SPX FLOW FLEX Series, FLEX FLX 1.1, FLEX FLX 4.1, FLEX FLX 4.5, FLEX FLX 5.5 Instruction Manual
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INSTRUCTION MANUAL
FLEX Series
Refrigerated Type Compressed Air Dryers
Models: FLX 1.1, FLX 1.2, FLX 2.1, FLX 4.1, FLX 4.5, FLX 5.5
FORM NO.: 7440062 R EVISION: 01/2017 READ AND U NDE RSTAND THIS MANUAL PRI OR TO OPERATING OR SERVICI NG THI S PRODUCT.
Contents
INTRODUCTION ................................................................................................... 1
SAFETY ................................................................................................................ 1
INSTALLATION ...................................................................................................... 1
HOW IT WORKS ................................................................................................... 3
OPTI-ECO CONTROLLER ...................................................................................... 4
START-UP/OPERATION ......................................................................................... 5
MAINTENANCE .................................................................................................... 6
FIELD SERVICE GUIDE .......................................................................................... 7
ENGINEERING DATA ............................................................................................ 8, 9
SPECIFICATIONS
General Arrangement Drawings
Model: FLX 1.1 ............................................................................................ 10
Model: FLX 1.2 ............................................................................................ 11
Model: FLX 2.1 ............................................................................................ 12
Models: FLX 4.1, FLX 4.5 ............................................................................. 13
Model: FLX 5.5 ............................................................................................ 14
Electrical Schematics
Models: FLX 1.1, FLX 1.2 (115V/1PH/60Hz) ................................................ 15
Models: FLX 2.1, FLX 4.1 (230V/1Ph/60Hz) ................................................ 16
Models: FLX 4.5, FLX 5.5 (460V/3Ph/60Hz) ................................................ 17
Air and Refrigerant Flow Schematic
Models: FLX 1.1, FLX 1.2, FLX 2.1, FLX 4.1, FLX 4.5, FLX 5.5 .................. 18
REPLACEMENT PARTS ......................................................................................... 19
MAINTENANCE KITS ............................................................................................ 20
WARRANTY
INTRODUCTION
Compressed air is generated by compressing atmospheric air
of which contains moisture and other containments, into high
pressure air. After compression, the air is not saturated but when
it is cooled by the aftercooler, the RH remains 100%.
If it travels down the pipe line and cools further, moisture starts
to condensate into liquid water. Condensate water in the pipe
line is harmful to the manufacturing process as it causes rust
or sludge etc.
In order to avoid this problem, the only solution is to dry the
compressed air with an air dryer. Refrigerated compressed air
dryers are used as a cost effective and energy efficient solutions
for eliminating moisture from the compressed air system.
SPX’s discovery of using phase change material (PCM) as a
component in the refrigerated compressed air dryer to produce
latent heat has encouraged great energy savings. Through
latent heat properties, it is able to save up to 99% of energy at
no load condition. This is indeed a breakthrough in refrigerated
compressed air dryer technology.
Carefully read the following safety rules before proceeding with installation, operation or maintenance. The rules
are essential to ensure safe dryer operation. Failure to
follow these rules may void the warranty or result in dryer
damage or personal injury.
1. Do not install or try to repair a dryer that has been damaged
in shipment. See Receiving and Inspection for instructions.
2. Compressed air and electricity have the potential to cause
personal injury or equipment damage. Before doing any
work on the dryer, be sure the electrical supply has been
locked and tagged and the internal pressure of the dryer
has been vented to the atmosphere.
3. Do not operate the dryer at pressures or temperatures
above the maximum conditions shown on the data plate.
4. Always supply electrical power that complies with the
voltage shown on the data plate.
5. Do not readjust the dryer without factory authorization.
6. Do not operate the dryer with any dryer cabinet panel
removed.
SAFETY
The dryers are 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 necessary adjustments are made before shipment.
Follow the maintenance schedules outlined in this manual for
good performance and safe operation.
Only qualified personnel with proper tools should do
maintenance.
Safety instructions in this manual used to indicate hazard
seriousness levels are classified as follows:
Immediate hazard which WILL result in severe injury or
death.
Hazard or unsafe practice which COULD result in severe
injury or death.
Hazard or unsafe practice which COULD result in minor
injury or product damage.
Cooling air flow across the condenser may be reduced
if a dryer panel has been removed while the dryer
is operating, resulting in the dryer not functioning
properly and/or dryer failure. Failure to follow these
instructions may result in a non-warrantable dryer
failure.
7. Only a competent refrigeration mechanic works on the
refrigeration system.
8. Use only manufacturer’s genuine replacement parts. The
manufacturer bears no responsibility for hazards caused
by the use of unauthorized parts.
INSTALLATION
Inspect the dryer closely when it is received. Record any
indication of damage on the delivery receipt, especially if the
dryer will not be immediately uncrated. Obtain the delivery
person’s signed agreement to recorded damages to facilitate
future insurance claims .
Since the dryer is shipped F.O.B. Factory, the manufacturer’s
responsibility for the shipment ceases when the carrier signs
the bill of lading.
If goods are received short or in damaged condition, notify the
carrier and insist on a notation of the loss or damage across
the face of the freight bill. Otherwise no claim can be enforced
against the carrier.
If concealed loss or damage is discovered, notify your carrier
at once and request an inspection. This is absolutely necessary.
