Ingersoll-Rand 150-8000 Operator's Manual

October

HB Series Desiccant Dryer

I-R ORDER NUMBER: 81696181

CUSTOMER NAME: Woodward RCC c/o ALL Equipment

CUSTOMER CONTACT: Kerry Fang- 704-655-5364

CUSTOMER P.O. NUMBER: 78608

DRYER MODEL: HB3000 EMS

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

Models 150-8000

Operator’s Manual

Manual Del Operador

Manuel De L’opérateur

Manual do Operador

80442858

Revision E

2012

Save These Instructions

I-R ORDER NUMBER: 81696181

CUSTOMER NAME: Woodward RCC c/o ALL Equipment

CUSTOMER CONTACT: Kerry Fang- 704-655-5364

CUSTOMER P.O. NUMBER: 78608

DRYER MODEL: HB3000 EMS

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

CONTENTS

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

CONTENTS PAGE

1.0 CONTENTS 1

2.0 INTRODUCTION 2

3.0 WARRANTY 2

4.0 HEAT REACTIVATED DRYER NOMENCLATURE 2

5.0 RECEIVING AND INSPECTION 3

5.1 INSPECTIONS

5.2 UNPACKING AND HANDLING

6.0 SAFETY AND OPERATION PRECAUTIONS 3

7.0 PRINCIPLES OF OPERATION 4

7.1 INTRODUCTION

7.2 DRYING CYCLE

7.3 REGENERATION CYCLE

7.3.1 BLOWER PURGE REGENERATION

7.3.2 BLOWER PURGE REGENERATION WITH SELECTABLE COOL SWEEP

7.3.3 HEATLESS PRESSURE SWING REGENERATION

7.4 TOWER REPRESSURIZATION

7.4.1 BLOWER PURGE REPRESSURIZATION

7.4.2 BLOWER PURGE REPRESSURIZATION WITH SELECTABLE COOL SWEEP

7.4.3 HEATLESS PRESSURE SWING REPRESSURIZATION

7.5 VALVES

7.6 CONTROLS

7.6.1 MICROPROCESSOR CONTROL USER INTERFACE

7.6.2 STATUS PANEL USER INTERFACE

7.6.3 MICROPROCESSOR CONTROL DISPLAY PARAMETERS

7.7 TIMING SEQUENCE

7.7.1 BLOWER PURGE TIMER CYCLE

7.7.2 BLOWER PURGE TIMER CYCLE WITH SELECTABLE COOL SWEEP

7.7.3 HEATLESS PRESSURE SWING TIMER CYCLE

7.8 RESTART MODES

7.8.1 MANUAL MODE (ZERO)

7.8.2 AUTO RESTART MODE (LAST)

7.9 OPERATING TIMES

8.0 ALARMS AND INDICATORS 8

8.1 MOISTURE INDICATOR (STANDARD)

8.2 HEATER HIGH TEMPERATURE ALARM WITH INTERLOCK (STANDARD)

8.3 HEATER FAILURE ALARM (STANDARD)

8.4 FAILURE TO SHIFT ALARM (STANDARD)

8.4.1 FAILURE TO REPRESSURIZE

8.4.2 FAILURE TO DEPRESSURIZE

CONTENTS PAGE

8.5 HIGH DEW POINT ALARM (INCLUDED WITH EMS)

8.6 ENERGY MANAGEMENT SYSTEM (EMS) (OPTIONAL)

8.7 ALARM LIST

8.8 HIGH OUTLET TEMPERATURE (OPTIONAL)

9.0 TECHNICIAN MODE 10

9.1 ENTERING TECHNICIAN MODE

9.2 OPERATING MODE

9.3 COOL SWEEP

9.4 HEATER TEMPERATURE SETPOINT (BLOWER PURGE MODE ONLY)

9.5 ENERGY MANAGEMENT SYSTEM (OPTIONAL)

9.5.1 ENABLING / DISABLING ENERGY MANAGEMENT SYSTEM

9.5.2 SETPOINT ADJUSTMENT

9.6 PURGE TEMPERATURE (INCLUDED WITH OPTIONAL EMS MODE)

9.7 RESTART MODE

9.8 EXTENDED HEATING (OPTIONAL, BLOWER PURGE MODE)

9.9 HIGH DEW POINT ALARM (OPTIONAL)

9.9.1 DESCRIPTION AND ACTIVATION

9.9.2 SETPOINT ADJUSTMENT

9.10 PROGRAM JOG

9.11 SHUTDOWN SEQUENCE

10.0 INSTALLATION AND INITIAL START-UP 14

10.1 EQUIPMENT APPLICATION GUIDELINES

10.2 LOCATING AND MOUNTING

10.3 PIPING

10.4 FILTRATION

10.5 DEW POINT TRANSMITTER INSTALLATION (OPTIONAL)

10.6 ELECTRICAL CONNECTION

10.7 START-UP

10.8 SHUT DOWN PROCEDURES

11.0 MAINTENANCE AND SYSTEM CHECK 17

11.1 SCHEDULED MAINTENANCE

11.2 PRE-FILTERS AND POST-FILTERS

11.2.1 THREADED FILTERS

11.2.2 FLANGED FILTERS

11.3 MUFFLER CHANGE-OUT PROCEDURE

11.4 NO-LOSS DRAIN VALVES

11.5 PILOT OPERATED ACTUATOR

11.6 DESICCANT CHANGEOUT PROCEDURE

12.0 TROUBLESHOOTING 20

13.0 GENERAL ARRANGEMENT 21

14.0 WIRING DIAGRAM 36

15.0 FLOW DIAGRAM 42

16.0 REPLACEMENT PARTS 46

17.0 ENGINEERING SPECIFICATIONS 49

The Ingersoll Rand Blower Purge Desiccant Dryers are designed to adsorb moisture from compressed air. The dryers are constructed with two towers, each containing desiccant beads, that alternate between online (drying) and offline (regenerating) modes, yielding a continuous stream of dry air at the dryer's outlet.

During normal operation, wet air passes through the on-line tower and water vapor from the air is adsorbed (collected) on the desiccant beads. While air is being adsorbed in the on-line tower, the moisture on the desiccant in the offline tower is removed by a process called desorption (regeneration). In standard blower purge operation, after an initial rapid depressurization, air from a blower on the dryer skid passes through a

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

heater and over the desiccant bed and carries the moisture off the bed and out the dryer's exhaust. With the dryer's Bi-Mode feature, the dryers may also be operated in a Heatless mode, which uses dry compressed air as the purge air source but does not require use of the heater or blower.

