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ICP iDRY Instructions For Installation And Operation Manual

Instructions for installation and operation english
www.i compressorpartners.com
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Contents
1. SAFETY AND SYSTEM PRECAUTIONS ................................................................................................................................................... 3
1.1 Definition of the Safety Symbols............................................................................................................................................. 3
1.2 Operational Warnings ........................................................................................................................................................... 3
2. INSPECTION AND INSTALLATION ......................................................................................................................................................... 4
2.1 Incoming Inspection and Transportation .............................................................................................................................. 4
2.2 Design and Use of the Dryer ................................................................................................................................................. 4
2.3 Location and Installation ....................................................................................................................................................... 4
2.4 Filters Mounted with Bypass ................................................................................................................................................. 6
3. TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION ...................................................................................................................... 7
3.1 Technical Data by Model Size ................................................................................................................................................ 7
3.2 Correction Factors ................................................................................................................................................................. 8
3.3 General Function ................................................................................................................................................................... 8
3.4 Flow Diagram ........................................................................................................................................................................ 9
3.5 Cycle Operation ................................................................................................................................................................... 10
4. PURGE VALVE ADJUSTMENT .............................................................................................................................................................. 11
5. START-UP ............................................................................................................................................................................................ 12
5.1 Verification Prior to Start-up ............................................................................................................................................... 12
5.2 Start-up Procedures ............................................................................................................................................................ 13
5.3 General Operation .............................................................................................................................................................. 14
6. ISOLATION AND SHUT DOWN PROCEDURES ..................................................................................................................................... 14
7. CONTROLLER INFORMATION AND OPERATION ................................................................................................................................ 15
7.1 Display Overview ................................................................................................................................................................. 15
7.2 Startup ................................................................................................................................................................................ 15
7.3 Controller Inputs ................................................................................................................................................................. 15
7.4 Contoller Outputs ................................................................................................................................................................ 16
7.5 Controller Settings .............................................................................................................................................................. 16
7.6 Service Rest Button ............................................................................................................................................................. 18
7.8 Power Requirements ........................................................................................................................................................... 18
8. MAINTENANCE AND SERVICE ............................................................................................................................................................. 19
8.1 Routine Maintenance ................................................................................................................................................................... 19
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 1
8.2 Maintenance and Service Intervals .............................................................................................................................................. 20
8.3 Fuses ............................................................................................................................................................................................. 20
8.4 Desiccant Replacement ................................................................................................................................................................ 21
8.5 Inlet and Exhaust Valve Repair ..................................................................................................................................................... 21
9. TROUBLESHOOTING GUIDE ................................................................................................................................................................ 22
10. MAINTENANCE AND SPARE PARTS .................................................................................................................................................. 25
10.1 Required Maintenance Parts ...................................................................................................................................................... 25
10.2 Spare Parts ................................................................................................................................................................................. 27
11. DISMANTLING OF THE DRYER .......................................................................................................................................................... 28
12. ELECTRICAL WIRING DIAGRAM ........................................................................................................................................................ 29
13. GENERAL DESCRIPTION OF PARTS ................................................................................................................................................... 29
For technical product support please use website www.i compressorpartners.com
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 2
Before attempting any
service, please read
the manual
General Warning:
Risk of damage or injury
Electrical Hazard:
Possibility of
electrocution
Warning:
Under pressure
Warning:
High temperature
Warning:
Non-breathable air
Warning:
Water cannot be used
to extinguish fire
Warning:
Do not operate if parts
are missing or have been
tampered with
Warning:
Machine level noise may exceed 85 dBA
Warning:
Personal
protection
required
Warning:
All work to be
performed by qualified
personnel only
Operations that can be performed by qualified
operators1
Compressed air inlet connection
Compressed air outlet connection
Connection point for condensate drain
WARNING: VESSELS UNDER PRESSURE
In most countries, states, cities and/or local municipalities the installation, operation and maintenance of
devices where pressure vessels are in use are subject to local boiler and pressure vessel regulations.
The end user is responsible for following all of the relevant laws, rules and regulations and ensuring that only
experienced and trained personnel install and/or operate the dryer.
In most countries, states, cities and/or local municipalities the installation may only be carried out by a
licensed installation company. Inspections must be carried out by a qualified and licensed third-party firm in accordance with all applicable laws, rules and regulations for the region where the dryer is installed.
The pressure vessels used in this device are built according to the American Society of Mechanical Engineers
(ASME) standard Section 8, Division 1.