Unless you do this, the carrier will not consider any claim for
loss or damage. The carrier will make an inspection and may
grant a concealed damage notation. If you give the carrier a
clear receipt for the goods that have been damaged or lost in
transit, you do so at your own risk and expense.
The manufacturer is willing to assist you in collecting claims for
loss or damage. Willingness does not make the manufacturer
responsible for collecting claims or replacing material. Claim
filing and processing is your responsibility.
1
Ambient Air Temperature
Locate the dryer indoors where the ambient air temperature will
be between 39°F (4°C) and 122°F (50°C). Intermittent operation
at ambient temperatures up to 122°F (50°C) will not damage the
dryer but may result in a higher dew point or dryer shutdown
due to high refrigerant discharge pressure (see Field Service
Guide). Call your local distributor if prolonged operation at
ambient temperatures above 122°F (50°C) or below 39°F (4°C)
is unavoidable.
Do not operate air-cooled dryers at ambient air temperatures
below 39°F (4°C). Such operation may result in low suction
pressure, causing freeze-up.
Location and Clearance
Mount the dryer on a level base and bolt down if the base
vibrates. If the dryer is air cooled, install it in a clean, wellventilated area to reduce fouling of the condenser coils with
dirt and dust.
Allow 39 inches (1000 mm) clearance on the sides and the front
of the dryer for cooling airflow on air-cooled dryers and for
service access on air-cooled dryers.
System Arrangement
Liquid water adversely affects dryer performance. To prevent
“slugging” the dryer with liquid water, locate the dryer
downstream of an after cooler and a mechanical separator.
Install drain valves to discharge condensate that collects in
these areas.
If the airflow is relatively constant and will not cause short term
overloading of the dryer, it is recommended that the dryer be
located downstream of the receiver tank. If the nature of the
application is such that the air demand regularly exceeds the
dryer flow rating, it is recommended that the dryer be located
upstream of the receiver.
For safety and convenience, install inlet and outlet shutoff
valves and depressurization valves at the locations indicated.
These valves allow the dryer to be isolated and depressurized
for servicing. Bypass piping may be installed around the dryer
for uninterrupted airflow when the dryer is serviced. If the
compressed air operation cannot tolerate wet air for short
periods, install a second dryer in the bypass line.
Compressed air systems commonly require filters to remove
compressor oils, particulates, condensed liquids and other
contaminants. When an oil-removal filter is used, install the
filter downstream of the dryer. At this location, the life of the
replaceable filter element is prolonged since the dryer removes
some of the entrained oil and drained through the separator.
Drains
Condensate must be drained from the dryer to prevent an influx
into outlet air. The FLEX dryers are equipped with an automatic
no loss drain valve and internal drain hoses up to the drain
connections on the dryer cabinets.
The automatic no loss drain valve uses two electrostatic capacity
sensors (high level, low level), so any condensate from compressed air can be sensed correctly and discharged. Therefore,
the FLEX dryer can protect energy loss by discharging condensate selectively.
The user must install a discharge line from the drain connection
and run it to a waste disposal collection system that meets applicable regulations. Pipe or copper tubing 1/2 inch or larger is
recommended for condensate discharge lines. Install the drain
lines so that condensate can be seen as it drains.
NOTE: Discharge is at system pressure. Drain line should be
anchored.
NOTE: Condensate may contain oil. Comply with applicable
laws concerning proper disposal.
Drain Valve Operation
A. Verify that isolation valves are open. If the drain fails to
discharge after the valve is energized, the electronic control
circuit will repeatedly energize the valve in an attempt to
clear the discharge port. If, after 60 seconds, the drain still
fails to discharge, the control circuit then switches to the
alarm mode. In this mode the valve is de-energized and the
red alarm light is activated on the drain. The valve is then
automatically energized every 4 minutes for 5 seconds.
Check the drain operation. Push drain (push-to-test) button
on the drain or the Electronic Controller (if equipped) to
energize drain. A flow of condensate and/or air should be
present at the drain outlet. The alarm mode automatically
clears after the drain returns to normal operation.
B. The condensate flows through the feed line (1) into the
condensate drain and accumulates in the housing (2). A
capacitive sensor (3) continuously registers the liquid level.
As soon as the container is filled, a fixed waiting period
begins during which more condensate accumulates. After
the waiting time has expired the pilot valve (4) is then
activated and the diaphragm (5) opens the outlet line (6)
for discharging the condensate.
When the condensate drain has been emptied, the outlet
line is closed again quickly and tightly without wasting
compressed air.
Piping and Connections
The user must furnish piping unless otherwise specified.
Connections and fittings must be rated for the maximum
operating pressure given on the dryer data plate and must
be in accordance with applicable codes. Support all piping;
do not allow the weight of any piping to stress the dryer or
filters. Inlet and outlet shutoff valves and bypass valves are
recommended. Piping should be at least the size of the inlet and
outlet connections to minimize pressure drop in the air system.
See Specification Table for dryer inlet and outlet connections.
2
Figure 1.
Schematic diagram of the no loss drain valve
Electrical Connections
Operation of dryers with improper line voltage constitutes
abuse and could affect the dryer warranty.
The dryers are constructed according to NEMA Type 1 electrical
standards. Field wiring must comply with local and national fire,
safety and electrical codes. Installation must be in accordance
with the National Electrical Code. Confirm that your line voltage
is the same as the voltage listed on the dryer data plate. Refer
to Figures 6A, 6B, and 6C electrical schematics.
