LED On=valve open Off=valve closed

Left Tower Heating LED

Filter Service / Maintenance LED

Vacuum Fluorescent Text Display

Select switch

Power On LED

Data Display Switch

Communications Icon

Filter Service / Maintenance LED

Right Tower Pressure Switch LED: On=Tower pressurized

Right Tower Drying LED

Right Purge Valve LED On=valve open Off=valve closed

Right Tower Heating LED

Right Inlet Valve LED On=valve open Off=valve closed

Enter Switch

Maintenance / Service Reminder LED

Alarm LED

Reset Switch for Alarm

Left Tower Pressure Switch LED: On=Tower Pressurized

RS232

6.5.3 Front Panel Operation

1. There are five operating modes for the Heated Desiccant Dryer Control. a. Program Mode b. Setup Mode c. Alarm & Service Mode d. Display Mode e. Test Mode

2. Each Mode is described below.

6.5.4 Program Mode

1. Press and hold and for 3 seconds to enter Program Mode.

2. Program Mode is comprised of the screens that are described below.

3. There are three (3) ways to exit Program Mode.

a. Press after making the selection in the ﬁnal

b. At any screen, press and hold for 3 sec-

c. The controller automatically exits Program Mode

screen.

onds.

if no button is pressed within 60 seconds.

Figure 6

Front Panel Overlay

4. Upon exiting Program Mode the controller will switch

Screen 1: Select the Language

1. Press to scroll through the choices: ENGLISH,

2. When ﬁnished, press to save the selection and

Screen 2: Select the Service Level

1. Pr ess to toggle bet w een N ORMA L and

to Display Mode.

ENGLISH

FRANCAIS and ESPANOL.

move to next screen.

SERVICE LEVEL NORMAL

SEVERE. a. NORMAL Service Intervals are:

i. 4000 hours for ﬁlters ii. 8000 hours for desiccant iii. 8000 hours for valves

b. SEVERE Service Intervals are:

i. 2000 hours for ﬁlters ii. 4000 hours for desiccant iii. 4000 hours for valves

2. When ﬁnished, press to save the selection and

move to next screen.

Screen 3: Reset the Timer for Filter Service

FILTER SERVICE RESET? NO

1. Press to toggle between NO and YES.

2. When finished, press to acknowledge the

selection and move to next screen.

Screen 4: Reset the Timer for Desiccant Service

DESICCANT SERVICE RESET? NO

1. Press to toggle between NO and YES.

2. When finished, press to acknowledge the

selection and move to next screen.

Screen 5: Reset the Timer for Valve Service

VALVE SERVICE RESET? NO

Screen 7: Set Point for Dew Point Demand Control

(Displayed only when JP3 “on”)

DPNT CNTL SETPT ±XX°C ±XXX°F

1. Press to increment the setting to the desired value. a. Standard set point is

-30°C -22°F

b. The allowable range of values is from

-80°C -112°F

+10°C +50°F

in 5°C/9°F

increments.

Note: Must be set “drier” than Dew Point Sensor

Alarm Set Point (screen 6).

2. When finished, press to acknowledge the selection and exit the Program Mode.

Screen 8: Set the Heat Termination Set Point

HEAT TERM SET-PT XX°C XXX°F

1. Press to increment the setting to the desired temperature value. a. Refer to P&ID diagrams in the back of this manual

for Heat Termination set points (see set point values for RTD1 and RTD2).

b. The allowable range of values are:

60° - 160°C 140° - 320°F

in 10°C increments.

1. Press to toggle between NO and YES.

2. When ﬁnished, press to acknowledge the selection and move to next screen.

Screen 6: Set Alarm Point for the Dew Point

Sensor (Displayed only when JP3 “on”)

DEWPOINT ALARM ±XX°C ±XXX°F XX MIN SW DELAY

1. Press to increment the setting to the desired value. a. Standard set point is

-20°C -4°F

b. Th e a l l o w a b l e r a n g e o f v a l u e s i s f r o m

-80°C -112°F

+10°C +50°F

in 5°C/9°F

increments.

2. When ﬁnished, press to acknowledge the selection and scroll to the switchover delay set point screen. a. Standard set point is b. The allowable range of values are

60 MIN

30 to 120 MIN

in 10 minute increments.

3. When ﬁnished, press to acknowledge the selection and move to next screen. Exit Program Mode when there are no more active screens to display.

2. When ﬁnished, press to acknowledge the selection and move to next screen. Exit Program Mode when there are no more active screens to display.

Screen 9: Set Points for Energy Management (Displayed only when JP8 “on”)

ENRGY MGMT SETPT XX%RH XX MBAR .XXX PSI

1. Press to increment the setting to the desired maximum RH value. a. Factory set point is

60%RH

. The factory setting

should not require adjustment.

b. The allowable range of values are

20 to 80%RH

in 5% increments.

2. When ﬁnished, press to acknowledge the selection and scroll to the pressure set point screen.

3. Press to increment the setting to the desired maximum vapor pressure value.

a. Standard set point for a -40°F dew point dryer

16 MBAR (0.232 PSI)

Note: Standard set point for a -100°F dew point

dryer

b. The allowable range of values

3 to 34 MBAR (0.044 to 0.493 PSI)

4 MBAR (0.058 PSI)

1 MBAR

increments.

c. This setting may be ﬁeld adjusted to increase or

decrease the outlet dew point at tower switchover.

4. When ﬁnished, press to acknowledge the selection and move to next screen.

Screen 10: Set Points for High Humidity Alarm (Displayed only when JP8 “on”)

HIGH HUMIDITY XX%RH XX MBAR .XXX PSI XX MIN SW DELAY

. Press to increment the setting to the desired

maximum RH value. a. Factory set point is

75%RH

. The factory setting

should not require adjustment.

b. The allowable range of values are

20 TO 80%RH

in 5% increments.

Note: Value must be set above Energy Manage-

ment Maximum RH Value Set Point (screen 9).

6.5.5 Setup Mode

1. Press and hold for 3 seconds to enter Setup Mode.

2. Setup Mode is comprised of the screens that are described below.

3. There are two ways to exit Setup Mode.

Press after making the selection in Screen 1.

b. The controller automatically exits Setup Mode if

no button is pressed with 60 seconds.

4. One of two things will happen upon exiting Setup Mode. a. The controller will switch to Display Mode if

ENERGY MANAGEMNT, FIXED CYCLE or DEWPOINT CONTROL is selected.

b. The controller will switch to Test Mode if TEST

CYCLE is selected.

Screen 1: Select the Cycle Type

CYCLE TYPE ENERGY MANAGEMNT

2. When ﬁnished, press to acknowledge the selection and scroll to the pressure set point screen.

3. Press to increment the setting to the desired maximum vapor pressure value.

a. Factory set point for a -40°F dew point dryer is

24 MBAR (0.348 PSI)

Note: Factory set point for a -100°F dew point

dryer is

5 MBAR (0.073 PSI)

b. The allowable range of values is

3 to 34 MBAR (0.044 to 0.493 PSI)

in 1 MBAR incre-

ments.

Note: Value must be set above Energy Man-

agement Maximum Vapor Pressure Set Point (screen 9).

4. When ﬁnished, press to acknowledge the selection and scroll to the switchover delay set point screen. a. Factory set point is b. The allowable range of values are

60 MIN.

30 to 120 MIN

in 10 minute increments.

5. When ﬁnished, press to acknowledge the selection and move to next screen. Exit Program Mode when there are no more active screens to display.

1. Press to scroll through the choices: a. ENERGY MANAGEMNT (displayed only when

JP2 is in the ON position)

b. DEWPOINT CONTROL (displayed only when JP3

is in the ON position) c. FIXED CYCLE d. MANUAL CYCLE

2. When ﬁnished, press to save the selection and exit the Setup Mode.

6.5.6 Alarm & Service Mode

1. Alarm & Service Mode is active when the controller is in Display Mode. It is not active in Program Mode, Setup Mode, or Test Mode.

2. Local alarm consists of a blinking alarm LED and an alarm message display.

3. Alarm messages have prior ity over Se rvice messages. Service messages have priority over Display Messages.

4. After an alarm condition has been corrected, if: a. Alarm is “self-clearing” then,

i. The alarm LED stops blinking (LED on); the

alarm message continues to be displayed.

ii. The alarm reset button must be depressed to

clear the alarm LED (LED off) and the alarm message.

b. Alarm must be manually reset, then:

i. The alarm LED continues to blink and the

alarm message continues to be displayed.

ii. The alarm reset button must be depressed

to:

1. Clear the alarm LED (LED off)

2. Clear the alarm message and

3. Restart the dryer cycle.

5. When an alarm condition has not been corrected and the “alarm reset” button is pressed, the alarm will not clear except as follows: a. The alarm conditions will clear for 5 seconds,

then reappear if the alarm condition persists, this applies to the following alarms: i. Heater: High Inlet Temperature. ii. Heater: Low Temperature iii. Humidity Sensor: High Humidity Alarm iv. Humidity Sensor: Under-Range or Over-

Range Alarm v. Dew Point Sensor: High Dew Point Alarm vi. Dew Point Sensor: Under-Range or Over-

Range Alarm

6. There are three alarms for each tower that are triggered by the tower pressure switches. These alarms can occur in any operating mode (Manual, Fixed, Energy Management, or Dew Point Demand Cycle).

Following is a brief description of each alarm.

a. Left or Right tower, drying, low pressure

i. Drying tower pressure switch is open during

the drying cycle.

b. Left or Right tower, regenerating, high pressure

i. Regenerating tower pressure switch is closed

while purge valve is open (after an initial time delay).

c. Left or Right tower, regenerating, low pressure

i. Regenerating tower pressure switch is open

at the end of the regenerating cycle.

d. On alarm condition, the blower and heater are

de-energize, the cycle sequence is stopped, a local alarm is displayed and the common alarm relay is de-energized.

e. These alarms are self-clearing.

7. Heater High Inlet Temperature a. Model sizes 3200, 3600 and 4300 are equipped

with a temperature switch located in the piping between the blower and heater.

b. If during the Heat Cycle this temperature switch

opens, indicating a rise in temperature above the factory setting (refer to Electrical Schematic drawings at the back of this manual for set point), an alarm is activated.

c. On alarm condition, the blower and heater are

de-energized, the cycle sequence is stopped, a local alarm is displayed and the common alarm relay is de-energized.

d. This alarm must be manually reset.