Compressed Air Warning: Compressed air is a highly dangerous energy source.
Never work on the dryer while components are under pressure. Never point the compressed air stream or the condensate drain outlet towards anybody.
The end user is responsible for the installation of the dryer as laid out in this manual. If proper commissioning steps are not followed, the warranty will be void and dangerous situations involving injury or death and/or damages to the machine could occur.
Only qualified personnel can use and service electrically powered devices. Before attempting any maintenance:
Ensure that no part of the machine is powered and is locked out of the electrical mains by following proper
“Lock-out, Tag-out” procedures and requirements.
Ensure that no part of the dryer is under pressure by isolating the dryer from the compressed air system.
Any change to the machine or to the standard operating parameters (see page 5), if not previously verified and authorized by the manufacturer, in addition to creating a potentially dangerous situation, will void the warranty.
Don’t use water to extinguish fire on the dryer or in the surrounding area.
ARIA
AIR
LUFT
AIR
1. SAFETY AND SYSTEM PRECAUTIONS
1.1 Definition of the Safety Symbols
1 Only experienced and trained personnel familiar with all of the relevant laws, rules and regulations, capable to perform the needed activities and to
identify and avoid possible dangerous situations while handling, installing, using and servicing the machine.
1.2 Operational Warnings
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 3
The packaging materials are recyclable. Each material must be properly disposed in a manner complying with the rules and regulations of the local municipality government.
The purpose of the machine is the separation of water vapor that is present in compressed air. It is not intended to separate oil or other contaminants that are present in compressed air. The dried compressed air output from this dryer cannot be used for respiration purposes of any kind.
Serious consideration should be given when selecting the installation site for the dryer, as an improper location could directly affect the proper operation of the dryer.
This unit is not suitable to be used in explosive atmospheres, where risk of fire could exist, in the presence of gaseous or solid pollutants or in outdoor applications or areas exposed to the elements.
Do not use water to extinguish fire on the dryer or in the surrounding area.
Machine level noise could be higher than 85 dBA. Install the unit in a dedicated area where people are not normally present. The installer and/or end user is responsible for the correct installation of the dryer in order to prevent excessive noise exposure in the work environment. The installer and/or end user is responsible to install proper safety signs at the installation site.
2. INSPECTION AND INSTALLATION
2.1 Incoming Inspection and Transportation
All dryers are tested and inspected at the factory prior to shipping. Thoroughly inspect and verify the integrity of the packaging upon receipt and note any damage on the freight bill. Place the unit as close as possible to the installation point before unpacking the contents and inspect for concealed damage. Freight claims are to be filed with the carrier immediately and the manufacturer’s technical service department notified thereafter.
To move the packaged unit, we suggest the use of a suitable crane or forklift. We do not recommend moving the
unit by any hand operated or manual mechanism.
Handle with care. Heavy blows could cause irreparable damage. Even when packaged, keep the machine protected from severe weather.
2.2 Design and Use of the Dryer
This dryer has been designed, manufactured and tested to be used only to separate the humidity normally contained in compressed air, any other use is considered to be improper. The manufacturer is not responsible for any problems arising from the improper use of this machine.
The end user, in any and all cases, is responsible for any resulting damages.
Moreover, the correct use of this machine requires the verification of certain installation conditions, in particular:
Voltage and frequency of the electrical power supplied Pressure, temperature, flow rate and chemical composition of the incoming compressed air Ambient temperatures
The dryer is supplied as tested and fully assembled. The only operation left for the end user is the connection to the plant and adjustment of the purge rate in compliance with the instructions given in this manual. Factory settings are at nominal conditions at 100 psig and the stated model flow rate (see page 5).
2.3 Location and Installation
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 4
Technicians that service the machine must wear hearing and eye protection while servicing the dryer. Each employee must select a proper personal protection device (PPD) hearing protector such as earmuffs, ear canal caps or earplugs in order to prevent permanent hearing damage or loss.
Incorrect installation may void warranty.
1. Inlet piping including an isolation valve
2. Outlet piping including an isolation valve
3. Coalescing pre-filter and particulate post-filter
We recommend the dryer be installed with a 0.01 micron iPUR coalescing pre-filter at the inlet and a 1.0 micron iPUR particulate post-filter at the outlet. It is recommended to install both 5.0 micron and
1.0 micron filters upstream of the dryer in order to maintain the operational lifespan of the inlet filter to the dryer. In addition, we recommend the use of a iMAT zero air loss drain on the pre-filter and at all other condensate collection points, especially those upstream of the dryer.