The continuous, alternating process of adsorption and desorption is controlled using a customized Programmable Logic Controller that switches the towers in a specific timed sequence. Very dry compressed air dew points are achieved through the continuous switching and operation of this dryer.

The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in material and workmanship for a period of twelve months from the date of placing the Equipment in operation or eighteen months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period, whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or, furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and operated such Equipment in accordance with good industry practices and has complied with specific recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the Equipment or any costs of labor performed by the Purchaser or others without Company's prior written approval.

The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are limited to those specifically stated within the Company's proposal. Unless responsibility for meeting such performance warranties are limited to specified tests, the Company's obligation shall be to correct in the manner and for the period of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER, EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE HERBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.

The Purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company in writing of its intention to do so. Any such use of Equipment will be at Purchaser's sole risk and liability.

Note that this is Ingersoll Rand standard warranty. Any warranty in force at the time of purchase of the equipment or negotiated as part of the purchase order may take precedence over this warranty.

2.0 INTRODUCTION

3.0 WARRANTY

4.0 HEAT REACTIVATED DRYER NOMENCLATURE

NOMINAL*

FLOW POWER / NEMA/ ELECTRICAL ELECTRICAL MECHANICAL PREFIX (SCFM) DEW POINT MAWP OPTION OPTION OPTION FILTERS HB 150-8000 4 = 460-3-60 / -40 H = NEMA 4 / 0 = Standard 0 = Standard 0 = Standard A = Filters Attached

6 = 575/3/60 / -40 150 psig MAWP N = EMS L = Filters Loose

* Nominal Flows indicated are for 100°F inlet temperature, 100°F ambient temperature and 100 psig compressed air pressure.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

5.1 INSPECTION

Upon receiving your Ingersoll Rand air dryer, please inspect the unit closely. If rough handling has been detected, please note it on your delivery receipt, especially if the dryer will not be immediately uncrated. Obtaining the delivery person's signed agreement to any noted damages will facilitate any insurance claims

5.2 UNPACKING AND HANDLING

WARNING

Under no circumstances should any person attempt to lift heavy objects without proper lifting equipment (i.e., crane, hoist, slings or fork truck). Lifting any unit without proper lifting equipment, can cause serious injury.

5.0 RECEIVING AND INSPECTION

Refer to the General Arrangement drawing for the appropriate means for lifting or moving the dryer. When lifting the dryer, ensure that no stress is applied to the piping or valving. Refer to Section 10.2 for locating and mounting of dryer.

6.0 SAFETY AND OPERATION PRECAUTIONS

Because an air dryer is pressurized and contains rotating parts, the same precautions should be observed as with any piece of machinery of this type where carelessness in operation or maintenance could be hazardous to personnel. In addition to obvious safety rules that should be followed with this type of machinery, safety precautions as listed below must be observed:

1. Only qualified personnel shall be permitted to adjust, perform maintenance or repair this air dryer.

2. Read all instructions completely before operating unit.

3. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before attempting to work or perform maintenance on the unit.

4. Do not attempt to service any part while machine is in an operational mode.

5. Do not attempt to remove any parts without first relieving the entire air system of pressure.

6. Do not operate the dryer at pressures in excess of its rating.

7. Do not operate the dryer without guards, shields and screen in place.

8. Inspect unit daily to observe and correct any unsafe operating conditions.

OSHA

Heading Descriptions

WARNING

“Warning” is used to indicate a hazardous situation which has some probability of death or severe injury. Warning should not be considered for property damage accidents unless personal injury risk is present.

CAUTION

“Caution” is used to indicate a hazardous situation which may result in minor or moderate injury.

NOTICE

“Notice” is used to indicate a statement of company policy as the message relates directly or indirectly to the safety of personnel or protection of property. Notice should not be associated directly with a hazard or hazardous situation and must not be used in place of “Danger,” “Warning,” or “Caution.”

NOTICE

The user of any air dryer manufactured by Ingersoll Rand, is hereby warned that failure to follow the above Safety and Operation Precautions may result in personal injury or equipment damage. However, Ingersoll Rand does not state as fact, nor does it mean to imply, that the preceding list of Safety and Operating Precautions is all inclusive, and further, that the observance of this list will prevent all personal injury or equipment damage.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

7.1 INTRODUCTION

As described in Section 2, water vapor is removed from compressed air by diverting air flow alternately between two towers filled with activated alumina desiccant. While one tower processes the compressed air stream adsorbing water vapor, the opposite tower regenerates by desorbing the water vapor and venting it to atmosphere.

The Microprocessor Controller provides the ability to select between blower purge or heatless regeneration. Both blower purge and heatless regeneration methods are described in the following sections.

NOTICE

The Microprocessor Controller must be in the OFF position prior to changing the mode (blower / heatless) of the dryer. After the change is made and the Microprocessor Control is subsequently turned ON, the dryer will be in the new mode of operation.

7.2 DRYING CYCLE

Saturated compressed air enters the dryer and is diverted to the appropriate tower by the Inlet Flow Valves. (Refer to the Process and Instrumentation Diagram.) The Right Tower Flow Valve is actuated to a closed position to prevent air flow from entering the regenerating tower. Simultaneously, the Left Tower Flow Valve is actuated to an open position allowing air flow to the drying tower. During this time, the Left Tower Purge Valve is actuated to a closed position, preventing the compressed air from venting to atmosphere. As the compressed air flows through the desiccant material in the left tower at pressure, removal of water vapor from the air stream begins to occur through adsorption. In the adsorption process, the desiccant material draws water vapor out of the compressed air and "holds" it until the left tower drying cycle is complete. Compressed air flows out of the tower for delivery to the process use. The Outlet Flow Check Valves provide air flow diversion to the outlet air connection of the dryer.

7.3 REGENERATION CYCLE

Previously adsorbed moisture removed from the process stream gets stripped or desorbed from the desiccant material in the regeneration process. The first stage of regeneration is tower de-pressurization. After the Inlet Flow Valves are switched to divert air flow away from the regenerating tower, the Depressurization Valve opens and the tower will be depressurized. Through depressurization, a significant portion of the previously adsorbed water vapor is stripped off of the desiccant material and exhausted to atmosphere.

CAUTION

Any time the dryer is switched between two operating modes, care must be taken to ensure the purge adjustment valve is adjusted correctly. Refer to the specification sheet in this manual for proper gauge setting.

7.3.1 BLOWER PURGE REGENERATION

In the blower mode, there is no dry compressed air used for regeneration. Ambient air is drawn into the blower intake and then discharged through the purge heater and through the regenerating tower. After tower depressurization, the heater and blower operate for 3 hours, 44 minutes. The blower continues to operate for ten minutes to cool the heater element.