8. The dryer is equipped with RTD temperature sensors. There are out of range alarms for each.

a. The standard left tower, right tower, and heater

RTDs (RTD1, RTD2, RTD3) are scaled from

-20°F(-28°C) to 890°F (477°C), “Out of Range” conditions are as follows: i. Over-range - temperature abov e 850°F

(454°C)

ii. Under-range - temperature below -20°F

(-28°C)

iii. Note: The controller will annunciate a “Heater

Overtemperature” alarm in lieu of an “Over Range” alarm when the heater sensor is disconnected.

b. The Energy Management RTD4 is scaled from

-20°F(-28°C) to 429°F(220°C), “Out of Range” conditions are as follows:

i. Over-range - temperatures above 400°F

(204°C)

ii. Under-range - temperatures below -20°F (-

28°C)

c. On alarm condition, a local alarm is displayed and

the common alarm relay is de-energized.

d. Over-range and Under-range alarms are self-

clearing.

ALARM MESSAGES

LEFT TOWER ALARMS RIGHT TOWER ALARMS OTHER ALARMS

ALARM LEFT TOWER DRYING LOW PRESSURE

ALARM LEFT TOWER REGENERATING HIGH PRESSURE

ALARM LEFT TOWER REGENERATING LOW PRESSURE

ALARM LEFT TOWER TEMP UNDER-RANGE

ALARM LEFT TOWER TEMP OVER-RANGE

ALARM LEFT TOWER OUTLET DEW POINT

ALARM RIGHT TWR DRYING LOW PRESSURE

ALARM RIGHT TWR REGENERATING HIGH PRESSURE

ALARM RIGHT TWR REGENERATING LOW PRESSURE

ALARM RIGHT TWR TEMP UNDER-RANGE

ALARM RIGHT TWR TEMP OVER-RANGE

ALARM RIGHT TWR OUTLET DEW POINT

ALARM HEATER OVER-TEMPERATURE

ALARM HEATER LOW TEMPERATURE

ALARM ENRGY MGNT UNDER-RANGE

ALARM ENRGY MGNT OVER-RANGE

ALARM BLOWER MOTOR OVERLOAD

ALARM HEATER HIGH TEMP IN

ALARM LEFT TOWER HIGH HUMIDITY

ALARM LEFT TOWER DEW POINT UNDER-RANGE

ALARM LEFT TOWER DEW POINT OVER-RANGE

ALARM RIGHT TWR HIGH HUMIDITY

ALARM RIGHT TWR DEW POINT UNDER-RANGE

ALARM RIGHT TWR DEW POINT OVER-RANGE

9. Heat Low Temperature a. RTD3 is used to detect Heater Low Tempera-

ture.

b. Alarm if the heater temperature is less than 250°F

(121°C) within 15 minutes after the Heat Cycle is initiated (15 minute delay also applies after power recovery).

c. On alarm condition, display local alarm and de-

energize common alarm relay.

d. This alarm is self-clearing.

10. Heater Over-Temperature a. RTD3 is used to detect Heater Over-Tempera-

ture.

b. Alarms anytime that the Heater temperature

exceeds 650°F (343°C).

c. On alarm condition, de-energize heat cycle, stop

cycle sequence, display local alarm and de-energize common alarm relay.

d. This alarm must be manually reset.

11. Blower Overload a. Alarm condition when blower overload contact

closes.

13. Dew Point Sensor a. High Dewpoint Alarm

i. The user enters an alarm value through the

Program Mode.

ii. If the measured dew point exceeds the alarm

value, the outlet dew point alarm is indicated.

b. Under-range alarm - Dew point below -148°F

(-100°C)

c. Over-range alarm - Dew point greater than

+109°F (+43°C)

d. On alarm condition,

i. Local alarm is displayed and the common

alarm relay is de-energized.

ii. If dryer is set up for Dewpoint Control, the dryer

sequence continues, but bypasses the “HOLD” step and proceeds to tower switchover after 4 hours of drying.

iii. This alarm is self-clearing, at which time the

alarm LED stops blinking and control switches back to Dewpoint Control.

b. On alarm condition, de-energize heat cycle, stop

cycle sequence, display local alarm and de-energize common alarm relay.

c. This alarm must be manually reset.

Alarms for Optional Devices

12. Energy Management a. High Humidity Alarm:

i. Measured moisture level exceeds the air alarm

value entered through the Program Mode.

b. Humidity Sensor:

i. Under-range: RH% < -15% ii. Over-range: RH% > 115%

c. RTD:

i. Over-range: Temperature above 448°F

(231°C) ii. Under-range: Temperature below -20°F (-28°C)

d. On alarm condition:

i. Local alarm is displayed and the common

alarm relay is de-energized. ii. If the dryer is set up for Energy Management

Control, the dryer sequence continues, but

bypasses the “HOLD” step and proceeds to

tower switchover after 4 hours of drying. iii. This alarm is self-clearing, at which time the

alarm LED stops blinking and control switches

back to Energy Management control.

Service Due Messages

14. There are two service levels (normal and severe) as described in Program Mode. Each service level has preset time intervals for servicing the ﬁlters, desiccant, and valves. Time continues to accumulate as long as power is supplied to the controller, whether the controller is switched on or off.

When a service time interval expires (see also 14.d

below), the controller operates as follows.

a. The service LED blinks and the appropriate

service message is shown on the text display.

i. When the service interval for ﬁlters has expired

(see also d below), the three ﬁlter LED’s also blink.

b. The dryer continues to cycle normally. The LED’s

for the valve’s, pressure switches, and desiccant towers are not used for service indication.

c. Press the Reset button to extinguish the service

LED and to clear the service message from the text display.

d. If the dryer has 1 or 2 ﬁlter monitors, the timer

for ﬁlter service is disabled. When the ﬁlter monitor(s) send an alarm signal (change ﬁlter) to the controller, the controller displays the same LED’s and messages it would if the timer for ﬁlter service had expired.

6.5.7 Display Mode

1. Display Mode is active when the user exits Program Mode or Setup Mode and no alarms are active (unless MANUAL CYCLE was selected in Setup Mode).

2. Display Mode is comprised of dryer status screens and dryer display screens (described below). The controller automatically alternates the display between the Status Screens and selected Display Screens.

3. The user can override the automatic screen scroll by pressing to step through each of the Display Screens shown on the next page. Automatic scrolling will resume when is pressed or if not depressed for 60 seconds.

4. The Ene rgy Sa vings and Service Reminders Display Screens (Filters, Desiccant, and Valves) are alternated in sequence with the current dryer status screen.

15. Examples of the text display are shown on page 18 and below for each alarm and service reminder. The second line of the alarm screens contains up to three messages which are scrolled through, displaying each one for 2 seconds.

SERVICE DUE MESSAGES

SERVICE DRYER FILTERS

SERVICE DRYER DESICCANT

SERVICE DRYER VALVES

DRYER STATUS SCREENS

LEFT TOWER DRYING

LT DRYING RT DEPRESSURIZE

LT DRYING RT HEATING

LT DRYING RT COOLING

LT DRYING RT REPRESSURIZE

LT DRYING RT HOLDING

(Not displayed in FIXED Cycle)

TOWER SWITCHOVER TOWER SWITCHOVER

RIGHT TOWER DRYING

LT DEPRESSURIZE RT DRYING

LT HEATING RT DRYING

LT COOLING RT DRYING

LT REPRESSURIZE RT DRYING

LT HOLDING RT DRYING

(Not displayed in FIXED Cycle)

Energy Savings

(Not displayed in FIXED Cycle)

ENERGY SAVINGS XX%

Note: Energy Savings will appear after seven days of continuous use.

Service reminder (ﬁlters)

HOURS TO SERVICE FILTERS: XXXX

Service reminder (desiccant)

HOURS TO SERVICE DESICCANT: XXXX

Service reminder (valves)

HOURS TO SERVICE VALVES: XXXX

DRYER DISPLAY SCREENS

Outlet Dew Point

(Displayed only if JP3 is ON)

DEW POINT ±XX°C ±XXX°F

Left Tower Temperature

LT TEMP ±XX°C ±XXX°F

Right Tower Temperature

RT TEMP ±XX°C ±XXX°F

Heater Temperature

HEATER TEMP ±XX°C ±XXX°F

Dewpoint Demand SetPoint

(Displayed only if JP3 is ON)

DWPT CNTL SETPT ±XX°C ±XXX°F

Energy Mgmt Signal

(Displayed only if JP2 is ON)

ENERGY MGMT SGNL XX%RH XXX°F XX°C XX MBAR X.XX PSI

Energy Mgmt Setpoint

(Displayed only if JP2 is ON)

ENERGY MGMT SET XX MBAR X.XX PSI

(This is the calculated “hold” set-point, which is based on the sample air temperature.)

6.5.8 Test Mode

1. Test Mode is active when the user exits Program

5. Upon entering Test Mode, the program can be at any one of the ten steps.

Mode after selecting operation in MANUAL CYCLE.

6. To exit Test Mode: a. Press and hold for 3 seconds to exit Test

2. Test Mode is comprised of ten (10) screens (screen descriptions follow the table below on the next page). Each screen corresponds to one of ten program steps (described in the table below).

3. Press to advance from one screen (test step) to the next.

Mode. The display switches to Screen 2 of Setup Mode.

b. Use to select ENERGY MANAGEMENT,

DEWPOINT CONTROL or FIXED CYCLE.

c. Press and hold for 3 seconds to exit Setup

Mode and activate Display Mode.

d. Dryer operation continues from the last step active

IMPORTANT: Be sure to read and understand all

when exiting the Test Mode.

cautions listed with the screen (program step) descriptions.

4. If the temperature is out of range, the second line of the display will read “OVER-RANGE” or “UNDERRANGE” instead of the temperature reading. (Refer to screens 2, 3, 4, 6, 7, and 8.)