4. IMPORTANT! Bypass piping is necessary. Only bubble tight valves should be used.
5. Make the required electrical connections; please refer the type plate of your dryer. The end user is
responsible for providing short circuit protection for the dryer.
6. Points of access should be provided upstream and downstream of the dryer for periodic monitoring of
dew point, pressure and temperature prior to finalizing the installation. Taking periodic dew point measurements just downstream of the dryer gives the best indication of whether the dryer is performing optimally. We recommend using METPOINT® instrumentation to ensure accurate measurements.
7. All piping must be adequately supported and at least of equal size to the dryer connections.
Minimum Installation Requirements:
Select a clean, dry room that is free of dust and protected from atmospheric disturbances. The location must be smooth, horizontally level, able to bear the weight of the dryer and vibration free Minimum ambient temperature of +40 °F Maximum ambient temperature of +120 °F Allow a clearance of at least 3’ on all sides of the dryer in order easily facilitate all maintenance needs The dryer is not required to be anchored to the supporting surface Coalescing pre-filter with drain must be installed The location of an air receiver tank will vary depending on compressor type and application conditions
NOTE: All piping and electrical connections should be inspected prior to installation to ensure they have maintained their integrity during shipping and locating the dryer.
First, make the initial connections as follows:
Locate the coalescing pre-filter as close to the dryer as possible while still maintaining sufficient space for routine maintenance and service. Inlet air entering the dryer must pass through a coalescing pre-filter in order remove entrained condensate and oil to prevent fouling of the desiccant and maintain standard operation. Any liquid condensate entering the desiccant bed will lead to overloading of the dryer, poor dew point performance and rapid deterioration of the desiccant material. Any oil entering the desiccant bed may permanently reduce the capacity of the desiccant material.
Desiccant dust traveling downstream of the dryer may cause contamination and/or accelerated wear to other components and equipment. Therefore, a particulate post-filter should be provided to prevent desiccant dust from traveling downstream. Activated alumina is considered a nuisance dust and proper precautions should be taken when handling desiccant (refer to applicable MSDS sheet).
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 5
Before any attempt is made to operate the dryer, the operator must thoroughly read and understand this installation and operation manual.
Optimal Installation Diagram
1 Air Compressor
2 After Cooler
3 iPUR Inline Water Separator
4 iPUR 5.0 Micron (Grade G) Filtration
5 Receiver Tank
6 iPUR 1.0 Micron (Grade F) Filtration
7 iDRY iDHLBe Desiccant Dryer with iPUR Pre and Post-filtration
8 Dry Air Outlet
9 Condensate Drainage Points for iMAT
We recommend the dryer be installed with a 0.01 micron iPUR coalescing pre-filter at the inlet and a 1 micron iPUR particulate post-filter at the outlet. It is recommended to install both 5 micron and 1 micron filters upstream of the dryer in order to maintain the operational lifespan of the inlet filter.
Optimal installation is with moderately sized receivers at the inlet and outlet side of the dryer. This allows for the
additional free cooling and moisture collection and more consistent dryer inlet flow provided by an upstream receiver, while providing the most reliable shop air supply due to the downstream receiver.
Under no circumstances should the peak demand air flow exceed the maximum rated air flow of the dryer.
2.4 Mounted Filters with Bypass
Mounted Filters with Bypass is an optional setup for the heatless regenerative dryer. The three valve system bypass allows for the flow of air to be uniterupted while servicing or completing preventative maintinance such as:
Exchange pre- and post- filters Services exhaust sIlencers Change desiccant
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 6
iDRY iDHLBe
Model Size
080
100
120
160
200
250
300
400
500
650
800
Flow Rate
scfm
80
100
120
160
200
250
300
400
500
650
800
Inlet / Outlet Connection
in. (NPT-F)
¾ 1 1
1 ¼
1 ¼
1 ½
1 ½ 2 2
2 ½
2 ½
Height (A)
in.
69
69
69
69
69
70
70
73
75
76
76
Width (B)
in.
31
34
34
39
39
45
45
51
54
62
63
Depth (C)
in.
22
24
24
27
27
32
32
36
38
41
44
Adsorbent Material
Activated Alumina
⅛”
Total per Dryer
Lbs.