Electronic Over Current Relay (EOCR)
Models FLX 4.5 & FLX 5.5
If the refrigerant compressor is tripped during dryer operation,
or an “E01” error code is displayed in the LCD window, check
the High Pressure Switch or EOCR in the electric box. Red and
green fault LEDs on the EOCR may be used to check the status
of the compressor motor circuit.
A. In case of overcurrent, the red fault LED will illuminate
and flicker at 0.4 second intervals if overcurrent is detected
during motor operation. If the motor contactor is tripped,
the red fault LED will illuminate solid.
B. In case of phase unbalance, the red fault LED will
illuminate and flicker at 0.4 second intervals if the phase
unbalance rate is over 50%.
C. In case of phase failure, the motor contactor is tripped
within 3 seconds of a phase failure in three (3) phase load.
D. In case of reverse phase, the red and green fault LED’s
will flicker alternately.
Refer to the following table for further information.
HOW IT WORKS
Phase Change Mechanism of the FLEX Dryer
1. When the refrigeration compressor and the condenser fan
are running, the cold refrigerant in the chiller (evaporator)
cools the liquid Phase Change Material (PCM) which
gradually solidifies.
2. When the PCM is sufficiently cooled and solidified, the
refrigeration compressor and condenser fan will stop.
3. The compressed air is continuously cooled by the PCM
while the refrigeration compressor is inactive. No power
is consumed during this period.
4. The PCM gradually liquefies as it adsorbs heat from the
compressed air, and when fully melted, the refrigeration
compressor and condenser fan resume to cool the PCM.
Compressed Air flow
The dryers use refrigeration cooling to condense entrained
moisture out of the air stream. Warm saturated air enters the
air-to-air heat exchanger where it is cooled by outgoing cold
air. The inlet air is further cooled in the refrigeration chiller. The
condensate is removed from the air stream by an electronic
drain valve.
The cold, dry air is reheated by incoming warm air as it passes
back through the air-to air heat exchanger. Using the outgoing air to pre-cool the inlet air condenses up to 65 percent of
the moisture out of the inlet air before it reaches the chiller.
Pre-cooling the inlet air reduces the heat load on the refrigerant compressor, permitting the use of a smaller refrigerant
compressor.
Figure 2.
Schematic diagram of the compressed air flow and
refrigerant
3
OPTi-ECO CONTROLLER
There are two kinds of OPTi-Eco Controller, the Level 1 has
basic functions while the Level 2 has advanced functions like
communication and operating status data storage.
The Level 1 OPTi-Eco Controller is standard for models FLX1.1
and FLX1.2. The Level 2 version is standard for models FLX2.1,
FLX4.1, FLX4.5, and FLX5.5.
Figure 3.
OPTi-Eco Controller
a: DRYER ON/OFF SWITCH
b: ALARM LIGHT
c: REFRIGERANT COMPRESSOR RUNNING LIGHT
d: DRYER RUNNING LIGHT
e: ENERGY SAVING RATIO (%)
f: DEWPOINT TEMPERATURE INDICATOR
g: RUNNING TIME SELECT BUTTON
h: DRYER RUNNING / REFRIGERANT COMPRESSOR RUNNING TIME
i: ENERGY SAVING (GRAPH)
j: TIMER BUTTON (LEVEL 2 ONLY)
k: MICRO-USB CONNECTION PORT (LEVEL 2 ONLY)
Functions
1. OPTi-Eco Controller (Level 1, Basic function)
(i) Dryer On/Off
(ii) Display energy saving ratio (%)
(iii) Display alarm signal
(iv) Display dryer and refrigerant compressor running
time
(v) Display dew point level by indicator
2. Additional functions (Level 2)
(i) Save the operating data
a. Refrigerant compressor on/off status, Alarm, Dew
point level, Inlet air temperature
b. Memory chip can save maximum 30 days
c. When there is no space to save, then erase the first
one
(ii) MICRO-USB connection port
a. Automatically download operating data
b. Automatically upgrade firmware program
(iii) Communication port
a. Bluetooth monitoring (Option)
b. RS485: Modbus monitoring (Option)
Operation
1. OPTi-Eco Controller indicates the energy saving %, dryer’s
operating time, refrigeration compressor’s operating time
and dew point level.
2. To start the FLEX dryer, turn on the (a) dryer on/off switch.
3. When the refrigeration compressor and the condenser fan
are running, the cold refrigerant in the chiller (evaporator)
cools the liquid Phase Change Material (PCM) which
gradually solidifies. During this time, the refrigeration
compressor running light (c) is illuminated on the LCD
window.
4. Energy saving percent (e) is displayed on the LCD window
by calculating dryer running time and refrigeration
compressor operating time.
5. Pressure dew point level (f) is displayed on the LCD window.
6. Dryer running time (h) is displayed on the LCD window,
when the power on or dryer running time select button (g)
is pressed, then refrigerating compressor running time is
displayed. When the (j) button is pressed over 10 seconds,
dryer running time is erased and displayed “0 H”. (timer
reset)
7. Check the dryer operating status when the alarm light (b)
blinks according to Table 1 below.