Program Step 1 2 3 4 5 6 7 8 9 10

LT status Drying Drying Drying Drying Drying Off Depress Heat Cool Repress

RT status Off Depress Heat Cool Repress Drying Drying Drying Drying Drying

1PS Closed Closed Closed Closed Closed Closed

2PS Closed

3PS Closed Closed Closed Closed Closed Closed

4PS Closed

LT drying solenoid (B) On On On On On Off Off Off Off Off

LT depress solenoid (F) Off Off Off Off Off Off On On On Off

LT purge solenoid (C) Off Off Off Off Off Off Off On On Off

RT drying solenoid (A) Off Off Off Off Off On On On On On

RT depress solenoid (G) Off On On On Off Off Off Off Off Off

RT purge solenoid (D) Off Off On On Off Off Off Off Off Off

LT inlet valve (V1) Open Open Open Open Open Closed Closed Closed Closed Closed

LT depress valve (V9) Closed Closed Closed Closed Closed Closed Open Open Open Closed

LT purge valve (V3) Closed Closed Closed Closed Closed Closed Closed Open Open Closed

RT inlet valve (V2) Closed Closed Closed Closed Closed Open Open Open Open Open

RT depress valve (V10) Closed Open Open Open Closed Closed Closed Closed Closed Closed

RT purge valve (V4) Closed Open Open Open Closed Closed Closed Closed Closed Closed

Repress valve (V11) Open Closed Closed Open Open Open Closed Closed Open Open

Temp display - location Left Right Right Right Right Right Left Left Left Left

Closed

then Open

Closed

then Open

Open Open

Open then

Closed

Open then

Closed

Closed Closed Closed Closed Closed

Closed

then Open

Closed

then Open

Open Open

Open then

Closed

Open then

Closed

Table 2

Cycle Sequence Steps

TEST MODE SCREENS

Screen 1: Step 1

TEST1: LT DRYING LT: XX°C XXX°F

Screen 2: Step 2

TEST2: DEPR RT RT: XX°C XXX°F

Note: Sequence step will not advance to HEAT

until depressurization time has elapsed and tower has fully depressurized. Exception: If switching failure is disabled then pressure condition is ignored.

Screen 3: Step 3

TEST3: HEAT RT RT: XX°C XXX°F

To prevent bed over-heating in test mode: If the RT temperature > heat termination set point, then Screen 3 will display for a maximum of 1 minute before automatically advancing to next step.

Screen 6: Step 6

TEST6: RT DRYING RT: XX°C XXX°F

Screen 7: Step 7

TEST7: DEPR LT LT: XX°C XXX°F

Note: Sequence step will not advance to HEAT

until depressurization time has elapsed and tower has fully depressurized. Exception: If switching failure is disabled then pressure condition is ignored.

Screen 8: Step 8

TEST8: HEAT LT LT: XX°C XXX°F

To prevent bed over-heating in test mode: If the LT temperature > heat termination set point, then Screen 8 will display for a maximum of 1 minute before automatically advancing to next step.

Screen 4: Step 4

TEST4: COOL RT LT: XX°C XXX°F

If the RT temperature < cool termination set point, then Screen 4 will display for a maximum of 1 minute before automatically advancing to next step.

Screen 5: Step 5

TEST5: REPR RT LT: XX°C XXX°F

Note: Sequence step will not advance to tower

SWITCHOVER until repressurization time has elapsed and tower has fully pressurized. Exception: If switching failure is disabled then pressure condition is ignored.

Screen 9: Step 9

TEST9: COOL LT LT: XX°C XXX°F

If the LT temperature < cool termination set point, then Screen 9 will display for a maximum of 1 minute before automatically advancing to next step.

Screen 10: Step 10

TEST10: REPR LT LT: XX°C XXX°F

Note: Sequence step will not advance to tower

SWITCHOVER until repressurization time has elapsed and tower has fully pressurized. Exception: If switching failure is disabled then pressure condition is ignored.

6.6 Start-up

6.6.1 Controller Settings

Set or verify settings on Controller. Detailed operational points are presented in section 6.5.

WARNING - Enclosure may have live electric parts. De-energize dryer before opening enclosure.

6.6.2 Initial Pressurization

SLOWLY pressurize dryer to full line pressure. (If the

dryer was installed with inlet and outlet isolation valves, the inlet isolation valve should be slowly opened while the outlet isolation valve remains closed.)

During initial start-up, check the entire system for leaks. If necessary, de-pressurize the dryer and correct any leaks.

NOTE: Read the off-line tower pressure gauge when the tower is purging (air exhausting from mufﬂer).

6.7.5 Process Valves

Determine if air control valves are operating and sequencing correctly.

6.7.5.1 Valves – Models 500 and 600

Inlet switching valves are normally open, pneumatically piston-actuated, Y-angle poppet valves. A yellow indicator can be seen through a clear window at the top of the actuator housing when the valve is in the open position.

Purge exhaust valves are normally closed, pneumatically piston-actuated, Y-angle poppet valves. A yellow indicator can be seen through a clear window at the top of the actuator housing when the valve is in the open position.

6.6.2.1 Energy Management Sensor (if installed)

Open and adjust the sample exhaust valve until a very slight, continuous gas bleed is felt exhausting out of the sample cell.

6.6.2.2 Dew Point Sensor (if installed)

Ensure that the supply air valve is open (one turn). Open and adjust the sample exhaust valve until a very slight, continuous gas bleed is felt exhausting out of the sample cell.

6.6.3 Energizing the Dryer

Energize the dryer controls.

NOTE: The switching failure alarm may be activated if the unit is energized before it is pressurized. To deactivate alarm, allow dryer to cycle to next step and press the reset button.

6.6.4 Bringing the Dryer On-line

Establish a normal ﬂow through the dryer. Slowly open the outlet isolation valve if present. Close any dryer bypass valves.

6.7 Operational Check Points

6.7.1 Power to unit

Check periodically that there is power to the unit (indicating lights illuminated).

6.7.2 Alarms

Periodically check for ﬂashing red alarm LED.

6.7.3 Tower Status LEDs

Illuminated LEDs indicate which tower is on-line drying or off-line regenerating.

6.7.4 Tower Pressure Gauges

Periodically check tower pressure gauges to verify that the pressure gauge of the on-line tower reads line pressure and the pressure gauge of the off-line tower reads below 2 psig (0.14 kgf/ cm2).

12 volt DC, normally-closed, 3-way pilot solenoid valves are wired to the controller and are used to direct pilot air to the actuators of the inlet switching and purge/repressurization valves.

Dryers are equipped with a safety relief valve that has been sized to provide overpressure protection due to a ﬁre for both desiccant towers.

6.7.5.2 Valves – Models 750 through 4300

Inlet switching valves are resilient seated butterﬂy valves with double acting pneumatic rack and pinion actuators. A yellow arrow indicator located on the top of the actuator output shaft points to valve position indicator icons. Pilot air is directed to actuator ports to open both inlet valves upon loss of power.

(Model 750 only) Purge exhaust valves are normally closed, pneumatically piston-actuated, Y-angle poppet valves. A yellow indicator can be seen through a clear window at the top of the actuator housing when the valve is in the open position.

(Models 900 through 4300) Purge exhaust valves are resilient seated butterﬂy valves with spring return, fail closed, pneumatic rack and pinion actuators. A yellow arrow indicator located on the top of the actuator output shaft points to valve position indicator icons. Pilot air is directed to actuator ports to close both purge/repressurization valves upon loss of power.

12 volt DC, single solenoid, 4-way pilot valves are wired to the controller and are used to direct pilot air to the actuators of the inlet switching and purge/repressurization valves.

Two mainline outlet and two purge line check valves are installed in the upper piping to control the ﬂow of outlet and purge air. Check valve sticking will result in excessive air discharge through a mufﬂer. Excessive air discharge through the mufﬂer can be associated with a leaking outlet check valve on the same side or a purge check valve of the opposite side tower.

Dryers are equipped with a safety relief valve that has been sized to provide overpressure protection due to a ﬁre for both desiccant towers.

b. Advances directly to the beginning of whichever

stage of HEAT or COOL it had been at when power was interrupted.

The tower pressure gauge of the on-line tower should read line pressure. Air should not be leaking from the purge-repressurization valve of the on-line tower.

The tower pressure gauge of the off-line tower should read below 2 psig (0.14 kgf/ cm2) while that tower is purging. If excessive air is exhausting during the purge cycle, the inlet-switching valve on the same side may have failed to close or a check valve may be sticking.

6.8 Dryer Shut Down

1. If the dryer installation is equipped with dryer bypass

and inlet and outlet isolation valves, the bypass valve should be opened and the inlet and outlet isolation valves closed.

2. De-energize the dryer’s electrical supply.

3. SLOWLY open the tower blow down valves (refer

to Figure 3 for general location) to vent the dryer internal pressure.

4. When all dryer pressure gauges indicate zero pres-

sure, close the tower blow down valves. Depressurization is complete.

2. If th e off-li ne tower was at any oth er step (SWITCHOVER, DEPRESSURIZATION, REPRESSURIZATION or HOLD) when power was lost, then the sequence simply resumes at that step.

6.10 Operating Parameters

Control valves are designed so that upon loss of power the air dryer is capable of drying air until the desiccant exposed to the airﬂow is saturated.

6.11 Using the RS-232 Port

The RS-232 port is used to monitor dryer operation from a host computer.

RS-232 connections are made at the 3-pin connector labeled J3 and located at the upper left-hand corner of the control board.

Interface to a PC requires a (1 to 1) DB-9 cable.

Cable Pin Out:

- Data transmitted on pin 2

- Data received on pin 3

- Ground is pin 5

- Pins 7 and 8 are jumpered at the dryer

6.9 Loss of Power

Control valves are designed so that upon loss of power the air dryer is capable of drying air until the desiccant exposed to the airﬂow is saturated.

6.9.1 Power Recovery:

6.9.1.1 On loss of electrical power –

All controller outputs turn off causing the dryer operating valves to react as follows:

1a. For models with poppet style inlet valves (models

500 - 600): both inlet valves will open. Both towers will repressurize.

1b. For models with butterﬂy inlet valves (models 750 -

4300): inlet valves will remain in position. Any minor leakage through the inlet valve or check valve will slowly repressurize the off-line tower.

