Reading this user manual will fully familiarize you with the Ingersoll-Rand adsorption
dryer. You will be better able to run this equipment in accordance with its intended use.
This manual contains important information for safe, proper and economic dryer
installation, start-up, operation and maintenance. Always keep it within reach where the
adsorption dryer is being used.
It is necessary to follow all instructions as written. Careful reading will avert danger,
avoid unnecessary downtime, and minimize work for yourself and wear on the
equipment.
In addition to carefully reading this technical manual in its entirety, you must understand
your National, State and local rules and regulations regarding safety in the workplace,
their necessary precautions and procedures.
Each person responsible for the set-up, start-up, operation, maintenance or repair of
this adsorption dryer must have first read and understood this user manual – including
all the safety tips.
NOTE: Ingersoll-Rand recommends that installation, start-up and maintenance
be carried out by its factory-trained technicians in a regularly scheduled,
site-dedicated program. This will ensure the safety of personnel, the
integrity of equipment and the surety of warranty coverage.
1.3.1 Identification of Signs and Symbols in this Manual.....................................................................................2
1.3.2 General Safety Tips for Assembly, Inspection and Maintenance.................................................................3
1.4 TECHNICAL DATA SHEET ....................................................................................................................................4
1.4.1 Models TZE400 to TZE820 ..........................................................................................................................4
1.4.2 Models TZE1000 to TZE1800......................................................................................................................5
1.4.3 Models TZE2100 to TZE3500......................................................................................................................6
1.6 TRANSPORT .........................................................................................................................................................8
2.5 EMS CONTROL CONNECTION ...........................................................................................................................12
3.1 GENERAL OPERATING PRINCIPLES ....................................................................................................................13
3.1.1 Dryer Program Steps .................................................................................................................................14
3.2 OPERATOR CONTROLS / LOW-VOLTAGE CONTROL PANEL ...............................................................................16
3.2.1 Dryer Status ...............................................................................................................................................18
3.2.2Alarm Information .....................................................................................................................................19
3.2.4 Heater Sheath Information ........................................................................................................................20
3.2.5 Heater Outlet Information .........................................................................................................................21
3.2.6 Regeneration Outlet Information ...............................................................................................................21
3.2.7 Dryer Off, Dryer On, EMS On – 3-Position Switch..................................................................................21
3.2.8 Status Lamps..............................................................................................................................................22
4.2 CHANGING THE FILTER ELEMENT......................................................................................................................28
4.3 REPLACEMENT OF THE DESICCANT ...................................................................................................................29
5. PARTS LISTINGS ...............................................................................................................................................31
5.1 PARTS LIST FOR TZE400 TO TZE650................................................................................................................31
5.2 PARTS LIST FOR TZE820 TO TZE1225..............................................................................................................32
5.3 PARTS LIST FOR TZE1500 TO TZE2100............................................................................................................33
5.4 PARTS LIST FOR TZE2500 TO TZE3500.............................................................................................................34
6. FAULTS AND TROUBLESHOOTING .............................................................................................................38
6.1 DEWPOINT HAS DETERIORATED .............................................................................................................38
6.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE ...................................................................................39
6.3 PRESSURE DROP TOO HIGH .......................................................................................................................39
This adsorption dryer includes the latest technology and safety features. Its use,
however, can endanger life and limb and can lead to considerable damage to the
equipment and other material assets if:
• it is operated by personnel not instructed in its use,
• it is improperly used,
• it is improperly maintained or serviced.
Furthermore, ignorance of its use and proper service can result in the loss of any claim
for damage.
This adsorption dryer is designed for neutral media (such as air or nitrogen) which is
free of aggressive water, oil and solid elements. Ingersoll-Rand accepts no liability for
corrosion damage or malfunctions caused by aggressive media.
Applications other than those mentioned in this manual must be agreed to by IngersollRand and confirmed in writing.