95
150
150
230
230
340
340
480
625
795
940
Outlet Pressure Dew Point
°F
-40
Minimum Ambient Temperature
°F
40
Maximum Ambient Temperature
°F
120
Standard Inlet Air Temperature
°F
100
Maximum Inlet Air Temperature
°F
120
Minimum Air Pressure
psig
60
Standard Air Pressure
psig
100
Maximum Air Pressure
psig
150
Dryer ratings adhere to the following inlet conditions per ISO 7183, Table 2, Option A2:
Inlet Compressed Air Temperature 100 °F (38 °C) Inlet Compressed Air Pressure 100 psig (7 bar) Maximum Ambient Air Temperature 100 °F (38 °C) Inlet Compressed Air Relative Humidity 100% (Saturated)
3. TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION
3.1 Technical Data by Model Size
SCFM is defined as the volume of free air in cubic feet per minute measured at 14.7 psia (1.013 bar) at 68 °F (20 °C) temperature with 0% relative humidity (0 WVP).
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 7
Correction Factors
≤ 90°F
95°F
100°F
105°F
110°F
115°F
120°F
60 PSIG
0.89
0.76
0.65
0.59
0.49
0.44
0.38
70 PSIG
1.00
0.85
0.73
0.66
0.55
0.49
0.42
80 PSIG
1.00
0.96
0.82
0.74
0.62
0.55
0.48
90 PSIG
1.06
1.05
0.90
0.81
0.68
0.60
0.52
100 PSIG
1.10
1.10
1.00
0.90
0.76
0.67
0.58
110 PSIG
1.15
1.15
1.15
1.04
0.87
0.77
0.67
120 PSIG
1.20
1.20
1.20
1.08
0.91
0.80
0.70
130 PSIG
1.24
1.24
1.24
1.12
0.94
0.83
0.72
140 PSIG
1.28
1.28
1.28
1.15
0.97
0.86
0.74
150 PSIG
1.33
1.33
1.33
1.20
1.01
0.89
0.77
3.2 Correction Factors
Operating Pressure and Inlet Air Temperature
How to size the dryer capacity for actual conditions: How to select the dryer for actual conditions:
ADJUSTED CAPACITY = Standard Flow Rate x Correction Factor System Flow Rate ÷ Correction Factor
Example: Example:
Dryer Model: iDRY iDHLBe 250 System Flow Rate: 300 scfm Standard Flow Rate: 250 scfm Operating Conditions: 130 psig / 100 °F Operating Conditions: 110 psig / 110 °F ADJUSTED CAPACITY = 300 scfm ÷ 1.24 = 242 scfm ADJUSTED CAPACITY = 250 scfm x 0.87 = 218 scfm Select Dryer Model: iDRY iDHLBe 250
3.3 General Function
The iDRY iDHLBe heatless desiccant dyer series are fitted with two pressure vessels, positioned parallel to one another and filled with adsorption material (⅛” activated alumina as standard). While the compressed air is dried in one tower, the saturated desiccant is regenerated in the second. A minimal portion of the treated air is used for the regeneration process and expelled along with the condensate, through the silencers.
The saturated inlet air is cycled through each of the two desiccant beds in an alternating sequence where one bed is on­line at full line pressure and flow, adsorbing the water vapor. This is the drying bed.
The other bed is then considered to be in an off-line state at atmospheric pressure and is being regenerated by a depressurized portion of the dried, treated outlet air (purge air). This is the regenerating bed.
The purge air is routed from the dry outlet air through the purge flow control valve, desiccant bed, purge exhaust valve and finally exhausted to atmosphere through silencers to finish the regeneration process. Purge air consumption is generally the highest cost involved with operating a heatless adsorption dryer and is non-recoverable. Therefore, the air system where the dryer is installed must account for this usage (approximately 15% of the inlet air flow).
Just before the freshly regenerated bed is brought to an on-line state to become the drying bed, it is slowly pressurized from atmospheric pressure up to line pressure. This is the re-pressurization step that prevents desiccant bed fluidization (bed lifting) and dusting. The desiccant beds will now switch functions where the fresh desiccant bed is now drying and the saturated bed is now regenerating.
This cycle will continue automatically unless the dryer is shut down.
All desiccant dryers work using the principle of adsorption, which is the process by which water vapor is removed from the compressed air being dried. All desiccant material types are adversely affected by oil, aerosols, dirt, rust, scale and
ADJUSTED CAPACITY =
iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 8
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