2. Purge exhaust valves close.

3. Depressurization solenoid valves close.

4. Repressurization valve closes.

6.9.1.2 On restoration of power –

1. If power is lost when the off-line tower is in either the HEAT or COOL step, the off-line tower will be either partially or fully repressurized. On power recovery the sequence:

a. Resumes at the DEPRESSURIZATION step to

let down the pressure in the off-line tower then,

Operation:

1. Fixed baud rate of 9600

2. Asynchronous format is 8 bit, no parity, 1 stop bit (“8,N,1”)

3. No check sum or error correction values are provided. If required, request status string two (or more) times and compare for agreement.

4. Request data by sending ASCII ? character (3FH). Response may take up to two seconds as certain processing functions may require completion before the serial port is acknowledged.

5. The dryer responds with line feed (0AH), carriage return (0DH), and a character string as follows:

STX Start of text character 0x02

109 Three character ASCII device identiﬁer

, comma character x ASCII representation of the cycle type , xx ASCII representation of the cycle step , xxxxx ASCII representation of the current cycle time

in seconds , xxx ASCII representation of the inlet temperature

(°F)

, xxx ASCII representation of the heater tempera-

ture (°F) , xxx ASCII representation of the left bed tempera-

ture (°F) , xxx ASCII representation of the right bed tem-

perature (°F) , xxx ASCII representation of the humidity sensor

temperature (°F) , xxx ASCII representation of the humidity sensor

relative humidity (%) , xxxx ASCII representation of the dew point reading

(°F) , xxxx ASCII representation of the ﬁlter time to ser-

vice (hours) , xxxx ASCII representation of the desiccant time to

service (hours) , xxxx ASCII representation of the valve time to

service (hours) , x ASCII representation of programming jump-

ers , 1 or 0 Is the unit alarmed? 1 = alarm , 1 or 0 Is service required? 1 = service , xx ASCII representation of the energy savings

(%) , x Reserved for future use, always 1 for now , ETX end of text character OxO3 CR carriage return LF line feed

Determining jumper positions:

Each jumper 8 bits weighted by position

JP Value 8 128

7 64 6 32 5 16 4 8 3 4 2 2 1 1

Example:

If jumper 8, 5, and 1 are installed, a value of 128+16+1 = 145 is returned

To decode, the algorithm:

· If (number >= 128)  jumper 8 = on

· number = number - 128

· If (number >= 64)  jumper 7 = on

· number = number - 64;

· etc.....

JUMPERS:

The programming jumpers are as follows (0=off, 1=on):

JP Bit 1 0 off = externally heated on = blower dryer 2 1 on = energy management sensor installed 3 2 on = dew point sensor installed 4 3 on = no cooling (blower purge only) 5 4 on = tower pressure switches installed 6 5 on = not used (fast cycle for development,

V3.5 and prior)

7 6 on = to download language text (factory

use)

8 7 on = to enable factory set-up screens

7.0 Maintenance

WARNING - This equipment is a pressure-containing device. Depressurize before servicing.

Note: The Dryer Controller is equipped with Service Reminder functions for ﬁlters, desiccant and valves.

7.1 Desiccant Replacement

NOTE: The use of the correct replacement desiccant

is necessary for proper dryer operation. Never use hygroscopic sa lts of the type commonly used in “deliquescent ” type dryers.

1. Frequency Of Desiccant Replacement

Desiccant should be replaced whenever the required

dew point cannot be maintained while the dryer is being operated within its design conditions and there are no mechanical malfunctions.

NOTE: Desiccant life is determined by the quality of

the inlet air. Proper ﬁltering of the inlet air will extend the life of the desiccant. Typically desiccant life is 2 years.

2. Procedure for Desiccant Charge Replacement

a. Depressurize and de-energize the dryer.

b. Remove the ﬁll and drain plugs or ﬂanges (where

applicable) from the desiccant tower and drain the

spent desiccant. Place a container at the base of

the vessel to collect the desiccant. If necessary

tap the sides of the vessels with a rubber mallet

to loosen desiccant.

NOTE: Use extreme care when inserting rods or

other tools through the desiccant ﬁll or drain ports to loosen packed desiccant. Internal ﬂow diffusers at the ends of the desiccant beds can be damaged or punctured by sharp instruments. These diffusers are necessary to distribute the airﬂow and keep the desiccant beads within the tower. Desiccant beads in exhaust mufﬂers, afterﬁlters, or the piping connected to the desiccant towers may indicate a perforation of a diffuser.

c. Replace the drain plug using Teﬂon tape or another

pipe thread sealant suitable for compressed air

service. Reinstall drain port ﬂange cover (where

applicable) in each desiccant tower.

d. Refer to Table 1 (on page 5) for desiccant quan-

tity per tower.

When using Table 1 you will ﬁnd the desiccant

quantities listed in layers. Each layer will vary in

depth due to the type, quantity and purpose of the

desiccant. Layer 1 must be installed ﬁrst at the

bottom of the vessel followed by layer number 2

etc., until the complete charge of desiccant has

been installed.

e. Utilizing an appropriate sized funnel, ﬁll each

desiccant tower as follows:

1) Install the required quantity of tabular support (model 4300 only) or activated alumina in layer 1 of each tower.

2) Level layer 1 and each subsequent layer of desiccant as added to each tower.

3) Finish ﬁlling each tower with desiccant until all desiccant has been installed. LIGHT tapping on the tower sides with a soft-face mallet should yield additional free space to allow installation of all desiccant required. DO NOT TAMP OR RAM DESICCANT.

f. Clean the ﬁll port closure. Replace the ﬁll plug

using Teﬂon tape or another pipe thread sealant suitable for compressed air service. Reinstall ﬁll port ﬂange cover (where applicable) in desiccant tower.

3. Insuring Desiccant Dryness

Replacement desiccant is shipped in airtight

containers. Keep the covers on these containers tightly closed until use to avoid moisture contamination. If desiccant is exposed to air it can be heated in an oven at 400°F (204°C) for four hours before use. Alternatively, if the dryer is not reﬁlled with dry desiccant, it may be necessary to operate the unit with an inlet ﬂow rate of less than 50% of maximum rated inlet capacity until the desiccant has regenerated fully.

7.2 Purge Mufﬂers

Purge mufﬂers should be checked regularly, changed annually. Mufﬂer disseminator elements become clogged with desiccant dust over time, creating back pressure and restricted purge ﬂow.

7.3 Valves

1. Process and pilot valves should be checked frequently for leaks and proper operation.

2. Purge pressure adjustment valve should be checked frequently for proper adjustment.

7.4 Pilot Air Filter Element Replacement

1. Frequency of replacement

The pilot air ﬁlter contains a ﬁlter element that should

be changed yearly. Replacement may be required sooner if pressure drop across cartridge prevents valves from actuating properly.

Warning – The pilot air ﬁlter housing is a pressurecontaining device, depressurize before servicing. Slowly open manual drain valve on bottom of filter bowl by turning clockwise to verify that the housing is depressurized before removing bowl.

2. Procedure for element replacement

a. Isolate dryer from air supply

b. Depressurize dryer by running dryer and allowing

system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/ repressurization valves from opening. Remaining pressure can be vented to atmosphere through the manual drain on the pilot air ﬁlter. The system must be fully depressurized before removing the bowl.

c. Remove the filter bowl by pushing up, turn-

ing counterclockwise and then pulling straight down.

d. Clean the ﬁlter bowl.

e. Replace the element.

f. Clean and lubricate o-ring at top of bowl and

reassemble in reverse order.

7.5 Dew Point Analyzer Filter (optional) Element Replacement

1. Frequency of replacement

The Dew Point Analyzer ﬁlter contains a ﬁlter element

that should be changed yearly. Replacement may be required sooner if pressure drop across cartridge prevents the Dew Point Analyzer from operating properly.

Warning – The Dew Point Analyzer ﬁlter housing is a pressure-containing device, depressurize before servicing. Slowly open manual drain valve on bottom of ﬁlter bowl by turning clockwise to verify that the housing is depressurized before removing bowl.

2. Procedure for element replacement

a. Isolate dryer from air supply

b. Depressurize dryer by running dryer and allowing

c. Remove the filter bowl by pushing up, turn-

ing counterclockwise and then pulling straight down.

d. Clean the ﬁlter bowl.

e. Replace the element.

f. Clean and lubricate o-ring at top of bowl and

reassemble in reverse order.

8.0 Troubleshooting

WARNING - A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS. Some of the troubleshooting checks may require gaining access to the dryer’s electrical enclosure(s) while the power supply is energized and should be performed by a qualiﬁed electrical technician.

WARNING - Before performing any electrical or mechanical repairs or maintenance, or removing or disassembling any component, be sure to deenergize and depressurize the dryer.

SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

Indicator lights not illuminated 1. No power to unit.

2. Loss of power supply to (or at) dryer’s electrical disconnect switch or breaker. (customer supplied)

3. Blown fuse.

4. Board malfunction.

Excessive pressure drop in dryer 1. Inlet/Outlet screens on desiccant tow-

Low Pressure Alarm

Left Tower or Right Tower Drying

ers are dirty

2. Excessive ﬂow rate

1. Loss of dryer air supply.

2. Excessive air demand.

3. Faulty drying tower pressure switch

4. Drying tower Inlet Valve failed to open

5. Drying tower Purge Exhaust Valve failed to close.

6. Drying tower Depressurization Valve failed to close

7. Regenerating tower Outlet Check Valve failed to close

8. Drying tower Purge Check Valve leaking

1. Check voltage at terminal board.

2. Check disconnect switch or breaker closed. If tripped breaker or blown fuse is noted, investigate and Remedy cause.

3. Replace fuse.

4. Replace board.

1. Clean screens; follow desiccant removal instructions in the Maintenance section.

2. Check ﬂow rate of inlet air. Reduce to design ﬂow rate.

1. Check compressor supplying dryer.

2. Check equipment downstream of dryer.

3. Check pressure switch operation using tower pressure gauge for comparison. Replace switch if defective.

4a. Check for loss of pilot air - ensure manual drain valve on

bottom of pilot air ﬁlter is fully closed, ensure pilot air ﬁlter cartridge is not clogged, ensure pilot air shut-off valve is open

4b. Check for inlet pilot air solenoid valve failure. Check valve

operation. Repair or replace as necessary.