Ingersoll-Rand reserves the right to make changes at any time as may be necessary for
increasing safety or efficiency, or In the interests of further product development.
1.2 PRODUCT INFORMATION
The adsorption dryer is used for the purpose of drying compressed air and other gases
according to its contracted design. Depending on certain conditions at the inlet, it
provides pure, dry and oil-free compressed air or gases. The standard model of
adsorption dryer is equipped with two desiccant vessels and a prefilter and afterfilter.
This specific model of dryer includes an Energy Management System (EMS) that
provides automatic monitoring and control of the work/regeneration cycle to optimize
equipment efficiency. This manual includes references to optionally available Low Dew
Point (LDP) and 3-valve bypass (3V) systems/assemblies which may or may not be
provided. Selected options included with this dryer are indicated on the cover page by
an “X” mark in the box.
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USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006
1.2.1 PRESSURE VESSEL REGULATIONS
The pressure vessels are designed and built to meet the American Society of
Mechanical Engineers (ASME) standards. They fulfill the test of the certifying procedure
and carry the ASME symbols U or UM.
RANGE OF APPLICATION
Design Pressure Max: 150 psig
Design Temperature
Max: 500 °F (260 °C)
Min: -20 °F (-29 °C)
1.2.2 LEAK TEST
Each Ingersoll-Rand adsorption dryer is subjected to, and passes, a leak test prior to
shipment.
1.3 SAFETY INSTRUCTIONS
This manual contains basic tips which must be followed during set-up, operation and
servicing. It is of utmost importance that it be read by the assembly technician before
installation and start-up as well as by the specialist/operator in charge. It must always
be within reach at the place where the adsorption dryer is being used.
1.3.1 IDENTIFICATION OF SIGNS AND SYMBOLS IN THIS MANUAL
The safety tips contained in this manual, whose disregard could endanger people and
equipment, are indicated by a general danger sign and the additional markings Danger!
or Attention! or Warning!
Danger! / Attention!
Safety sign in accordance with DIN 4844 - W9
Warning – high voltage!
Safety sign in accordance with DIN 4844 - W8
Safety tips printed directly on the adsorption dryer must be heeded at all times and must
be kept completely legible.
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USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006
1.3.2 GENERAL SAFETY TIPS FOR ASSEMBLY, INSPECTION AND MAINTENANCE
The purchaser is to ensure that all assembly, maintenance and inspection work is
carried out by personnel qualified to do it.
The personnel involved in assembly, operation, maintenance and inspection must have
the corresponding qualifications to do this work. Areas of responsibility and supervision
of the personnel must be clearly established by the purchaser. Should the personnel
not possess the necessary knowledge, then they must be instructed. If need be, this
training may be carried out by the manufacturer/supplier at the request of the purchaser.
Further, the purchaser is to ensure that all personnel completely understand and follow
the content of this manual.
Attention!
• Never make structural changes to the adsorption dryer
• Only use recommended spare parts as listed in section 5
• Never weld on a pressure vessel or change it in any way
• Carry out maintenance only when the adsorption dryer is OFF,
depressurized and disconnected from the electric power supply.
Danger!
• Review the Material Safety Data Sheet (MSDS) provided with the
desiccant
• Wear protective clothing and goggles when working with the
desiccant
• If desiccant comes into contact with the eyes, rinse eyes
immediately with a lot of clear water
• If the desiccant is spilled, clean up without causing swirls of dust
• In case of fire, there is no restriction on the use of fire extinguishing
material; the reaction with water and foam is defined as strong
• A mask must be worn whenever handling desiccant.