7.3.2 BLOWER PURGE REGENERATION WITH SELECTABLE COOL SWEEP

With the Cool Sweep feature, which uses a portion of dried compressed air to cool the bed at the end of the regeneration cycle, the heater and blower operate for 2 hours and 57 minutes. The blower continues to operate for an additional ten minutes to cool the heater. The Repressurization Valve is then opened, allowing dry compressed air to pass through the regenerating tower for 48 minutes.

7.0 PRINCIPLES OF OPERATION

7.3.3 HEATLESS PRESSURE SWING REGENERATION

In the heatless mode, following depressurization, regeneration uses approximately 15% of the dry compressed air, expanded to atmospheric pressure to complete the desorption process. As shown on the P & ID, the compressed air exits the drying tower and a portion of the air flows through the Purge Adjustment Valve and the Purge Orifice. Once the air has passed through the Purge Orifice, it expands to atmospheric pressure and continues the regeneration process. Desorption occurs as the desiccant releases water vapor into the regeneration air and is exhausted through the Purge Valves. Note that in the Heatless Pressure Swing Mode, proper setting of the purge flow is necessary to achieve optimum dryer performance. Setting the purge flow too high will waste compressed air and if set too low, the dryer will not achieve dew point performance. The purge adjustment manifold consists of the purge adjustment valve, purge pressure gauge, and the purge orifice. Manually adjust the purge adjustment valve until the reading on purge pressure gauge matches the purge pressure setting listed on the tag attached to the gauge.

NOTICE

When operating dryer in standard Blower Purge mode, dryer may exhibit high discharge temperatures at tower switchover (300 °F) and dew point spikes (+20°F). This is considered normal operation for this equipment. Operator must insure that equipment located downstream of dryer be capable of tolerating these conditions.

7.4 TOWER REPRESSURIZATION

Upon completion of tower regeneration, and prior to changing the Inlet Flow Valve position to switch towers, the regenerated tower must be repressurized.

NOTICE

Failure to repressurize prior to tower switchover will result in shocking the desiccant material and cause premature desiccant dusting.

7.4.1 BLOWER PURGE REPRESSURIZATION

Three minutes prior to tower switch-over, the blower will be shut off and the Purge Valves and Depressurization Valves will close. The Repressurization Valve will then open, allowing air from the outlet of the dryer to pressurize the tower prior to switch-over. During normal tower regeneration, the Repressurization Valve is closed, so that the blower supplies the only source of regeneration air.

7.4.2 BLOWER PURGE REPRESSURIZATION WITH SELECTABLE COOL SWEEP

Three minutes prior to tower switch-over, the Purge Valves and Depressurization Valves will close. The Repressurization Valve will then open, allowing air from the outlet of the dryer to pressurize the tower prior to switch-over.

7.4.3 HEATLESS PRESSURE SWING REPRESSURIZATION

45 seconds prior to tower switch-over, repressurization is accomplished by closing the appropriate Purge Valve and the Depressurization Valve. When the Purge Valve closes, the regeneration air begins to pressurize the tower. In addition, the Repressurization Valve opens, allowing additional air from the outlet of the dryer to assist the purge air and to ensure adequate pressurization. During normal tower regeneration, is held closed so that the only source of air for regeneration passes through the purge adjustment assembly.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

7.0 PRINCIPLES OF OPERATION

7.5 VALVES

Actuated valves are two-way valves that are switched using double acting actuators. Each valve is actuated by a four-way solenoid valve as shown on the P & ID.

NOTICE

Actuated valves require 75 psi min. pressure for proper operation.

The Inlet Flow Valves are connected as normally open valves. When the dryer is de-energized, the solenoid valves for these valves supply air to the "open" port on the appropriate valve actuator.

Purge Valves are connected as Normally Closed valves. When the dryer is de-energized, the solenoid valves for these valves supply air to the "closed" port on the appropriate valve actuator.

Outlet Check Valves, as well as Purge Check Valves, are single direction check valves that will allow flow in the direction shown on the P&ID but not allow flow in the opposite direction. Valve positions must be changed accordingly for the appropriate mode selected.

7.6 CONTROLS

7.6.1 MICROPROCESSOR CONTROL USER INTERFACE

The Microprocessor Control display provides the user with the operating parameters and their corresponding values. When power is supplied to the dryer, the Microprocessor Control will illuminate and default to the "Standby" mode, displaying the "Press ON" prompt.

The following illustration summarizes the keypad functions.

Figure 1 - Microprocessor Controller

BUTTONS

• ON

Initiates PLC program. Begins system monitoring and valve switching functions.

• OFF

Stops PLC program. Stops valve switching functions. Initiates Shutdown Sequence. Opens Inlet Flow Valves. Closes Purge Valves.

• SELECT DISPLAY

Allows the user to scroll through the available displays. The last display selected will remain displayed as the default display.

• + / -

Allows user to increase set point values. Set point values cycle through a fixed range. Also allows entering negative numbers in Technician Mode.

• 

Allows user to step backwards to the previous level of the menu.

• RESET

Pressing once clears the local alarm indication and de-energizes the remote alarm contact for many alarm conditions. Should the alarm condition persist, the alarm will return after the alarm inhibit time has expired.

• SET

Permits the adjustment of parameters in TECHNICIAN MODE.

• ENTER

Used to accept changed parameters and set point values.

• TEST

Not used in Desiccant Dryer applications

• i

Restricted Level access for factory use only.



PRESS ON

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

7.6.2 STATUS PANEL USER INTERFACE

The status panel provides clear indication of dryer status via bright LED indicators. The following illustration summarizes the panel’s features:

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

7.0 PRINCIPLES OF OPERATION

Dryer ON (Green)

Left Tower Regeneration

(Yellow)

Left Tower Drying

(Yellow)

Dryer OFF / Alarm (Red)

Right Tower Regeneration (Yellow)

Right Tower Drying (Yellow)

Figure 2 - Status Panel

Heater Operation (Green)

Blower Operation

(Green)

NOTE: Ingersoll Rand solid state temperature controller modulates the heater repeatedly during the heating cycle. Pulsating of the heater LED will occur as a result and should be considered normal dryer operation.

7.6.3 MICROPROCESSOR CONTROL DISPLAY PARAMETERS

The Microprocessor Controller is capable of displaying a number of system parameters in the default CUSTOMER MODE. The following summarizes the parameters that can be accessed by depressing the SELECT DISPLAY button from the Microprocessor Controller. (Note that some displays are optional and may not appear on all models):

• Tower Status {LT DRY / RT REGEN or LT REGEN / RT DRY}: Provides visual confirmation of tower drying and regenerating status.