4c. Check for drying tower Inlet Valve failure - examine valve

and actuator for damage. Repair or replace as necessary.

5a. Check for air ﬂow out of drying tower Purge Valve or ex-

haust piping indicating valve is not completely closed.

5b. Check for loss of pilot air - ensure manual drain valve on

bottom of pilot air ﬁlter is fully closed, ensure pilot air ﬁlter cartridge is not clogged, ensure pilot air shut-off valve is open

5c. Check for purge pilot air solenoid valve failure. Check valve

operation. Repair or replace as necessary.

5d. Check for drying tower Purge Exhaust Valve failure - exam-

ine valve and actuator for damage. Repair or replace as necessary.

6. Check for air ﬂow out of drying tower Depressurization Mufﬂer indicating valve is not completely closed. Repair or replace as necessary.

7. Indicated by excessive ﬂow out of regenerating tower Purge Valve. Examine valve internals. Repair or replace as necessary.

8. Indicated by excessive ﬂow out of regenerating tower Purge Valve or reverse air ﬂow through heater and blower, i.e., out of the blower intake ﬁlter, examine valve internals. Repair or replace as necessary.

CAUTION: Air ﬂowing backwards through heater and

blower may be very hot.

SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

High Pressure Alarm

Left Tower or Right Tower Regenerating

Low Pressure Alarm

Left Tower or Right Tower Regenerating

Temperature Under-Range or Temperature Over-Range Alarm

Left Tower or Right Tower

Dew Point Under-Range or Dew Point Over-Range Alarm

Left Tower or Right Tower Regenerating

1. Faulty regenerating tower pressure switch

2. Regenerating tower Depressurization Mufﬂer clogged.

3. Regenerating tower Depressurization Valve failed to open.

4. Regenerating tower purge exhaust piping obstructed.

5. Regenerating tower Purge Exhaust Valve failed to open.

6. Repressurization valve (V11) failed to close.

1. Faulty left tower pressure switch.

2. Regenerating tower Purge Exhaust Valve failed to close.

3. Regenerating tower Depressurization Valve failed to close.

4. Repressurization valve (V11) failed to open.

5. Repressurization oriﬁces are blocked.

1. Tower temperature sensor failure.

Under-Range  Short circuit on sensor Over-Range  Open circuit on sensor

1. Energy Management temperature sensor (RTD4) failure.

1. Check pressure switch operation using tower pressure gauge for comparison. Replace switch if defective.

2. Examine inner core and clean or replace as necessary.

3. Check valve operation. Repair or replace as possible.

4. Ensure piping is free of obstructions.

5a. Check for loss of pilot air - ensure manual drain valve on

bottom of pilot air ﬁlter is fully closed, ensure pilot air ﬁlter cartridge is not clogged, ensure pilot air shut-off valve is open.

5b. Check for purge pilot air solenoid valve failure. Check valve

operation. Repair or replace as necessary.

5c. Check for regenerating tower Purge Exhaust Valve failure -

examine valve and actuator for damage. Repair or replace as necessary.

6a. Check for loss of pilot air - ensure manual drain valve on

bottom of pilot air ﬁlter is fully closed, ensure pilot air ﬁlter cartridge is not clogged, ensure pilot air shut-off valve is open.

6b. Check for Repressurization Valve (V11) failure. Check valve

operation. Repair or replace as necessary.

1. Check pressure switch operation using tower pressure gauge for comparison. Replace switch if defective.

2a. Check for air ﬂow out of regenerating tower Purge Valve or

exhaust piping indicating valve is not completely closed.

2b. Check for loss of pilot air - ensure manual drain valve on

bottom of pilot air ﬁlter is fully closed, ensure pilot air ﬁlter cartridge is not clogged, ensure pilot air shut-off valve is open

2c. Check for purge pilot air solenoid valve failure. Check valve

operation. Repair or replace as necessary.

2d. Check for regenerating tower Purge Exhaust Valve failure -

examine valve and actuator for damage. Repair or replace as necessary.

3. Check for air ﬂow out of regenerating tower Depressurization Mufﬂer indicating valve is not completely closed. Repair or replace as necessary.

4a. Check for loss of pilot air - ensure manual drain valve on

bottom of pilot air ﬁlter is fully closed, ensure pilot air ﬁlter cartridge is not clogged, ensure pilot air shut-off valve is open.

4b. Examine repressurization valve (V11) for damage. Repair

or replace as necessary.

5. Check oriﬁces for obstruction and clean as necessary.

1. Check temperature circuit for continuity. Repair or replace as necessary.

SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION

Outlet Dew Point Alarm

Left Tower or Right Tower

High Humidity Alarm

Left Tower or Right Tower

Heater Over-Temperature Alarm

Heater Low-Temperature Alarm

Energy Management UnderRange Alarm or Energy Management OverRange Alarm

Blower Motor Overload Alarm 1. Restricted or blocked purge air ﬂow.

Heater High Inlet Temperature

(models 3200, 3600, & 4300 only)

1. Inlet air ﬂow higher than the sizing condition.

2. Liquids entering the dryer inlet.

3. Inlet air temperature higher than the sizing condition.

4. Desiccant dusting.

5. Contaminated desiccant (e.g. with oil).

6. Heater temperature set too low.

7. Heating malfunction due to heater failure or heater contactor failure.

1. Desiccant bed overloaded.

2. Dew point sensor or monitor damaged or defective.

3. Loss of desiccant drying capacity

1. Insufﬁcient purge gas ﬂow.

2. Temperature sensor failure.

1. Heating malfunction due to heater failure or heater contactor failure.

2. Temperature sensor failure.

1. Energy Management sensor failure. 1. Check circuit for continuity. Repair or replace as neces-

2. Line failure

1. On-line tower purge check valve is leaking.

2. Temperature sensor failure.

1. Reduce inlet ﬂow to sizing condition.

2. Check the inlet air line for liquids. Inspect preﬁlter and drain valve. Clean, repair or replace automatic drain valve.

3. Check the compressor aftercooler and cooling system. Reduce inlet air temperature to sizing condition.

4. Check air pressure, airﬂow and airﬂow surges and correct as necessary. Replace desiccant.

5. Check preﬁlter and automatic drain valve. Replace preﬁlter element. Clean, repair or replace drain valve as necessary. Consult factory concerning need for desiccant replacement.

6. Adjust controller set point.

7. Replace heater or heater contactor.

1. Check inlet air ﬂow rate, temperature and pressure. Higher than design ﬂow, and temperature, and lower than design pressure will result in overloading of the dryer.

2. Examine sensor for physical damage and check monitor/ sensor operation. Replace sensor or monitor as necessary.

3. Inlet air improperly ﬁltered causing desiccant contamination

- examine ﬁlter elements and drains. Repair or replace as necessary. Useful life of desiccant has been exceeded.

1. Check for purge blockage, temperature sensor failure, etc.

2. Repair and replace as required.

1. Replace heater or heater contactor.

2. Repair and replace as required.

sary.

1a. Dirty intake ﬁlter on blower - examine ﬁlter element and

clean or replace.

1b. Regenerating tower purge exhaust valve failed to open -

1) Check for loss of pilot air - ensure manual drain valve on bottom of pilot air ﬁlter is fully closed, ensure pilot air ﬁlter cartridge is not clogged, ensure pilot air shut-off valve is open.

2) Check for purge pilot air solenoid valve failure. Check valve operation. Repair or replace as necessary.

3) Check for regenerating tower Purge Exhaust Valve failure examine valve and actuator for damage. Repair or replace as necessary.

1c. Purge exhaust piping obstructed - ensure piping is free of

obstructions.

1d. Regenerating tower purge check valve failed to open - ex-

amine valve internals. Repair or replace as necessary.

2. Check voltages and currents in the motor circuit.

1. Examine valve internals. Repair or replace as required.

2. Repair and replace as required.

P&ID Schematic

WET GAS INLET

DRY GAS OUTLET

SOL 'D'

SOL 'F'

EXH.

RTD

SOL 'B

EXH.

SOL 'A

SOL 'G'

RTD

1PS

(RTD4/HS1)

ENERGY MGMT OPTION

SET @ 176°F

DRYING

EXH.

3PS

SET

5 PSIG

SOL 'C'

LEFT

TOWER

SET

45 PSI

RTD 3

SET @ 650°F

1TC

SET @ 370°F

2PS

SET @ 176°F

4PS

SET

5 PSIG

REGE

SET

45 PSIG

SET AT 100 PSIG

RIGH

TOWE

V12 V13

SOL 'E'

V7 V11

SET @ 165 PSI

DEWPOINTER OPTION

SOLENOID VA

LVES 'B'� 'D'� � 'G' ARE SHOWN ENERGI�ED �

SYMBOLS ARE PER ANSI Y32.10 �GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS.�

SOLENOID VALVES 'A'� 'C'� 'E'� � 'F' ARE SHOWN DE�ENERGI�ED .

AS SHOWN FLOW DIRECTION IS

�

INDICATES OPTIO

PILOT GAS LINE

RIGHT CHAMBER REGEN

LEFT CHAMBER DRYING

NOTES

Models 500 through 600 (Contact factory to request certiﬁed drawings)

LEGEND

LEFT CHAMBER DRYING (RIGHT CHAMBER REGEN)

CLOSED

3 WAY

3 WA

SOLENOID VALVE 'D'

SOLENOID VALV

E 'C'

N.O.

VALV

E 'E'

SOLENOID

3 WAY

HEATER

OPEN

CLOSED

OPEN

CLOSED

YES

CLOSED

OPEN

OFF

YES

FIXED CYCLE TIMING

IME IN MINUTES)

ENER

IZED

PROCESS

MPONENT

ELECTRIC

AL CO

MPONENT

3 WAY

SOLENOID VALVE 'A'

SOLENOID VALV

E 'B'

ATUS

PROCESS

MPONENT

DEPRESSURIZA

TION

ATIN

OPEN

CLOSED

OPEN

YES

257178

RIGHT CHAMBER DRYING (LEFT CHAMBER REGEN)

ATIN

HOL

2ND ST

E RE

GENERA

TION

REPRESSURIZA

TION

DEPRESSURIZA

TION

3 1782

HOL

REPRESSURI

TION

VALVE 'F'

SOLENOID VALV

E 'G'

N.C.