Inlet Connection 3 in RF FLG 3 in RF FLG 3 in RF FLG 4 in RF FLG
Outlet Connection 3 in RF FLG 3 in RF FLG 3 in RF FLG 4 in RF FLG
Recommended Prefilter
Recommended Afterfilter
Pilot Air Filter
Standard Electric Rqmt 460 Vac/3-phase/60 Hz
Heater 17 kW 21 kW 25 kW 28 kW
Cycle Time
Outlet Pressure Dewpoint -40°F PDP (-100°F LDP)
EMS Control Setting -40°F PDP (-100°F LDP)
High Humidity Alarm -35°F PDP (-95°F LDP)
Pressure Switch Setpoints
Purge Pressure Setting 70 psig 60 psig 65 psig 70 psig
Low Purge Alarm Setpoint
Heater Outlet Set Point 425°F
End Heating Temperature 180°F
End Cooling Temperature 120°F
Heater Sheath Alarm 1000°F
Flow Directions Downward Drying - Upward Regeneration
The specific size/model of your dryer was selected to meet performance requirements
based on an analysis of air supply and demand capacities. The model selection chart
provided following should confirm that this dryer remains suitable for its intended use.
The table following is based on -40oF PDP, 8-hour cycle, activated alumina and average
inlet air flow for non-LDP-equipped dryers with EMS. Consult our factory for rated air
flows on LDP-equipped dryers.
Rated inlet air flow (scfm) at given pressures (psig)
(Based upon 100oF inlet air temperature)
Higher pressures are optionally available. Consult factory.
To correct for an inlet temperature other than 100oF, multiply dryer capacity by the
temperature correction factor listed below.
CORRECTION FACTOR FOR INLET TEMPERATURE
TEMPERATURE
DEGREES F
Correction Factor
Example: To size for an inlet flow of 950 SCFM @ 105 F and 110 psig.
1. Select model that produce at least 950 SCFM at 110 psig. This case would be the TZE1000 which
can dry 1140 SCFM.
2. Multiply pressure corrected flow by the temperature correction factor to obtain the flow of the dryer
corrected for pressure and temperature:
1140 X (0.85) = 969 SCFM
3. Confirm model selection. Model TZE1000 can flow 969 SCFM at the inlet conditions specified;
requirements of 950 SCFM are less: TZE1000 is correct.
80 90 100 105 110 115 120
1.1 1.1 1.0 0.85 0.69 0.565 0.455
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USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006
NOTE: Settings for EMS: Standard Dryers: EMS Control -40°F (-40°C)
High Humidity -35°F (-35°C)
LDP Dryers: EMS Control -100°F (-74°C) High Humidity -95°F (-69°C).
1.5 OVERLOADING
Attention! Protect the adsorption dryer from overloads!
The adsorption dryer can become overloaded if:
• The flow volume of the medium to be dried increases
• The temperature of the air at entry and, correspondingly, its
humidity increases
• The minimum operating pressure decreases
• The prefiltration and separation of impurities are not sufficient or the
filter drain fails
• Introduction of oil into the air stream.
1.6 TRANSPORT
Immediately upon delivery of the adsorption dryer, it must be checked for any damage
that may have occurred during transport. If necessary, the damage must be recorded
on the shipping waybill/receipt. Liability for such damage usually rests with the shipper.
Contact Ingersoll-Rand to arrange for any required service or replacement parts.
Attention!
For transport within your company site, only the skids of the adsorption
dryer may be used. Lifting at any other points on the equipment will void
the warranty and damage the equipment.
1.7STORAGE
If the adsorption dryer is to be stored for a long period of time, its place of storage must
be dry and free of dust. The ambient temperature cannot go below 33°F (+1°C).
1.8USE OF A PREFILTER AND AFTERFILTER
In order to prevent droplets of condensate, oil and dirt from getting into the desiccant, a
Ingersoll-Rand prefilter must be installed upstream of the adsorption dryer. An oil film
on the desiccant reduces the drying capacity and the dewpoint. In order to prevent
breakdown in downstream consumers caused by material that has been abraded from
the desiccant bed, a Ingersoll-Rand afterfilter must be mounted behind the adsorption
dryer. Since no condensate accumulates in the afterfilter, this filter is always equipped
with a manual vent valve.
