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INSTRUCTION MANUAL
IBP Series
Blower Purge Desiccant Compressed Air Dryer
FORM NO.: 3158144 R EVISION: 07/2014 READ AND U NDE RSTAND THIS MANUAL PRI OR TO OPERATING OR SERVICI NG THI S PRODUCT.
MODELS
IBP500
IBP600
IBP750
IBP900
IBP1050
IBP1300
IBP1500
IBP1800
IBP2200
IBP2600
IBP3200
IBP3600
IBP4300
RATED
FLOW
500 SCFM
600 SCFM
750 SCFM
900 SCFM
1050 SCFM
1300 SCFM
1500 SCFM
1800 SCFM
2200 SCFM
2600 SCFM
3200 SCFM
3600 SCFM
4300 SCFM
MODEL
REFERENCE
500
600
750
900
1050
1300
1500
1800
2200
2600
3200
3600
4300
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Contents
1.0 General Safety Information ........................... 1
2.0 Receiving, Storing, and Moving ..................... 1
3.0 Description .................................................... 2
4.0 Installation ..................................................... 2
5.0 Instrumentation .............................................. 7
6.0 Operation ....................................................... 11
7.0 Maintenance .................................................. 28
8.0 Troubleshooting ............................................. 30
DRAWINGS
Electrical Schematic – 460VAC, 3 phase .............. 33
Electrical Schematic – 575VAC, 3 phase .............. 34
Electrical Data – Fusing & Wire Sizing .................. 35
P&ID Schematic - Models 500 through 600 ......... 36
P&ID Schematic - Models 750 through 4300 ....... 38
REPLACEMENT PARTS
Models 500 through 600 ........................................ 40
Models 750 through 1800 ...................................... 42
Models 2200 through 2600 .................................... 44
Models 3200 through 4300 .................................... 46
WARRANTY
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1.0 General Safety Information
This equipment is designed and built with safety as a
prime consideration; industry-accepted safety factors
have been used in the design. Each dryer is checked at
the factory for safety and operation. All pressure vessels which fall under the scope of ASME Section VIII,
are hydrostatically tested in accordance with the latest
addenda. A factory-installed safety relief valve is standard
on each dryer.
WARNING — The following safety rules must be
observed to ensure safe dryer operation. Failure to
follow these rules may void the warranty or result in
dryer damage or personal injury.
1. Never install or try to repair any dryer that has been
damaged in shipment. See the Receiving and Inspection instructions in this manual for appropriate
action.
2. This equipment is a pressure-containing device.
Never operate the dryer at pressures or temperatures
above the maximum conditions shown on the data
plate.
Never dismantle or work on any component of the
dryer or compressed air system under pressure.
Vent internal air pressure to the atmosphere before
servicing.
3. This equipment requires electricity to operate. Install
equipment in compliance with national and local
electrical codes. Standard equipment is supplied
with NEMA 4, 4X electrical enclosures and is not
intended for installation in hazardous environments.
Never perform electrical service on the dryer unless
the main power supply has been disconnected. Parts
of the control circuit may remain energized when the
power switch is turned off.
4. Air treated by this equipment may not be suitable
for breathing without further purication. Refer to
OSHA standard 1910.134 for the requirements for
breathing quality air.
5. Certain parts of the dryer are not insulated and may
become hot during normal operation of the dryer. Do
not touch any of these areas without rst determining
the surface temperature.
6. Use only genuine replacement parts from the manufacturer. The manufacturer bears no responsibility for
hazards caused by the use of unauthorized parts.
Safety instructions in this manual are boldfaced for
emphasis. The signal words DANGER, WARNING and
CAUTION are used to indicate hazard seriousness levels
as follows:
DANGER—Immediate hazard which will result in severe
injury or death.
WARNING—Hazard or unsafe practice which could
result in severe injury or death.
CAUTION—Hazard or unsafe practice which could result
in minor injury or in product or property damage.
The dryer data plate, attached to the electrical control
box, contains critical safety and identication information. If the data plate is missing or defaced, immediately
contact your local distributor for a replacement.
2.0 Receiving, Storing, and Moving
2.1 Receiving and Inspection
This shipment has been thoroughly checked, packed and
inspected before leaving our plant. It was received in
good condition by the carrier and was so acknowledged.
Immediately upon receipt, thoroughly inspect for visible
loss or damage that may have occurred during shipping.
If this shipment shows evidence of loss or damage at
time of delivery to you, insist that a notation of this loss
or damage be made on the delivery receipt by the carrier’s agent. Otherwise no claim can be enforced against
the carrier.
Also check for concealed loss or damage. When a shipment has been delivered to you in apparent good order,
but concealed damage is found upon unpacking, notify
the carrier immediately and insist on his agent inspecting
the shipment. The carrier will not consider any claim for
loss or damage unless an inspection has been made. If
you give the carrier a clear receipt for goods that have
been damaged or lost in transit, you do so at your own
risk and expense. Concealed damage claims are not our
responsibility as our terms are F.O.B. point of shipment.
Shipping damage is not covered by the dryer warranty.
2.2 Storing
Store the dryer indoors to prevent damage to any electrical or mechanical components. All packaging material
should be left in place until the dryer is in position.
2.3 Handling
The dryer is designed to be moved by means of the shipping skid or the base channels. The dryer may also have
lifting lugs for use with an overhead crane. Be sure to
attach all of the lift points and use appropriate spreader
bars to prevent damage to the dryer.
CAUTION — Never lift the dryer by attaching hooks
or slings to the piping, or to any part other than the
lifting lugs. Severe structural damage could occur.
1
Page 4
3.0 Description
3.1 Function
Blower purge type regenerative dryers are an economical and reliable way to dry compressed air to dew points
below the freezing point of water. Desiccant dryers lower
the dew point of compressed air by adsorbing the water
vapor present in the compressed air onto the surface of
the desiccant. Adsorption continues until equilibrium is
reached between the partial pressure of the water vapor
in the air and that on the surface of the desiccant.
These dryers continuously dry compressed air by using
two identical towers, each containing a desiccant bed.
While one tower is on-stream drying, the other tower is
off-stream being regenerated (reactivated, i.e. dried out).
The towers are alternated on- and off-stream so that dry
desiccant is always in contact with the wet compressed
air. In this way a continuous supply of dry air downstream
of the dryer is possible. The switching from one tower
to the other is controlled by a solid-state controller on
either a xed time basis (standard) or a demand basis
(optional).
When a tower is placed off-line, it is slowly depressurized and the desiccant is regenerated. First, a blower
draws in ambient air which is heated. The heated air
ows through the desiccant bed, desorbs the moisture
from the desiccant, and carries the desorbed water out
of the dryer. The blower and heater are turned off when
the desiccant bed is fully heated. When congured for
cooling, a portion of the dry compressed air is diverted
from the main air ow and throttled to near atmospheric
pressure. This extremely dry, low pressure air passes
through the hot off-line tower, partially cooling the desiccant bed and reducing the dew point spike after tower
change over. At the end of the cooling stage, the tower
is repressurized to full line pressure. This prevents desiccant bed movement and downstream pressure loss when
the tower goes back on-line.
4.0 Installation
be required upstream of the Oil Removal Filter if heavy
liquid or solid loads are present.
To ensure downstream air purity (prevent desiccant dust
from traveling downstream) adequate ltration downstream of the dryer is required. A High Temperature
Afterlter, typically rated at 450°F (232°C) operating
temperature and capable of removing all desiccant nes
1 micron and larger should be installed at the dryer outlet.
DANGER — This dryer must be tted with a high
efciency coalescing lter and liquid drainer that is
maintained properly. Failure to do so could result
in an in-line re.
WARNING — The afterlter, if installed, must be rated
for 450°F (232°C).
4.2 Ambient Air Temperature
Locate the dryer under cover in an area where the ambient air temperature will remain between 35°F (2°C) and
120°F (49°C).
NOTE: If dryer is installed in ambients below 35°F
(2°C), low ambient protection requiring heat tracing
and insulation of the prelter bowls, auto drains and/
or sumps, and lower piping with inlet switching and
purge/repressurization valves is necessary to prevent
condensate from freezing. If installing heat tracing, observe electrical class code requirements for type of duty
specied. Purge mufers and their relief mechanisms
must be kept clear from snow and ice buildup that could
prevent proper discharge of compressed air.
4.3 Location and Clearance
Install the dryer on a level pad. Ensure the dryer is level
by grouting or shimming as necessary. Holes are provided
in the dryer base members for oor anchors. Securely
anchor the dryer frame to the oor. Allow 24 inches clear-
ance on all sides of the dryer for servicing. Provide ad-
equate clearance for prelter element, afterlter element
and heater element replacement. Provide protection for
the dryer if it is installed where heavy vehicles or similar
portable equipment is likely to cause
damage.
4.1 System Arrangement
Install the dryer downstream of an aftercooler, separator,
receiver, and high-efciency oil-removing lter(s) so that
the dryer inlet air is between 40°F (4.4°C) and 120°F
(49°C) and contains no liquid water or oil. Liquid water
and/or inlet air temperatures above 100°F (37.8°C) can
reduce drying capacity. Contact your local distributor
for information on proper dryer sizing at elevated inlet
air temperatures.
Adequate ltration is required upstream of the dryer in
order to protect the desiccant bed from liquid and solid
contamination. Use an Air Line Filter in systems supplied by a non-lubricated (oil-free) air compressor. In
systems supplied by a lubricated air compressor, use a
High Efciency Oil Removal Filter. A coarser lter will
2
4.3.1 Blower Installation
(
NOTE: Field installation of the purge blower to the dryer
unit is required on model sizes 3200, 3600, and 4300.
Refer to Figure 3b for assistance in connecting the purge
blower to the dryer unit.
1. Align and install the purge blower skid to the dryer
Models 3200 through 4300 only)
unit utilizing the expansion joint provided (shipped
mounted to the purge blower). Use the mounting
hardware (nuts, bolts, ange gasket, etc.) provided
to connect the purge blower skid to the dryer unit.
Ensure the purge blower skid is level by grouting or
shimming as necessary. Holes are provided in the
purge blower skid base members for oor anchors.
Securely anchor the purge blower skid to the oor.
Page 5
Compressor Aftercooler Separator Receiver Prefilters Afterfilters ReceiverDesiccant Dryer
Typical System Conguration
2.
Remove all mounting bolts from blower base which
MAY have been used for shipping purposes. The
blower is designed to vibrate freely on its vibration
pad during operation.
NOTE: The blower manufacturer cautions that the
blower should not be bolted down during operation.
3. Reconnect
the blower motor power connections to
the dryer unit according to the electrical drawings
in the back of this manual. Be sure to follow all
applicable electrical codes.
CAUTION: The blower and motor have been completely
checked and operated prior to shipment from the factory. After connecting the power supply to the motor,
momentarily energize the blower motor starter. Blower
rotation should match the indicator arrow on the blower
housing. If not, disconnect power and reverse the wiring
connections.
4.4 Piping and Connections
All external piping must be supplied by the user unless
otherwise specied. Refer to Figure 2 for connection
sizes. Inlet and outlet isolation valves and a vent valve
are recommended so the dryer can be isolated and
depressurized for servicing. The connections and pipe
ttings must be rated for or exceed the maximum operating pressure given on the dryer nameplate and must
be in accordance with industry-wide codes. Be sure all
piping is supported. Do not allow the weight of any pip-
ing to bear on the dryer or lters. Piping should be the
same size as or larger than the dryer connection. Piping
smaller than the dryer connections will cause high pressure drop and reduce drying capacity.
If the purge exhaust piping must be extended outside the
dryer area, choose a combination of diameters, lengths,
and turns that limits the additional pressure drop to 1/4
psid or less. BACK PRESSURE WILL CAUSE DRYER
MALFUNCTION. Consult the factory for piping details
if required.
WARNING — Do not operate dryer without installed
mufers. Exhausting compressed air directly to
atmosphere will result in noise levels above OSHA
permissible levels and rapidly expanding gas could
potentially cause harm to persons or property.
Figure 1
Dryer bypass piping may be installed to allow uninterrupted airow during servicing. If the downstream application cannot tolerate unprocessed air for short periods,
install a second dryer in the bypass line.
CAUTION — Do not hydrostatically test the piping
with the dryer in the system. The desiccant will be
damaged if saturated with water.
4.5 Electrical Connections
WARNING — These procedures require entering
gaining access to the dryer’s electrical enclosure(s).
All electrical work must be performed by a qualied
electrical technician.
Connect the proper power supply to the dryer according
to the electrical drawings in the back of this manual. Be
sure to follow all applicable electrical codes.
NOTE: A disconnect switch is not provided as standard
equipment and therefore, must be supplied by the customer.
Dry contacts (voltage free) are provided in the low tension electrical enclosure for a remote alarm. The contact
ratings are shown on the electrical drawing.
Connections to voltage-free common alarm contacts
with a minimum 5-amp rating can be made at terminals
TB4-1 through 3.
• Terminal TB4-3 is the common alarm connection.
• Terminal TB4-1 is the N.O.. (normally open) contact
connection.
• Terminal TB4-2 is the N.C. (normally closed) contact
connection.
• The alarm relay coil is energized when power is
supplied to the controller input terminals and there
is no alarms.
• The coil is de-energized when power is removed or
when an alarm condition exists.
• The common alarm is designed to activate on:
a) either a dryer fault condition or a service reminder,
or b) a dryer fault condition. This is user selectable.
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CENTERLINE OF
CUSTOMER DRY GAS
OUTLET CONNECTION
TOP VIEW
R
SLOT
(TYP 4 PLACES)
CENTERLINE OF
CUSTOMER WET GAS
INLET CONNECTION
SIDE VIEW
(RIGHT CHAMBER REMOVED FOR CLARITY)
T
GAS OUTLET
E
(MAX)
F
G
C
D
B
A
(MAX)
H
K
N
(MAX)
P
L
S
GAS INLET
M
FACE OF CUSTOMER
WET GAS INLET
CONNECTION
FACE OF CUSTOMER
DRY GAS OUTLET
CONNECTION
R
SLOT
(TYP 4 PLACES)
TOP VIEW
SIDE VIEW
(RIGHT CHAMBER REMOVED FOR CLARITY)
S
GAS INLET
T
GAS OUTLET
H
E
(MAX)
F
G
C
D
B
A
(MAX)
N
(MAX)
P
L
M
K
E
(MAX)
R
SLOTS
(TYP 4 PLACES)
TOP VIEW
SIDE VIEW
(RIGHT CHAMBER REMOVED FOR CLARITY)
S
AIR INLET
T
AIR OUTLET
F
C
D
B
A
N
(MAX)
M
L
P
K
G
Dimensions and Connections – Dryer Only
Figure 2 (continued on next page)
(For construction purposes, contact factory to request certied drawings when mounted lters are included with order)
VIEW III
3200 through 4300 scfm
VIEW II
750 through 2600 scfm
4
VIEW I
500 — 600 scfm
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Dimensions and Connections
Figure 2 (continued from previous page)
DIMENSIONS IN INCHES
A 53 55 60 60 64 66 80 80 85 85 85 85 109
B 46.3/4 47.9/16 52.11/16 52.11/16 56.7/16 57.5/16 69.13/16 69.13/16 73.3/8 73.3/8 82.7/8 82.7/8 93.3/8
MODEL 500 600 750 900 1050 1300 1500 1800 2200 2600 3200 3600 4300
VIEW REF. I I II II II II II II II II III III III
C 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4 1.1/4
E 59 60 68 68 62 73 79 79 86 89 107 116 123
D 23.3/8 23.13/16 26.5/8 26.5/8 29.9/16 30 34.7/8 34.7/8 38.9/16 38.9/16 36.9/16 36.9/16 41.13/16
F 45.1/2 45.1/2 53.1/2 53.1/2 53.1/2 53.1/2 53.1/2 53.1/2 59.1/2 59.1/2 59.1/2 59.1/2 63.1/2
G 22.3/4 22.3/4 26.3/4 26.3/4 26.3/4 26.3/4 26.3/4 26.3/4 29.3/4 29.3/4 29.3/4 29.3/4 31.3/4
DIMENSIONS IN MILLIMETERS
L 12.11/16 13.3/16 13.7/16 13.7/16 13.3/16 13.3/16 15.5/8 15.5/8 17.1/4 17.1/4 14.9/16 16.9/16 16.1/4
K 3 3 8 8 8 8 8 8 7.1/4 7.1/4 15.7/8 15.7/8 15.7/8
H — — 1.1/4 1.1/4 3.1/4 3.1/4 5.15/16 5.15/16 4.3/8 4.3/8 3/4 5 2
M 96.15/16 100.7/16 100.11/16 100.11/16 99.13/16 104.13/16 101.7/8 101.7/8 115.7/8 115.7/8 115.13/16 122.1/16 118.1/2
N 105 108 114 114 113 11 8 116 11 6 128 128 128 134 130
P 13.3/16 14.3/16 15.3/4 15.3/4 16.3/4 17.3/4 20.3/4 20.3/4 22.1/4 22.1/4 26.1/2 27.1/2 30.1/2
S 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE
R 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4 7/8 X 1.1/4
T 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE 6 FLANGE
WT/LBS 1,900 2,200 2,500 2,600 3,000 3,600 5,400 5,500 8,100 8,200 9,400 9,900 12,350
MODEL 500 600 750 900 1050 1300 1500 1800 2200 2600 3200 3600 4300
A 1346 1397 1524 1524 1626 1676 2032 2032 2159 2159 2159 2159 2769
B 1187 1208 1338 1338 1434 1456 1773 1773 1864 1864 2106 2106 2372
C 32 32 32 32 32 32 32 32 32 32 32 32 32
VIEW REF. I I II II II II II II II II III III III
D 594 604 677 677 750 761 886 886 980 980 929 929 1062
E 1491 1531 1734 1734 1580 1862 2009 2009 2186 2256 2708 2955 3132
F 1156 1156 1359 1359 1359 1359 1359 1359 1511 1511 1511 1511 1613
G 578 578 679 679 679 679 679 679 756 756 756 756 806
L 322 335 341 341 335 335 397 397 438 438 370 421 413
K 76 76 203 203 203 203 203 203 184 184 403 403 403
H — — 32 32 83 83 151 151 111 111 19 127 51
M 2462 2551 2557 2557 2535 2662 2588 2588 2943 2943 2942 3100 3010
N 2664 2753 2903 2903 2870 2997 2946 2946 3246 3246 3246 3404 3313
P 335 360 400 400 425 451 527 527 565 565 673 699 775
S 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE
R 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32 22 X 32
T 2 NPT 2 NPT 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE 6 FLANGE 6 FLANGE 6 FLANGE
WT/KGS 862 998 1,134 1,179 1,361 1,633 2,449 2,495 3,674 3,719 4,264 4,491 5,602
5
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• For the common alarm to activate on either a dryer
fault condition or a service reminder, the jumper at
JP6 is removed. This is the default conguration.