YES

OPEN

CLOSED

V10

SOLENOID

YES OPEN

MOTOR

OFF

YES

V11

BLOWER

(JUMPE

R SELECT

)

2ND ST

E REGENERA

(JUMPE

SELECT

)

1. INLET VALVE (V1 LEFT, V2 RIGHT)

2. PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT)

3. PURGE CHECK VALVE (V5 LEFT, V6 RIGHT)

4. OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT)

5. DEPRESS SOLENOID VALVE (V9 LEFT, V10 RIGHT)

6. PURGE HEATER WITH INSULATION

7. HEATER TEMPERATURE THERMOCOUPLE

8. HEATER OVERTEMPERATURE RTD

9. CHAMBER RTD (LEFT & RIGHT)

10. RELIEF VALVE

11. CHAMBER PRESSURE GAUGES (LEFT & RIGHT)

12. CHAMBER PRESSURE SWITCH (LEFT & RIGHT)

13. SERVICE VALVE

14. PILOT AIR FILTER

15. PRESSURE REGULATOR & GAUGE

16. SOLENOID VALVE

17. MUFFLER

18. DESICCANT CHAMBER

19. DESICCANT RETAINING SCREEN (TOP & BOTTOM)

20. DESICCANT FILL PORT

21. DESICCANT DRAIN PORT

22. HOT PIPE INSULATION

23. PURGE PRESSURE GAUGE

24. PURGE BLOWER AND MOTOR

25. PURGE SUCTION FILTER SILENCER

26. REPRESS/SWEEP SOLENOID VALVE (V11)

27. REPRESS/SWEEP CHECK VALVE (V12 LEFT, V13 RIGHT)

28. REPRESS/SWEEP ORIFICE

29. CHAMBER BLOW-DOWN VALVE

ENERGY MANAGEMENT OPTION

42. ENERGY MANAGEMENT PILOT OPERATED VALVE

43. ENERGY MANAGEMENT SENSOR (RTD4/HS1)

DEWPOINTER OPTION

44. DEWPOINT ANALYZER 44A. DEWPOINT ANALYZER FILTER

INSULATION OPTION

54. CHAMBER INSULATION

Sequence of Operation

(Models 500 through 600)

P&ID Schematic

WET GAS INLET

DRY GAS OUTLET

SOL 'D'

SOL 'F'

EXH.

RTD

SOL 'B

SOL 'A

EXH.

SOL 'G

RTD

1PS

(RTD4/HS1)

ENERGY MGMT OPTION

SET @ 176°F

DRYING

EXH.

3PS

SET

5 PSIG

SOL 'C'

LEFT

TOWER

SET

45 PSI

(225°F)

RTD

SET @ 650°F

1TC

SET @ 370°F

2PS

REGE

SET @ 176°F

4PS

SET

5 PSIG

RIGH

TOWER

SET

45 PSIG

SET AT 100 PSIG

V12 V13

SOL 'E'

V11V7

SET @ 165 PSI

DEWPOINTER OPTION

DPA

44A

MODEL 750 ONLY

(SEE DETAIL 'A

FOR 900-4300)

SOLENOID VA

LVES 'B', 'D', & 'G' ARE SHOWN ENERGIZED,

SYMBOLS ARE PER ANSI Y32.10 "GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS."

SOLENOID VA

LVES 'A', 'C', 'E', & 'F' ARE SHOWN DE-ENERGIZED.

AS SHOWN FLOW DIRECTION IS:

INDICATES OPTION

PILOT GAS LINE

RIGHT CHAMBER REGEN

LEFT CHAMBER DRYING

NOTES

OPEN 5 TURNS FROM FULL CLOSED AND LOCK IN PLAC

Models 750 through 4300 (Contact factory to request certiﬁed drawings)

LEGEND

= FAILS IN POSITION

LEFT CHAMBER DRYING (RIGHT CHAMBER REGEN)

CLOSEDNO

3 WAY

3 WA

SOLENOID VALVE 'D'

SOLENOID VALV

E 'C'

N.O.

VALV

E 'E'

SOLENOID

3 WA

HEATER

OPEN

CLOSED

OPEN

CLOSED

YES

CLOSED

OPEN

OFF

YES

FIXED CYCLE TIMING

IME IN MINUTES)

ENER

IZED

PROCESS

MPONENT

ELECTRICAL CO

MPONEN

3 WAY

SOLENOID VALVE 'A'

SOLENOID VALV

E 'B'

ATUS

PROCESS

MPONENT

DEPRESSURIZ

TION

ATIN

OPEN

CLOSED

OPEN

YES

257178

RIGHT CHAMBER DRYING (LEFT CHAMBER REGEN)

ATIN

HOL

2ND ST

E REGENE

TIO

REPRESSURI

DEPRESSURIZ

TION

3 1782

HOL

SS OF POWER

REPRESSURI

TION

VALVE 'F'

SOLENOID VALV

E 'G'

N.C.

YES

OPEN

CLOSED

V10

SOLENOID

YES OPEN

MOTOR

OFF

YES

V11

BLOWER

(JUMPER SE

ECTABLE)

2ND ST

AGE RE

GENE

(JUMPER

SELECT

ABL

DETAIL 'A' (MODELS 900-4300)

SOL 'C'

SOL 'D'

1. INLET VALVE (V1 LEFT, V2 RIGHT) 1A. FLOW CONTROL VALVE

2. PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT)

3. PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) (NO SPRING)

4. OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT)

5. DEPRESS SOLENOID VALVE (V9 LEFT, V10 RIGHT)

6. PURGE HEATER WITH INSULATION

7. HEATER TEMPERATURE THERMOCOUPLE

8. HEATER OVERTEMPERATURE RTD

9. CHAMBER RTD (LEFT & RIGHT)

10. RELIEF VALVE

11. CHAMBER PRESSURE GAUGES (LEFT & RIGHT)

12. CHAMBER PRESSURE SWITCH (LEFT & RIGHT)

13. SERVICE VALVE

14. PILOT AIR FILTER

15. PRESSURE REGULATOR & GAUGE

16. SOLENOID VALVE

17. MUFFLER

18. DESICCANT CHAMBER

19. DESICCANT RETAINING SCREEN (TOP & BOTTOM)

20. DESICCANT FILL PORT

21. DESICCANT DRAIN PORT

22. HOT PIPE INSULATION

23. PURGE PRESSURE GAUGE

24. PURGE BLOWER AND MOTOR

25. PURGE SUCTION FILTER SILENCER

26. REPRESS/SWEEP SOLENOID VALVE (V11)

27. REPRESS/SWEEP CHECK VALVE (V12 LEFT, V13 RIGHT)

28. REPRESS/SWEEP ORIFICE

29. CHAMBER BLOW-DOWN VALVE

30. TEMPERATURE SWITCH (MODELS 3200 - 4300 ONLY)

ENERGY MANAGEMENT OPTION

42. ENERGY MANAGEMENT PILOT OPERATED VALVE

43. ENERGY MANAGEMENT SENSOR (RTD4/HS1)

DEWPOINTER OPTION

44. DEWPOINT ANALYZER 44A. DEWPOINT ANALYZER FILTER

INSULATION OPTION

54. CHAMBER INSULATION

Sequence of Operation

(Model 750 through 4300)

Electrical Schematic – 460VAC, 3 phase

LOCATED

EXTERNALLY

HEATER OVERTEMPERATURE

RPS

IN2

D5-

IN1

LPS

D3-

D3+

D5+

D4-

D4+

RTD1

RTD

RIGHT CHAMBER

LEFT CHAMBER

RTD3

RTD2

ANLG2+

ANLG2-

D2-

RTD2+

+5VDC

DC COM

D1-

D1+

ANLG1-

ANLG1+

+12VDC

DC COM

SET @ 45 PSIG2PS

PRESSURE SWITCH

RIGHT CHAMBER

SET @ 45 PSIG1PS

PRESSURE SWITCH

LEFT CHAMBER

SENSOR

5VDC

1-5VDC OUT

DEWPOINT

TRANSMITTER

1TC

+ -

K TYPE

L DRY

ALARM

OUT2

CONTACTS

R DRY

OUT1

R DRY

DRY

SOLENOID "B"

SOLENOID "A"

PURGE

R PURGE

IN3

2CR

3CR

LOW TENSION ENCLOSURE

HIGH TENSION ENCLOSURE

CUSTOMER PROVIDED

460VAC, 3 PHASE

(FOR FUSING AND WIRE

407

101A

460V

115V

2CR1

3CR1

SOLENOID "F

SOLENOID "G

2FU

1FU

3FU

HC1

HC2

HC3

404

405

406

+ 4-20MA OUT

ENERGY MGMT

OPTION

1HTR

102

101

102

1CR

102

101

109

111

101

107

SOLENOID "C"

LEFT CHAMBER PURGE EXHAUST

HEAT ENABLE

C NO

101

102

TB3

+12VDC

FROM TB6

SOLENOID "E

+12VDC

20 21

4CR

1CR1

104

105

102

+ -

RED

ORANGE

GREEN

BROWN

BLACK

249 OHM

1/8W

EXTERNALLY

LOCATED

OPTION

102

120VAC TO

TB3

101

102

101

120VAC

FROM TB5

101

109

3PS

110

CLOSES @ 5 PSIG

4CR1

104

101

5CR1

MC-AUX

LEFT CHAMBER DEPRESS

111

4PS

SOLENOID "D

102

5CR

RIGHT CHAMBER DEPRESS

EXHAUST

RIGHT CHAMBER PURG

MC1

MC3

MC2

403

402

401

MOTOR

{

SIZING SEE TABLE 1)

106

4CR2

5CR2

+12VDC FROM TB6-1 FROM TB6-

DC COM

OL-AUX

H1 H3

X1 X2

OL1

OL2

OL3

H2 H4

GREEN

BLACK

RED

SET @ 225°F

1TS

3200, 3600 & 4300

USED ON MODEL

0.5 AM

1.25 AMP

TB5

CLOSES @ 5 PSIG

1TR (OFF-DELAY, SET @ 180S)

108

102

15 18

1TR1

A1B1A2

102

105

101

OL-AUX

104

101

NOTE

: SET 1TR ON MODE "D". (SIGNAL OFF-DELAY)