No. Alarm display Description
1 lamp (b) blinks rapidly
and “E01” is displayed
Ref. compressor has
no signal
on (h)
2 lamp (b) blinks and
“E02” is displayed on
Temperature sensor
signal open
(h)
3 lamp (b) light is on
“E03” is displayed on
Drain valve has some
trouble
(h)
Table 1. Alarm display mode
4
START-UP/OPERATION
Never use the disconnect switch to shut down the dryer
for an extended period of time (except for repair). Failure
to follow these instructions may result in a non-warrantable compressor failure.
IMPORTANT: For models FLX 2.1 through FLX 5.5, energize
dryer for 24 hours prior to starting refrigerator compressor! Failure to follow these instructions may result in a
non-warrantable compressor failure.
Follow the procedure below to start your dryer. Failure to follow
the prescribed start-up procedure will invalidate the warranty.
If problems arise during start-up, call your distributor. Before
repair, vent the internal pressure of the dryer to atmospheric
pressure.
Before starting dryer
Drain connections must be made before the dryer can be operated. The dryers are fully automatic and require no auxiliary
controls.
1. Turn the dryer on/off switch to off.
2. Check that the main electrical supply voltage matches the
voltage specified on the dryer data plate.
3. Check proper connection and support of compressed air
lines to the dyer; check bypass valve system, if installed.
4. SLOWLY pressurize the dryer. The outlet valves of the dryer
should be closed to prevent flow through the dryer.
5. Turn on the main electrical power to the dryer.
6. Ensure adequate ventilation for air cooled dryers.
7. Do not operate the dryer with any dryer cabinet panel
removed.
6. Confirm that the condensate lines from the drain valve
discharge into a collection tank or an environmentally
approved disposal system.
The FLEX dryer is designed to run and stop repeatedly. Let the
FLEX dryer operate even when the demand for compressed air
is interrupted; the FLEX dryer will not freeze up.
Shutdown
When the dryer must be shutdown for maintenance or other
reasons, use the following procedure.
1. Turn off the power switch.
2. Disconnect the main power supply.
3. Lock out and tag the power supply in accordance with OSHA
requirements.
If mechanical repairs are to be made or service is performed,
vent the internal pressure of the dryer to atmospheric pressure.
Restart the dryer according to the start-up instructions.
Disconnect power supply and depressurize dryer before
servicing. Dismantling or working on any component of
the compressed air system under pressure may cause
equipment failure and serious personal injury.
Cooling air flow across the condenser may be reduced
if a dryer panel has been removed while the dryer
is operating, resulting in the dryer not functioning
properly and/or dryer failure. Failure to follow these
instructions may result in a non-warrantable dryer
failure.
To start dryer
IMPORTANT: For models FLX 2.1 through FLX 5.5, energize dryer
for 24 hours prior to starting refrigerator compressor! Failure
to follow these instructions may result in a non-warrantable
compressor failure.
1. Turn the power switch to ON. The refrigerant compressor
will turn on.
2. Allow the dryer to run 15 minutes. Confirm that the
temperature indicators are in the green zone.
3. SLOWLY open the dryer outlet valves permitting flow
through the dryer.
4. Confirm that condensate is discharging from the drain valve
by pressing the “Push-to Test” button.
5. Confirm that the inlet air temperature, pressure and
airflow to the dryer meet the specified requirements (see
Engineering Data section).
5
MAINTENANCE
The FLEX Dryer requires little maintenance for satisfactory operation. Good dryer performance can be expected if the following
routine maintenance steps are taken.
General
For continued good performance of your refrigerated dryer,
all refrigeration system maintenance should be performed by
a competent refrigeration mechanic.
NOTE: Before corrective maintenance is done during the warranty period, call your local distributor and proceed according to
instructions. Refer to the warranty for limits of your coverage.
Models FLX 1.1, FLX 1.2, FLX 2.1, FLX 4.1
Head
Bowl O-Ring
Bowl
Element
Daily Maintenance
Check the operation of the no loss drain valve at least once
daily. See the Field Service Guide for remedies to drain valve
malfunctions.
Monthly Maintenance
It is recommended to inspect the condenser coils monthly.
If necessary, remove dirt or other particles with compressed
air from an OSHA-approved air nozzle that limits its discharge
pressure to 30 psig (2.1 kgf/cm2).
Yearly Maintenance
It is recommended to replace the drain service unit annually.
For units purchased with mounted filtration, replace prefilter
and afterfilter elements annually.
Maintenance kits are available to facilitate annual maintenance.
Float Drain
Drain Line
Connection
Model FLX 4.5, FLX 5.5
Head
Bowl O-Ring
Element
Bowl
Drain Connection
Figure 4.
Mounted Filtration
6
FIELD SERVICE GUIDE
PROBLEM SYMPTOM POSSIBLE CAUSE REMEDY
Water downstream of
dryer.
High pressure drop
across dryer.
No condensate from
no loss drain valve.
No discharge from no loss drain
valves.
Inlet air temperature is too high. Aftercooler malfunction. Check aftercooler discharge temperature.
Liquid water entering dryer. Aftercooler drain valve malfunction. Dismantle aftercooler drain valve; clean, repair or
Excessive airflow (may also cause
high pressure drop).
Compressor cuts out on internal
overload.
Compressor windings read open or
shorted.
The dew point level is red on LCD
window.
Inlet air temperature is too low. Low ambient temperature. Consult your local distributor.
Excessive airflow (may also cause
water downstream of dryer).