• Step Timer {ie STEP 4 TIME 120}: Information screen displaying the current step in the program and the time remaining for the displayed step.

• Dew Point Temperature (OPTIONAL) - {DEW POINT TEMP: XX}: When equipped with the optional EMS feature, provides accurate display of dryer outlet pressure dew point.

• Purge Status (OPTIONAL) - {PURGE / NO PURGE}: Indicates whether unit is currently consuming purging air. Requires EMS.

• Heater Status (BLOWER PURGE MODE ONLY) - {On / Off}: Indicates that the heater is being given a signal to heat the purge air.

• Blower Status (BLOWER PURGE MODE ONLY) - {On / Off}: Indicates that the blower is being given a signal to supply the purge air.

• Heater Temperature (BLOWER PURGE MODE ONLY) {HEATER TEMP: XX}: Indicates the heater temperature set point.

• Alarms {ALARM LIST - PRESS ENTER}: Depressing <ENT> at this prompt permits viewing of current alarm status and alarm history, which includes the time and date of the alarm occurrence.

• Operating & Purge Times - {OPERATING TIMES - PRESS ENTER}: Depressing <ENT> at this prompt provides access to the operating and purge hours of operation.

• Operating Mode {OPERATING MODE: HEATLESS / BLOWER PURGE}: HB dryers are capable of operating in Blower Purge and Heatless Pressure Swing modes. This display indicates mode of operation for dryer.

Once the last screen is displayed, depressing the SELECT DISPLAY button will return the display to the top of the list.

7.7 TIMING SEQUENCE

All timing functions are performed by Ingersoll Rand’s Microprocessor Controller, an advanced micro PLC designed exclusively for Ingersoll Rand dryers. The Microprocessor Controller is completely programmed at the factory and does not require any further adjustment. The standard timing cycle switches the Inlet Flow Valves, which alternates the drying tower. At the same time as the Inlet Flow Valve opens, the appropriate tower Purge Valve opens to begin the purge flow generation. Once the purge regeneration flow portion of the dryer cycle is complete, tower repressurization begins as previously described.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

7.0 PRINCIPLES OF OPERATION

7.7.1 BLOWER PURGE TIMER CYCLE

In the blower purge operating mode, the Microprocessor Control controls an eight-hour cycle. The tower switch-over occurs every four hours. After switch-over occurs, the regenerating tower depressurizes for 2 minutes. The optional EMS feature may reduce the heating time.

7.7.2 BLOWER PURGE TIMER CYCLE WITH SELECTABLE COOL SWEEP

The Cool Sweep feature makes use of approximately 8% of the dried compressed air for a portion of the drying cycle. Using dry purge air cools the regenerating bed, which results in a lower compressed air temperature at switchover as well as reduced dew point spikes. In this mode, after switch-over occurs, the regenerating tower depressurizes for 2 minutes. Once the tower is depressurized, the blower and heater operated as described in Section 7.3. The optional EMS feature may reduce the heating time.

7.7.3 HEATLESS PRESSURE SWING TIMER CYCLE

In the heatless operating mode, the Microprocessor Control controls a ten-minute cycle. The tower switch-over occurs every five minutes. Ten seconds after tower switch-over occurs, the regenerating tower depressurizes and tower regeneration occurs for four minutes and 15 seconds. At that time, tower repressurization begins.

7.8 RESTART MODES

The Microprocessor Controller includes a Shutdown Sequence that is activated when the dryer OFF button is depressed. This feature positions the valves to their failsafe position and resets the program and is the recommended method of shutting down the dryer. When the dryer is subsequently energized, the dryer starts at the beginning of the program. Should, however, power be cut to the dryer before the Shutdown Sequence has been initiated, the dryer can be configured to restart in one of two restart modes.

7.8.1 MANUAL MODE (ZERO)

Ingersoll Rand dryers are shipped from the factory in the Manual Mode. After power is re-supplied to the dryer, the user will be presented with the "PRESS ON" display. The valve switching and timing operations will only start once the ON button is depressed. In this configuration, to restart the dryer, the user must manually depress the ON button on the Microprocessor Control's control panel.

7.8.2 AUTO RESTART MODE (LAST)

In this mode, the dryer will re-start automatically once power is applied to the dryer. The Microprocessor Control will pick up where it left off in the program once power is applied.

7.9 OPERATING TIMES

In the CUSTOMER MODE, the Microprocessor Controller provides access to the operating hours of the dryer. The following describe the method to access and review the operating and purge hours for the dryer:

Depress the SELECT DISPLAY button until the OPERATING TIMES display appears.

OPERATING TIMES

PRESS ENTER

SELECT

DISPLAY

Depressing the ENTER button enters the OPERATING TIMES menu.

BEGIN TIMES

Depressing the SELECT DISPLAY button displays the cumulative operating hours of the dryer.

OPERATING HOURS

000000065

SELECT

DISPLAY

PURGE HOURS

000000009

SELECT

DISPLAY

ENTER

Depressing the SELECT DISPLAY button displays the cumulative hours the dryer has used purge air.

Depressing the ENTER button returns the display to the top of the OPERATING TIMES menu.

BEGIN TIMES

SELECT

DISPLAY

Depressing the  button returns the controller to the CUSTOMER MODE



OPERATING TIMES

PRESS ENTER

HEATER HOURS

000000009

SELECT

DISPLAY

Depressing the SELECT DISPLAY button displays the cumulative hours the heater has been energized.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

8.1 MOISTURE INDICATOR (STANDARD)

The moisture indicator senses a sample of the control air which is taken from the dryer outlet. The indicator provides a gross indication of dew point deterioration at the outlet of the dryer. Under normal operating conditions, the indicator is blue. In the event of a dryer malfunction or prolonged dryer shut down, it will turn gray in the presence of moisture.

8.2 HEATER HIGH TEMPERATURE ALARM WITH INTERLOCK (STANDARD)

The Heater High Temperature Alarm monitors the internal temperature of the heater housing. Should a component failure occur or system conditions result in the heater temperature rising above the alarm set point, the dryer will alarm. During the alarm condition, the heater is prevented from operating, the Microprocessor Control halts the program at the point where the alarm occurred and displays the condition in the Microprocessor Control LCD display. The dryer will be unable to be reset until the temperature of the heater has fallen below the alarm point. To reinstate the dryer, depress the RESET button on the Microprocessor Controller AND manually reset the Heater High Temperature Safety in the electrical enclosure. Note that the alarm condition will return should proper corrective action not be taken.