YELLOW

(Contact factory to request certiﬁed drawings)

Electrical Schematic – 575VAC, 3 phase

LOCATED

EXTERNALLY

HEATER OVERTEMPERATURE

TB1-12

TB1-11

TB1-13

TB2-1

TB1-16

TB1-15

TB1-14

TB2-2

TB2-6

TB2-5

TB2-4

TB2-7

TB2-8

TB2-3

RPS

IN2

RTD5

IN1

LPS

RTD3

RTD5

RTD4

RIGHT CHAMBER

LEFT CHAMBER

TB5-1

TB5-3

TB5-2

TB6-2

TB1-1

TB1-2

TB1-7

TB1-6

TB1-5

TB1-4

TB1-8

TB1-3

TB6-1

TB1-10

TB1-9

ANLG2+

ANLG2-

RTD2

+5VDC

DC COM

RTD1

ANLG1-

ANLG1+

+12VDC

DC COM

SET @ 45 PSIG2PS

PRESSURE SWITCH

RIGHT CHAMBER

SET @ 45 PSIG1PS

PRESSURE SWITCH

LEFT CHAMBER

SENSOR

5VDC

1-5VDC OUT

DEWPOINT

TRANSMITTER

1TC

+ -

K TYPE

1HC

TB3-5L DRY

TB3-6

TB3-8

TB3-7

TB3-11

TB3-10

TB3-9

TB3-12

TB4-1

TB4-3

TB4-2

ALARM

OUT2

CONTACTS

R DRY

OUT1

R DRY

DRY

SOLENOID "B"

SOLENOID "A"

TB2-10

TB3-1

TB2-9

TB3-3

TB3-2

TB3-4

PURGE

R PURGE

IN3

2CR

3CR

LOW TENSION ENCLOSURE

HIGH TENSION ENCLOSURE

510

101A

575V

115V

2CR1

3CR1

SOLENOID "F

SOLENOID "G

2FU

1FU

3FU

2HC1

2HC2

2HC3

507

508

509

+ 4-20MA OUT

ENERGY MGMT

OPTION

2HTR

102

101

102

1CR

102

101

109

101

107

SOLENOID "C

LEFT CHAMBER DEPRESS

LEFT CHAMBER PURGE EXHAUST

HEAT ENABLE

C NO

101

102

TB3

+12VDC

FROM TB6

SOLENOID "E"

+12VDC

20 21

4CR

1CR1

104

105

102

+ -

RED

ORANGE

GREEN

BROWN

BLACK

249 OHM

1/8W

EXTERNALLY LOCATED

OPTION

102

120VAC TO

TB3

101

102

101

120VAC

FROM TB5

101

109

3PS

CLOSES @ 5 PSI

4CR1

104

101

5CR1

MC-AUX

LEFT CHAMBER DEPRESS

CLOSES @ 5 PSI

111

4PS

SOLENOID "D

102

5CR

RIGHT CHAMBER DEPRESS

EXHAUST

RIGHT CHAMBER PURGE

RIGHT CHAMBER DEPRESS

106

4CR2

5CR2

~ ~

+12VDC FROM TB6-1 FROM TB6-2

DC COM

OL-AUX

X1 X3

GREEN

BLACK

RED

SET @ 225°F

1TS

3200, 3600 & 4300

USED ON MODELS

{

MC2

(FOR FUSING AND WIRE

SIZING SEE TABLE 1)

MC3 OL

503

575VAC, 3 PHASE

CUSTOMER PROVIDED

MC1 OL

501

502

MOTOR

1HC1

1HC3

1HC2

506

505

504

1HTR

2HC

102

3200, 3600 & 4300

USED ON MODEL

3200, 3600 & 4300

USED ON MODEL

101

OL-AUX

105

1TR1

108

15 18

A1 A2

102

(SIGNAL OFF-DELAY

)

SET 1TR ON MODE "D".

NOTE:

1TR (OFF-DELAY, SET @ 180S

)

0.5 AM

1.25 AM

YELLOW

(Contact factory to request certiﬁed drawings)

Electrical Schematic – 380VAC, 3 phase

LOCATED

EXTERNALLY

HEATER OVERTEMPERATURE

RPS

IN2

D5-

IN1

LPS

D3-

D3+

RTD5+

D4-

D4+

RTD

RIGHT CHAMBER

LEFT CHAMBER

RTD

ANLG2+

ANLG2-

D2-

D2+

+5VDC

DC COM

D1-

D1+

ANLG1-

ANLG1+

+12VDC

DC COM

SET @ 45 PSIG2PS

PRESSURE SWITCH

RIGHT CHAMBER

SET @ 45 PSIG1PS

PRESSURE SWITCH

LEFT CHAMBER

SENSOR

5VDC

1-5VDC OUT

DEWPOINT

TRANSMITTER

1TC

+ -

L1 N

K TYPE

DRY

ALARM

OUT2

CONTACTS

R DRY

OUT1

R DRY

DRY

SOLENOID "B

SOLENOID "A"

PURGE

R PURGE

IN3

2CR

3CR

LOW TENSION ENCLOSURE

HIGH TENSION ENCLOSURE

CUSTOMER PROVIDED

380VAC, 3 PHASE

(FOR FUSING AND WIRE

307

101A

380VAC

110V

2CR1

3CR1

SOLENOID "F

SOLENOID "G

2FU

1FU

3FU

HC1

HC2

HC3

304

305

306

+ 4-20MA OUT

ENERGY MGMT

OPTION

1HTR

102

101

102

1CR

102

101

109

111

101 107

SOLENOID "C"

LEFT CHAMBER DEPRESS

LEFT CHAMBER PURGE EXHAUST

HEAT ENABLE

C NO

101

102

TB3

+12VDC

FROM TB6

SOLENOID "E"

+12VDC

20 21

4CR

1CR1

104

105

102

+ -

RED

ORANGE

GREEN

ORANGE

BLACK

249 OHM

1/8W

EXTERNALLY LOCATED

OPTION

102

120VAC TO

TB3

101

102

101

120VAC

FROM TB5

101

109

3PS

110

CLOSES @ 5 PSIG

4CR1

104

101

5CR1

MC-AUX

LEFT CHAMBER DEPRESS

CLOSES @ 5 PSIG

111

4PS

SOLENOID "D

102

5CR

RIGHT CHAMBER DEPRES

EXHAUST

RIGHT CHAMBER PURG

RIGHT CHAMBER DEPRES

MC1

MC3

MC2

303

302

301

MOTOR

{

SIZING SEE TABLE 1)

106

4CR2

5CR2

+12VDC FROM TB6-1 FROM TB6-2

DC COM

OL-AUX

H1 H3

X1 X4

OL1

BLACK

GREEN

RED

1TS

USED ON MODELS 3200, 3600 & 4300

SET @ 225°F

(.5AMP

)

(.5 AMP

)

(1.25 AMP

)

TB5

104

101

1TR (OFF-DELAY, SET @ 180S

)

OL-AUX

114

1815

1TR1

108

105

101

A1B1A2

102

NOTE

(SIGNAL OFF-DELAY)

SET 1TR ON MODE "D".

102

YELLOW

(Contact factory to request certiﬁed drawings)

Electrical Schematic – 415VAC, 3 phase

LOCATED

EXTERNALLY

HEATER OVERTEMPERATURE

RPS

IN2

D5-

IN1

LPS

D3-

D3+

D5+

D4-

D4+

RTD

RIGHT CHAMBER

LEFT CHAMBER

RTD

ANLG2+

ANLG2-

D2-

D2+

+5VDC

DC COM

D1-

D1+

ANLG1-

ANLG1+

+12VDC

DC COM

SET @ 45 PSIG2PS

PRESSURE SWITCH

RIGHT CHAMBER

SET @ 45 PSIG1PS

PRESSURE SWITCH

LEFT CHAMBER

SENSOR

5VDC

1-5VDC OUT

DEWPOINT

TRANSMITTER

1TC

+ -

K TYPE

DRY

ALARM

OUT2

CONTACTS

R DRY

OUT1

R DRY

DRY

SOLENOID "B"

SOLENOID "A"

PURGE

L PURGE

R PURGE

IN3

2CR

3CR

LOW TENSION ENCLOSURE

HIGH TENSION ENCLOSURE

CUSTOMER PROVIDED

415VAC, 3 PHASE

(FOR FUSING AND WIRE

407

101A

415VAC

120V

2CR1

3CR1

SOLENOID "F

SOLENOID "G

2FU

1FU

3FU

HC1

HC2

HC3

404

405

406

+ 4-20MA OUT

ENERGY MGMT

OPTION

1HTR

102

101

102

1CR

102

101

109

111

101 107

SOLENOID "C"

LEFT CHAMBER DEPRESS

LEFT CHAMBER PURGE EXHAUST

HEAT ENABLE

C NO

101

102

TB3

+12VDC

FROM TB6

SOLENOID "E"

+12VDC

20 21

4CR

1CR1

104

105

102

+ -

RED

ORANGE

GREEN

ORANGE

BLACK

249 OHM

1/8W

EXTERNALLY LOCATED

OPTION

102

120VAC TO

TB3

101

102

101

120VAC

FROM TB5

101

109

3PS

110

CLOSES @ 5 PSIG

4CR1

104

101

5CR1

MC-AUX

LEFT CHAMBER DEPRESS

CLOSES @ 5 PSIG

111

4PS

SOLENOID "D

102

5CR

RIGHT CHAMBER DEPRESS

EXHAUST

RIGHT CHAMBER PURG

RIGHT CHAMBER DEPRES

MC1

MC3

MC2

403

402

401

MOTOR

{

SIZING SEE TABLE 1)

106

4CR2

5CR2

+12VDC FROM TB6-1 FROM TB6-2

DC COM

OL-AUX

H1 H3

X2 X4

OL1

OL2

OL3

BLACK

GREEN

RED

1TS

USED ON MODELS 3200, 3600 & 4300

SET @ 225°F

0.5 AM

1.25 AMP

TB5

HEATER & MOTOR FUSES BY CUSTOMER

101

OL-AUX

105

1TR1

108

15 18

A1 A2

102

(SIGNAL OFF-DELAY)

SET 1TR ON MODE "D".