Dryer icing up. Adjust operating conditions to meet sizing condi-
Valve venting. But no condensate
from valve.
Valve continuously venting. Clogged valve orifice. Replace valve.
Valve not cycling. No electrical power. Check and correct power supply and connections.
No response when test button is
pushed.
Drain valve failure or accumulation
of dirt in drain valve strainer.
Dryer improperly sized. Check airflow and dryer capacity (See Engineering
Inadequate ventilation of refrigerant compressor.
Leak in refrigeration system. Locate leak, repair and recharge. Motor will restart
Compressor burned out. Have a refrigeration mechanic check and replace.
Inlet air temperature too high. Reduce aftercooler discharge temperature to design
Excessive airflow. Check airflow and system capacity. Reduce airflow or
Condenser fouled or clogged. Clean or replace condenser.
Fan motor inoperative. Replace fan motor.
High ambient temperature. Ventilate area.
Dryer improperly sized. Check airflow and dryer capacity. Reduce airflow or
Accumulation of dirt in valve
strainer.
Short in electrical component. Check and replace connector or OPTi-ECO controller
Drain valve malfunction. Replace drain valve.
No electrical power. Check and correct power supply and connections.
Burn out fuse. Check solenoid coil and wiring cable and replace
Dismantle drain valve: clean, repair or replace.
See maintenance section.
Reduce temperature to 122°F (50°C) max.; reduce
airflow if temperature is above 95°F (35°C).
replace.
Data Tables).
Reduce airflow or resize and replace dryer.
Ensure adequate ventilation of the condensing unit
(see Clearance).
Motor will restart automatically when compressor
is cool.
automatically when compressor is cool.
conditions (See Engineering Data Tables).
resize and replace system.
See Engineering Data Tables.
resize and replace dryer.
tions.
Dismantle valve strainer.
Strainer clean or replace.
assembly.
fuse.
7
ENGINEERING DATA
SPECIFICATIONS
MODEL
FLX 1.1
FLX 1.2
FLX 2.1
FLX 4.1
FLX 4.5
FLX 5.5
1
Rated Flow Capacity - Conditions for rating dryers are in accordance with ISO 7183 (Option A2).
Compressed air at dryer inlet: 100 psig (6.9 barg) and 100°F (38°C); ambient air temperature: 100°F (38°C), operating on 60 Hz power
supply.
2
Refer to dryer data plate for refrigerant charge.
Rated Capacity1
(scfm)
75 NPT 1”
100 NPT 1”
200 NPT 2”
400 NPT 2”
450 NPT 2”
550 NPT 2”
Inlet /Outlet
Connections
Dimensions - inches (mm)
Height Width Length
29.6
(751)
28.0
(711)
30.0
(761)
35.9
(911)
35.9
(911)
40.6
(1,032)
14.3
(363)
14.3
(363)
17.4
(443)
19.4
(493)
19.4
(493)
19.4
(493)
23.7
(603)
30.7
(781)
37.8
(961)
43.7
(1,111)
43.7
(1,111)
47.4
(1,203)
Net Weight
lbs (kg)
120
(54.5)
147
(66.5)
217
(98.5)
335
(152)
368
(167)
437
(198)
ELECTRICAL DATA
Power
Consumption
(kW)
Refrigerant
R-134a
MODEL
FLX 1.1
FLX 1.2
Power Supply
Voltage Phase Hz
115 1 60 0.54
115 1 60 0.64
FLX 2.1
FLX 4.1
1
FLX 4.5
1
FLX 5.5
1
Please be advised that while models FLX 4.5 and FLX 5.5 are NEC compliant, they have not been NRTL tested or certified. As such, all pur-
chasers of these models are responsible for ensuring that these models are suitable for their intended use and that these models do not
violate any applicable laws, rules, regulations or codes of the jurisdiction in which these models will be used. If you have any questions or
concerns about these model’s suitability for your use, please do not hesitate to contact your authorized Hankison representative.
Please also be aware that Hankison expects to make a NRTL certified version of this model available later in 2017.