8.3 HEATER FAILURE ALARM (STANDARD)

This feature produces an alarm should the heater fail to generate heat at the beginning of the heating cycle. During the initial ten minutes of the heating cycle, the Microprocessor Controller monitors the heater temperature. Should the heater temperature fail to rise to 150 °F within the ten minute period, the Heater Failure Alarm will be triggered. During this alarm condition, power to the heater is removed and the program is halted. Depressing the RESET button on the Microprocessor Controller will reinstate the program and provided the heater problem has been remedied, continue with normal operation.

8.4 FAILURE TO SHIFT ALARM (STANDARD)

Ingersoll Rand Failure To Shift Alarm monitors the dryer sequencing functions to insure proper dryer operation by sensing the pressure in each tower via tower pressure switches. Should one of the following conditions occur, the Microprocessor Controller will communicate the alarm condition. There are several types of switching failure modes that can be detected by the Failure To Shift Alarm feature. They are as follows:

8.4.1 FAILURE TO REPRESSURIZE

At the end of the repressurization stage of the dryer operation, both towers should be at line pressure. Should the pressure switches indicate that both towers are not at line pressure, the Failure to Shift Alarm will activate and the Microprocessor Control will stop the program at its current position in the program. The user must depress the RESET button followed by the ON button, at which time the Microprocessor Control will start at the beginning of the program.

8.4.2 FAILURE TO DEPRESSURIZE

At the end of the depressurization stage of the dryer operation, the regenerating tower should be at atmospheric pressure. Should the pressure switches indicate that this is not the case, the Failure to Shift Alarm will activate and the Microprocessor Control will stop the program at its current position in the program. The user must depress the RESET button followed by the ON button, at which time the Microprocessor Control will start at the beginning of the program.

8.0 ALARMS AND INDICATORS

8.5 HIGH DEW POINT ALARM (INCLUDED WITH EMS)

The purpose of the High Dew Point Alarm is to provide the operator an alarm indication should the equipment fail to supply air at its designed pressure dew point. The EMS dew point sensor communicates the pressure dew point reading to the Microprocessor Controller. Should the pressure dew point rise above the alarm set point, the Microprocessor Controller will display the alarm condition on the controller screen.

8.6 ENERGY MANAGEMENT SYSTEM (EMS) (OPTIONAL)

EMS is an energy savings feature that matches moisture loading and regeneration energy usage. Drying equipment is typically operated below full flow rating and/or below maximum water loading capacity of the desiccant bed. The EMS option includes a dew point transmitter that transmits the outlet pressure dew point to the Microprocessor Controller. The Microprocessor Controller displays the outlet pressure dew point in real-time. The EMS feature utilizes the data communicated from the dew point sensor and extends the normal timed switching sequence in proportion to the moisture loading on the dryer. When the EMS feature is turned off, all switching sequences occur as described in Section 7.7. When the EMS feature is activated, the drying sequence is governed by the outlet pressure dew point as measured by the dew point sensor. When the sampled outlet dew point registers below the customer set point (-43°F default for -40°F dryers; -102°F on -100°F dryers), an immediate change in dryer operation will not be noticeable. The dryer will continue its normal regeneration process through tower re-pressurization. Once the tower is re-pressurized, both towers will be at line pressure but air will only flow through the tower indicated by the status panel. Tower switch over sequence is delayed until the dew point elevates above the EMS set point, at which point tower switch over will occur.

In addition to monitoring the outlet pressure dew point of the drying tower, the EMS feature monitors the temperature of the purge exhaust air on the regenerating tower. After a tower switch-over, and at the beginning of tower regeneration, the purge exhaust temperature will be relatively low (normally 90 to 110°F). The purge exhaust temperature will increase as desiccant regeneration progresses. As nearly all of the previously adsorbed moisture is driven off of the desiccant, the exhaust temperature will begin to rise. The timing for the temperature change will vary depending on moisture loading on the towers. When the purge exhaust temperature reaches 195°F, which indicates that the desiccant heating is complete, the Microprocessor Controller will remove power to the heater and subsequently the blower. If the Cool Sweep feature is activated, the Cool Sweep runtime will commence. Otherwise, the offline tower will repressurize and remain pressurized until tower switchover.

8.7 ALARM LIST

The Microprocessor Controller stores the 20 most recent alarm conditions. These alarms are stored with the type of alarm as well as the date and time the alarm occurred. This list can greatly facilitate troubleshooting the dryer and provide an indication of dryer operation during unattended service. The following describe the method to access and review the alarms stored in the Microprocessor Controller:

Depress the SELECT DISPLAY button until the ALARM LIST display appears.

ALARM LIST

PRESS ENTER

SELECT

DISPLAY

8.8 HIGH OUTLET TEMPERATURE (OPTIONAL)

This option provides continuous monitoring of the dryer discharge air temperature via a thermostat that senses the outlet air temperature during dryer operation. Should a high outlet temperature condition exist, the alarm is displayed on the Microprocessor Controller to alert maintenance personnel of a malfunction. This alarm does not interrupt the dryer program. Depressing the RESET button will clear the alarm provided the alarm condition has been addressed. Note that the alarm will clear automatically once the high temperature condition is corrected.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

Depressing the ENTER button enters the ALARM LIST menu.

BEGIN ALARMS

Depressing the SELECT DISPLAY button advances the menu to the current alarm status.

ALARM OFF

SELECT

DISPLAY

ENTER

8.0 ALARMS AND INDICATORS

Depressing the SELECT DISPLAY button will reveal the previous alarm condition(s), as well as the remaining available alarm placeholders for alarms. To EXIT the ALARM LIST, perform the following:

Depressing the  button returns the controller to the top of the ALARM LIST.

BEGIN ALARMS



Depressing the  button again returns the controller to the CUSTOMER MODE.

ALARM LIST

PRESS ENTER



Depressing the SELECT DISPLAY list displays the most recent of the alarms stored by the Microprocessor Control. Refer to the diagram at the end of this section for an explanation of the ALARM LIST Display.

FAIL TO SHIFT

TM 1635 DATE 1104

SELECT

DISPLAY

FAIL TO SHIFT

TM 1635 DATE 1104

Alarm Condition

Date of Alarm (Date-Month) Example shows April 11

Time of Alarm (Military Time)

Figure 3 - Alarm Screen Details

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

9.0 TECHNICIAN MODE

The Microprocessor Control provides a protected TECHNICIAN MODE to manipulate several parameters not accessible by the casual operator. Below is a list of parameters that can be accessed and manipulated by the technician in the TECHNICIAN MODE:

* NOTE: Setpoints indicated are adjustable ONLY when dryer is

equipped with the Energy Management System / Dew Point Display option. Setpoints are non-adjustable on dryers

9.1 ENTERING TECHNICIAN MODE

WARNING

TECHNICIAN MODE should only be entered by qualified service personnel. Altering the set points in TECHNICIAN MODE will have a significant effect on the operation of the dryer. Incorrect set points may damage dryer and cause potential serious injury.