NOTE

1TR (OFF-DELAY, SET @ 180S

)

YELLOW

(Contact factory to request certiﬁed drawings)

Electrical Data – Fusing & Wire Sizing

Electrical Service: 460VAC, 3 phase

MODEL COMPONENT RATING

HEATER 10 KW 12.6 20 AMPS #12 AWG

500

600

750

900

1050

1300

1500

1800

2200

2600

3200

3600

4300

MOTOR 2.5 HP 4.1 7.5 AMPS #12 AWG

HEATER 12 KW 15.1 20 AMPS #12 AWG

MOTOR 4 HP 6.2 10 AMPS #12 AWG

HEATER 14 KW 17.6 25 AMPS #12 AWG

MOTOR 4 HP 6.2 10 AMPS #12 AWG

HEATER 17 KW 21.3 30 AMPS #10 AWG

MOTOR 4 HP 6.2 10 AMPS #12 AWG

HEATER 19 KW 23.8 30 AMPS #10 AWG

MOTOR 5 HP 7.6 12 AMPS #12 AWG

HEATER 23 KW 28.9 40 AMPS #8 AWG

MOTOR 7.5 HP 11 17.5 AMPS #12 AWG

HEATER 28 KW 35.1 45 AMPS #8 AWG

MOTOR 10 HP 14 20 AMPS #12 AWG

HEATER 33 KW 41.4 60 AMPS #6 AWG

MOTOR 10 HP 14 20 AMPS #12 AWG

HEATER 40 KW 50.2 70 AMPS #4 AWG

MOTOR 10 HP 14 20 AMPS #12 AWG

HEATER 45 KW 56.5 80 AMPS #4 AWG

MOTOR 15 HP 21 30 AMPS #10 AWG

HEATER 54 KW 67.8 90 AMPS #2 AWG

MOTOR 5 HP 7.6 12 AMPS #12 AWG

HEATER 60 KW 75.3 100 AMPS #2 AWG

MOTOR 5 HP 7.6 12 AMPS #12 AWG

HEATER 70 KW 87.9 110 AMPS #2 AWG

MOTOR 7.5 HP 11 17.5 AMPS #12 AWG

F.L.A.

@460VAC

SUGGESTED

FUSING

WIRE SIZE

Electrical Service: 575VAC, 3 phase

MODEL COMPONENT RATING

HEATER 10 KW 10.0 15 AMPS #12 AWG

500

600

750

900

1050

1300

1500

1800

2200

2600

3200*

3600*

4300*

MOTOR 2.5 HP 3.3 6 AMPS #12 AWG

HEATER 12 KW 12.0 20 AMPS #12 AWG

MOTOR 4 HP 5 9 AMPS #12 AWG

HEATER 14 KW 14.1 20 AMPS #12 AWG

MOTOR 4 HP 5 9 AMPS #12 AWG

HEATER 17 KW 17.1 25 AMPS #12 AWG

MOTOR 4 HP 5 9 AMPS #12 AWG

HEATER 19 KW 19.1 25 AMPS #12 AWG

MOTOR 5 HP 6.1 9 AMPS #12 AWG

HEATER 23 KW 23.1 30 AMPS #8 AWG

MOTOR 7.5 HP 9 15 AMPS #12 AWG

HEATER 28 KW 28.1 40 AMPS #8 AWG

MOTOR 10 HP 11 17.5 AMPS #12 AWG

HEATER 33 KW 33.1 50 AMPS #8 AWG

MOTOR 10 HP 11 17.5 AMPS #12 AWG

HEATER 40 KW 40.2 60 AMPS #6 AWG

MOTOR 10 HP 11 17.5 AMPS #12 AWG

HEATER 45 KW 45.2 60 AMPS #6 AWG

MOTOR 15 HP 17 25 AMPS #10 AWG

HEATER 2 – 27 KW 2 – 27.1 2 – 40 AMPS 2 – #8 AWG

MOTOR 5 HP 6.1 9 AMPS #12 AWG

HEATER 2 – 30 KW 2 – 31.1 2 – 40 AMPS 2 – #8 AWG

MOTOR 5 HP 6.1 9 AMPS #12 AWG

HEATER 2 – 35 KW 2 – 35.1 2 – 40 AMPS 2 – #8 AWG

MOTOR 7.5 HP 9 15 AMPS #12 AWG

F.L.A.

@575VAC

* Models 3200, 3600 and 4300 use a two-stage heater circuit with two contactors,

six fuses, and six wires.

SUGGESTED

FUSING

WIRE SIZE

Electrical Service: 380VAC, 3 phase

MODEL COMPONENT RATING

HEATER 10 KW 15.2 25 AMPS #12 AWG

500

600

750

900

1050

1300

1500

1800

2200

2600

3200

3600

4300

MOTOR 3 HP 6 12 AMPS #12 AWG

HEATER 12 KW 18.2 25 AMPS #12 AWG

MOTOR 5 HP 9 17.5 AMPS #12 AWG

HEATER 14 KW 21.3 30 AMPS #10 AWG

MOTOR 3 HP 6 12 AMPS #12 AWG

HEATER 17 KW 25.8 35 AMPS #10 AWG

MOTOR 3 HP 6 12 AMPS #12 AWG

HEATER 19 KW 28.9 40 AMPS #8 AWG

MOTOR 5 HP 9 17.5 AMPS #12 AWG

HEATER 23 KW 34.9 45 AMPS #8 AWG

MOTOR 7.5 HP 13 20 AMPS #12 AWG

HEATER 28 KW 42.5 55 AMPS #6 AWG

MOTOR 10 HP 16 30 AMPS #10 AWG

HEATER 33 KW 50.1 65 AMPS #6 AWG

MOTOR 12.5 HP 23.7 40 AMPS #10 AWG

HEATER 40 KW 60.8 80 AMPS #4 AWG

MOTOR 7.5 HP 13 20 AMPS #12 AWG

HEATER 45 KW 68.4 90 AMPS #2 AWG

MOTOR 15 HP 24 40 AMPS #12 AWG

HEATER 54 KW 82.0 100 AMPS #2 AWG

MOTOR 7.5 HP 13 20 AMPS #12 AWG

HEATER 58 KW 88.1 110 AMPS #2 AWG

MOTOR 7.5 HP 13 20 AMPS #12 AWG

HEATER 70 KW 106.4 150 AMPS #1/0 AWG

MOTOR 7.5 HP 13 20 AMPS #12 AWG

F.L.A.

@380VAC

SUGGESTED

FUSING

WIRE SIZE

Electrical Service: 415VAC, 3 phase

MODEL COMPONENT RATING

HEATER 10 KW 13.9 20 AMPS #12 AWG

500

600

750

900

1050

1300

1500

1800

2200

2600

3200

3600

4300

MOTOR 3 HP 6 10 AMPS #12 AWG

HEATER 12 KW 16.7 25 AMPS #10 AWG

MOTOR 5 HP 8 15 AMPS #12 AWG

HEATER 14 KW 19.5 25 AMPS #10 AWG

MOTOR 3 HP 6 10 AMPS #12 AWG

HEATER 17 KW 23.7 30 AMPS #10 AWG

MOTOR 4.2 HP 5.6 15 AMPS #12 AWG

HEATER 19 KW 26.4 40 AMPS #8 AWG

MOTOR 5 HP 8 15 AMPS #12 AWG

HEATER 23 KW 32.0 40 AMPS #8 AWG

MOTOR 7.5 HP 12 20 AMPS #12 AWG

HEATER 28 KW 39.0 50 AMPS #8 AWG

MOTOR 10 HP 15 25 AMPS #10 AWG

HEATER 33 KW 45.9 60 AMPS #6 AWG

MOTOR 12.5 HP 17 30 AMPS #10 AWG

HEATER 40 KW 55.6 70 AMPS #4 AWG

MOTOR 7.5 HP 12 20 AMPS #12 AWG

HEATER 45 KW 62.6 80 AMPS #4 AWG

MOTOR 15 HP 22 40 AMPS #8 AWG

HEATER 53 KW 73.7 100 AMPS #2 AWG

MOTOR 5 HP 8 15 AMPS #12 AWG

HEATER 58 KW 80.7 110 AMPS #2 AWG

MOTOR 7.5 HP 12 20 AMPS #12 AWG

HEATER 70 KW 97.4 125 AMPS #1 AWG

MOTOR 7.5 HP 12 20 AMPS #12 AWG

F.L.A.

@415VAC

SUGGESTED

FUSING

WIRE SIZE

WARRANTY

SPX Dehydration & Filtration

1000 Philadelphia Street Canonsburg, PA 15317-1700 U.S.A. Phone: 724-745-1555 • Fax: 724-745-6040 Email: hankison.service@dehydration.spx.com www.hankisonintl.com

The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor, or eighteen months from the date of shipment from the factory, whichever occurs ﬁrst, provided such defect is discovered and brought to the manufacturer’s attention the aforesaid warranty period. The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within the warranty period, provided such defect occurred in normal service and not as the result of misuse, abuse, neglect, or accident.

The warranty covers parts and labor for the warranty period. Repair or replacement shall be made at the factory or the installation site, at the sole option of the manufacturer. The manufacturer must ﬁrst authorize any service performed on the product by anyone other than the manufacturer. Normal maintenance items requiring routine replacement are not warranted. Unauthorized service voids the warranty and any resulting charge or subsequent claim will not be paid.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WRITTEN, ORAL, OR STATUTORY,

AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT

LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE, OR INSPECTION OF THE EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN. THE MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR OTHER INCIDENTAL OR CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING FROM BREACH OF WARRANTY, NEGLIGENCE OR STRICT LIABILITY IN TORT.

The manufacturer does not warranty any product, part, material, component, or accessory manufactured by others and sold or supplied in connection with the sale of the manufacturer’s products.

AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE

MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.

SERVICE DEPARTMENT : (724) 746-1100

HANKISON HBP, HBP500, HBP600, HBP750, HBP900 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.0 General Safety Information

2.0 Receiving, Storing, and Moving

3.0 Description

4.0 Installation

5.0 Instrumentation

6.0 Operation

7.0 Maintenance

8.0 Troubleshooting

WARRANTY