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USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006
Both filters are equipped with a differential pressure indicator to ensure a direct display
of the degree of contamination of the filter elements.
2. INSTALLATION
2.1 GENERAL
Ensure that the installation site is free of dust, dirt and litter. The site floor must be level
and strong enough to support the equipment. The site itself must be an heated
environment (minimum 50°F) to ensure proper operation and warranty protection.
Ensure that the Ingersoll-Rand adsorption dryer is carried only by its skid base frame.
The adsorption dryer must be positioned so that the side from which it is to be operated
is easily accessible. The piping is to be connected at a slightly downward slope. Install
isolation valves on the inlet and outlet sides of the adsorption dryer. Also, a bypass
pipe with an additional isolation valve should be mounted onto the adsorption dryer to
allow for an uninterrupted supply of compressed air in case the adsorption dryer
requires maintenance or repair. The bypass assembly is optionally provided (see
paragraph 1.2) or can be customer furnished. If vibrations occur at the installation site,
the adsorption dryer skid frame is to be placed onto vibration dampers.
2.2 MECHANICAL ASSEMBLY
• The equipment should be located in an area with adequate clearances for
service. An overhead clearance of not less than two feet above each desiccant
tower is required for loading of the desiccant.
• Remove all protective shipping crates, flange covers, etc.
• Using the mounting holes provided on the skid, anchor the dryer to a solid, level
foundation designed to support the equipment.
• Do not hydrostatically test the pressure vessels. All TZE dryer pressure vessels
and welded piping are hydrostatically tested at one and one-half times the design
pressure after fabrication and before assembly.
• Desiccant for models TZE820 and up is shipped loose and must be installed on
site. Refer now to paragraph 4.3 for instructions on installing the desiccant.
• If the equipment is installed in a high traffic area, protective barriers may be
required to prevent possible damage of equipment and to prevent contact with
hot surfaces.
• Due to vibration during shipping some tube fittings may have loosened.
Therefore, inspect all connections and tighten if required.
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USER MANUAL
TZE400 to TZE3500 with EMS
REV 10 – 23 February 2006
• Ensure that the inlet and outlet connections to and from the dryer are made using
the correctly rated fittings and piping to meet the design conditions.
NOTE: System isolation and by-pass valves should be installed. If not supplied
by Ingersoll-Rand as part of the equipment package (i.e., 3V option – see
paragraph 1.2), they should be supplied and installed by others. Ensure
that this bypass facility is installed so that future servicing of the dryer
system off-line may take place.
• Full flow relief valves to protect the system from over-pressure must be
customer-provided in accordance with local regulations.
• The purge exhaust on the TZE650 and smaller dryers is equipped with an
exhaust muffler. If required, the muffler can be removed and purge exhaust can
be connected to a vent header. Follow recommendations for pipe sizing listed
below.
• The purge exhaust connection on the TZE820 and larger dryers must be
connected to a vent header. To ensure satisfactory regeneration of the desiccant
chambers, the purge exhaust piping should be sized as follows to prevent backpressure build up.
EXTENDED LENGTH PIPE SIZE REQUIRED
TO 10 FEET SAME SIZE AS DRYER EXHAUST
TO 25 FEET 1 SIZE LARGER THAN DRYER EXHAUST
TO 50 FEET 2 SIZES LARGER THAN DRYER EXHAUST
TO 100 FEET 3 SIZES LARGER THAN DRYER EXHAUST
Caution!
The noise at the outlet of the exhaust header may exceed 100 dBa, and
the flow velocity will be high. Exhaust must be piped to an area where
these flow velocities and noise levels can be safely tolerated.
2.3 FILTER INSTALLATION
2.3.1 PREFILTER INSTALLATION (SHIPPED LOOSE)
• Mount prefilter in such a way as to allow clearance for the element installation
and removal.
• Locate the prefilter as close to the dryer inlet connection as possible.
• The filter must be piped so that the correct flow direction indicated on the filter is
followed.
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