• To have the common alarm activate on a dryer fault
condition only, the jumper at JP6 is installed.
NOTE: Before turning high voltage on to the dryer,
an ohmic test should be performed on the heater elements to insure they are dry before proceeding with
start-up. This should be done after extended shut
downs and long delays between delivery and startup. Connect one lead of a megger to an unpainted
surface of the control panel or dryer frame. Connect
the other lead to each phase on the load side of the
contactor. Adjust the megger to the 1500 volt setting.
Perform the ohmic test on each zone of the heaters.
A minimum value of 500k ohms must be obtained.
CAUTION - Failure to ohmic test heaters after extended periods may cause heater failure.
4.5.1 RS-232 Connections
RS-232 connections can be made at the 3-pin connector
labeled J3 and located at the upper left-handed corner
of the control board. A cable for this connection can be
purchased through your distributor.
3. Refer to Table 1 for desiccant quantity per tower.
When using Table 1 you will nd the desiccant quan-
tities listed in layers. Each layer will vary in depth
due to the type, quantity and purpose of the desic-
cant. Layer 1 must be installed rst at the bottom of
the vessel followed by layer number 2 etc., until the
complete charge of desiccant has been installed.
4. Utilizing an appropriate sized funnel, ll each desiccant tower as follows:
a. Install the required quantity of tabular support or
activated alumina in layer 1 of each tower.
b. Level layer 1 and each subsequent layer of desic-
cant as added to each chamber.
c. Finish lling each tower with desiccant until all
desiccant has been installed. LIGHT tapping
on the tower sides with a soft-face mallet should
yield additional free space to allow installation of
all desiccant required. DO NOT TAMP OR RAM
DESICCANT.
5. Clean the ll port closure. Replace the ll plug using
Teon tape or another pipe thread sealant suitable
for compressed air service. Reinstall ll port ange
cover (where applicable) in each desiccant tower.
4.6 Initial Desiccant Charge
Blower purge type regenerative dryers use activated
alumina as the desiccant in the dryer towers.
Models 500 through 1050 are shipped with activated
alumina (1/8” bead) in the dryer towers. Desiccant is
shipped loose with all other standard models.
All desiccant shipped loose must be added to the
dryer chambers before the dryer is put into service
Refer to TABLE 1, DESICCANT REQUIREMENTS for
desiccant type and quantity per tower.
TO ADD DESICCANT
WARNING — The following procedure provides instructions for adding the initial desiccant to the towers. If replacing desiccant, refer to the “Procedure
for Desiccant Charge Replacement” in Section 7.0.
1. Verify pressure gauges of both towers indicate
0 psig. If not, depressurize the towers according to
the shutdown instructions in Section 6.
2. Remove the pipe plug or ll port ange cover (where
applicable) from the desiccant ll port at the top of
each tower. Refer to Figure 3 for the ll port location.
CAUTION – Pouring desiccant creates a ne dust;
safety goggles, gloves and a dust mask should be
worn by personnel installing desiccant. Refer to the
Material Safety Data Sheet that accompanies desiccant shipped loose for more complete information.
CAUTION – Do not tamp the desiccant in the towers.
Tamping damages desiccant and causes dusting.
TABLE 1
DESICCANT REQUIREMENTS
(Quantity per Tower)
Model
500 354 AA-4 — — — —
600 453 AA-4 — — — —
750 590 AA-4 — — — —
900 590 AA-4 — — — —
1050 710 AA-4 — — — —
1300 48 AA-25 876 AA-4 — —
1500 92 AA-25 1167 AA-4 — —
1800 92 AA-25 1167 AA-4 — —
2200 161 AA-25 1706 AA-4 — —
2600 161 AA-25 1706 AA-4 — —
3200 258 AA-25 2119 AA-4 — —
3600 258 AA-25 2353 AA-4 — —
4300 719 TS-50 146 AA-25 2679 AA-4
AA = Activated Alumina
TS = Tabular Support
Layer #1 Layer #2 Layer #2
(lbs.) (p/n) (lbs.) (p/n) (lbs.) (p/n)
6
Page 9
5.0 Instrumentation
The following instrumentation helps in monitoring dryer
operation and performance. Instruments which are
available as options are so noted.
Blower Purge Air dryers are rated NEMA 4 and include
the following:
• Solid State Controls
• Chamber Pressure Gauges
• Purge Flow Pressure Gauge
• Energy Management (Option A)
• Energy Management System & Dew Point Transmitter
(Option B)
5.1 Controls
The solid-state dryer controls are located in a
polycarbonate, NEMA Class 4/4X, IP66 rated electrical
enclosure mounted to a center panel located between
the two desiccant towers. Control features include:
• 15 LED’s to indicate operating status and fault
conditions.
• Two line text display to provide status and diagnostic
messages.
• Upon power loss, dryer “fails safe” (inlet valve
remains in position). On power recovery, controller
resumes where power was lost.
5.5 Dew Point Transmitter
This option monitors and displays outlet pressure dew
points and provides an alarm signal if the dew point
exceeds user-specified set point. Recommended
calibration interval is 12 months. Contact the service
department for details.
Operation – The dew point is measured at the dryer
operating pressure and is displayed in the operator
interface. If the dew point is outside of the temperature
range, the display will indicate an over-range (high
dew point) or under-range (low dew point) condition. A
defective sensor assembly or an electronics malfunction
could also cause the transmitter to indicate under-range.
5.2 Chamber Pressure Gauges
A gauge mounted on the gauge panel indicates which
chamber is on-stream and which is regenerating. The
gauge for the onstream tower indicates operating
pressure; the gauge for the regenerating tower indicates
0 psig.
5.3 Purge Flow Pressure Gauge
A gauge mounted on the gauge panel of the dryer
indicates purge air pressure.
5.4 Energy Management System
The optional Energy Management System (EMS)
automatically adjusts dryer operation to compensate
for changes in operating conditions. Air samples are
continuously taken from the on-stream tower and
passed over a moisture probe which senses both
temperature and relative humidity. The moisture content
of the air within the desiccant bed is then precisely
determined. The on-stream tower will not depressurize
and regenerate until a predetermined set point has been
reached. This elimination of unnecessary regeneration
reduces energy consumption and extends dryer
desiccant and component life.
7
Page 10
ENERGY MANAGEMENT
SENSOR LOCATION
(OPTIONAL)
TOP VIEW
PURGE INLET
CHECK VALVE
HEATER TEMP
THERMOCOUPLE
(CENTER END IN PIPE)
(OPPOSITE SIDE)
HEATER OVERTEMP RTD
PURGE
HEATER WITH
INSULATION
PURGE SUCTION
FILTER SILENCER
PURGE BLOWER
AND MOTOR
ASME RELIEF VALVE
OUTLET CHECK VALVE
DESICCANT
FILL PORT
REAR VIEW
HOT PIPE INSULATION
ASME CODE TAG
TOWER INLET
VALVE
REPRESS VALVE
PURGE
PRESSURE GAUGE
RIGHT TOWER
PRESSURE GAUGE
CONTROL
ENCLOSURE
LEFT TOWER
PRESSURE GAUGE
PRESSURE REGULATOR
& PILOT AIR FILTER
DEWPOINTER
(OPTIONAL)
TOWER PURGE
EXHAUST VALVE
TOWER
DEPRESS VALVE
FRONT VIEW
HIGH TENSION
ENCLOSURE
TOWER
INSULATION
(OPTIONAL)
DESICCANT
DRAIN PORT
TOWER BLOWDOWN VALVE
Figure 3
General Layout Drawing
(Models 500 through 600)
8
Page 11
ENERGY MANAGEMENT
SENSOR LOCATION (OPTIONAL)
REPRESS VALVE
TOP VIEW
HEATER TEMP
THERMOCOUPLE
(CENTER END IN PIPE)
(OPPOSITE SIDE)
HEATER OVERTEMP RTD
PURGE
HEATER WITH
INSULATION
PURGE SUCTION
FILTER SILENCER
PURGE BLOWER
AND MOTOR
ASME RELIEF VALVE
OUTLET CHECK VALVE
REAR VIEW
HOT PIPE INSULATION
PURGE INLET CHECK VALVE
ASME CODE TAG
CHAMBER INLET
VALVE
PURGE
PRESSURE GAUGE
DESICCANT
FILL PORT
LEFT TOWER
PRESSURE GAUGE
PRESSURE REGULATOR
& PILOT AIR FILTER
DEWPOINTER
(OPTIONAL)
TOWER PURGE
EXHAUST VALVE
TOWER
DEPRESS VALVE
FRONT VIEW
Figure 3a
General Layout Drawing
(Models 750 through 2600)
RIGHT TOWER
PRESSURE GAUGE
CONTROL
ENCLOSURE
HIGH TENSION
ENCLOSURE
TOWER
INSULATION
(OPTIONAL)
DESICCANT
DRAIN PORT
TOWER BLOWDOWN VALVE
9
Page 12
ENERGY MANAGEMENT
SENSOR LOCATION
(OPTIONAL)
TOP VIEW
HEATER INLET
TEMPERATURE SWITCH
OUTLET CHECK VALVE
ASME RELIEF VALVE
REPRESS
VALVE
HEATER TEMP
THERMOCOUPLE
(CENTER END
IN PIPE)
(OPPOSITE SIDE)
HEATER
OVERTEMP RTD
PURGE
HEATER WITH
INSULATION
PURGE SUCTION
FILTER SILENCER
PURGE BLOWER
THROTTLING VALVE
PURGE BLOWER
AND MOTOR
DESICCANT
FILL PORT
REAR VIEW
HOT PIPE
INSULATION
PURGE INLET
CHECK VALVE
TOWER
INLET VALVE
PURGE PRESSURE
GAUGE
RIGHT TOWER
PRESSURE GAUGE
10
LEFT TOWER
PRESSURE GAUGE
PRESSURE REGULATOR
& PILOT AIR FILTER
DEWPOINTER
(OPTIONAL)
TOWER PURGE
EXHAUST VALVE
TOWER BLOW-
DOWN VALVE
FRONT VIEW
Figure 3b
General Layout Drawing
(Models 3200 through 4300)
CONTROL
ENCLOSURE
HIGH TENSION
ENCLOSURE
TOWER INSULATION
(OPTIONAL)
DESICCANT
DRAIN PORT
TOWER
DEPRESS VALVE
Page 13
6.0 Operation
6.1 Controls
A solid-state controller controls valve and heater operation, monitors all critical operating conditions, and indicates operating status on a 2-line LCD display operator
interface. The controller receives input data from pressure switches, temperature sensors and the operator
interface. The operator interface displays information
about the dryer operating status and is used to change
the dryer operating mode.
6.2 Operating Modes
6.2.1 Automatic and Manual Advance
The drying and regeneration cycles are divided into
discrete steps. The operator selects either one of the
automatic advance modes (Energy Management, Dew
Point Control, or Fixed Cycle) or manual advance mode
(Test Cycle) through the operator interface.
Selecting any of the automatic advance modes enables
a timer in the controller to advance the program step-bystep according to the programmed schedule.
Setting up the controller for manual advance disables the
timer and the operator can advance the program one step
at a time. This mode is used for diagnostic purposes.
6.2.2 Fixed, Energy Management or Dew Point
Control Operation
The operator interface is used to select either Fixed,
Energy Management or Dew Point Control operation. In
Fixed Cycle operation, each tower is on-line (drying) for a
xed time period regardless of the operating conditions.
In Energy Management or Dew Point Control operation,
a tower remains on-line until the desiccant bed has been
fully utilized. For lower than designed moisture loads,
this results in longer drying cycles, longer time between
regenerations and, therefore lower energy consumption.
Energy Management or Dew Point Control operation
are optional features.
6.3 Operating Sequence Description
1. Left Tower Drying – Right Tower Regenerating
At the start of the Left Tower Drying cycle, Left Inlet
Valve V1 opens, Right Inlet Valve V2 closes to iso-
late the two towers. Wet, compressed air ows up
through the left tower where it is dried. The dry air
exits the dryer through the Left Outlet Check Valve
V7.
Next, the Right Depressurization Valve V10 is
opened and the right tower is slowly depressurized.
Air exits through exhaust mufer M2.
After the right tower has depressurized, the Right
Purge Valve V4 is opened and the Blower M and
Heater H1 are energized. The heated air ows
through the Right Purge Check Valve V6, down
through the right tower, and exits through the Right
Purge Valve V4. The Blower intake air is ltered
to keep dust and dirt from entering the dryer. The
Blower M and Heater H1 are de-energized when
the temperature at the bottom of the right tower,
as sensed by the Right Tower Temperature Sensor
RTD2, reaches the Heat Termination set point. This
indicates that the bed has been fully heated.
NOTE: Blower will continue to run briey at the end
of the Heating Step to sweep residual heat from the
heater.
The Repressurization Valve V11 is opened. A portion
of the dry air from the left tower now ows through
Repressurization Valve V11. This air is throttled to
near atmospheric pressure by Repressurization/
Sweep Orice O2. The dry, low pressure air ows
down through the right tower cooling the desiccant
bed, and exits through the Right Tower Purge Exhaust Valve V4.
The Cooling Step continues until:
a) the right tower bed temperature falls to 150°F
or,
b) it is time to repressurize the right tower,
whichever occurs rst.
NOTE: In xed cycle, the bed will normally be
partially cooled because the repressurization step
will occur before the bed temperature can fall to
150°F.
NOTE: In Energy Management or Dew Point Con-
trol, as the drying time extends beyond 4 hours,
additional cooling time becomes available thus the
cooling step will frequently terminate based on temperature providing complete bed cooling.
At the end of the Cooling Step, the Right Tower Purge
Exhaust Valve V4 is closed. The right tower slowly
repressurizes to full line pressure and is ready to go
back on-line.
NOTE: Bed cooling can be disabled by moving JP4
to the “ON” position.
2. Right Tower Drying – Left Tower Regenerating
At the start of the Right Tower Drying cycle, Right
Inlet Valve V2 opens, Left Inlet Valve V1 closes to
isolate the two towers. Wet, compressed air ows
up through the right tower where it is dried. The dry
air exits the dryer through the Right Outlet Check
Valve V8.
Next, the Left Depressurization Valve V9 is opened
and the left tower is slowly depressurized. Air exits
through exhaust mufer M1.
11
Page 14
SET @ 165 PSIG
DRY GAS
OUTLET
LEFT
V7 V8
F1 O1 O2
M
PI3
PI1 PI2
SET @
45 PSIG
1PS
SET @
5 PSIG
3PS
EXH.
SET @ 176°F
RTD 1
(RTD4/HS1)
ENERGY MGMT OPTION
SOL 'F'
2
SOL 'C'
V12 V13
H1
3
1
V11
1TC
SET @ 370°F
RTD 3
SET @ 650°F
SOL 'D'
SOL 'E'
V14
F2
DPA
DEWPOINTER OPTION
V6V5
SOL 'G'
PR&G
SET @
45 PSIG
SET @
5 PSIG
SET AT
100 PSIG
2PS
4PS
SET @ 176°F
RTD 2
CHAMBERCHAMBER
RIGHT
REGENDRYING
WET GAS
INLET
V9
M1
BD1 BD2
V3
V4
V1 V2
NOTES
SYMBOLS ARE PER ANSI Y32.10 "GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS."
1.
AS SHOWN FLOW DIRECTION IS:
2.
SOLENOID VALVES 'B', 'D', & 'G' ARE SHOWN ENERGIZED,
3.