230 1 60 1.30
230 1 60 2.55
R-407c
460 3 60 2.75
460 3 60 3.05
8
ENGINEERING DATA
MINIMUM - MAXIMUM OPERATING CONDITIONS ALL MODELS
Min.-Max. Inlet Air Pressure (compressed air at inlet to dryer) 43.5 - 232 psig (3 - 16 barg)
Min.-Max. Inlet Air Temperature (compressed air at inlet to dryer) 39°F - 122°F (4°C - 50°C)
Min.-Max. Ambient Temperature 36°F - 113°F (2°C - 45°C)
REFRIGERANT PRESSURE SWITCH SETTINGS
Refrigerant Compressor Control
High Pressure Switch Setting
Model Refrigerant
FLX 1.1
FLX 1.2
FLX 3.1
FLX 4.1
FLX 4.5
FLX 5.5
R-134a
R-407c
Cut-Out
psig (barg)
304 psig
(21 barg)
406 psig
(28 barg)
CORRECTION FACTORS (MULTIPLIERS)
Air Inlet
Temp
80°F
90°F
100°F
110°F
120°F
Multiplier
1.46
1.23
1.00
0.82
0.68
Air Inlet
Pressure
75 psig
100 psig
120 psig
150 psig
225 psig
Multiplier
Cut-In
(psig)
Manual
Reset
Manual
Reset
0.86
1.00
1.04
1.09
1.15
Ambient Air
Temp
80°F
90°F
100°F
110°F
120°F
Multiplier
1.12
1.06
1.00
0.83
0.68
9
SPECIFICATIONS: General Arrangement Drawing
Figure 5A
Model: FLX 1.1
MODEL
FLX 1.1
DIMENSIONS, INCHES (MM)
A B C D E F G H I J K
4.69
4.97
8.41
19.20
14.27
29.58
12.75
(119)
(126.2)
(213.5)
(487.7)
(362.4)
(751.2)
(324)
23.72
(602.5)
3.39
(86.2)
15.40
(391.2)
TOP VIEW
E
H
22.14
(562.4)
DRIED AIR OUTLET
WETTED AIR INLET
C
INLET/OUTLET
CONNECTIONS
1" NPT
A B
WEIGHT
Lb. (kg)
120
(54.5)
F
G
COOLING
AIR FLOW
D
J
I
MAIN POWER CABLE
DRAIN OUTLET
K
FRONT VIEW REAR VIEWRIGHT SIDE VIEW
4-Ø10 MOUNTING HOLES
FOOT PRINT
10
SPECIFICATIONS: General Arrangement Drawing
Figure 5B
Model: FLX 1.2
MODEL
FLX 1.2
DIMENSIONS, INCHES (MM)
A B C D E F G H I J K
3.41
4.97
6.75
19.25
(86.5)
(126.2)
(172)
(489.2)
14.28
(363)28(711.2)
12.75
(324)
30.75
(781.3)
5.56
(141.2)
19.28
(490)
TOP VIEW
E
H
INLET/OUTLET
CONNECTIONS
29.19
(741.2)
DRIED AIR OUTLET
WETTED AIR INLET
C
1" NPT
WEIGHT
Lb. (kg)
147
(66.5)
A B
F
COOLING
AIR FLOW
G
FRONT VIEW REAR VIEWRIGHT SIDE VIEW
5-Ø10 MOUNTING HOLES
FOOT PRINT
D
J
K
I
POWER CORD
DRAIN OUTLET
11
SPECIFICATIONS: General Arrangement Drawing
Figure 5C
Model: FLX 2.1
MODEL
FLX 2.1
DIMENSIONS, INCHES (MM)
A B C D E F G H I J K
4.86
7.86
3.63
24.38
17.44
29.97
15.91
(123.5)
(199.6)
(92)
(619.2)
(443)
(761.2)
(404)
37.85
(961.3)
3.39
(86.2)
29.53
(750)
TOP VIEW
E
H
36.27
(921.2)
C
INLET/OUTLET
CONNECTIONS
2" NPT
DRIED AIR OUTLET
WETTED AIR INLET
WEIGHT
Lb. (kg)
217
(98.5)
A B
F
COOLING
D
AIR FLOW
G
J
I
MAIN POWER CABLE
DRAIN OUTLET
K
FRONT VIEW REAR VIEW
RIGHT SIDE VIEW
5-Ø10 MOUNTING HOLES
FOOT PRINT
12
SPECIFICATIONS: General Arrangement Drawing
Figure 5D
Models: FLX 4.1, FLX 4.5
MODEL
FLX 4.1
FLX 4.5
DIMENSIONS, INCHES (MM)
A B C D E F G H I J K
4.86
8.58
8.34
25.56
19.41
35.88
17.88
43.75
3.39
(123.5)
4.86
(123.5)
(218)
8.58
(218)
(212)
8.34
(212)
(649.2)
25.56
(649.2)
(493)
19.41
(493)
(911.2)
35.88
(911.2)
(454)
17.88
(454)
(1111.3)
43.75
(1111.3)
(86.2)
3.39
(86.2)
35.44
(900)
35.44
(900)
TOP VIEW
E
H
42.17
(1071.2)
42.17
(1071.2)
INLET/OUTLET
CONNECTIONS
2" NPT
2" NPT
DRIED AIR OUTLET
WETTED AIR INLET
C
WEIGHT
Lb. (kg)
335
(152)
368
(167)
A B
F
G
COOLING
AIR FLOW
D
J
I
K
MAIN POWER CABLE
DRAIN OUTLET
FRONT VIEW REAR VIEWRIGHT SIDE VIEW
5-Ø10 MOUNTING HOLES
FOOT PRINT
13
SPECIFICATIONS: General Arrangement Drawing
Figure 5E
Model: FLX 5.5
MODEL
FLX 5.5
DIMENSIONS, INCHES (MM)
A B C D E F G H I J K L
4.87
8.58
9.78
30.83
19.43
40.61
17.72
19.30
1.97
41.73
(123.8)
(218)
(248.6)
(783)
(493.5)
(1031.6)
(450)
(490)
(50)
(1060)
45.67
(1160)
TOP VIEW
E
L
47.35
(1202.8)
DRIED AIR OUTLET
WETTED AIR INLET
C
INLET/OUTLET
CONNECTIONS
2" NPT
A B
WEIGHT
Lb. (kg)
403
(183)
COOLING
F
AIR FLOW
D
G
H
FRONT VIEW REAR VIEW
RIGHT SIDE VIEW
4-Ø10 MOUNTING HOLES
J
K
I
MAIN POWER CABLE
DRAIN OUTLET
FOOT PRINT
14
SPECIFICATIONS: Electrical Schematic
Figure 6A
Models: FLX 1.1, FLX 1.2 (115V/1PH/60Hz)
DIP SW
PCB
2 3 4
1
TS1 TS2
COM
ON
DRAIN
RBRA
COM
ALARM1
ON
COM
R2
COMP1
S2
S1
R1
AC IN1
FG
N.C.