To enter the TECHNICIAN MODE, perform the following keystrokes:

9.2 OPERATING MODE

As described in Section 7, Blower Purge Dryers come standard with the Bi-Mode feature, permitting the dryer to operate in a blower purge mode as well as a heatless pressure swing mode. To change the operation mode of the dryer, perform the following keystrokes:

NOTICE

CAUTION

When switching the dryer operation from Heatless to Blower Purge mode, the purge adjustment valve must be set to the closed position prior to operating dryer. Failure to do so may cause damage to dryer.

Parameter Display Set Point

OPERATION MODE

HTLS, BLOWER

PURGE COOL SWEEP COOL SWEEP OFF, ON HEATER TEMPERATURE

SETPOINT

HEATER TEMP 300 - 425

ENERGY MANAGEMENT SYSTEM (OPTIONAL)

EMS OFF, ON

ENERGY MANAGEMENT SYSTEM SETPOINT (OPTIONAL)

EMS SET POINT -76 - +68

PURGE TEMPERATURE PURGE TEMP OFF, ON RESTART MODE RESTART LAST, ZERO

EXTENDED HEATING EXTENDED HTG OFF, ON HIGH DEW POINT ALARM

ACTIVATION (OPTIONAL)

HI DEW POINT OFF, ON

Pressing the “2” and “3” buttons simultaneously enters the TECHNICIAN MODE.

BEGIN

TECHNICIAN MODE

SELECT

DISPLAY

Depressing SELECT DISPLAY scrolls through the available parameters.

SET OPMODE

HEATLESS

Depress the +/- button until the desired operating mode is displayed. Pressing SELECT DISPLAY saves the current selection.

SELECT

DISPLAY

Depress the SELECT DISPLAY button until the SET OPERATION MODE screen is displayed.

SET OP MODE

BLOWER PURGE

SET OP MODE

HEATLESS

9.3 COOL SWEEP

The Cool Sweep feature cools the regenerating bed prior to switchover. For applications requiring tight dew point control, using compressed air to cool the bed prior to switchover will provide a more consistent dew point and lower outlet compressed air temperatures. To enable the Cool Sweep mode, perform the following keystrokes:

Depress the +/- button until the desired set point is displayed. Pressing SELECT DISPLAY saves the current selection.

Depress the SELECT DISPLAY button until the COOL SWEEP screen is displayed.

COOL SWEEP

OFF

SELECT

DISPLAY

COOL SWEEP

9.4 HEATER TEMPERATURE SETPOINT (BLOWER PURGE MODE ONLY)

The Microprocessor Controller permits the user to adjust the temperature of the heater, thereby altering the regeneration temperature in the heated purge mode. Note that the value must be between 300 F and 425 F.

WARNING

The user is advised to only alter the regeneration temperature after being instructed to do so by Ingersoll Rand factory personnel. Improper or inappropriate manipulation of the heater temperature can result in degraded dryer performance, equipment damage and serious injury. Notify Ingersoll Rand Compressed Air Solutions prior to altering the heater temperature.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

9.0 TECHNICIAN MODE

Depress the SELECT DISPLAY button until the HEATER TEMPERATURE SET POINT screen is displayed.

HEATER TEMP

375

SELECT

DISPLAY

Depressing ENTER saves the selected set point.

SET

Pressing the SET button permits the value of the HEATER TEMPERATURE SETPOINT to be changed

HEATER TEMP

___

ENTER

Use the numbers on the keypad to enter the desired value for the HEATER TEMPERATURE setpoint.

HEATER TEMP

3__

HEATER TEMP

38_

HEATER TEMP

380

Use the numbers on the keypad to enter the desired value for the HEATER TEMPERATURE setpoint.

HEATER TEMP

380

Use the numbers on the keypad to enter the desired value for the HEATER TEMPERATURE setpoint.

NOTICE

New desiccant has a moisture holding capacity higher than the dryer’s design regeneration capacity. The desiccant ages in a three- to sixmonth time period at which point it stabilizes to an "aged" state. During this aging process at initial start-up or after desiccant replacement, the Energy Management System feature should be deactivated.

9.5.1 ENABLING / DISABLING ENERGY MANAGEMENT SYSTEM

The following illustrates the method of accessing and adjusting the Energy Management System feature:

Depress the +/- button until the desired set point is displayed. Pressing SELECT DISPLAY saves the current selection.

Depress the SELECT DISPLAY button until the ENERGY MANAGEMENT SYSTEM screen is displayed.

EMS:

OFF

SELECT

DISPLAY

EMS:

9.5.2 SETPOINT ADJUSTMENT

On dryers equipped with the optional Energy Management System the setpoint can be adjusted to match the dryers operation to the desired pressure dew point.

The following illustrates the method of adjusting the setpoint for the Energy Management System feature:

The following illustrates the method of adjusting the setpoint for the heater temperature:

9.5 ENERGY MANAGEMENT SYSTEM (OPTIONAL)

The Energy Management System option includes a dew point sensor that transmits the outlet pressure dew point to the Microprocessor Controller. The Microprocessor Controller displays the outlet pressure dew point in real-time. This option package also includes Energy Management System, an energy savings feature that matches moisture loading and regeneration energy usage. The Energy Management System feature utilizes the data communicated from the dew point sensor and extends the normal timed switching sequence in proportion to the moisture loading on the dryer.

When the Energy Management System feature is turned off, all switching sequences occur as described in Section 7.7. When the Energy Management System feature is activated, the drying sequence is governed by the outlet pressure dew point as measured by the dew point sensor. When the sampled outlet dew point registers below the customer set point (-43°F default for -40°F dryers), an immediate change in dryer operation will not be noticeable. The dryer will continue its normal regeneration process through tower re-pressurization. Once the tower is re-pressurized, both towers will be at line pressure but air will only flow through the tower indicated by the status panel. Tower switch over sequence is delayed until the dew point elevates above the Energy Management System setpoint, at which point tower switch over will occur.

To enter a negative number, depress the +/- button. Otherwise, proceed to the next step.

Depress the SELECT DISPLAY button until the EMS SET POINT screen is displayed.