SOLENOID VALVES 'A', 'C', 'E', & 'F' ARE SHOWN DE-ENERGIZED.
4.
V10
INDICATES OPTION
M2
LEFT CHAMBER DRYING
RIGHT CHAMBER REGEN
PILOT GAS LINE
Figure 4
Sequence of Operation — Fixed Cycle Operation
Left Chamber Drying – Right Chamber Regenerating (shown)
(continued on next page)
SOL 'A'
SOL 'B'
12
Page 15
After the left tower has depressurized, the Left Purge
P
EMS
LEFT
TOWER
RIGHT
TOWER
Valve V3 is opened and the Blower M and Heater
H1 are energized. The heated air ows through the
Left Purge Check Valve V5, down through the left
tower, and exits through the Left Purge Valve V3.
The Blower intake air is ltered to keep dust and dirt
from entering the dryer. The Blower M and Heater
H1 are de-energized when the temperature at the
bottom of the left tower, as sensed by the Left Tower
Temperature Sensor RTD1, reaches the Heat Termination set point. This indicates that the bed has
been fully heated.
The Repressurization Valve V11 is opened. A portion
of the dry air from the right tower now ows through
Repressurization Valve V11. This air is throttled to
near atmospheric pressure by Repressurization/
Sweep Orice O1. The dry, low pressure air ows
down through the left tower cooling the desiccant
bed, and exits through the Left Tower Purge Exhaust
Valve V3.
The Cooling Step continues until:
a) the left tower bed temperature falls to 150°F
or,
b) it is time to repressurize the left tower,
whichever occurs rst.
6.3.1 Energy Management Control (optional)
Operation of the Energy Management Control cycle is
identical to the xed cycle except the cycle is extended
until the desiccant bed in the on-line tower has been fully
utilized. The off-line tower is regenerated and remains
in a stand-by mode after being repressurized.
Figure 5 shows the air sampling system for the Energy
Management System – EMS option. A 3-way pilot valve
directs an air sample from the drying tower to the EMS
sensor. The EMS sensor detects the relative humidity
and temperature of the air sample. The air sample then
exhausts to atmosphere. The drying tower remains online until the moisture front arrives at the sensor.
NOTE: In xed cycle, the bed will normally be
partially cooled because the repressurization step
will occur before the bed temperature can fall to
150°F.
NOTE: In Energy Management or Dew Point Con-
trol, as the drying time extends beyond 4 hours,
additional cooling time becomes available thus the
cooling step will frequently terminate based on temperature providing complete bed cooling.
At the end of the Cooling Step, the Left Tower Purge
Exhaust Valve V3 is closed. The left tower slowly
repressurizes to full line pressure and is ready to go
back on-line.
NOTE: Bed cooling can be disabled by moving JP4
to the “ON” position.
Figure 5
Optional Moisture Sensing
Energy Management System (EMS)
13
Page 16
6.4 Control Board Jumpers
In the upper left hand corner of the control board there
are eight two-pin jumpers labeled JP1 through JP8. Only
six of the eight jumper pairs are utilized. Pairs JP7-JP8
are used for factory settings and testing. NOTE: Do
not install jumpers in the ON position on pairs JP7
through JP8. The jumper is a removable bridge that is
used to make or break continuity between two pins that
form a pair. When installed in the ON position, the jumper
is place on both pins of the pair and continuity between
the pins is established. When installed in the OFF position, the jumper is removed or stored on a single pin and
continuity is broken. Jumper functions are as follows:
7. JP7 – Download Language Text
Jumper JP7 is factory installed in the OFF position
to disable Language Text download. The jumper is
installed in the ON position to allow for language text
download due to either language corrections or new
language installation.
8. JP8 – Set Up
Jumper JP8 is factory installed in the OFF position
to disable access to “factory” set up screens. The
jumper is installed in the ON position during nal
inspection at the factory to set controller to match
customer requirements.
1. JP1 – Dryer Type
Jumper JP1 is used to select the dryer type congu-
ration. It is installed in the ON position for Blower
Purge dryer conguration.
2. JP2 – Energy Management
Jumper JP2 is installed in the ON position when an
Energy Management sensor is installed. The jumper
is installed in the OFF position when no Energy
Management sensor is installed.
3. JP3 – Dew Point Transmitter
Jumper JP3 is installed in the ON position when a
Dew Point Transmitter is installed. The jumper is
installed in the OFF position when no Dew Point
Transmitter is installed.
NOTE: “Energy Management” can co-exist with the
dew point transmitter option. Dryer control based
on the ENERGY MANAGEMENT or DEWPOINT
CONTROL is selected on Screen 1 of the Set Up
Mode.
If DEWPOINT CONTROL is not selected then the
dew point signal does not control the dryer cycle but
still serves a monitoring and alarm function.
4. JP4 – Cooling Cycle
Jumper JP4 is installed in the ON position to disable
the Cooling Cycle. The jumper is installed in the OFF
position to enable a Cooling Cycle.
5. JP5 – Switching Failure
Jumper JP5 is installed in the ON position to enable
Switching Failure. The jumper is installed in the OFF
position if Switching Failure is disabled.
6. JP6 – Common Alarm
Jumper JP6 is installed in the OFF position to en-
able both the dryer fault alarms and service alarms
to activate the common alarm. This is the default
conguration. Install jumper JP6 in the ON position
if the common alarm is to activated by a dryer fault
alarm only.
6.5 Operator Interface
Refer to Figure 6 , Front Panel Overlay for information
regarding the location and function of the LEDs, switches,
and text display.
6.5.1 Front Panel LED’s
• Power On - green
• Alarm - red
• Service / Maintenance reminder - amber
• Filters (pre, after, and pilot) service / maintenance
reminders - amber
• Inlet switching and purge / repressurization valve status (On = valve open; Off = valve closed) - green
• Left and right tower status (heating) - amber
• Left and right tower status (drying) - green
• Left and right tower pressure switch status (On =
switch closed; Off = switch open) - green
6.5.2 Front Panel Switches
The front panel contains four momentary-contact pushbutton switches. Refer to Figure 6, Front Panel Overlay
for the appropriate icon associated with each switch.
Pushing on the overlay icon actuates the switch.
Data Display Switch
This switch is used to step through the display
screens.
Select Switch
This button is located to the left of the text display window.
Refer to the Front Panel Operation Section for additional
information.
ENTER Switch
This button is located to the right of the text display
window. Refer to the Front Panel Operation Section for
additional information.
Alarm Reset Switch
This button is normally used to reset an alarm or service
reminder. Refer to the Front Panel Operation Section
for additional information.
NOTE: Jumpers JP7 and JP8 are used by the fac-
tory during nal inspection to download language
text and to enable ‘factory’ set-up screens.
14
Page 17
Left Tower Drying LED
Left Purge Valve LED
On=valve open
Off=valve closed
Left Inlet Valve LED
On=valve open
Off=valve closed
Left Tower
Heating LED
Filter Service /
Maintenance LED
Vacuum Fluorescent
Text Display
Select switch
Power On LED
Data Display Switch
Communications Icon
Filter Service /
Maintenance LED
Filter Service /
Maintenance LED
Right Tower Pressure
Switch LED:
On=Tower pressurized
Right Tower Drying LED
Right Purge Valve LED
On=valve open
Off=valve closed
Right Tower
Heating LED
Right Inlet Valve LED
On=valve open
Off=valve closed
Enter Switch
Maintenance / Service
Reminder LED
Alarm LED
Reset Switch for Alarm
Left Tower Pressure
Switch LED:
On=Tower Pressurized
RS232
6.5.3 Front Panel Operation
1. There are five operating modes for the Heated
2. Each Mode is described below.
6.5.4 Program Mode
1. Press and hold and for 3 seconds to enter
2. Program Mode is comprised of the screens that are
3. There are three (3) ways to exit Program Mode.
Front Panel Overlay
Desiccant Dryer Control.
a. Program Mode
b. Setup Mode
c. Alarm & Service Mode
d. Display Mode
e. Test Mode
Program Mode.
described below.
a. Press after making the selection in the nal
screen.
b. At any screen, press and hold for 3 sec-
onds.
c. The controller automatically exits Program Mode
if no button is pressed within 60 seconds.
Figure 6
4. Upon exiting Program Mode the controller will switch
to Display Mode.
Screen 1: Select the Language
1. Press to scroll through the choices: ENGLISH,
FRANCAIS and ESPANOL.
2. When nished, press to save the selection and
move to next screen.
ENGLISH
Screen 2: Select the Service Level
SERVICE LEVEL
NORMAL
1. Press to toggle between NORMAL and
SEVERE.
a. NORMAL Service Intervals are:
i. 4000 hours for lters
ii. 8000 hours for desiccant
iii. 8000 hours for valves
15
Page 18
b. SEVERE Service Intervals are:
i. 2000 hours for lters
ii. 4000 hours for desiccant
iii. 4000 hours for valves
2. When nished, press to save the selection and
move to next screen.
Screen 3: Reset the Timer for Filter Service
FILTER SERVICE
RESET? NO
1. Press to toggle between NO and YES.
2. When finished, press to acknowledge the
selection and move to next screen.
Screen 4: Reset the Timer for Desiccant Service
DESICCANT SERVICE
RESET? NO
1. Press to toggle between NO and YES.
2. When finished, press to acknowledge the
selection and move to next screen.
Screen 5: Reset the Timer for Valve Service
VALVE SERVICE
RESET? NO
Screen 7: Set Point for Dew Point Demand Control
(This feature is only active when JP3 is “on”)
DPNT CNTL SETPT
±XX°C ±XXX°F
1. Press to increment the setting to the desired
value.
a. Standard set point is
-30°C -22°F
.
b. The allowable range of values is from
-80°C -112°F
+10°C +50°F
to
in 5°C/9°F
increments.
NOTE: Must be set “drier” than Dew Point Sensor
Alarm Set Point (screen 6).
2. When finished, press to acknowledge the
selection and exit the Program Mode.
Screen 8: Set the Heat Termination Set Point
HEAT TERM SET-PT
XX°C XXX°F
1. Press to increment the setting to the desired
temperature value.
a. Refer to P&ID diagrams in the back of this manual
for Heat Termination set points (see set point
values for RTD1 and RTD2).
b. The allowable range of values are:
60° - 160°C 140° - 320°F
in 10°C increments.
1. Press to toggle between NO and YES.
2. When nished, press to acknowledge the selection and move to next screen.
Screen 6: Set Alarm Point for the Dew Point
Sensor (This feature is only active when
JP3 is “on”)
DEWPOINT ALARM
±XX°C ±XXX°F
XX MIN SW DELAY
1. Press to increment the setting to the desired
value.
a. Standard set point is
-20°C -4°F
.
b. The allowable range of values is from
-80°C -112°F
+10°C +50°F
to
in 5°C/9°F
increments.
2. When nished, press to acknowledge the selection and scroll to the switchover delay set point
screen.
a. Standard set point is
b. The allowable range of values are
60 MIN
.
30 to 120 MIN
in 10 minute increments.
3. When nished, press to acknowledge the selection and move to next screen. Exit Program Mode
when there are no more active screens to display.
2. When nished, press to acknowledge the selection and move to next screen. Exit Program Mode
when there are no more active screens to display.
Screen 9: Set the Sweep Termination Set Point
SWEEP TERM SET-PT
XX°C XXX°F
1. Press to increment the setting to the desired
temperature value.
The allowable range of values are:
48° - 60°C 118° - 150°F
in 2°C increments.
2. When nished, press to acknowledge the selection and move to next screen. Exit Program Mode
when there are no more active screens to display.
Screen 10: Set Points for Energy Management
(This feature is only active when JP2 is “on”)
ENRGY MGMT SETPT
XX%RH
XX MBAR .XXX PSI
1. Press to increment the setting to the desired
maximum RH value.
a. Factory set point is
60%RH
. The factory setting
should not require adjustment.
b. The allowable range of values are
20 to 80%RH
in 5% increments.
16
Page 19
2. When nished, press to acknowledge the selection and scroll to the pressure set point screen.
3. Press to increment the setting to the desired
maximum vapor pressure value.
a. Standard set point for a -40°F dew point dryer
16 MBAR (0.232 PSI)
.
is
NOTE: Standard set point for a -100°F dew point
dryer
b. The allowable range of values
3 to 34 MBAR (0.044 to 0.493 PSI)
4 MBAR (0.058 PSI)
is
.
in
is
1 MBAR
increments.
c. This setting may be eld adjusted to increase or
decrease the outlet dew point at tower switchover.
4. When nished, press to acknowledge the selection and move to next screen.
Screen 11: Set Points for High Humidity Alarm
(This feature is only active when JP2 is “on”)
HIGH HUMIDITY
XX%RH
XX MBAR .XXX PSI
XX MIN SW DELAY
1
. Press to increment the setting to the desired
maximum RH value.
a. Factory set point is
75%RH
. The factory setting
should not require adjustment.
b. The allowable range of values are
20 TO 80%RH
in 5% increments.
NOTE: Value must be set above Energy Manage-
ment Maximum RH Value Set Point (screen 9).
2. When nished, press to acknowledge the selection and scroll to the pressure set point screen.
5. When nished, press to acknowledge the selection and move to next screen. Exit Program Mode
when there are no more active screens to display.
6.5.5 Setup Mode
1. Press and hold for 3 seconds to enter Setup
Mode.
2. Setup Mode is comprised of the screens that are
described below.
3. There are two ways to exit Setup Mode.
a.
Press after making the selection in Screen 1.
b. The controller automatically exits Setup Mode if
no button is pressed with 60 seconds.
4. One of two things will happen upon exiting Setup
Mode.
a. The controller will switch to Display Mode if
ENERGY MANAGEMNT, FIXED CYCLE or
DEWPOINT CONTROL is selected.
b. The controller will switch to Test Mode if TEST
CYCLE is selected.
Screen 1: Select the Cycle Type
CYCLE TYPE
ENERGY MANAGEMNT
1. Press to scroll through the choices:
a. ENERGY MANAGEMNT (displayed only when
JP2 is in the ON position)
b. DEWPOINT CONTROL (displayed only when JP3
is in the ON position)
c. FIXED CYCLE
d. MANUAL CYCLE
2. When nished, press to save the selection and
exit the Setup Mode.
3. Press to increment the setting to the desired
maximum vapor pressure value.
a. Factory set point for a -40°F dew point dryer is
24 MBAR (0.348 PSI)
.
NOTE: Factory set point for a -100°F dew point
dryer is
5 MBAR (0.073 PSI)
.
b. The allowable range of values is
3 to 34 MBAR (0.044 to 0.493 PSI)
in 1 MBAR incre-
ments.
NOTE: Value must be set above Energy Man-
agement Maximum Vapor Pressure Set Point
(screen 9).
4. When nished, press to acknowledge the selection and scroll to the switchover delay set point
screen.
a. Factory set point is
b. The allowable range of values are
60 MIN.
.
30 to 120 MIN
in 10 minute increments.
17
Page 20
6.5.6 Alarm & Service Mode
1. Alarm & Service Mode is active when the controller
is in Display Mode. It is not active in Program Mode,
Setup Mode, or Test Mode.
2. Local alarm consists of a blinking alarm LED and an
alarm message display.
3. Alarm messages have priority over Service
messages. Service messages have priority over
Display Messages.
4. After an alarm condition has been corrected, if:
a. Alarm is “self-clearing” then,
i. The alarm LED stops blinking (LED on); the
alarm message continues to be displayed.
ii. The alarm reset button must be depressed to
clear the alarm LED (LED off) and the alarm
message.
b. Alarm must be manually reset, then:
i. The alarm LED continues to blink and the
alarm message continues to be displayed.
ii. The alarm reset button must be depressed
to:
1. Clear the alarm LED (LED off)
2. Clear the alarm message and
3. Restart the dryer cycle.
5. When an alarm condition has not been corrected
and the “alarm reset” button is pressed, the alarm
will not clear except as follows:
a. The alarm conditions will clear for 5 seconds,
then reappear if the alarm condition persists, this
applies to the following alarms:
i. Heater: High Inlet Temperature.
ii. Heater: Low Temperature
iii. Humidity Sensor: High Humidity Alarm
iv. Humidity Sensor: Under-Range or Over-
Range Alarm
v. Dew Point Sensor: High Dew Point Alarm
vi. Dew Point Sensor: Under-Range or Over-
Range Alarm
6. There are three alarms for each tower that are
triggered by the tower pressure switches. These
alarms can occur in any operating mode (Manual,
Fixed, Energy Management, or Dew Point Demand
Cycle).
Following is a brief description of each alarm.
a. Left or Right tower, drying, low pressure
i. Drying tower pressure switch is open during
the drying cycle.
b. Left or Right tower, regenerating, high pressure
i. Regenerating tower pressure switch is closed
while purge valve is open (after an initial time
delay).
c. Left or Right tower, regenerating, low pressure
i. Regenerating tower pressure switch is open
at the end of the regenerating cycle.
d. On alarm condition, the blower and heater are
de-energize, the cycle sequence is stopped, a
local alarm is displayed and the common alarm
relay is de-energized.
e. These alarms are self-clearing.
7. Heater High Inlet Temperature
a. Model sizes 3200, 3600 and 4300 are equipped
with a temperature switch located in the piping
between the blower and heater.
b. If during the Heat Cycle this temperature switch
opens, indicating a rise in temperature above
the factory setting (refer to Electrical Schematic
drawings at the back of this manual for set point),
an alarm is activated.
c. On alarm condition, the blower and heater are
de-energized, the cycle sequence is stopped, a
local alarm is displayed and the common alarm
relay is de-energized.
d. This alarm must be manually reset.
8. The dryer is equipped with RTD temperature sensors.
There are out of range alarms for each.
a. The standard left tower, right tower, and heater
RTDs (RTD1, RTD2, RTD3) are scaled from
-20°F(-28°C) to 890°F (477°C), “Out of Range”
conditions are as follows:
i. Over-range - temperature above 850°F
(454°C)
ii. Under-range - temperature below -20°F
(-28°C)
iii. NOTE: The controller will annunciate a
“Heater Overtemperature” alarm in lieu of an
“Over Range” alarm when the heater sensor
is disconnected.
b. The Energy Management RTD4 is scaled from
-20°F(-28°C) to 429°F(220°C), “Out of Range”
conditions are as follows:
i. Over-range - temperatures above 400°F
(204°C)
ii. Under-range - temperatures below -20°F (-
28°C)
c. On alarm condition, a local alarm is displayed and
the common alarm relay is de-energized.
d. Over-range and Under-range alarms are self-
clearing.
18
Page 21
ALARM MESSAGES
LEFT TOWER ALARMS RIGHT TOWER ALARMS OTHER ALARMS
ALARM LEFT TOWER
DRYING
LOW PRESSURE
ALARM LEFT TOWER
REGENERATING
HIGH PRESSURE
ALARM LEFT TOWER
REGENERATING
LOW PRESSURE
ALARM LEFT TOWER
TEMP UNDER-RANGE
ALARM LEFT TOWER
TEMP OVER-RANGE
ALARM LEFT TOWER
OUTLET DEW POINT
ALARM RIGHT TWR
DRYING
LOW PRESSURE
ALARM RIGHT TWR
REGENERATING
HIGH PRESSURE
ALARM RIGHT TWR
REGENERATING
LOW PRESSURE
ALARM RIGHT TWR
TEMP UNDER-RANGE
ALARM RIGHT TWR
TEMP OVER-RANGE
ALARM RIGHT TWR
OUTLET DEW POINT
ALARM HEATER
OVER-TEMPERATURE
ALARM HEATER
LOW TEMPERATURE
ALARM ENRGY MGNT
UNDER-RANGE
ALARM ENRGY MGNT
OVER-RANGE
ALARM BLOWER
MOTOR OVERLOAD
ALARM HEATER
HIGH TEMP IN
ALARM LEFT TOWER
HIGH HUMIDITY
ALARM LEFT TOWER
DEW POINT
UNDER-RANGE
ALARM LEFT TOWER
DEW POINT
OVER-RANGE
ALARM RIGHT TWR
HIGH HUMIDITY
ALARM RIGHT TWR
DEW POINT
UNDER-RANGE
ALARM RIGHT TWR
DEW POINT
OVER-RANGE
19
Page 22
9. Heat Low Temperature
a. RTD3 is used to detect Heater Low Tempera-
ture.
b. Alarm if the heater temperature is less than 250°F
(121°C) within 15 minutes after the Heat Cycle is
initiated (15 minute delay also applies after power
recovery).
c. On alarm condition, display local alarm and de-
energize common alarm relay.
d. This alarm is self-clearing.
10. Heater Over-Temperature
a. RTD3 is used to detect Heater Over-Tempera-
ture.
b. Alarms anytime that the Heater temperature
exceeds 650°F (343°C).
c. On alarm condition, de-energize heat cycle, stop
cycle sequence, display local alarm and de-energize common alarm relay.
d. This alarm must be manually reset.
11. Blower Overload
a. Alarm condition when blower overload contact
closes.
13. Dew Point Sensor
a. High Dewpoint Alarm
i. The user enters an alarm value through the
Program Mode.
ii. If the measured dew point exceeds the alarm
value, the outlet dew point alarm is indicated.
b. Under-range alarm - Dew point below -148°F
(-100°C)
c. Over-range alarm - Dew point greater than
+109°F (+43°C)
d. On alarm condition,
i. Local alarm is displayed and the common
alarm relay is de-energized.
ii. If dryer is set up for Dewpoint Control, the dryer
sequence continues, but bypasses the “HOLD”
step and proceeds to tower switchover after 4
hours of drying.
iii. This alarm is self-clearing, at which time the
alarm LED stops blinking and control switches
back to Dewpoint Control.
b. On alarm condition, de-energize heat cycle, stop
cycle sequence, display local alarm and de-energize common alarm relay.
c. This alarm must be manually reset.
Alarms for Optional Devices
12. Energy Management a. High Humidity Alarm:
i. Measured moisture level exceeds the air alarm
value entered through the Program Mode.
b. Humidity Sensor:
i. Under-range: RH% < -15%
ii. Over-range: RH% > 115%
c. RTD:
i. Over-range: Temperature above 448°F
(231°C)
ii. Under-range: Temperature below -20°F
(-28°C)
d. On alarm condition:
i. Local alarm is displayed and the common
alarm relay is de-energized.
ii. If the dryer is set up for Energy Management
Control, the dryer sequence continues, but
bypasses the “HOLD” step and proceeds to
tower switchover after 4 hours of drying.
iii. This alarm is self-clearing, at which time the
alarm LED stops blinking and control switches
back to Energy Management control.
20
Page 23
Service Due Messages
14. There are two service levels (normal and severe)
as described in Program Mode. Each service level
has preset time intervals for servicing the lters,
desiccant, and valves. Time continues to accumulate
as long as power is supplied to the controller, whether
the controller is switched on or off.
When a service time interval expires (see also 14.d
below), the controller operates as follows.
a. The service LED blinks and the appropriate
service message is shown on the text display.
i. When the service interval for lters has expired
(see also d below), the three lter LED’s also
blink.
b. The dryer continues to cycle normally. The LED’s
for the valve’s, pressure switches, and desiccant
towers are not used for service indication.
c. Press the Reset button to extinguish the service
LED and to clear the service message from the
text display.
d. If the dryer has 1 or 2 lter monitors, the timer
for lter service is disabled. When the lter
monitor(s) send an alarm signal (change lter)
to the controller, the controller displays the same
LED’s and messages it would if the timer for lter
service had expired.
6.5.7 Display Mode
1. Display Mode is active when the user exits Program
Mode or Setup Mode and no alarms are active
(unless MANUAL CYCLE was selected in Setup
Mode).
2. Display Mode is comprised of dryer status screens
and dryer display screens (described below). The
controller automatically alternates the display
between the Status Screens and selected Display
Screens.
3. The user can override the automatic screen scroll
by pressing to step through each of the Display
Screens shown on the next page. Automatic
scrolling will resume when is pressed or if
not depressed for 60 seconds.
4. The Energy Savings and Service Reminders
Display Screens (Filters, Desiccant, and Valves) are
alternated in sequence with the current dryer status
screen.
15. Examples of the text display are shown on page 18
and below for each alarm and service reminder. The
second line of the alarm screens contains up to three
messages which are scrolled through, displaying
each one for 2 seconds.
SERVICE DUE MESSAGES
SERVICE DRYER
FILTERS
SERVICE DRYER
DESICCANT
SERVICE DRYER
VALVES
21
Page 24
DRYER STATUS SCREENS
LEFT TOWER DRYING
LT DRYING
RT DEPRESSURIZE
LT DRYING
RT HEATING
LT DRYING
RT COOLING
LT DRYING
RT REPRESSURIZE
LT DRYING
RT HOLDING
(Not displayed in FIXED Cycle)
TOWER SWITCHOVER TOWER SWITCHOVER
RIGHT TOWER DRYING
LT DEPRESSURIZE
RT DRYING
LT HEATING
RT DRYING
LT COOLING
RT DRYING
LT REPRESSURIZE
RT DRYING
LT HOLDING
RT DRYING
(Not displayed in FIXED Cycle)
Energy Savings
(Not displayed in FIXED Cycle)
ENERGY SAVINGS
XX%
NOTE: Energy Savings will appear
after seven days of continuous use.
Service reminder (lters)
HOURS TO SERVICE
FILTERS: XXXX
Service reminder (desiccant)
HOURS TO SERVICE
DESICCANT: XXXX
Service reminder (valves)
HOURS TO SERVICE
VALVES: XXXX
DRYER DISPLAY SCREENS
Outlet Dew Point
(Displayed only if JP3 is ON)
DEW POINT
±XX°C ±XXX°F
Left Tower Temperature
LT TEMP
±XX°C ±XXX°F
Right Tower Temperature
RT TEMP
±XX°C ±XXX°F
Heater Temperature
HEATER TEMP
±XX°C ±XXX°F
Dewpoint Demand SetPoint
(Displayed only if JP3 is ON)
DWPT CNTL SETPT
±XX°C ±XXX°F
Energy Mgmt Signal
(Displayed only if JP2 is ON)
ENERGY MGMT SGNL
XX%RH XXX°F XX°C
XX MBAR X.XX PSI
Energy Mgmt Setpoint
(Displayed only if JP2 is ON)
ENERGY MGMT SET
XX MBAR X.XX PSI
(This is the calculated “hold” set-point,
which is based on the sample air temperature.)
22
Page 25
6.5.8 Test Mode
1. Test Mode is active when the user exits Program
Mode after selecting operation in MANUAL CYCLE.
2. Test Mode is comprised of twelve (12) screens
(screen descriptions follow the table below on the
next page). Each screen corresponds to one of
twelve program steps (described in the table below).
5. To exit Test Mode:
a. Press and hold for 3 seconds to exit Test
Mode. The display switches to Screen 2 of Setup
Mode.
b. Use to select ENERGY MANAGEMENT,
DEWPOINT CONTROL or FIXED CYCLE.
c. Press and hold for 3 seconds to exit Setup
Mode and activate Display Mode.
d. Dryer operation continues from the last step active
3. Press to advance from one screen (test step) to
when exiting the Test Mode.
the next.
IMPORTANT: Be sure to read and understand all
cautions listed with the screen (program step) descriptions.
4. Upon entering Test Mode, the program can be at any
one of the twelve steps.
Program Step 1 2 3 4 5 6 7 8 9 10 11 12
LT status Drying Drying Drying Drying Drying Drying Off Depress Heat
RT status Off Depress Heat
1PS Closed Closed Closed Closed Closed Closed Closed
2PS Closed
3PS Closed Closed Closed Closed Closed Closed Closed
4PS Closed
LT drying solenoid (B) On On On On On On Off Off Off Off Off Off
LT depress solenoid (F) Off Off Off Off Off Off Off On On On On Off
LT purge solenoid (C) Off Off Off Off Off Off Off Off On On On Off
RT drying solenoid (A) Off Off Off Off Off Off On On On On On On
RT depress solenoid (G) Off On On On On Off Off Off Off Off Off Off
RT purge solenoid (D) Off Off On On On Off Off Off Off Off Off Off
LT inlet valve (V1) Open Open Open Open Open Open Closed Closed Closed Closed Closed Closed
LT depress valve (V9) Closed Closed Closed Closed Closed Closed Closed Open Open Open Open Closed
LT purge valve (V3) Closed Closed Closed Closed Closed Closed Closed Closed Open Open Open Closed
RT inlet valve (V2) Closed Closed Closed Closed Closed Closed Open Open Open Open Open Open
RT depress valve (V10) Closed Open Open Open Open Closed Closed Closed Closed Closed Closed Closed
RT purge valve (V4) Closed Open Open Open Open Closed Closed Closed Closed Closed Closed Closed
Repress valve (V11) Closed Closed Closed Closed Open Open Closed Closed Closed Closed Open Open
Temp display - location Left Right Right Right Right Right Right Left Left Left Left Left
Closed
then Open
Closed
then Open
Open Open Open
Open Open Open
Cool
Down
Sweep Repress Drying Drying Drying Drying Drying Drying
Open then
Closed
Open then
Closed
Closed
then Open
Closed Closed Closed Closed Closed Closed
Closed
then Open
Closed Closed Closed Closed Closed Closed
Open Open Open
Open Open Open
Cool
Down
Sweep Repress
Open then
Closed
Open then
Closed
Table 2
Cycle Sequence Steps
23
Page 26
TEST MODE SCREENS
Screen 1: Step 1
TEST1: LT DRYING
LT: XX°C XXX°F
Screen 2: Step 2
TEST2: DEPR RT
RT: XX°C XXX°F
NOTE: Sequence step will not advance to HEAT until
tower has fully depressurized. Exception: If
switching failure is disabled then pressure
condition is ignored.
Screen 3: Step 3
TEST3: HEAT RT
RT: XX°C XXX°F
Screen 4: Step 4
TEST4: COOL RT
RT: XX°C XXX°F
Screen 7: Step 7
TEST7: RT DRYING
RT: XX°C XXX°F
Screen 8: Step 8
TEST8: DEPR LT
LT: XX°C XXX°F
NOTE: Sequence step will not advance to HEAT until
tower has fully depressurized. Exception: If
switching failure is disabled then pressure
condition is ignored.
Screen 9: Step 9
TEST9: HEAT LT
LT: XX°C XXX°F
Screen 10: Step 10
TEST10: COOL LT
LT: XX°C XXX°F
Screen 5: Step 5
TEST5: SWEEP RT
RT: XX°C XXX°F
NOTE: If sweep cycle is disabled then Test 5 is
ignored.
Screen 6: Step 6
TEST6: REPR RT
RT: XX°C XXX°F
NOTE: Sequence step will not advance to tower
SWITCHOVER until tower has fully
pressurized. Exception: If switching failure
is disabled then pressure condition is
ignored.
Screen 11: Step 11
TEST11: SWEEP LT
LT: XX°C XXX°F
NOTE: If sweep cycle is disabled then Test 10 is
ignored.
Screen 12: Step 12
TEST12: REPR LT
LT: XX°C XXX°F
NOTE: Sequence step will not advance to tower
SWITCHOVER until tower has fully
pressurized. Exception: If switching failure
is disabled then pressure condition is
ignored.
24
Page 27
6.6 Start-up
6.6.1 Controller Settings
Set or verify settings on Controller. Detailed operational
points are presented in section 6.5.
WARNING - Enclosure may have live electric parts.
De-energize dryer before opening enclosure.
6.6.2 Initial Pressurization
SLOWLY pressurize dryer to full line pressure. (If the
dryer was installed with inlet and outlet isolation valves,
the inlet isolation valve should be slowly opened while
the outlet isolation valve remains closed.)
During initial start-up, check the entire system for leaks.
If necessary, de-pressurize the dryer and correct any
leaks.
NOTE: Read the off-line tower pressure gauge when the
tower is purging (air exhausting from mufer).
6.7.5 Process Valves
Determine if air control valves are operating and
sequencing correctly.
6.7.5.1 Valves – Models 500 and 600
Inlet switching valves are normally open, pneumatically
piston-actuated, Y-angle poppet valves. A yellow indicator
can be seen through a clear window at the top of the actuator housing when the valve is in the open position.
Purge exhaust valves are normally closed, pneumatically piston-actuated, Y-angle poppet valves. A yellow
indicator can be seen through a clear window at the top
of the actuator housing when the valve is in the open
position.
6.6.2.1 Energy Management Sensor (if installed)
Open and adjust the sample exhaust valve until a very
slight, continuous gas bleed is felt exhausting out of the
sample cell.
6.6.2.2 Dew Point Sensor (if installed)
Ensure that the supply air valve is open (one turn).
Open and adjust the sample exhaust valve until a very
slight, continuous gas bleed is felt exhausting out of the
sample cell.
6.6.3 Energizing the Dryer
Energize the dryer controls.
NOTE: The switching failure alarm may be activated if the
unit is energized before it is pressurized. To deactivate
alarm, allow dryer to cycle to next step and press the
reset button.
6.6.4 Bringing the Dryer On-line
Establish a normal ow through the dryer. Slowly open
the outlet isolation valve if present. Close any dryer
bypass valves.
6.7 Operational Check Points
6.7.1 Power to unit
Check periodically that there is power to the unit
(indicating lights illuminated).
6.7.2 Alarms
Periodically check for ashing red alarm LED.
6.7.3 Tower Status LEDs
Illuminated LEDs indicate which tower is on-line drying
or off-line regenerating.
6.7.4 Tower Pressure Gauges
Periodically check tower pressure gauges to verify
that the pressure gauge of the on-line tower reads line
pressure and the pressure gauge of the off-line tower
reads below 2 psig (0.14 kgf/ cm2).
12 volt DC, normally-closed, 3-way pilot solenoid valves
are wired to the controller and are used to direct pilot air
to the actuators of the inlet switching and purge/repressurization valves.
Dryers are equipped with a safety relief valve that has
been sized to provide overpressure protection due to a
re for both desiccant towers.
6.7.5.2 Valves – Models 750 through 4300
Inlet switching valves are resilient seated buttery valves
with double acting pneumatic rack and pinion actuators.
A yellow arrow indicator located on the top of the actuator
output shaft points to valve position indicator icons. Pilot
air is directed to actuator ports to open both inlet valves
upon loss of power.
(Model 750 only) Purge exhaust valves are normally
closed, pneumatically piston-actuated, Y-angle poppet
valves. A yellow indicator can be seen through a clear
window at the top of the actuator housing when the valve
is in the open position.
(Models 900 through 4300) Purge exhaust valves are
resilient seated buttery valves with spring return, fail
closed, pneumatic rack and pinion actuators. A yellow
arrow indicator located on the top of the actuator output
shaft points to valve position indicator icons. Pilot air is
directed to actuator ports to close both purge/repressurization valves upon loss of power.
12 volt DC, single solenoid, 4-way pilot valves are wired
to the controller and are used to direct pilot air to the
actuators of the inlet switching and purge/repressurization valves.
Two mainline outlet and two purge line check valves
are installed in the upper piping to control the ow of
outlet and purge air. Check valve sticking will result in
excessive air discharge through a mufer. Excessive air
discharge through the mufer can be associated with a
leaking outlet check valve on the same side or a purge
check valve of the opposite side tower.
25
Page 28
Dryers are equipped with a safety relief valve that has
been sized to provide overpressure protection due to a
re for both desiccant towers.
b. Advances directly to the beginning of whichever
stage of HEAT or COOL it had been at when
power was interrupted.
The tower pressure gauge of the on-line tower should
read line pressure. Air should not be leaking from the
purge-repressurization valve of the on-line tower.
The tower pressure gauge of the off-line tower should
read below 2 psig (0.14 kgf/ cm2) while that tower is
purging. If excessive air is exhausting during the purge
cycle, the inlet-switching valve on the same side may
have failed to close or a check valve may be sticking.
6.8 Dryer Shut Down
1. If the dryer installation is equipped with dryer bypass
and inlet and outlet isolation valves, the bypass valve
should be opened and the inlet and outlet isolation
valves closed.
2. De-energize the dryer’s electrical supply.
3. SLOWLY open the tower blow down valves (refer
to Figure 3 for general location) to vent the dryer
internal pressure.
4. When all dryer pressure gauges indicate zero pressure, close the tower blow down valves. Depressurization is complete.
2. If the off-line tower was at any other step
(SWITCHOVER, DEPRESSURIZATION,
REPRESSURIZATION or HOLD) when power was
lost, then the sequence simply resumes at that step.
6.10 Operating Parameters
Control valves are designed so that upon loss of power
the air dryer is capable of drying air until the desiccant
exposed to the airow is saturated.
6.11 Using the RS-232 Port
The RS-232 port is used to monitor dryer operation from
a host computer.
RS-232 connections are made at the 3-pin connector
labeled J3 and located at the upper left-hand corner of
the control board.
Interface to a PC requires a (1 to 1) DB-9 cable.
Cable Pin Out:
- Data transmitted on pin 2
- Data received on pin 3
- Ground is pin 5
- Pins 7 and 8 are jumpered at the dryer
6.9 Loss of Power
Control valves are designed so that upon loss of power
the air dryer is capable of drying air until the desiccant
exposed to the airow is saturated.
6.9.1 Power Recovery:
6.9.1.1 On loss of electrical power –
All controller outputs turn off causing the dryer operating
valves to react as follows:
1a. For models with poppet style inlet valves (models
500 - 600): both inlet valves will open. Both towers
will repressurize.
1b. For models with buttery inlet valves (models 750 -
4300): inlet valves will remain in position. Any minor
leakage through the inlet valve or check valve will
slowly repressurize the off-line tower.
2. Purge exhaust valves close.
3. Depressurization solenoid valves close.
4. Repressurization valve closes.
6.9.1.2 On restoration of power –
1. If power is lost when the off-line tower is in either the
HEAT or COOL step, the off-line tower will be either
partially or fully repressurized. On power recovery
the sequence:
a. Resumes at the DEPRESSURIZATION step to
let down the pressure in the off-line tower then,
Operation:
1. Fixed baud rate of 9600
2. Asynchronous format is 8 bit, no parity, 1 stop bit
(“8,N,1”)
3. No check sum or error correction values are provided. If required, request status string two (or more)
times and compare for agreement.
4. Request data by sending ASCII ? character (3FH).
Response may take up to two seconds as certain
processing functions may require completion before
the serial port is acknowledged.
5. The dryer responds with line feed (0AH), carriage
return (0DH), and a character string as follows:
STX Start of text character 0x02
109 Three character ASCII device identier
, comma character
x ASCII representation of the cycle type
,
xx ASCII representation of the cycle step
,
xxxxx ASCII representation of the current cycle time
in seconds
,
xxx ASCII representation of the inlet temperature
(°F)
26
Page 29
,
xxx ASCII representation of the heater tempera-
ture (°F)
,
xxx ASCII representation of the left bed tempera-
ture (°F)
,
xxx ASCII representation of the right bed tem-
perature (°F)
,
xxx ASCII representation of the humidity sensor
temperature (°F)
,
xxx ASCII representation of the humidity sensor
relative humidity (%)
,
xxxx ASCII representation of the dew point reading
(°F)
,
xxxx ASCII representation of the lter time to ser-
vice (hours)
,
xxxx ASCII representation of the desiccant time to
service (hours)
,
xxxx ASCII representation of the valve time to
service (hours)
,
x ASCII representation of programming jump-
ers
,
1 or 0 Is the unit alarmed? 1 = alarm
,
1 or 0 Is service required? 1 = service
,
xx ASCII representation of the energy savings
(%)
,
x Reserved for future use, always 1 for now
,
ETX end of text character OxO3
CR carriage return
LF line feed
Determining jumper positions:
Each jumper 8 bits weighted by position
JP Value
8 128
7 64
6 32
5 16
4 8
3 4
2 2
1 1
Example:
If jumper 8, 5, and 1 are installed, a value of 128+16+1
= 145 is returned
To decode, the algorithm:
· If (number >= 128) è jumper 8 = on
· number = number - 128
· If (number >= 64) è jumper 7 = on
· number = number - 64;
· etc.....
JUMPERS:
The programming jumpers are as follows (0=off,
1=on):
JP Bit
1 0 off = externally heated on = blower dryer
2 1 on = energy management sensor installed
3 2 on = dew point sensor installed
4 3 on = no cooling (blower purge only)
5 4 on = tower pressure switches installed
6 5 on = not used (fast cycle for development,
V3.5 and prior)
7 6 on = to download language text (factory
use)
8 7 on = to enable factory set-up screens
27
Page 30
7.0 Maintenance
WARNING - This equipment is a pressure-containing
device. Depressurize before servicing.
NOTE: The Dryer Controller is equipped with Service
Reminder functions for lters, desiccant and valves.
7.1 Desiccant Replacement
NOTE: The use of the correct replacement desiccant
is necessary for proper dryer operation. Never use
hygroscopic salts of the type commonly used in
“deliquescent ” type dryers.
1. Frequency Of Desiccant Replacement
Desiccant should be replaced whenever the required
dew point cannot be maintained while the dryer is
being operated within its design conditions and there
are no mechanical malfunctions.
NOTE: Desiccant life is determined by the quality of
the inlet air. Proper ltering of the inlet air will extend
the life of the desiccant. Typically desiccant life is 2
years.
2. Procedure for Desiccant Charge Replacement
a. Depressurize and de-energize the dryer.
b. Remove the ll and drain plugs or anges (where
applicable) from the desiccant tower and drain the
spent desiccant. Place a container at the base of
the vessel to collect the desiccant. If necessary
tap the sides of the vessels with a rubber mallet
to loosen desiccant.
NOTE: Use extreme care when inserting rods or
other tools through the desiccant ll or drain ports
to loosen packed desiccant. Internal ow diffusers
at the ends of the desiccant beds can be damaged
or punctured by sharp instruments. These diffusers
are necessary to distribute the airow and keep the
desiccant beads within the tower. Desiccant beads in
exhaust mufers, afterlters, or the piping connected
to the desiccant towers may indicate a perforation of
a diffuser.
c. Replace the drain plug using Teon tape or another
pipe thread sealant suitable for compressed air
service. Reinstall drain port ange cover (where
applicable) in each desiccant tower.
d. Refer to Table 1 (on page 5) for desiccant quan-
tity per tower.
When using Table 1 you will nd the desiccant
quantities listed in layers. Each layer will vary in
depth due to the type, quantity and purpose of the
desiccant. Layer 1 must be installed rst at the
bottom of the vessel followed by layer number 2
etc., until the complete charge of desiccant has
been installed.
e. Utilizing an appropriate sized funnel, ll each
desiccant tower as follows:
1) Install the required quantity of tabular support
(model 4300 only) or activated alumina in
layer 1 of each tower.
2) Level layer 1 and each subsequent layer of
desiccant as added to each tower.
3) Finish lling each tower with desiccant until
all desiccant has been installed. LIGHT tapping on the tower sides with a soft-face mallet
should yield additional free space to allow
installation of all desiccant required. DO NOT
TAMP OR RAM DESICCANT.
f. Clean the ll port closure. Replace the ll plug
using Teon tape or another pipe thread sealant
suitable for compressed air service. Reinstall ll
port ange cover (where applicable) in desiccant
tower.
3. Insuring Desiccant Dryness
Replacement desiccant is shipped in airtight
containers. Keep the covers on these containers tightly
closed until use to avoid moisture contamination.
If desiccant is exposed to air it can be heated in
an oven at 400°F (204°C) for four hours before
use. Alternatively, if the dryer is not relled with
dry desiccant, it may be necessary to operate
the unit with an inlet ow rate of less than 50% of
maximum rated inlet capacity until the desiccant has
regenerated fully.
7.2 Purge Mufers
Purge mufers should be checked regularly, changed
annually. Mufer disseminator elements become clogged
with desiccant dust over time, creating back pressure
and restricted purge ow.
7.3 Valves
1. Process and pilot valves should be checked frequently for leaks and proper operation.
2. Purge pressure adjustment valve should be checked
frequently for proper adjustment.
7.4 Pilot Air Filter Element Replacement
1. Frequency of replacement
The pilot air lter contains a lter element that should
be changed yearly. Replacement may be required
sooner if pressure drop across cartridge prevents
valves from actuating properly.
WARNING – The pilot air lter housing is a pressure-
containing device, depressurize before servicing.
Slowly open manual drain valve on bottom of lter
bowl by turning clockwise to verify that the housing
is depressurized before removing bowl.
28
Page 31
2. Procedure for element replacement
a. Isolate dryer from air supply
b. Depressurize dryer by running dryer and allowing
system pressure to purge to atmosphere. Loss
of pilot pressure will eventually prevent purge/
repressurization valves from opening. Remaining
pressure can be vented to atmosphere through
the manual drain on the pilot air lter. The system
must be fully depressurized before removing the
bowl.
c. Remove the filter bowl by pushing up, turn-
ing counterclockwise and then pulling straight
down.
d. Clean the lter bowl.
e. Replace the element.
f. Clean and lubricate o-ring at top of bowl and
reassemble in reverse order.
7.5 Dew Point Analyzer Filter (optional)
Element Replacement
1. Frequency of replacement
The Dew Point Analyzer lter contains a lter element
that should be changed yearly. Replacement may
be required sooner if pressure drop across cartridge
prevents the Dew Point Analyzer from operating
properly.
WARNING – The Dew Point Analyzer lter housing
is a pressure-containing device, depressurize before
servicing. Slowly open manual drain valve on bottom
of lter bowl by turning clockwise to verify that the
housing is depressurized before removing bowl.
2. Procedure for element replacement
a. Isolate dryer from air supply
b. Depressurize dryer by running dryer and allowing
system pressure to purge to atmosphere. Loss
of pilot pressure will eventually prevent purge/
repressurization valves from opening. Remaining
pressure can be vented to atmosphere through
the manual drain on the pilot air lter. The system
must be fully depressurized before removing the
bowl.
c. Remove the filter bowl by pushing up, turn-
ing counterclockwise and then pulling straight
down.
d. Clean the lter bowl.
e. Replace the element.
f. Clean and lubricate o-ring at top of bowl and
reassemble in reverse order.
29
Page 32
8.0 Troubleshooting
WARNING - A POTENTIAL ELECTRICAL SHOCK
HAZARD EXISTS. Some of the troubleshooting
checks may require gaining access to the dryer’s
electrical enclosure(s) while the power supply is
energized and should be performed by a qualied
electrical technician.
WARNING - Before performing any electrical or
mechanical repairs or maintenance, or removing
or disassembling any component, be sure to deenergize and depressurize the dryer.
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Indicator lights not illuminated 1. No power to unit.
2. Loss of power supply to (or at) dryer’s
electrical disconnect switch or breaker.
(customer supplied)
3. Blown fuse.
4. Board malfunction.
Excessive pressure drop in dryer 1. Inlet/Outlet screens on desiccant tow-
Low Pressure Alarm
Left Tower or Right Tower
Drying
ers are dirty
2. Excessive ow rate
1. Loss of dryer air supply.
2. Excessive air demand.
3. Faulty drying tower pressure switch
4. Drying tower Inlet Valve failed to open
5. Drying tower Purge Exhaust Valve
failed to close.
6. Drying tower Depressurization Valve
failed to close
7. Regenerating tower Outlet Check
Valve failed to close
8. Drying tower Purge Check Valve leaking
1. Check voltage at terminal board.
2. Check disconnect switch or breaker closed. If tripped
breaker or blown fuse is noted, investigate and Remedy
cause.
3. Replace fuse.
4. Replace board.
1. Clean screens; follow desiccant removal instructions in the
Maintenance section.
2. Check ow rate of inlet air. Reduce to design ow rate.
1. Check compressor supplying dryer.
2. Check equipment downstream of dryer.
3. Check pressure switch operation using tower pressure
gauge for comparison. Replace switch if defective.
4a. Check for loss of pilot air - ensure manual drain valve on
bottom of pilot air lter is fully closed, ensure pilot air lter
cartridge is not clogged, ensure pilot air shut-off valve is
open
4b. Check for inlet pilot air solenoid valve failure. Check valve
operation. Repair or replace as necessary.
4c. Check for drying tower Inlet Valve failure - examine valve
and actuator for damage. Repair or replace as necessary.
5a. Check for air ow out of drying tower Purge Valve or ex-
haust piping indicating valve is not completely closed.
5b. Check for loss of pilot air - ensure manual drain valve on
bottom of pilot air lter is fully closed, ensure pilot air lter
cartridge is not clogged, ensure pilot air shut-off valve is
open
5c. Check for purge pilot air solenoid valve failure. Check valve
operation. Repair or replace as necessary.
5d. Check for drying tower Purge Exhaust Valve failure - exam-
ine valve and actuator for damage. Repair or replace as
necessary.
6. Check for air ow out of drying tower Depressurization
Mufer indicating valve is not completely closed. Repair or
replace as necessary.
7. Indicated by excessive ow out of regenerating tower
Purge Valve. Examine valve internals. Repair or replace
as necessary.
8. Indicated by excessive ow out of regenerating tower Purge
Valve or reverse air ow through heater and blower, i.e., out
of the blower intake lter, examine valve internals. Repair
or replace as necessary.
CAUTION: Air owing backwards through heater and
blower may be very hot.
30
Page 33
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
High Pressure Alarm
Left Tower or Right Tower Regenerating
Low Pressure Alarm
Left Tower or Right Tower Regenerating
Temperature Under-Range
or
Temperature Over-Range
Alarm
Left Tower or Right Tower
Dew Point Under-Range
or
Dew Point Over-Range Alarm
Left Tower or Right Tower Regenerating
1. Faulty regenerating tower pressure
switch
2. Regenerating tower Depressurization
Mufer clogged.
3. Regenerating tower Depressurization
Valve failed to open.
4. Regenerating tower purge exhaust piping obstructed.
5. Regenerating tower Purge Exhaust
Valve failed to open.
6. Repressurization valve (V11) failed to
close.
1. Faulty left tower pressure switch.
2. Regenerating tower Purge Exhaust
Valve failed to close.
3. Regenerating tower Depressurization
Valve failed to close.
4. Repressurization valve (V11) failed to
open.
5. Repressurization orices are blocked.
1. Tower temperature sensor failure.
Under-Range è Short circuit on sensor
Over-Range è Open circuit on sensor
1. Energy Management temperature sensor (RTD4) failure.
1. Check pressure switch operation using tower pressure
gauge for comparison. Replace switch if defective.
2. Examine inner core and clean or replace as necessary.
3. Check valve operation. Repair or replace as possible.
4. Ensure piping is free of obstructions.
5a. Check for loss of pilot air - ensure manual drain valve on
bottom of pilot air lter is fully closed, ensure pilot air lter
cartridge is not clogged, ensure pilot air shut-off valve is
open.
5b. Check for purge pilot air solenoid valve failure. Check valve
operation. Repair or replace as necessary.
5c. Check for regenerating tower Purge Exhaust Valve failure -
examine valve and actuator for damage. Repair or replace
as necessary.
6a. Check for loss of pilot air - ensure manual drain valve on
bottom of pilot air lter is fully closed, ensure pilot air lter
cartridge is not clogged, ensure pilot air shut-off valve is
open.
6b. Check for Repressurization Valve (V11) failure. Check valve
operation. Repair or replace as necessary.
1. Check pressure switch operation using tower pressure
gauge for comparison. Replace switch if defective.
2a. Check for air ow out of regenerating tower Purge Valve or
exhaust piping indicating valve is not completely closed.
2b. Check for loss of pilot air - ensure manual drain valve on
bottom of pilot air lter is fully closed, ensure pilot air lter
cartridge is not clogged, ensure pilot air shut-off valve is
open
2c. Check for purge pilot air solenoid valve failure. Check valve
operation. Repair or replace as necessary.
2d. Check for regenerating tower Purge Exhaust Valve failure -
examine valve and actuator for damage. Repair or replace
as necessary.
3. Check for air ow out of regenerating tower Depressurization Mufer indicating valve is not completely closed.
Repair or replace as necessary.
4a. Check for loss of pilot air - ensure manual drain valve on
bottom of pilot air lter is fully closed, ensure pilot air lter
cartridge is not clogged, ensure pilot air shut-off valve is
open.
4b. Examine repressurization valve (V11) for damage. Repair
or replace as necessary.
5. Check orices for obstruction and clean as necessary.
1. Check temperature circuit for continuity. Repair or replace
as necessary.
1. Check temperature circuit for continuity. Repair or replace
as necessary.
31
Page 34
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Outlet Dew Point Alarm
Left Tower or Right Tower
High Humidity Alarm
Left Tower or Right Tower
Heater Over-Temperature
Alarm
Heater Low-Temperature
Alarm
Energy Management UnderRange Alarm
or
Energy Management OverRange Alarm
Blower Motor Overload Alarm 1. Restricted or blocked purge air ow.
Heater High Inlet Temperature
(models 3200, 3600, & 4300
only)
1. Inlet air ow higher than the sizing
condition.
2. Liquids entering the dryer inlet.
3. Inlet air temperature higher than the
sizing condition.
4. Desiccant dusting.
5. Contaminated desiccant (e.g. with oil).
6. Heater temperature set too low.
7. Heating malfunction due to heater
failure or heater contactor failure.
1. Desiccant bed overloaded.
2. Dew point sensor or monitor damaged
or defective.
3. Loss of desiccant drying capacity
1. Insufcient purge gas ow.
2. Temperature sensor failure.
1. Heating malfunction due to heater
failure or heater contactor failure.
2. Temperature sensor failure.
1. Energy Management sensor failure. 1. Check circuit for continuity. Repair or replace as neces-
2. Line failure
1. On-line tower purge check valve is
leaking.
2. Temperature sensor failure.
1. Reduce inlet ow to sizing condition.
2. Check the inlet air line for liquids. Inspect prelter and
drain valve. Clean, repair or replace automatic drain valve.
3. Check the compressor aftercooler and cooling system.
Reduce inlet air temperature to sizing condition.
4. Check air pressure, airow and airow surges and correct
as necessary. Replace desiccant.
5. Check prelter and automatic drain valve. Replace prelter
element. Clean, repair or replace drain valve as necessary.
Consult factory concerning need for desiccant replacement.
6. Adjust controller set point.
7. Replace heater or heater contactor.
1. Check inlet air ow rate, temperature and pressure. Higher
than design ow, and temperature, and lower than design
pressure will result in overloading of the dryer.
2. Examine sensor for physical damage and check monitor/
sensor operation. Replace sensor or monitor as necessary.
3. Inlet air improperly ltered causing desiccant contamination
- examine lter elements and drains. Repair or replace as
necessary. Useful life of desiccant has been exceeded.
1. Check for purge blockage, temperature sensor failure, etc.
2. Repair and replace as required.
1. Replace heater or heater contactor.
2. Repair and replace as required.
sary.
1a. Dirty intake lter on blower - examine lter element and
clean or replace.
1b. Regenerating tower purge exhaust valve failed to open -
1) Check for loss of pilot air - ensure manual drain valve on
bottom of pilot air lter is fully closed, ensure pilot air lter
cartridge is not clogged, ensure pilot air shut-off valve is
open.
2) Check for purge pilot air solenoid valve failure. Check valve
operation. Repair or replace as necessary.
3) Check for regenerating tower Purge Exhaust Valve failure examine valve and actuator for damage. Repair or replace
as necessary.
1c. Purge exhaust piping obstructed - ensure piping is free of
obstructions.
1d. Regenerating tower purge check valve failed to open - ex-
amine valve internals. Repair or replace as necessary.
2. Check voltages and currents in the motor circuit.
1. Examine valve internals. Repair or replace as required.
2. Repair and replace as required.
32
Page 35
Electrical Schematic – 460VAC, 3 phase
(Contact factory to request certied drawings)
DETAIL A
(2-WIRE DEWPOINT TRANSMITTER)
20
21
72
21
249 OHM
1/8W
+12VDC
20
21
21
EXTERNALLY LOCATED
RED
BLACK
DEWPOINT
3
TRANSMITTER
+ 4-20MA OUT
1
CUSTOMER PROVIDED
460VAC, 3 PHASE
(FOR FUSING AND WIRE
SIZING SEE TABLE 1)
{
LOW TENSION
ENCLOSURE
L
L
TB5
N
N
PE
PE
+12VDC
DC COM
RTD1+
RTD1-
ANLG1+
ANLG1-
ANLG2+
ANLG2-
+5VDC
DC COM
RTD2+
RTD2-
RTD3+
RTD3-
RTD4+
RTD4-
RTD5+
RTD5-
IN1
LPS
LPS
RPS
RPS
IN2
IN3
L PURGE
L PURGE
R PURGE
R PURGE
L DRY
L DRY
R DRY
R DRY
OUT1
OUT2
ALARM
CONTACTS
20
21
80
81
70
249 OHM
1/8W
72
21
10
11
84
85
86
87
88
89
32
33
34
35
36
37
38
39
50
+
51
52
+
53
54
+
55
56
+
57
-
25
21
59
20
NO
NC
C
3-WIRE DEWPOINT TRANSMITTER
(FOR 2-WIRE, SEE DETAIL A)
+12VDC
RED
20
BLACK
21
GREEN
BROWN
BLACK
GREEN
21
RED
ORANGE
+ -
20 21
+12VDC
EXTERNALLY LOCATED
DEWPOINT
3
TRANSMITTER
G
+ 4-20MA OUT
1
OPTION
HEATER OVERTEMPERATURE
RTD3
RTD
RIGHT CHAMBER
RTD2
RTD
LEFT CHAMBER
RTD1
RTD
54
SOLENOID "B"
56
SOLENOID "A"
25
SOLENOID "E"
EXTERNALLY
LOCATED
ENERGY MGMT
SENSOR
RTD4
+
1-5VDC OUT
+
5VDC
YELLOW
G
-
OPTION
55
57
+12VDC
20
21
L1
L2
L3
L4
L5
L6
101
101
101
4CR1
101 107
5CR1
101
101
+12VDC DC COM
20
20
32
33
SET @ 45PSIG
1PS
35
34
SET @ 45PSIG
2PS
OL-AUX
36
1TS
+ -
50
+ -
52
+ -
59
L2
L1
20
1PSB
1CR1
104
104
104
2CR1
3CR1
37
2CR
53
3CR
1CR
MC1
MC2
MC3
2FU
1FU
3FU
+12VDC
+V -V
L N
G
MC-AUX
105
105
OL-AUX
26
28
LEFT CHAMBER
PRESSURE SWITCH
RIGHT CHAMBER
PRESSURE SWITCH
USED ON MODELS
3200, 3600 & 4300
51
21
HEAT ENABLE
401
OL1
402
OL2
403
OL3
404
HC1
405
HC2
406
HC3
0.5 AMP
407
0.5 AMP
H1 H3
408
1.25 AMP
101A
21
K TYPE
1TC
+ -
L1 N
106
C NO
1TR (OFF-DELAY, SE T @ 180S)
101
A1B1A2
1TR1
114
15 18
SOLENOID "F"
3PS
26
27
5PSIG
SOLENOID "G"
4PS
28
29
5PSIG
460VAC
X1 X2
115VAC
102
108
SOLENOID "C"
SOLENOID "D"
HIGH TENSION
ENCLOSURE
H2 H4
1T
102
102
102
102
HC
102
102
MC
21
21
4CR
21
21
21
5CR
21
MOTOR1M
1HTR
21
NOTE:
SET 1TR ON MODE "D".
(SIGNAL OFF-DELAY)
LEFT CHAMBER DEPRESS
LEFT CHAMBER PURGE
EXHAUST
RIGHT CHAMBER DEPRESS
RIGHT CHAMBER PURGE
EXHAUST
33
Page 36
Electrical Schematic – 575VAC, 3 phase
(Contact factory to request certied drawings)
DETAIL A
(2-WIRE DEWPOINT TRANSMITTER)
+12VDC
20
21
249 OHM
72
21
20
21
1/8W
21
LOW TENSION
ENCLOSURE
L
L
N
N
PE
TB5
PE
+12VDC
DC COM
RTD1+
RTD1-
ANLG1+
ANLG1-
ANLG2+
ANLG2-
+5VDC
DC COM
RTD2+
RTD2-
RTD3+
RTD3-
RTD4+
RTD4-
RTD5+
RTD5-
IN1
LPS
LPS
RPS
RPS
IN2
IN3
L PURGE
L PURGE
R PURGE
R PURGE
L DRY
L DRY
R DRY
R DRY
OUT1
OUT2
ALARM
CONTACTS
20
21
80
81
70
249 OHM
1/8W
72
21
10
11
84
85
86
87
88
89
32
33
34
35
36
37
38
39
50
+
51
52
+
53
54
+
55
56
+
57
-
25
21
59
20
NO
NC
C
EXTERNALLY LOCATED
RED
BLACK
+12VDC
20
RED
ORANGE
DEWPOINT
3
TRANSMITTER
+ 4-20MA OUT
1
3-WIRE DEWPOINT TRANSMITTER
(FOR 2-WIRE, SEE DETAIL A)
RED
BLACK
21
GREEN
BROWN
BLACK
GREEN
21
+ -
20 21
+12VDC
CUSTOMER PROVIDED
575VAC, 3 PHASE
(FOR FUSING AND WIRE
SIZING SEE TABLE 1)
EXTERNALLY LOCATED
DEWPOINT
3
TRANSMITTER
G
+ 4-20MA OUT
1
HEATER OVERTEMPERATURE
RTD3
RTD
RIGHT CHAMBER
RTD2
RTD
LEFT CHAMBER
RTD1
RTD
54
SOLENOID "B"
56
SOLENOID "A"
25
SOLENOID "E"
OPTION
L1
L2
{
EXTERNALLY
LOCATED
ENERGY MGMT
SENSOR
RTD4
+
1-5VDC OUT
+
5VDC
YELLOW
G
-
OPTION
55
57
+12VDC
20
21
L3
L4
L5
L6
101
101
101
4CR1
101 107
5CR1
101
101
+12VDC DC COM
20
20
32
33
SET @ 45PSIG
1PS
35
34
SET @ 45PSIG
2PS
OL-AUX
36
1TS
+ -
50
+ -
52
+ -
59
L2
L1
+12VDC
20
1PSB
1CR1
104
104
104
2CR1
3CR1
37
2CR
53
3CR
21
1CR
MC1
MC2
MC3
2FU
1FU
3FU
+V -V
L N
G
MC-AUX
105
105
OL-AUX
26
28
LEFT CHAMBER
PRESSURE SWITCH
RIGHT CHAMBER
PRESSURE SWITCH
USED ON MODELS
3200, 3600 & 4300
51
HEAT ENABLE
401
OL1
402
OL2
403
OL3
404
HC1
405
HC2
406
HC3
0.5 AMP
407
0.5 AMP
H1 H3
408
1.25 AMP
101A
21
K TYPE
1TC
+ -
L1 N
106
C NO
1TR (OFF-DELAY, SE T @ 180S)
101
A1B1A2
1TR1
114
15 18
SOLENOID "F"
3PS
26
27
5PSIG
SOLENOID "G"
4PS
28
29
5PSIG
575VAC
H2 H4
X1 X2
115VAC
1HC
102
108
MC
4CR
SOLENOID "C"
5CR
SOLENOID "D"
MOTOR1M
1HTR
1T
102
21
102
102
102
102
102
21
21
21
21
21
21
NOTE:
SET 1TR ON MODE "D".
(SIGNAL OFF-DELAY)
LEFT CHAMBER DEPRESS
LEFT CHAMBER PURGE
EXHAUST
RIGHT CHAMBER DEPRESS
RIGHT CHAMBER PURGE
EXHAUST
HIGH TENSION
ENCLOSURE
34
Page 37
Electrical Data – Fusing & Wire Sizing
Electrical Service: 460VAC, 3 phase
MODEL COMPONENT RATING
HEATER 10 KW 12.6 20 AMPS #12 AWG
500
MOTOR 2.5 HP 4.1 7.5 AMPS #14 AWG
HEATER 12 KW 15.1 20 AMPS #12 AWG
600
MOTOR 4 HP 6.2 10 AMPS #14 AWG
HEATER 14 KW 17.6 25 AMPS #12 AWG
750
MOTOR 4 HP 6.2 10 AMPS #14 AWG
HEATER 17 KW 21.3 30 AMPS #10 AWG
900
MOTOR 4 HP 6.2 10 AMPS #14 AWG
1050
1300
1500
1800
2200
2600
3200
3600
4300
HEATER 19 KW 23.8 30 AMPS #10 AWG
MOTOR 5 HP 7.6 12 AMPS #14 AWG
HEATER 23 KW 28.9 40 AMPS #8 AWG
MOTOR 7.5 HP 11 17.5 AMPS #14 AWG
HEATER 28 KW 35.1 45 AMPS #8 AWG
MOTOR 10 HP 14 20 AMPS #14 AWG
HEATER 33 KW 41.4 60 AMPS #6 AWG
MOTOR 10 HP 14 20 AMPS #14 AWG
HEATER 40 KW 50.2 70 AMPS #4 AWG
MOTOR 10 HP 14 20 AMPS #14 AWG
HEATER 45 KW 56.5 80 AMPS #4 AWG
MOTOR 15 HP 21 30 AMPS #10 AWG
HEATER 54 KW 67.8 90 AMPS #2 AWG
MOTOR 5 HP 7.6 12 AMPS #14 AWG
HEATER 60 KW 75.3 100 AMPS #2 AWG
MOTOR 7.5 HP 9.0 12 AMPS #14 AWG
HEATER 70 KW 87.9 110 AMPS #2 AWG
MOTOR 7.5 HP 11 17.5 AMPS #14 AWG
F.L.A.
@460VAC
SUGGESTED
FUSING
WIRE SIZE
Electrical Service: 575VAC, 3 phase
MODEL COMPONENT RATING
HEATER 10 KW 10.0 15 AMPS #12 AWG
500
MOTOR 2.5 HP 3.3 6 AMPS #14 AWG
HEATER 12 KW 12.0 20 AMPS #12 AWG
600
MOTOR 4 HP 5.0 9 AMPS #14 AWG
HEATER 14 KW 14.1 20 AMPS #12 AWG
750
MOTOR 4 HP 5.0 9 AMPS #14 AWG
HEATER 17 KW 17.1 25 AMPS #12 AWG
900
MOTOR 4 HP 5.0 9 AMPS #14 AWG
1050
1300
1500
1800
2200
2600
3200
3600
4300
HEATER 19 KW 19.1 25 AMPS #12 AWG
MOTOR 5 HP 6.1 9 AMPS #14 AWG
HEATER 23 KW 23.1 30 AMPS #8 AWG
MOTOR 7.5 HP 9.0 15 AMPS #14 AWG
HEATER 28 KW 28.1 40 AMPS #8 AWG
MOTOR 10 HP 11.0 17.5 AMPS #14 AWG
HEATER 33 KW 33.1 50 AMPS #8 AWG
MOTOR 10 HP 11.0 17.5 AMPS #14 AWG
HEATER 40 KW 40.2 60 AMPS #6 AWG
MOTOR 10 HP 11.0 17.5 AMPS #14 AWG
HEATER 45 KW 45.2 60 AMPS #6 AWG
MOTOR 15 HP 17.0 25 AMPS #10 AWG
HEATER 54 KW 54.2 70 AMPS #4 AWG
MOTOR 5 HP 6.1 9 AMPS #14 AWG
HEATER 60 KW 60.2 80 AMPS #4 AWG
MOTOR 7.5 HP 6.1 9 AMPS #14 AWG
HEATER 70 KW 70.3 90 AMPS #2 AWG
MOTOR 7.5 HP 9.0 15 AMPS #14 AWG
F.L.A.
@575VAC
SUGGESTED
FUSING
WIRE SIZE
35
Page 38
P&ID Schematic - Models 500 through 600
(Contact factory to request certied drawings)
DRY GAS
OUTLET
4 26
27
28
25
19
20
24
23
6
13
43
42
16
29
21
LEFT
SET @ 176°F
RTD 1
M
SET @
45 PSIG
1PS
SET @
5 PSIG
3PS
EXH.
(RTD4/HS1)
ENERGY MGMT OPTION
SOL 'F'
SET @ 165 PSIG
V7 V8
2
SOL 'C'
V12 V13
3
1
V11
1TC
SET @ 370°F
RTD 3
SET @ 650°F
SOL 'D'
SOL 'E'
10
DPA
DEWPOINTER OPTION
V6V5
SET AT
100 PSIG
RIGHT
CHAMBERCHAMBER
REGENDRYING
SOL 'G'
SET @
45 PSIG
SET @
5 PSIG
2PS
4PS
SET @ 176°F
RTD 2
13
14
44A
44
22
3
15
7
8
11
12
9
18
54
WET GAS
INLET
36
19
5
17
2
1
EXH.
V9
V3
V4
V1 V2
NOTES
SYMBOLS ARE PER ANSI Y32.10 "GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS."
1.
AS SHOWN FLOW DIRECTION IS:
2.
SOLENOID VALVES 'B', 'D', & 'G' ARE SHOWN ENERGIZED,
3.
SOLENOID VALVES 'A', 'C', 'E', & 'F' ARE SHOWN DE-ENERGIZED.
4.
V10
INDICATES OPTION
EXH.
LEFT CHAMBER DRYING
RIGHT CHAMBER REGEN
PILOT GAS LINE
SOL 'A'
SOL 'B'
Page 39
LEGEND
1. INLET VALVE (V1 LEFT, V2 RIGHT)
2. PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT)
3. PURGE CHECK VALVE (V5 LEFT, V6 RIGHT)
4. OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT)
5. DEPRESS VALVE (V9 LEFT, V10 RIGHT)
6. PURGE HEATER WITH INSULATION
7. HEATER TEMPERATURE THERMOCOUPLE
8. HEATER OVERTEMPERATURE RTD
9. CHAMBER RTD (LEFT & RIGHT)
10. RELIEF VALVE
11. CHAMBER PRESSURE GAUGES (LEFT & RIGHT)
12. CHAMBER PRESSURE SWITCH (LEFT & RIGHT)
13. SERVICE VALVE
14. PILOT AIR FILTER
15. PRESSURE REGULATOR & GAUGE
16. SOLENOID VALVE
17. MUFFLER
18. DESICCANT CHAMBER
19. DESICCANT RETAINING SCREEN (TOP & BOTTOM)
20. DESICCANT FILL PORT
21. DESICCANT DRAIN PORT
22. HOT PIPE INSULATION
23. PURGE PRESSURE GAUGE
24. PURGE BLOWER AND MOTOR
25. PURGE SUCTION FILTER SILENCER
26. REPRESS/SWEEP VALVE (V11)
27. REPRESS/SWEEP CHECK VALVE (V12 LEFT, V13 RIGHT)
28. REPRESS/SWEEP ORIFICE
29. CHAMBER BLOW-DOWN VALVE
ENERGY MANAGEMENT OPTION
42. ENERGY MANAGEMENT PILOT OPERATED VALVE
43. ENERGY MANAGEMENT SENSOR (RTD4/HS1)
DEWPOINTER OPTION
44. DEWPOINT ANALYZER
44A. DEWPOINT ANALYZER FILTER
INSULATION OPTION
54. CHAMBER INSULATION
FIXED CYCLE TIMING
(TIME IN MINUTES)
ELECTRICAL COMPONENT
ENERGIZED
SOLENOID
VALVE 'A'
3 WAY
SOLENOID
VALVE 'B'
3 WAY
SOLENOID
VALVE 'C'
3 WAY
SOLENOID
VALVE 'D'
3 WAY
SOLENOID
VALVE 'E'
N.C.
SOLENOID
VALVE 'F'
N.C.
SOLENOID
VALVE 'G'
N.C.
HEATER
BLOWER
MOTOR
LEFT CHAMBER DRYING (RIGHT CHAMBER REGEN)
2
176
PROCESS COMPONENT
PROCESS COMPONENT
DEPRESSURIZATION
STATUS
CLOSED
YES
V1
OPEN
NO
CLOSED
YES
V2
OPEN
NO
OPEN
YES
V3
NO
CLOSED
YES
OPEN
V4
NO
CLOSED
CLOSED
NO
V11
OPEN
YES
YES OPEN
V9
NO
CLOSED
YES
OPEN
V10
NO
CLOSED
ON
YES
OFF
NO
YES
ON
OFF
NO
3 1762
55
4 4
2ND STAGE REGENERATION
(JUMPER SELECTABLE)
HEATER COOL DOWN
HEATING
RIGHT CHAMBER DRYING (LEFT CHAMBER REGEN)
REPRESSURIZATION
DEPRESSURIZATION
HOLD
HEATING
55
2ND STAGE REGENERATION
(JUMPER SELECTABLE)
HEATER COOL DOWN
3
REPRESSURIZATION
HOLD
Sequence of Operation
(Models 500 through 600)
37
Page 40
P&ID Schematic - Models 750 through 4300
(Contact factory to request certied drawings)
SET @ 165 PSIG
26
4
27
28
25
19
20
24
23
30
6
13
43
42
16
29
21
LEFT
SET @ 176°F
RTD 1
DRY GAS
OUTLET
M
SET @
45 PSIG
1PS
SET @
5 PSIG
3PS
EXH.
(RTD4/HS1)
ENERGY MGMT OPTION
SOL 'F'
V7 V8
1TS
(225°F)
2
SOL 'C'
V12 V13
3
1
V11
1TC
SET @ 370°F
RTD 3
SET @ 650°F
SOL 'D'
SOL 'E'
V6V5
SET @
45 PSIG
SET @
5 PSIG
SOL 'G'
10
DPA
DEWPOINTER OPTION
SET AT
100 PSIG
2PS
4PS
SET @ 176°F
RTD 2
CHAMBERCHAMBER
RIGHT
REGENDRYING
13
14
44A
44
22
3
15
7
8
11
12
9
18
54
38
19
5
17
2
OPEN 5 TURNS
FROM FULL CLOSED
& LOCK IN PLACE
1
MODEL 750 ONLY
(SEE DETAIL 'A'
FOR 900-4300)
1A
EXH.
V9
WET GAS
INLET
V10
V3
V4
V2
V1
NOTES
SYMBOLS ARE PER ANSI Y32.10 "GRAPHIC SYMBOLS FOR FLUID POWER DIAGRAMS."
1.
AS SHOWN FLOW DIRECTION IS:
2.
SOLENOID VALVES 'B', 'D', & 'G' ARE SHOWN ENERGIZED,
3.
SOLENOID VALVES 'A', 'C', 'E', & 'F' ARE SHOWN DE-ENERGIZED.
4.
EXH.
INDICATES OPTION
SOL 'A'
SOL 'B'
LEFT CHAMBER DRYING
RIGHT CHAMBER REGEN
PILOT GAS LINE
Page 41
LEGEND
DETAIL 'A' (MODELS 900-4300)
V4
SOL 'C'
V3
2
3
4
1
5
2
3
SOL 'D'
4
1
5
1. INLET VALVE (V1 LEFT, V2 RIGHT)
1A. FLOW CONTROL VALVE
2. PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT)
3. PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) (NO SPRING)
4. OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT)
5. DEPRESS VALVE (V9 LEFT, V10 RIGHT)
6. PURGE HEATER WITH INSULATION
7. HEATER TEMPERATURE THERMOCOUPLE
8. HEATER OVERTEMPERATURE RTD
9. CHAMBER RTD (LEFT & RIGHT)
10. RELIEF VALVE
11. CHAMBER PRESSURE GAUGES (LEFT & RIGHT)
12. CHAMBER PRESSURE SWITCH (LEFT & RIGHT)
13. SERVICE VALVE
14. PILOT AIR FILTER
15. PRESSURE REGULATOR & GAUGE
16. SOLENOID VALVE
17. MUFFLER
18. DESICCANT CHAMBER
19. DESICCANT RETAINING SCREEN (TOP & BOTTOM)
20. DESICCANT FILL PORT
21. DESICCANT DRAIN PORT
22. HOT PIPE INSULATION
23. PURGE PRESSURE GAUGE
24. PURGE BLOWER AND MOTOR
25. PURGE SUCTION FILTER SILENCER
26. REPRESS/SWEEP VALVE (V11)
27. REPRESS/SWEEP CHECK VALVE (V12 LEFT, V13 RIGHT)
28. REPRESS/SWEEP ORIFICE
29. CHAMBER BLOW-DOWN VALVE
30. TEMPERATURE SWITCH (MODELS 3200 - 4300 ONLY)
ENERGY MANAGEMENT OPTION
42. ENERGY MANAGEMENT PILOT OPERATED VALVE
43. ENERGY MANAGEMENT SENSOR (RTD4/HS1)
DEWPOINTER OPTION
44. DEWPOINT ANALYZER
44A. DEWPOINT ANALYZER FILTER
INSULATION OPTION
54. CHAMBER INSULATION
FIXED CYCLE TIMING
(TIME IN MINUTES)
ELECTRICAL COMPONENT
PROCESS COMPONENT
ENERGIZED
SOLENOID
VALVE 'A'
3 WAY
SOLENOID
VALVE 'B'
3 WAY
SOLENOID
VALVE 'C'
3 WAY
SOLENOID
VALVE 'D'
3 WAY
SOLENOID
VALVE 'E'
N.C.
SOLENOID
VALVE 'F'
N.C.
SOLENOID
VALVE 'G'
N.C.
HEATER
BLOWER
MOTOR
LEFT CHAMBER DRYING (RIGHT CHAMBER REGEN)
2
176
PROCESS COMPONENT
DEPRESSURIZATION
CLOSED
OPEN
CLOSED
OPEN
OPEN
CLOSED
OPEN
CLOSED
CLOSED
OPEN
CLOSED
OPEN
CLOSED
ON
OFF
ON
OFF
HEATING
STATUS
YES
V1
NO
YES
V2
NO
YES
V3
NO
YES
V4
NO
NO
V11
YES
YES OPEN
V9
NO
YES
V10
NO
YES
NO
YES
NO
(Model 750 through 4300)
3 1762
55
4 4
2ND STAGE REGENERATION
(JUMPER SELECTABLE)
HEATER COOL DOWN
= FAILS IN POSITION
*
RIGHT CHAMBER DRYING (LEFT CHAMBER REGEN)
REPRESSURIZATION
DEPRESSURIZATION
HOLD
Sequence of Operation
HEATING
55
2ND STAGE REGENERATION
(JUMPER SELECTABLE)
HEATER COOL DOWN
3
REPRESSURIZATION
HOLD
LOSS OF POWER
*
*
*
*
39
Page 42
Replacement Parts – Models 500 through 600
7
8
42
43
9
6
25
24
11
1514
1
REAR VIEW
10
3
AIR
OUT
26
4
23
LEFT CHAMBER RIGHT CHAMBER
11
CONTROL
ENCLOSURE
HIGH TENSION
ENCLOSURE
40
44
AIR
2
5
29
FRONT VIEW
(RIGHT CHAMBER REMOVED FOR CLARITY)
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
SIDE VIEW
IN
Page 43
MODEL
500 600
MAINTENANCE KITS
Year 2 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK2-04-A IBPMK2-06-A
Year 3 Maintenance Kit
Year 4 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK4-04-A IBPMK4-06-A
Year 5 Maintenance Kit
Desiccant Kit IBPDES-04 IBPDES-06
*NOTE: Replacement Prelter and Afterlter elements are included in Standard Kits.
All the contents of the 2 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
All the contents of the 4 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
IBPMK3-04-A IBPMK3-06-A
IBPMK5-04-A IBPMK5-06-A
REPLACEMENT PARTS
ID# DESCRIPTION
1 Inlet Valve Assembly (V1 & V2)
* Solenoid Valve (Sol “A”, “B”) 3203652 3203652 1 2
2 Purge Exhaust Valve Assembly (V3 & V4) 3152701 3152701 1 2
* Solenoid Valve (Sol “C”, “D”) 3203652 3203652 1 2
3 Purge Check Valve (V5 & V6) 3160401 3160401 1 2
4 Outlet Check Valve (V7 & V8) 3160401 3160401 1 2
5 Depress Valve (V9, V10) 4010085 4010085 1 2
* Depress Solenoid Valve (Sol “F”, “G”) 3203652 3203652 1 2
6 Purge Heater 3152742 3152741 1
7 Heater Temperature Thermocouple (1TC) 3153971 3153971 1
8 Heater Overtemperature RTD (RTD3) 3153224 3153224 1
9 Chamber RTD (RTD1, RTD2) 3153224 3153224 1 2
10 Pressure Relief Valve 7400684 7400684 1
11 Chamber Pressure Gauge 4011096 4011096 1 2
12 Chamber Pressure Switch (1PS, 2PS) 3149016 3149016 1 2
* Chamber Depressurization Pressure Switch (3PS, 4PS) 3152525 3152525 1 2
14 Pilot Air Filter Element 3158592 3158592 1 1
15 Pilot Air Pressure Regulator 3154237
17 Depress Mufer 3133635 3133635 2
* Depress Mufer Replacement Core 3075949 3075949 2 2
23 Purge Pressure Gauge 3158833 3158833 1
24 Blower (460V) 3157894 3158197 1
* Blower Hose 3251999 3242540 1
25 Silencer Assembly 3152461 3152461 1
* Blower Inlet Silencer Element 1270769 1270769 1
26 Repress/Sweep Valve (V11) 4010085 4010085 1 1
* Repress/Sweep Solenoid Valve (Sol “E”) 3203652 3203652 1 1
27 Repress/Sweep Check Valve (V12 & V13) 3151005 3151005 1 2
29 Chamber Blowdown Valve 4009894 4009894 2
42 Energy Management Pilot Operated Valve 1274209 1274209 1
43 Energy Management Sensor (RTD4/HS1) 3144864 3144864 1
* Energy Management Vent Needle Valve 3158747 3158747 1
44 Dew-point Sensor - Ceramic 3154859 3154859 1
* Dryer Controller 7417845 7417845 1
* Heater Contactor 3153829 3153829 1
* Blower Motor Contactor 3158056 3158056 1
* Relay, Overload, 3Pole, 600V Max, 3.2-16Amp 3158551 3158551 1
* Relay, SPDT 12VDC Coil, 120VAC, 10A (1CR, 2CR, 3CR, 4CR, 5CR) 3154359 3154359 1 5
* Fuse 1.25A 600V (3FU) 1240671 1240671 1 1
* Fuse .5A 600V (1FU, 2FU) 1241118 1241118 1 2
* Temperature Controller 7416897 7416897 1
* Timer, SPDT, 0.1S-120HR 3203083 3203083 1
Desiccant Evaluation Kit 3150628 3150628
Pre-Filter Assembly PCS15001G24
Auto-Drain 3044466 3044466
Afterlter Assembly PCS15001G24 PCS16001G32
NOTES:
1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specic unit.
2. All quantities for one dryer.
3. ID# correspond to P&ID legend (* Not pictured in diagrams.)
3151877 3151877 1 2
3154237 1
PCS16001G32
SAFETY
STOCK
DRYER
QTY.
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
41
Page 44
Replacement Parts – Models 750 through 1800
25
24
7
8
42
3
43
2
9
MODEL 750
6
1
1A
REAR VIEW
10
11
1514
44
4
LEFT CHAMBER RIGHT CHAMBER
2
23
11
CONTROL
ENCLOSURE
HIGH TENSION
ENCLOSURE
5
FRONT VIEW
26
AIR
OUT
29
SIDE VIEW
(RIGHT CHAMBER REMOVED FOR CLARITY)
AIR
IN
42
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
Page 45
MODEL
750 900 1050 1300 1500 1800
MAINTENANCE KITS
Year 2 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK2-08-A IBPMK2-10-A IBPMK2-12-A IBPMK2-14-A IBPMK2-16-A IBPMK2-18-A
Year 3 Maintenance Kit
Year 4 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK4-08-A IBPMK4-10-A IBPMK4-12-A IBPMK4-14-A IBPMK4-16-A IBPMK4-18-A
Year 5 Maintenance Kit
Desiccant Kit IBPDES-08 IBPDES-10 IBPDES-12 IBPDES-14 IBPDES-16 IBPDES-18
*NOTE: Replacement Prelter and Afterlter elements are included in Standard Kits.
All the contents of the 2 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
All the contents of the 4 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
IBPMK3-08-A IBPMK3-10-A IBPMK3-12-A IBPMK3-14-A IBPMK3-16-A IBPMK3-18-A
IBPMK5-08-A IBPMK5-10-A IBPMK5-12-A IBPMK5-14-A IBPMK5-16-A IBPMK5-18-A
REPLACEMENT PARTS
ID# DESCRIPTION
1 Inlet Valve Assembly (V1 & V2)
* Solenoid Valve (Sol “A”, “B”) 3203652 3203652 3203652 3203652 3203652 3203652 1 2
1A Inlet Pilot Operated Valve 3155189 3155189 3155189 3155189 3155189 3155189 1 2
2 Purge Exhaust Valve Assembly (V3 & V4) 3152701 3152394 3152394 3152394 3152394 3152394 1 2
* Solenoid Valve (Sol “C”, “D”) 3203652 4009880 4009880 4009880 4009880 4009880 1 2
3 Purge Check Valve (V5 & V6) 7405310
4 Outlet Check Valve (V7 & V8) 3160059 3160059 3160059 3160059 3160059 3160059 1 2
5 Depress Valve (V9, V10) 4010085 4010085 4010085 4010085 4010086 4010086 1 2
* Depress Solenoid Valve (Sol "F", "G") 3203652 3203652 3203652 3203652 3203652 3203652 1 2
6 Purge Heater 1200773 3152734 3152735 1171782 3152736 3152738 1
7 Heater Temperature Thermocouple (1TC) 3153971 3153971 3153971 3153971 3153971 3153971 1
8 Heater Overtemperature RTD (RTD3) 3153224 3153224 3153224 3153224 3153224 3153224 1
9 Chamber RTD (RTD1, RTD2) 3153224 3153224 3153224 3153224 3153224 3153224 1 2
10 Pressure Relief Valve 7400684 7400684 7400684 7400684 3100938 3100938 1
11 Chamber Pressure Gauge 4011096 4011096 4011096 4011096 4011096 4011096 1 2
12 Chamber Pressure Switch (1PS, 2PS) 3149016 3149016 3149016 3149016 3149016 3149016 1 2
* Chamber Depressurization Pressure Switch (3PS, 4PS) 3152525 3152525 3152525 3152525 3152525 3152525 1 2
14 Pilot Air Filter Element 3158592 3158592 3158592 3158592 3158592 3158592 1
15 Pilot Air Pressure Regulator 3154237 3154237 3154237 3154237 3154237 3154237 1
17 Depress Mufer 3133635
* Depress Mufer Replacement Core 3075949 3075949 3107791 3107791 3107791 3107791 2 2
23 Purge Pressure Gauge 3158833 3158833 3158833 3158833 3158833 3158833 1
24 Blower (460V) 3158197 3158197 3158198 3158199 3158200 3158200 1
* Blower Hose 3242540 3242540 3242540 3251998 3242539 3242539 1
25 Purge Suction Filter Silencer Assembly 3152728 3152728 3152728 3152729 3152729 3158021 1
* Blower Inlet Silencer Element 1270769 1270769 1270769 3153683 3153683 3159138 1 1
26 Repress/Sweep Valve (V11) 7010085 4010085 4010085 4010085 4010085 4010085 1 1
* Repress/Sweep Solenoid Valve (Sol ‘E’) 3203652 3203652 3203652 3203652 3203652 3203652 1 1
27 Repress/Sweep Check Valve (V12 & V13) 3151005 3151005 3151005 3151005 3151005 3151005 1 2
29 Chamber Blowdown Valve 4009894 4009894 4009894 4009894 4009900 4009900 2
42 Energy Management Pilot Operated Valve 1274209 1274209 1274209 1274209 1274209 1274209 1
43 Energy Management Sensor (RTD4/HS1) 3144864 3144864 3144864 3144864 3144864 3144864 1
* Energy Management Vent Needle Valve 3158747 3158747 3158747 3158747 3158747 3158747 1
44 Dew-point Sensor - Ceramic 3154859 3154859 3154859 3154859
* Dryer Controller 7417845 7417845 7417845 7417845 7417845 7417845 1
* Heater Contactor 3153829 3153829 3153829 3147965 3147965 3151845 1 1
* Blower Motor Contactor 3158056 3158056 3158056 3158653 3147640 3147640 1
* Relay, Overload, 3Pole, 600V Max, 3.2-16Amp 3158551 3158551 3158551 3158551 N/A N/A 1
* Relay, Overload, 3Pole, 600V Max, 5.4-27Amp N/A N/A N/A N/A 3158481 3158481 1
* Relay, SPDT 12VDC Coil, 120VAC, 10A (1CR, 2CR, 3CR, 4CR, 5CR) 3154359 3154359 3154359 3154359 3154359 3154359 1 5
* Fuse 1.25A 600V (3FU) 1240671 1240671 1240671 1240671 1240671 1240671 1 1
* Fuse .5A 600V (1FU, 2FU) 1241118 1241118 1241118 1241118 1241118 1241118 1 2
* Temperature Controller 7416897 7416897 7416897 7416897 7416897 7416897 2
* Timer, SPDT, 0.1S-120HR 3203083 3203083 3203083 3203083 3203083 3203083 1
Desiccant Evaluation Kit 3150628 3150628 3150628 3150628 3150628 3150628
Pre-Filter Assembly PCS18001G32 PCS19501G49 PCS112001G49C PCC114003G49 PCC118003G65 PCC118003G65
Auto-Drain 3044466 3044466 3044466 3044466 3044466 3044466
Afterlter Assembly PCS18001G32 PCS19501G49 PCS112001G49C PCC114003G49 PCC118003G65 PCC118003G65
NOTES:
1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specic unit.
2. All quantities for one dryer.
3. ID# correspond to P&ID legend (* Not pictured in diagrams.)
4. N/A - Not Applicable to this Model Size
3152393 3152393 3152393 3152393 3152393 3152393 1 2
7405310 7405310 7405310 7405310 7405310 1 2
3133635 3071392 3071392 3071392 3071392 2
3154859 3154859 1
SAFETY
STOCK
DRYER
QTY.
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
43
Page 46
Replacement Parts – Models 2200 through 2600
7
3
8
?
6
25
24
42
9
1 1A
43
REAR VIEW
4
26
23
LEFT CHAMBER
RIGHT CHAMBER
11
10
AIR
OUT
44
CONTROL
ENCLOSURE
11
1514
44
2
FRONT VIEW
HIGH TENSION
ENCLOSURE
5
29
SIDE VIEW
(RIGHT CHAMBER REMOVED FOR CLARITY)
AIR
IN
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
Page 47
MODEL
2200 2600
MAINTENANCE KITS
Year 2 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK2-20-A IBPMK2-22-A
Year 3 Maintenance Kit
Year 4 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK4-20-A IBPMK4-22-A
Year 5 Maintenance Kit
Desiccant Kit IBPDES-20 IBPDES-22
*NOTE: Replacement Prelter and Afterlter elements are included in Standard Kits.
All the contents of the 2 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
All the contents of the 4 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
IBPMK3-20-A IBPMK3-22-A
IBPMK5-20-A IBPMK5-22-A
REPLACEMENT PARTS
ID# DESCRIPTION
1 Inlet Valve Assembly (V1 & V2)
* Solenoid Valve (Sol “A”, “B”) 3203652 3203652 1 2
1A Inlet Pilot Operated Valve 3155189 3155189 1 2
2 Purge Exhaust Valve Assembly (V3 & V4) 3152394 3152394 1 2
* Solenoid Valve (Sol “C”, “D”) 4009880 4009880 1 2
3 Purge Check Valve (V5 & V6) 3160063 3160063 1 2
4 Outlet Check Valve (V7 & V8) 3160060 3160060 1 2
5 Depress Valve (V9, V10) 4010086 4010086 1 2
* Depress Solenoid Valve (Sol "F", "G") 3154249 3154249 1 2
6 Purge Heater 1217919 1205010 1
7 Heater Temperature Thermocouple (1TC) 3153971 3153971 1
8 Heater Overtemperature RTD (RTD3) 3153224 3153224 1
9 Chamber RTD (RTD1, RTD2) 3153224 3153224 1 2
10 Pressure Relief Valve 3100938 3100938 1
11 Chamber Pressure Gauge 4011096 4011096 1 2
12 Chamber Pressure Switch (1PS, 2PS) 3149016 3149016 2
* Chamber Depressurization Pressure Switch (3PS, 4PS) 3152525 3152525 2
14 Pilot Air Filter Element 3158592 3158592 1
15 Pilot Air Pressure Regulator 3154237 3154237 1
17 Depress Mufer 3204478 3204478 2
* Depress Mufer Replacement Core 3126761 3126761 1 2
23 Purge Pressure Gauge 3158833 3158833 1
24 Blower (460V) 3158200 3158201 1
* Blower Hose 3242539 3242539 1
25 Purge Suction Filter Silencer Assembly 3158021 3158021 1
* Blower Inlet Silencer Element 3159138 3159138 1 1
26 Repress/Sweep Valve (V11) 4010086 4010086 1 1
* Repress/Sweep Solenoid Valve (Sol ‘E’) 3154249 3154249 1 1
27 Repress/Sweep Check Valve (V12 & V13) 3152094 3152094 1 2
29 Chamber Blowdown Valve 4009900 4009900 2
42 Energy Management Pilot Operated Valve 1274209 1274209 1
43 Energy Management Sensor (RTD4/HS1) 3144864 3144864 1
* Energy Management Vent Needle Valve 3158747 3158747 1
44 Dew-point Sensor - Ceramic 3154859 3154859 1
* Dryer Controller 7417845 7417845 1
* Heater Contactor 3158650 3158650 1
* Blower Motor Contactor 3149521 3149521 1
* Relay, Overload, 3Pole, 600V Max, 5.4-27Amp 3158481 3158481 1
* Relay, SPDT 12VDC Coil, 120VAC, 10A (1CR, 2CR, 3CR, 4CR, 5CR) 3154359 3154359 1 5
* Fuse 1.25A 600V (3FU) 1240671 1240671 1 1
* Fuse .5A 600V (1FU, 2FU) 1241118 1241118 1 2
* Temperature Controller 7416897 7416897 1
* Timer, SPDT, 0.1S-120HR 3203083 3203083 1
Desiccant Evaluation Kit
Pre-Filter Assembly PCC124004G65 PCC136003G97
Auto-Drain 3044466 3044466
Afterlter Assembly PCC124004G65 PCC136003G97
NOTES:
1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specic unit.
2. All quantities for one dryer.
3. ID# correspond to P&ID legend (* Not pictured in diagrams.)
3152117 3152117 1 2
3150628 3150628
SAFETY
STOCK
DRYER
QTY.
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
45
Page 48
Replacement Parts – Models 3200 through 4300
26
3
7
8
6
25
24
42 43
9
1 1A
REAR VIEW
10 4
AIR
OUT
23
LEFT CHAMBER
11
1514
RIGHT CHAMBER
11
CONTROL
ENCLOSURE
HIGH
TENSION
ENCLOSURE
30
46
44
2
5
29
FRONT VIEW SIDE VIEW
(RIGHT CHAMBER REMOVED FOR CLARITY)
AIR
IN
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
Page 49
MODEL
3200 3600 4300
MAINTENANCE KITS
Year 2 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK2-24-A IBPMK2-26-A IBPMK2-28-A
Year 3 Maintenance Kit
Year 4 Maintenance Kit Elements*, Mufer, Drain, Desiccant Evaluation Kit IBPMK4-24-A IBPMK4-26-A IBPMK4-28-A
Year 5 Maintenance Kit
Desiccant Kit IBPDES-24 IBPDES-26 IBPDES-28
*NOTE: Replacement Prelter and Afterlter elements are included in Standard Kits.
All the contents of the 2 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
All the contents of the 4 Year Kit, Pressure
Switches, Valve Repair Kits, Blower Hose
IBPMK3-24-A IBPMK3-26-A IBPMK3-28-A
IBPMK5-24-A IBPMK5-26-A IBPMK5-28-A
REPLACEMENT PARTS
ID# DESCRIPTION
1 Inlet Valve Assembly (V1 & V2)
* Solenoid Valve (Sol “A”, “B”) 3203652 3203652 3203652 1 2
1A Inlet Pilot Operated Valve 3155189 3155189 3155189 1 2
2 Purge Exhaust Valve Assembly (V3 & V4) 3152093 3152093 3152093 1 2
* Solenoid Valve (Sol “C”, “D”) 4009880 4009880 4009880 1 2
3 Purge Check Valve (V5 & V6) 3160064 3160064 3160064 1 2
4 Outlet Check Valve (V7 & V8) 3160061 3160061 3160061 1 2
5 Depress Valve (V9, V10) 4010086 4010086 4010087 1 2
* Depress Solenoid Valve (Sol "F", "G") 3203652 3203652 3158444 1 2
6 Purge Heater 1181451 1185499 1276268 1
7 Heater Temperature Thermocouple (1TC) 3153971 3153971 3153971 1
8 Heater Overtemperature RTD (RTD3) 3153224 3153224 3153224 1
9 Chamber RTD (RTD1, RTD2) 3153224 3153224 3153224 1 2
10 Pressure Relief Valve 3100938 3100938 3119442 1
Chamber Pressure Gauge 4011096 4011096 4011096 2
11
12 Chamber Pressure Switch (1PS, 2PS) 3149016 3149016 3149016 1 2
* Chamber Depressurization Pressure Switch (3PS, 4PS) 3152525 3152525 3152525 1 2
14 Pilot Air Filter Element 3158592 3158592 3158592 1 1
15 Pilot Air Pressure Regulator 3154237 3154237 3154237 1
17 Depress Mufer 3130773 3130773 3130773 2
* Depress Mufer Replacement Core 3121200 3121200 3121200 1 2
23 Purge Pressure Gauge 3158833 3158833 3158833 1
24 Blower (460V) 3158474 3158475 3158475 1
* Purge Blower Throttling Valve 1170918 1170918 1170918 1
* Expansion Joint 1206327 1206327 1206327 1
25 Purge Suction Filter Silencer Assembly 3032795 3032795 3032795 1
* Blower Inlet Silencer Element 3504482 3504482 3504482 1 1
26 Repress/Sweep Valve (V11) 4010086 4010087 4010087 1 1
* Repress/Sweep Solenoid Valve (Sol ‘E’) 3203652 3203652 3158444 1 1
27 Repress/Sweep Check Valve (V12 & V13) 3152094 3152095 3152095 1 2
29 Chamber Blowdown Valve 4009900 4009900 4009900 2
30 Heater High Inlet Temperature Switch (1TS) 3159879 3159879 3159879 1
42 Energy Management Pilot Operated Valve 1274209 1274209 1274209 1
43 Energy Management Sensor (RTD4/HS1) 3144864 3144864 3144864 1
* Energy Management Vent Needle Valve 3158747 3158747 3158747 1
Dew-point Sensor - Ceramic 3154859 3154859 3154859 1
44
* Dryer Controller 7417845 7417845 7417845 1
* Heater Contactor 3158326 3158326 3158326 1
* Blower Motor Contactor 3158653 3158653 3158653 1
* Relay, Overload, 3Pole, 600V Max, 3.2-16Amp 3158551 3158551 3158551 1
* Relay, SPDT 12VDC Coil, 120VAC, 10A (1CR, 2CR, 3CR, 4CR, 5CR) 3154359 3154359 3154359 1 5
* Fuse 1.25A 600V (3FU) 1240671 1240671 1240671 1 1
* Fuse .5A 600V (1FU, 2FU) 1241118 1241118 1241118 1 2
* Timer, SPDT, 0.1S-120HR 3203083 3203083 3203083 1
* Temperature Controller 7416897 7416897 7416897 1
Desiccant Evaluation Kit 3150628 3150628 3150628
Pre-Filter Assembly PCC136003G97 PCC136003G97 PCC148004G97
Auto-Drain 3044466 3044466 3044466
Afterlter Assembly PCC136003G97 PCC136003G97 PCC148004G97
NOTES:
1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specic unit.
2. All quantities for one dryer.
3. ID# correspond to P&ID legend (* Not pictured in diagrams.)
3152117 3152798 3152798 1 2
SAFETY
STOCK
DRYER
QTY.
Phone: 1+ 352-873-5793
FAX: +1 352-873-5770
Email: ppc.americas.am@spx.com
Web: www.spx.com/pneumatic-products
47
Page 50
Page 51
WARRANTY
The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance
with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or
workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor,
or eighteen months from the date of shipment from the factory, whichever occurs rst, provided such defect is discovered and brought to
the manufacturer’s attention the aforesaid warranty period. The manufacturer will repair or replace any product or part determined to be
defective by the manufacturer within the warranty period, provided such defect occurred in normal service and not as the result of misuse,
abuse, neglect, or accident.
The warranty covers parts and labor for the warranty period. Repair or replacement shall be made at the factory or the installation site,
at the sole option of the manufacturer. The manufacturer must rst authorize any service performed on the product by anyone other than
the manufacturer. Normal maintenance items requiring routine replacement are not warranted. Unauthorized service voids the warranty
and any resulting charge or subsequent claim will not be paid.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WRITTEN, ORAL, OR STATUTORY,
AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT
LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE, OR INSPECTION OF
THE EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN. THE
MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR
OTHER INCIDENTAL OR CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING
FROM BREACH OF WARRANTY, NEGLIGENCE OR STRICT LIABILITY IN TORT.
The manufacturer does not warranty any product, part, material, component, or accessory manufactured by others and sold or supplied
in connection with the sale of the manufacturer’s products.
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE
MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
SERVICE DEPARTMENT: (352) 873-5793
Page 52
IBP SERIES
Blower Purge Desiccant
Compressed Air Dryer
SPX
4647 S.W. 40th Avenue
Ocala, Florida 34474-5788 U.S.A.
P: (352) 873-5793
F: (352) 873-5770
E: ppc.americas@spx.com
www.spx.com/pneumatic-products
Improvements and research are continuous at SPX.
Specifications may change without notice.
ISSUED 07/2014 Form No.: 3158144 Revision: I
COPYRIGHT ©2014 SPX Corporation
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