COM.
N.O.
TRAP1
DRAIN
F0: Main Fuse (Customer’s installation)
S0: Main Switch (Customer’s installation)
8 9 10 8
N1 L1
S3
MC1
TS1: Temperature Sensor 1
TS2: Temperature Sensor 2
SOL: No Loss Drain Valve
PCB: Control Board
SOL.
R: PTC Relay
S1: Switch “On-Off”
S2: Overload Protector
S3: High Pressure Switch
N1
L1
S1
Customer's installation
F0
NL E
(16A)
115V/1PH/60Hz
S0
MC1
M2
M
S2
M1
C
R
5
4
S
CS
3
CR
M1: Refrigerant Compressor
LEGEND
CS: Starting Capacitor (FLX 1.2 ONLY)
CR: Running Capacitor
M2: Fan Motor
MC1: Magnetic Contactor
15
SPECIFICATIONS: Electrical Schematic
Figure 6B
Models: FLX 2.1, FLX 4.1 (230V/1Ph/60Hz)
DIP SW
2 3 4
1
GND
RS485 -
RS485 +
GND
RS232 TX
RS232 RX
TS3 RS232 RS485
PCB
TS1 TS 2
COMONR1 S1FG S2 R2 COM ON COM RBRA
DRAIN
ALARM1
COMP1
AC IN1
SOL.
N.C.
COM.
N.O.
S0: Main Switch (Customer’s installation)
F0: Main Fuse (Customer’s installation)
TRAP1
DRAIN
8 9 10 8
N1 L1
S3
MC1
TS1: Temperature Sensor 1
TS2: Temperature Sensor 2
TS3: Temperature Sensor 3
SOL: No Loss Drain Valve
PCB: Control Board
S1: Switch “On-Off”
S2: Overload Protector
S3: High Pressure Switch
16
N1
CH
Customer's installation
F0
(16A)
NL E
L1
LEGEND
M1: Refrigerant Compressor
M2: Fan Motor
MC1: Magnetic Contactor
CR: Running Capacitor
S1
M2
CR
S
S2
C
M1
R
CH: Crankcase Heater
230V/1PH/60Hz
S0
MC1
SPECIFICATIONS: Electrical Schematic
Figure 6C
Models: FLX 4.5, FLX 5.5 (460V/3Ph/60Hz)
2 3 4
DIP SW
PCB
1
TS3 RS232 RS485
TS1 TS2
COM
DRAIN
ON
RBRA
COM
ALARM1
ON
COM
COMP1
R2
S2
S1
R1
AC IN1
FG
GND
RS485 -
RS485 +
GND
RS232 TX
RS232 RX
32 31
N.C.
COM.
N.O.
11 10 9 8R2 T2
DRAIN
TRAP1
H.P.S
L3L1 L2
MAIN POWER
460V/3PH/60HZ
CRANK CASE HEATER
MC1
MC2
8
9
SOL: No Loss Drain Valve
PCB: Control Board
9
8
7
EOCR OLP
TRAP
DRAIN
OLP: Oil Pressure Switch
H.P.S.: High Pressure Switch
TS1: Temperature Sensor 1
TS2: Temperature Sensor 2
EOCR
T2
R2
5
MC1
R1
0V
60Hz
50VA
0V
L1
L3L1 EL2
TB1
S1
4
F1(2A)
T1
120V
TRANSFORMER
480V
L3
MC2MC1
EOCR
LEGEND
MC1: Magnetic Contactor
FAN
MOTOR
W1U1 V1 W2U2 V2
COMP.
TS3: Temperature Sensor 3
MC2: Magnetic Contactor
EOCR: Electric Over Current Relay
F1: Fuse
S1: Switch “On-Off”
17
SPECIFICATIONS: Air and Refrigerant Flow Schematic
Figure 7
Models: FLX 1.1, FLX 1.2, FLX 2.1, FLX 4.1, FLX 4.5, FLX 5.5
CAPILLARY TUBE
TS2
TEMP. SENSOR2
MOISTURE SEPARATOR INTEGRATED
BRAZED PLATE HEAT EXCHANGER
TS1
TEMP. SENSOR1
<REF-PCM-AIR>
<AIR-AIR>
TEMP. SENSOR3 (FLX2.1~5.5 ONLY)
TS3
WETTED AIR INLET
DRIED AIR OUTLET
MANUAL VALVE
NO LOSS
DRAIN VALVE
DRAIN OUTLET
REFRIGERANT COMPRESSOR
COOLING AIR FLOW
FAN BLADES
FAN MOTOR
AIR-COOLED
CONDENSER
FILTER
HIGH PRESSURE SWITCH
H.P.S
REFRIGERANT FLOW
COMPRESSED AIR FLOW
18
REPLACEMENT PARTS
1
4
3
5
10
2
6
14
11
16 12 8
7
9
Model: FLX 1.1 Models: FLX 1.2, FLX 2.1, FLX 4.1, FLX 4.5, FLX 5.5
5
16 12 8
5
4
2
3
7
9
1
10
14
11
6
3
7
9
18 16 15 13 12 8
11
1
17
FLX 1.1 FLX 1.2 FLX 2.1 FLX 4.1 FLX 4.5 FLX 5.5
ID# Part name (115V) (115V) (230V) (230V) (460V) (460V
1 Refrigerant Compressor 7440069 7440070 7433661 7433664 7440048 7440049
2 Condenser 7440044 7440045 7439968 7439967 7439967 7439967
3 Fan Motor 3161243 1283304 1283304 3127739 7440057 7439969
4 Fan Grill 7426017 7426017 7426018 7440046 — —
5 Fan Grill (Ext.) 7440058 7440058 7440059 7440060 7440061 7440000
6 Filter Dryer 3142596 3142596 7433676 7433676 7433676 7433676
7 Plate Heat Exchanger 7440039 7440040 7440041 7440042 7440042 7440043
8 High Pressure Switch 3161273 3161273 7433678 7433678 7433678 7433678
9 No Loss Drain Valve 7440053 7440053 7440053 7440053 7440053 7440053
10 OPTi-Eco PCB+LCD 7440050 7440050 7440051 7440051 7440051 7440051
11 Temperature Sensor 7440054 7440054 7440055 7440056 7440056 7440056
12 Magnetic Contactor (Compressor) 7433697 7433697 7433697 7433698 3242864 3242864
13 Magnetic Contactor (Fan) — — — — 3242863 3242863
14 On/Off Switch 3209745 3209745 7440052 7440052 7440052 7440052
15 Start Capacitor — 7433696 — — — —
16 Run Capacitor 7440065 7433691 7433693 7433695 — —
17 Crankcase Heater — — 7440066 7440067 7439996 7439996
18 Voltage Transformer — — — — 7439965 7439965
4
10
14
2
6
Phone: 724-745-1555
FAX: 724-745-6040
Email: hankison.americas.am@spxflow.com
Web: www.spxflow.com/hankison
19
MAINTENANCE KITS
Model Kit Components
Standard Kit
Standard Kit
with Mounted
Filtration
No Loss Drain Valve Repair Kit,
Drain Cover
No Loss Drain Valve Repair Kit,
Drain Cover, Prefilter Element,
Afterfilter Element, Filter Drain
Valve Repair Kit (2)
FLX 1.1 FLX 1.2 FLX 2.1 FLX 4.1 FLX 4.5 FLX 5.5
FLXMK
(7461648)
FLX1.1-FPMK
(7461654)
FLXMK
(7461648)
FLX1.2-FPMK
(7461655)
FLXMK
(7461648)
FLX2.1-FPMK
(7461656)
FLXMK
(7461648)
FLX4.1-FPMK
(7461657)
FLXMK
(7461648)
FLX4.5-FPMK
(7461658)
FLXMK
(7461648)
FLX5.5-FPMK
(7461659)
20
Phone: 724-745-1555
FAX: 724-745-6040
Email: hankison.americas.am@spxflow.com
Web: www.spxflow.com/hankison
WARRANTY
The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with
procedures and recommendations outlined in manufacturer’s instruction manuals, to be free from defects in material or workmanship
for a period as specified below, provided such defect is discovered and brought to the manufacturer’s attention within 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 a result of misuse, abuse, neglect or accident. Normal maintenance items
requiring routine replacement are not warranted. The warranty covers parts and labor for the warranty period unless otherwise specified.
Repair or replacement shall be made at the factory or the installation site, at the sole option of the manufacturer. Any service performed
on the product by anyone other than the manufacturer must first be authorized by the manufacturer.
Unauthorized service voids the warranty and any resulting charge or subsequent claim will not be paid. Products repaired or replaced
under warranty shall be warranted for the unexpired portion of the warranty applying to the original product.
The foregoing is the exclusive remedy of any buyer of the manufacturer’s product. The maximum damages liability of the manufacturer
is the original purchase price of the product or part.
THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR STATUTORY, AND IS
EXPRESSLY 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 warrant any product, part, material, component, or accessory manufactured by others and sold or supplied
in connection with the sale of manufacturer’s products.
Warranty Period
Parts and labor for two (2) years from the date of shipment from the factory; heat exchangers are covered (parts only) for an additional
three (3) years (total of five [5]). On units that manufacturer requests be returned to the factory, a one time removal/reinstallation labor
allowance as noted in the Service Warranty Policies and Procedures Handbook will apply. Freight to the factory from the installation site
and to the installation site from the factory will be paid by the manufacturer; means of transportation to be specified by manufacturer.
AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE MATERIAL
IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.
SERVICE DEPARTMENT: (724) 746-1100
FLEX Series
Refrigerated Type Compressed Air Dryers
Models: FLX 1.1, FLX 1.2, FLX 2.1,
FLX 4.1, FLX 4.5, FLX 5.5
SPX FLOW
4647 S.W. 40th Avenue
Ocala, Florida 34474-5788 U.S.A.
P: (724) 745-1555
F: (724) 745-6040
E: hankison.americas@spxflow.com
www.spxflow.com/hankison
Improvements and research are continuous at SPX FLOW, Inc.
Specifications may change without notice.
ISSUED 01/2017 Form No.: 7440062 Revision: B
COPYRIGHT ©2017 SPX FLOW, Inc.
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