EMS SET POINT

-43

SELECT

DISPLAY

EMS SET POINT

-___

SET

Pressing the SET button permits the value of the EMS SETPOINT to be changed

EMS SET POINT

___

Use the numbers on the keypad to enter the desired pressure dew point temperature for the EMS setpoint.

EMS SET POINT

-4__

Use the numbers on the keypad to enter the desired pressure dew point temperature for the EMS setpoint.

EMS SET POINT

-41_

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

Depressing ENTER saves the selected set point.

ENTER

EMS SET POINT

-41

NOTICE

The Energy Management System set point should not be lower (wetter) than the dew point adjuster setting. Failure to do so will prevent the Energy Management System feature from operating. In addition, when operating in Energy Management System, the purge flow adjuster should be set to 100%.

9.6 PURGE TEMPERATURE (INCLUDED WITH OPTIONAL EMS MODE)

On dryers equipped with EMS, the temperature of the purge exhaust is monitored and displayed on the Microprocessor Controller. After a tower switch-over, and at the beginning of tower regeneration, the purge exhaust temperature will be relatively low (normally 90 to 110°F). The purge exhaust temperature will increase as desiccant regeneration progresses. As nearly all of the previously adsorbed moisture is driven off of the desiccant, the exhaust temperature will begin to rise. The timing for the temperature change will vary depending on moisture loading on the towers. When the purge exhaust temperature reaches 195°F, which indicates that the desiccant heating is complete, the Microprocessor Controller will remove power to the heater and subsequently the blower. On standard units, the towers will then repressurize and remain repressurized until the tower switchover sequence is initiated. On dryers with the optional Cool Sweep feature, the Cool Sweep routine will commence. After cooling, the Purge Valves close and the Repressurization Valve opens. The off-line tower remains pressurized until the tower switchover sequence is initiated. Activation of the Purge Temperature feature is via the Microprocessor Controller.

The following illustrates the method of accessing and activating the Purge Temperature feature:

Depress the +/- button until the desired set point is displayed. Pressing SELECT DISPLAY saves the current selection.

Depress the SELECT DISPLAY button until the PURGE TEMPERATURE screen is displayed.

PURGE TEMP:

OFF

SELECT

DISPLAY

PURGE TEMP:

To change the start mode from its current selection to the alternate setting, depress the +/- button until the desired set point is displayed. Pressing SELECT DISPLAY saves the current selection.

Depress the SELECT DISPLAY button until the START MODE screen is displayed.

RESTART

ZERO

SELECT

DISPLAY

RESTART

LAST

NOTICE

The restart modes will only effect restarting should power be unexpectedly removed from the dryer. After proper shut down, the dryer will require the user to depress the ON button to initiate the operation of the dryer program.

9.8 EXTENDED HEATING (OPTIONAL, BLOWER PURGE MODE)

On dryers equipped with the Energy Management System option, the dryer may be operated in an extended heating mode. In this mode, the heating cycle is extended while the Energy Management System function prolongs the drying cycle. This feature is particularly useful when operating the dryer with new desiccant. As described earlier in Section 2, new desiccant has the ability to adsorb more moisture than the dryer can desorb in a fixed regeneration cycle. With the Extended Heating operation, the Energy Management System feature can be used immediately without the need to age the desiccant. This feature is provided only when the dryer is equipped with the Energy Management System. To enable the Extended Heating mode, perform the following keystrokes:

Depress the +/- button until the desired set point is displayed. Pressing SELECT DISPLAY saves the current selection.

Depress the SELECT DISPLAY button until the EXTENDED HEATING screen is displayed.

EXTENDED HEATING

OFF

SELECT

DISPLAY

EXTENDED HEATING

Depress the SELECT DISPLAY button until the HIGH DEW POINT screen is displayed.

HIGH DEW PT

OFF

SELECT

DISPLAY

9.0 TECHNICIAN MODE

9.7 RESTART MODE

Ingersoll Rand dryers can be configured to restart in one of two operating modes. As described in Section 7.8, the dryer may be configured for Manual operation (factory default) or Auto Restart, which permits the dryer to operate automatically once power is re-applied to the dryer after a power failure. The following illustrates the method of accessing and adjusting the different start modes for the dryer:

9.9 HIGH DEW POINT ALARM (OPTIONAL)

9.9.1 DESCRIPTION AND ACTIVATION

When the dryer is equipped with the optional Energy Management System feature, the dew point sensor transmits the dew point to the Microprocessor Control Should the outlet pressure dew point exceed the customer specified set point, High Dew Point Alarm will activate.

The following illustrates the method of activating the High Dew Point Alarm feature:

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

Depress the +/- button until the desired set point is displayed. Pressing SELECT DISPLAY saves the current selection.

HIGH DEW PT

9.9.2 SETPOINT ADJUSTMENT

On dryers equipped with the optional Energy Management System, the High Dew Point Alarm setpoint can be adjusted as follows.

The following illustrates the method of adjusting the setpoint for the High Dew Point Alarm feature:

9.0 TECHNICIAN MODE

To enter a negative number, depress the +/- button. Otherwise, proceed to the next step.

HI PDP SETPOINT

-___

Depressing ENTER saves the selected set point.

ENTER

Use the numbers on the keypad to enter the desired pressure dew point temperature for the EMS setpoint.

HI PDP SETPOINT

-2__

Use the numbers on the keypad to enter the desired pressure dew point temperature for the HIGH DEW POINT ALARM setpoint.

HI HUMID SETPOINT

-21_

HI PDP SETPOINT

-21

9.10 PROGRAM JOG

All heated purge and blower purge dryers come equipped with a Program Jog feature that is accessible via the Microprocessor Controller. This feature allows the dryer cycle to be accelerated for troubleshooting and routine inspection purposes. By accessing the Program Jog routine in the Microprocessor Control, the customer can advance the program to the next program step. Note that the program advance feature will not advance through all steps of the program.

WARNING

When the Program Jog is initiated in the middle of the heating cycle, advancing the program without allowing normal tower cool down will result in an outlet air temperature that may exceed 300°F. As such, proper precautions must be taken to protect downstream equipment from high temperature exposure.

NOTICE

During the Program Jog routine, the display may show intermediate steps in the program that are not active in the current program set up. This should be considered normal operation.

The Microprocessor Controller will only permit the jog function during specific stages of the program. Should the program be at a stage where the program can not advance, the following will be displayed:

Depress the SELECT DISPLAY button until the HIGH DEW POINT SET POINT screen is displayed.

HI PDP SETPOINT

-10

SELECT

DISPLAY

SET

Pressing the SET button permits the value of the HIGH DEW POINT ALARM SETPOINT to be changed

HI PDP SETPOINT

___

Depress the SELECT DISPLAY button until the JOG MODE display appears. The WAIT prompt will appear should the program not be able to advance at this stage.

JOG MODE

WAIT

SELECT

DISPLAY

Should the program be at a stage whereby the Microprocessor Control permits the jog feature, the following will be displayed:

Depress the SELECT DISPLAY button until the JOG MODE display appears. The PRESS ENTER prompt will appear, along with the current step and remaining time, should the program be able to advance at this stage.

JOG: ENT TO JOG

STEP 6 TME10699

Depressing the ENTER button advances the program to the next step. The display will indicate the next step has been initiated.

JOG MODE

STEP 8 TME00550

ENTER

9.11 SHUTDOWN SEQUENCE

Pressing the OFF button turns the dryer off and initiates a 30 second shutdown sequence that repressurizes the offline tower, and leaves both inlet flow valves open and both purge valves closed.

NOTICE

The Program Jog advances steps #6, #8, #20 & #22, which are the longest program steps. The balance of the steps are not advanced in Program Jog Mode.

NOTICE

To exit the TECHNICIAN MODE, press “Select Display” key to the initial “SET OPMODE” screen or “BEGIN TECHNICIAN MODE” screen and depress the  button to return to the CUSTOMER MODE.

NOTICE

The High Dew Point Alarm set point should not be greater than the Energy Management System set point. Failure to do so will result in an alarm indication. Ingersoll Rand recommends setting the High Dew Point Alarm at least 10°F wetter than the Energy Management System setpoints.

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

10.0 INSTALLATION AND INITIAL START-UP

10.1 EQUIPMENT APPLICATION GUIDELINES

Ingersoll Rand Regenerative air dryers are shipped complete with desiccant up to and including model HB2100. On larger units, the desiccant is packaged separately for ease in handling. Refer to Section

11.6 for desiccant fill procedures.

To achieve the best dryer performance, carefully check that the design and installation requirements outlined below are satisfied.

Ingersoll Rand dryers are available with an operating range from 75 150 PSIG. Air available for your usage will vary with operating pressure. The maximum design pressure of the standard Desiccant Dryers is 150 PSIG. For units that require higher operating pressures, consult your Ingersoll Rand representative.

Dryers are sized according to flow and pressure drop, not pipe size. The difference between the inlet and the outlet flow is the amount of purge air required. This air is exhausted to atmosphere and is not available for use downstream. Make certain air supply to dryer meets air demand plus purge air requirements.

NOTICE

The standard dryer is not rated for any gas other than air.

NOTICE

Ingersoll Rand recommends that the mufflers be cleaned after initial startup to remove any desiccant dust generated during shipment. After running dryer for initial 30 minute period, de-energize / depressurize dryer and remove mufflers. Disassemble and clean the removable insert inside the muffler core. Reinstall mufflers prior to operating dryer.

10.2 LOCATING AND MOUNTING

The dryer must never be installed where air and/or ambient temperature exceeds 120°F or drops below +35°F. Locate dryer to avoid extremes of heat and cold from ambient or other conditions. Where applicable, dryer towers may be insulated to reduce heat loses. Avoid locating dryer outside or where it is exposed to the elements.

The dryer, or any air system component, must be located to avoid exposure to pulsation in the compressed air as well as possible surges due to fluctuating demand. In addition, care must be used to minimize exposure to vibration transmitted through mounting pads or piping.

Provide adequate space around the dryer for normal maintenance requirements and service.

If the dryer is shipped with the desiccant packaged separately, install the desiccant after locating and mounting. Desiccant has been provided separately to minimize handling difficulty and placing unnecessary stress on the dryer assembly.

Bolt the dryer to the foundation using the bolt holes provided in the base frame. Anchor bolts should project a minimum of 3.5 inches above the foundation and allow proper nut and washer assembly.

10.3 PIPING

Pipe the compressed air lines to the inlet and outlet connections. Locate the pre-filters as close as possible to the dryer. Ensure the positioning allows for ease of servicing.

Note that the wet air inlet is located at the dryer's upper manifold and the dry outlet air is located at dryer's lower manifold. In situations where air supply is required 24- hours a day (it is undesirable to interrupt the airflow), a three-valve bypass system is recommended to bypass the dryer. To keep pressure drop at a minimum, use the fewest elbows necessary

Once all piping has been connected all joints, including those on the dryer, should be soap bubble tested at line pressure to ensure no joints have been damaged in transit and site placement.

10.4 FILTRATION

It is important that a pre-filter and a post-filter be provided in your dryer installation. These filters are included with each dryer. They are mounted on model HB1500 and smaller.

NOTICE

All dryers must have proper filtration. Liquid water and oil must be removed before the air enters the dryer. Ensure separators, pre-filters and drains are in good working order. Failure to do so will void warranty.

It is recommended that a mechanical separator be installed immediately preceding the pre-filter to remove the bulk liquid and entrained water.

Coalescing pre-filters, located before the dryer, protect desiccant beds from contamination by oil, entrained water, pipe scale, etc., thereby, extending dryer desiccant life. Locate pre-filters as close to dryer as possible. FAILURE TO PROVIDE AND MAINTAIN A HIGH

EFFICIENCY COALESCING PRE-FILTER WILL VOID DRYER WARRANTY.

Post-filters, located after the dryer, help eliminate the possibility of desiccant dusting carrying over into the air system.

WARNING

High temperature filters must be used to prevent rupture possibility in the event dryer failure should occur. Consult your Ingersoll Rand representative for appropriate filter selection.

10.5 DEW POINT TRANSMITTER INSTALLATION (OPTIONAL)

On dryers equipped with EMS, the dew point transmitter is shipped in a separate container within the electrical enclosure to protect the transmitter during shipment. Prior to using the EMS feature, the transmitter must be installed in the sensor block located on the side of or behind the electrical enclosure and the transmitter cable fastened to the sensor. Note that the transmitter should only be installed when the dryer is ready to be commissioned.

To install the Dew Point Transmitter:

• Remove Transmitter from original packaging.

• Verify that Washer is placed below Transmitter hex.

• Thread the Transmitter into the Sensor Block as shown.

• Attach the Transmitter Cable to the Transmitter. Be sure to fully engage the Transmitter Cable Securing Screw into the mating thread in the Transmitter.

HB Series Desiccant Dryer Models 150-8000

ingersollrandproducts.com

120.26 Dryer - Operation, Installation, Maintenance Manual, and Parts

+ 35 hidden pages

Ingersoll-Rand 150-8000 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual