Van Air Systems HL-200, HL2000 User Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL

FOR

HEATLESS REGENERATIVE

COMPRESSED AIR DRYER

models

HL-200 through HL-2000

September 2007

P/N 32-0263-F

2950 Mechanic Street

Lake City, PA 16423 USA

Phone: [phone]

Corporate Fax: [phone]

Order Entry Fax: [phone]

www.vanairsystems.com

WARNING

READ ALL INFORMA TION IN THIS MANU AL BEFORE BEGINNING INST ALLA TION OR OPERATION OF THE
DRYER. BEFORE ST ARTING MAINTENANCE PR OCEDURES, TURN OFF THE MAIN POWER T O THE DR YER
AND COMPLETEL Y DEPRESSURIZE THE UNIT T O PREVENT PERSONAL INJURY.

DO NOT REMO VE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS PRESSURIZED.

NEVER OPERA TE THIS DRYER ABOVE THE RA TED OPERATING CONDITIONS. OPERA TION ABOVE SPECI­FIED CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO THE UNIT AND/
OR PERSONAL INJURY.

SEE BACK OF THIS MANUAL FOR ADDITIONAL SAFETY INSTRUCTIONS.

PAGE 1

HANDLING THE DRYER SECTION 1

1.1 HANDLING INSTRUCTIONS

WARNING

DO NOT LIFT THE DRYER BY PIPING OR CONTROL BOX. THESE
COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF THE
DRYER. PERSONAL INJURY AND/OR EQUIPMENT DAMAGE MAY
RESULT.

Lift the dryer by the lifting lugs on both vessels.
If the unit is to be lifted by an overhead device, attach the lifting chains or

cables to the skid angle and the vessel lifting lugs. Make sure that the
chains or cables are clear of all piping and dryer components.

1.2 STORAGE INSTRUCTIONS

The ideal place to store the unit is indoors. The location should be free
from corrosive gasses and extreme humidity. These conditions will cause
damage to the unit. The unit should be covered with a tarpaulin to keep
the unit clean.

If the unit is to be stored outdoors, it MUST BE covered completely.
The cover must be adequate to prevent rain or snow from
accumulating on the dryer. The location must be free of standing
water and mud. The preferred location, if outdoors, is on a paved
surface.

1.3 EQUIPMENT CHECK

Inspect the dryer for any damage that may have occurred during
shipment. Inspect all fittings, piping connections, fasteners, etc. for
loose connections. Also check gauges and lights for cracks or
breakage.

IF DRYER HAS BEEN DAMAGED DURING SHIPMENT:

(1) NOTIFY CARRIER IMMEDIATELY AND FILE A CLAIM.
(2) CONSULT FACTORY BEFORE OPERATING THE DRYER.

SAFETY INSTRUCTIONS SECTION 2

2.1 HANDLING

DO NOT LIFT THE DRYER BY PIPING OR CONTROL BOX. THESE
COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF
THE DRYER. PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
MAY RESULT.

WHEN LIFTING THE DRYER, ALWAYS USE THE LIFTING LUGS
PROVIDED ON BOTH TOWERS.

MAKE SURE THAT ALL LIFTING EQUIPMENT IS CAPABLE OF
SUPPORTING THE WEIGHT OF THE DRYER.

2.2 INSTALLATION

BEFORE STARTING INSTALLATION PROCEDURES, TURN OFF
POWER TO THE AREA WHERE THE DRYER WILL BE INSTALLED.
SERIOUS PERSONAL INJURY MAY RESULT IF THIS SAFETY RULE
IS NOT FOLLOWED.

THESE ASME CODE VESSELS MUST BE PROTECTED BY
PRESSURE RELIEF VALVES. Refer to OSHA 1910.169 Par. b, Sub.
Par (3) and ASME Boiler and Pressure Vessel Code, Section VIII,
Division 1, UG-125 through UG-136. Also comply with all state
and local codes.

2.3 OPERATION

DO NOT OPERATE DRYER IF EITHER VESSEL IS LEAKING.
IMMEDIATELY TAKE THE DRYER OUT OF SERVICE.

ANY DAMAGE TO THE VESSELS CAN MAKE THEM UNSAFE
TO USE. INSPECT OUTSIDE AND INSIDE OF VESSELS
REGULARLY FOR CORROSION AND ANY DAMAGE (I.E.,
DENTS, GOUGES OR BULGES). IF DAMAGED, TAKE OUT OF
SERVICE IMMEDIATELY.

DO NOT OPERATE THIS DRYER ABOVE THE MAXIMUM RATED
WORKING PRESSURE.

OPERATING CONDITIONS FOR PROPER PERFORMANCE OF
THIS DRYER ARE DIFFERENT THAN MAXIMUM OPERATING
CONDITIONS FOR THE VESSELS. BE SURE TO CHECK THE
DRYER OPERATING CONDITIONS. SEE SECTION 3.1.

USE THIS DRYER FOR COMPRESSED AIR ONLY.

AIR FROM THIS DRYER IS NOT SUITABLE FOR BREATHABLE
AIR SYSTEMS WITHOUT FURTHER TREATMENT.

WHEN INSTALLING AND OPERATING THIS EQUIPMENT, COMPLY
WITH THE NATIONAL ELECTRICAL CODE AND ALL APPLICABLE
FEDERAL, STATE, AND LOCAL CODES.

WHEN INSTALLING THIS DRYER, MAKE SURE THAT THE NEMA
RATING OF THE CONTROL BOX IS APPLICABLE TO THE
INSTALLATION.

MAKE SURE THAT ALL CUSTOMER SUPPLIED WIRING AND
ELECTRICAL DEVICES ARE PROPERLY SIZED TO HANDLE THE
ELECTRICAL REQUIREMENTS OF THE DRYER.

ALWAYS WEAR EYE PROTECTION, GLOVES AND A RESPIRATORY
PROTECTIVE DEVICE WHEN HANDLING THE DESICCANT.
DESICCANT DUST MAY CAUSE EYE AND SKIN IRRITATION. AVOID
BREATHING THE DUST AND PROLONGED CONTACT WITH THE
SKIN.

FIRST AID IN CASE OF EYE CONTACT WITH DESICCANT DUST;
IMMEDIATELY FLUSH THE EYES WITH PLENTY OF WATER FOR AT
LEAST 15 MINUTES. CONSULT A PHYSICIAN.

PAGE 2

DO NOT OPERATE THIS DRYER IF EITHER VESSEL HAS BEEN
DAMAGED BY FIRE. TAKE OUT OF SERVICE IMMEDIATELY
AND NOTIFY YOUR CERTIFYING AUTHORITY.

2.4 MAINTENANCE

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE
DRYER WHILE IT IS PRESSURIZED. TURN OFF MAIN POWER
TO THE DRYER AND DEPRESSURIZE THE DRYER COM­PLETELY BEFORE STARTING MAINTENANCE PROCEDURES.

DO NOT WELD OR GRIND EITHER VESSEL. IT WILL NOT BE
SAFE TO OPERATE. (Note: Any uncertified alteration to the
vessels VOIDS the ASME Code Certification and the
Warranty.)

DIMENSIONS AND SPECIFICATIONS SECTION 3

3.1 DRYER SPECIFICATIONS

WEIGHT (with desiccant installed)

HL-200 HL-250 HL-375 HL-500 HL-650 HL-800 HL-1000 HL-1250 HL-1500 HL-1750 HL-2000

N4 STANDARD 660 lbs 715 lbs 1035 lbs 1160 lbs 1680 lbs 1830 lbs 2635 lbs 2885 lbs 3870 lbs 4095 lbs 4370 lbs
ALL OTHERS 700 lbs 755 lbs 1075 lbs 1200 lbs 1720 lbs 1870 lbs 2675 lbs 2925 lbs 3910 lbs 4135 lbs 4410 lbs

DIMENSIONS .............. See SECTIONS 3.2 through 3.4

IN/OUT CONNECTION All models have 150# ANSI RF flanged inlet and outlet connections. Bolt holes straddle centerlines.

HL-200 HL-250 HL-375 HL-500 HL-650 HL-800 HL-1000 HL-1250 HL-1500 HL-1750 HL-2000

1-1/2" 1-1/2" 1-1/2" 1-1/2" 2-1/2" 2-1/2" 2-1/2' 2-1/2" 3" 3" 3"

VESSELS (desiccant towers)

Construction.................. Manufactured to the ASME CODE, Section VIII, Division 1.

Design Pressure ............ 150 PSIG

Design Temperature...... -20

PIPING

Threaded fittings: .......... ANSI B16.3

Threaded unions: .......... ANSI B16.39

Flanges:......................... ANSI B16.5

Pipe:............................... Carbon steel, Schedule 40

VALVES

Inlet ............................... Proprietary 3-Way piloted shuttle valve

Outlet ............................. Two (2) Check valves, butterfly type

Purge ............................. Normally closed, diaphragm type

Models HL-200 through HL-250 vessels stamped "UM" symbol. Models HL-375 and larger vessels stamped "U" symbol.

O

F TO 300OF

CONTROL AIR FILTER

Construction.................. Zinc housing

ELECTRICAL

Standard 115 Volt.......... 115-120V/1PH/50-60Hz

Optional 230 Volt:.......... Main power: 220-240V/1PH/50-60Hz

Control power: Transformed to 115-120V/1PH/50-60Hz, on Emcon II units only

DESICCANT

Material .......................... Activated Alumina, 1/8" (2-5 MM) Bead type

Quantity Per Tower (LBS)

HL-200 HL-250 HL-375 HL-500 HL-650 HL-800 HL-1000 HL-1250 HL-1500 HL-1750 HL-2000

106 130 203 266 366 440 560 678 872 986 1119

OPERATING CONDITIONS

Inlet Air Pressure ............................MIN 60 PSIG ......... MAX 150 PSIG

Inlet Air Temperature .....................MIN 40OF ............... MAX 120OF

Ambient Air Temperature ............... MIN 40OF ............... MAX 120OF

RATED INLET CONDITIONS

Inlet Air Pressure ............................ 100 PSIG

Inlet Air Temperature .....................100OF

Relative Humidity (saturation) ........100% RH

FLOW CAPACITIES (SCFM) at various pressures (1000F)

60 PSIG 80 PSIG 100 PSIG 110 PSIG 125 PSIG 140 PSIG 150 PSIG

HL-200 130 165 200 209 221 232 240
HL-250 163 206 250 261 276 290 300
HL-375 244 310 375 391 414 436 449
HL-500 326 413 500 521 552 581 599
HL-650 423 537 650 678 717 755 779
HL-800 521 661 800 834 883 929 959
HL-1000 651 826 1000 1043 1104 1161 1198
HL-1250 814 1032 1250 1303 1380 1452 1498
HL-1500 977 1238 1500 1564 1655 1742 1797
HL-1750 1140 1445 1750 1825 1931 2032 2097
HL-2000 1303 1651 2000 2085 2207 2323 2397

PAGE 3

DIMENSIONS AND SPECIFICATIONS SECTION 3

3.2 DIMENSIONS Models HL-200 through HL-800

AB CDEFGHIJKLMNOPQ

HL-200 37.50 24.00 12.00 18.75 9.00 84.38 4.38 3.38 3.75 3.25 1-1/2 35.00 20.00 2.00 1.25 8.50 .50
HL-250 37.50 24.00 12.00 18.75 9.00 84.38 4.38 3.38 3.75 3.25 1-1/2 35.00 20.00 2.00 1.25 8.50 .50
HL-375 43.13 24.00 12.00 21.57 9.00 81.13 4.38 3.38 7.25 8.00 1-1/2 40.63 20.00 2.00 1.25 8.50 1.00
HL-500 43.13 24.00 12.00 21.57 9.00 81.13 4.38 3.38 7.25 8.00 1-1/2 40.63 20.00 2.00 1.25 8.50 1.00
HL-650 53.75 36.00 18.00 26.88 16.75 95.25 5.50 4.00 8.00 13.25 2-1/2 50.50 32.00 2.00 1.63 8.50 1.50
HL-800 53.75 36.00 18.00 26.88 16.75 95.25 5.50 4.00 8.00 13.25 2-1/2 50.50 32.00 2.00 1.63 8.50 1.50

PAGE 4

DIMENSIONS AND SPECIFICATIONS SECTION 3

3.3 DIMENSIONS Models HL-1000 through HL-1250

PAGE 5

DIMENSIONS AND SPECIFICATIONS SECTION 3

3.4 DIMENSIONS Models HL-1500 through HL-2000

PAGE 6

INSTALLING THE DRYER SECTION 4

4.1 LOCATION

WARNING

DO NOT INSTALL THIS DRYER IN AN ENVIRONMENT OF
CORROSIVE CHEMICALS, EXPLOSIVE GASSES, POISONOUS
GASSES, OR SATURATED STEAM HEAT.

Basic bypass piping should include an inlet isolation valve, a bypass
valve, and an outlet isolation valve. The isolation and bypass valves
must be bubble-tight.

4.2-2 FILTERS

Locate dryer in a protected, well vented area where ambient
temperatures are between 40oF and 120oF. Allow sufficient clearance
over and around the dryer for access to desiccant fill and drain ports
and controls. Refer to SECTIONS 3.2 through 3.4 for dryer

dimensions.

If this dryer must be installed where ambient temperatures are below

o

F, insulation and heat tracing must be properly installed on the inlet

40
piping, purge exhaust line and the desiccant towers to prevent freezing
of the equipment.

Position the dryer in the upright position on a solid, level, vibration free
surface capable of supporting the dryer’s weight. Refer to SECTION

3.1 for dryer specifications.

The dryer should not be located in extremely dirty areas where
airborne contaminants can accumulate on the dryer. If this cannot be
prevented, the dryer should be cleaned periodically. An accumulation
of dirt on the dryer may cause the inlet transfer valve to fail.

4.2 PIPING AND ANCILLARY EQUIPMENT

CAUTION

Make sure that the inlet air piping is connected at the bottom and the
outlet air piping is connected at the top of the dryer.

Make sure that the inlet and outlet piping to and from the dryer is
properly supported. Excessive stress may cause damage and/or
dryer malfunction.

CAUTION

A PROPERLY RATED COALESCING PREFILTER MUST BE
INSTALLED BEFORE THE DRYER TO REMOVE LUBRICATING
OILS, DUST AND PIPE SCALE CONTAMINATION. FAILURE TO
USE A PREFILTER WILL RESULT IN DAMAGE TO THE DRYER
AND VOIDS THE WARRANTY.

Make sure that the elements are installed in all filter housings
prior to start up.

THE DRYER AND PREFILTER ARE NOT DESIGNED TO HANDLE
LIQUID WATER. IF LIQUID WATER IS PRESENT IN THE AIR
SYSTEM, A SEPARATOR WITH AN AUTOMATIC DRAIN MUST BE
INSTALLED UPSTREAM TO THE PREFILTER AND DRYER TO
PREVENT FLOODING.

A coalescing prefilter must be installed before the dryer to remove
lubricating oils, dust and pipe scale contamination. It is recommended
that a high efficiency coalescing filter with an automatic drain or
electric drain valve be installed. The filter should be equipped with a
pressure differential indicator to monitor the condition of the element.

A particulate afterfilter should be installed downstream of the dryer to
remove any desiccant dust. The filter should be equipped with a
pressure differential indicator to monitor the condition of the element.

Make sure that the filters are properly installed according to the
instructions provided with them.

Remove protective caps or covers from all valves before installing this
dryer.

If this dryer is to be installed into an existing piping system, clean the
existing inlet piping to remove all accumulated dirt, pipe scale, etc.,
before connecting the dryer. Make sure that the inlet and outlet
shutoff valves are tightly closed before connecting to the existing
piping system.

If excessive vibrations are present in the piping, install a flexible hose
between the compressor and the dryer inlet.

When installing the piping and any additional components, make sure
that adequate pipe supports are used. Excessive stress on the dryer
and components may cause damage or premature failure. Use either
overhead or stiff-leg type supports.

Make sure that the piping is correctly connected to the dryer. The inlet
is the bottom connection and the outlet is the top connection.

Reference SECTIONS 3.2 through 3.4 for dryer dimensions and
connection locations.

Once the location has been determined, place the dryer into position.
Lift the dryer by the lifting lugs only. Reference SECTION 1 for

handling instructions.

When the dryer is in place, it can be fastened to the mounting surface.

Reference SECTIONS 3.2 through 3.4 for dryer dimensions.

4.2-1 BYPASS PIPING (optional)

The installation of bypass piping is not required, but will allow the
dryer and filter(s) to be taken off stream without interrupting the air
system.

In Figure 4A, several recommended bypass piping layouts and
additional components are shown.

4.3 INSTALLING THE PRESSURE RELIEF VALVES

THESE ASME CODE VESSELS MUST BE PROTECTED BY
PRESSURE RELIEF VALVES. Refer to OSHA 1910.169 Par. b,
Sub. Par (3) and ASME Boiler and Pressure Vessel Code, Section
VIII, Division 1, UG-125 through UG-136. Also comply with all
state and local codes.

Connections are provided in the outlet piping for the installation of
pressure relief valves. Reference SECTIONS 3.2 through 3.4 for
location and connection size.

Install the pressure relief valves into the provided connections. If
pressure relief valves were not purchased with the dryer, the following
valve sets are available from your local VAN AIR representative.

DRYER
MODEL

HL-200
HL-250
HL-375
HL-500
HL-650

HL-800
HL-1000
HL-1250
HL-1500
HL-1750
HL-2000

PART NO.

14-1448 (2)
14-1448 (2)
14-1833 (2)
14-1833 (2)
14-1834 (2)
14-1834 (2)
14-1835 (2)
14-1835 (2)
14-1836 (2)
14-1836 (2)
14-1836 (2)

CAUTION

VALVE

PAGE 7

INSTALLING THE DRYER SECTION 4

FIGURE 4A RECOMMENDED PIPING CONFIGURATIONS AND COMPONENTS
3 VALVE BYPASS

9 VALVE BYPASS

11 VALVE BYPASS

MODEL

HL-200
HL-250
HL-375
HL-500
HL-650
HL-800
HL-1000
HL-1250
HL-1500
HL-1750
HL-2000

IN/OUT

1-1/2" RF FLG
1-1/2" RF FLG
1-1/2" RF FLG
1-1/2" RF FLG
2-1/2" RF FLG
2-1/2" RF FLG
2-1/2" RF FLG
2-1/2" RF FLG
3" RF FLG
3" RF FLG
3" RF FLG

PREFILTERDRYER

MODEL

F200-265-11/4-C

1

F200-265-1

/4-C
F200-350-11/2-C
F200-500-2-C
F200-600-3-C
F200-800-3-C
F200-1000-3-C
F101-1500-C
F101-1500-C
F101-2000-C
F101-2000-C

IN/OUT

1-1/4" NPT(F)
1-1/4" NPT(F)
1-1/2" NPT(F)
2" NPT(F)
3" NPT(F)
3" NPT(F)
3" NPT(F)
3" NPT(F)
3" NPT(F)
4" RF FLG
4" RF FLG

DRAIN

VALVE

MODEL

EDV-2006
EDV-2006
EDV-2006
EDV-2006
EDV-2006
EDV-2006
EDV-2006
EDV-2006
EDV-2006
EDV-2006
EDV-2006

DEL-P

IND.

MODEL

PD-5
PD-5
PD-5
PD-5
PD-5
PD-5
PD-5
PD-2
PD-2
PD-2
PD-2

AFTERFILTER

MODEL

1

F200-265-1
F200-265-1

/4-RB

1

/4-RB
F200-350-11/2-RB
F200-500-2-RB
F200-600-3-RB
F200-800-3-RB
F200-1000-3-RB
F101-1500-RB
F101-1500-RB
F101-2000-RB
F101-2000-RB

IN/OUT

NPT(F)

1-1/4"
1-1/4" NPT(F)
1-1/2" NPT(F)
2" NPT(F)
3" NPT(F)
3" NPT(F)
3" NPT(F)
3" NPT(F)
3" NPT(F)

4" RF FLG

4" RF FLG

DEL-P

IND.

MODEL

PD-5
PD-5
PD-5
PD-5
PD-5
PD-5
PD-5
PD-2
PD-2
PD-2
PD-2

PAGE 8

INSTALLING THE DRYER SECTION 4

4.4 REMOTE PURGE EXHAUST PIPING

To reduce noise during purging and tower depressurization, this dryer
was supplied with mufflers for installation on the purge exhaust valves.
If the sound or humidity discharged from the dryer is unacceptable, the
purge of this dryer can be remotely piped away.

Make sure that the piping is as short as possible and does not
create back pressure on the dryer. To prevent liquid accumula­tion in the piping and purge valves, the piping must be at the
same level or lower than the purge valves.

The purge line must be vented to atmospheric pressure. If the
ambient temperature at the venting end of the piping is subject
to temperatures below 40

The purge valves have threaded pipe connections. Reference
Sections 3.2 through 3.4 for location. Use adequate pipe supports to
prevent stress on valves.

The distance will determine the size of piping that is recommended.
For distances of 10 feet or less, use piping of the same size as the
purge valves. For distances up to 20 feet, use piping one size larger
than the purge valves.

IMPORTANT

o

F, freeze protection must be installed.

4.6-1 STANDARD CONTROL BOX (115V & 230V)

The power supply to the dryer is to be connected to the dryer control
box. A 7/8" dia hole was provided in the bottom of the box for the
connection of conduit or a cord grip connector.

Check the electrical rating of the dryer as listed on the dryer data tag.
Make sure that the power source is correct for the dryer rating.

Remove the box cover to access the power and alarm terminals.
Wire the power supply as shown in Figure 4C (Standard Control
Box). Connect the wiring to the dryer box. Comply with all codes
applicable for this installation.

FIGURE 4C ELECTRICAL CONNECTIONS

(STANDARD CONTROL BOX)

4.5 INSTALLING THE PURGE MUFFLERS

To reduce the sound level during purge and tower depressurization,
this dryer was supplied with mufflers for installation on the purge
exhaust valves.

Mufflers were shipped separately. They should NOT be installed until
the dryer has been operated for several hours. From desiccant
installation, some dust may be present in the desiccant towers.
Operating the dryer with the mufflers installed immediately after the
towers have been filled with the desiccant or during initial start up may
cause the mufflers to clog.

The dryer must be operated for several hours without the
mufflers after the towers have been filled with desiccant. This
will prevent the mufflers from becoming clogged.

IMPORTANT

FIGURE 4B PURGE MUFFLER INSTALLATION

NOTE
Dryer Models HL-1500 thru HL-2000
Have flanged muffler connections.

Control Power: 115V /1PH/50-60Hz; 230V/1PH/50-60Hz
Max amp draw: 0.3 AMPS; 0.15 AMPS
General Alarm Contacts: 115V-230V/1PH/60Hz, 0.25 amps

4.6-2 CYCLE SAVER / FAILURE TO SWITCH (115V & 230V)

Same instructions as Standard Control Box except wire the power
supply as shown in Figure 4D (Cycle Saver / Failure To Switch).

FIGURE 4D ELECTRICAL CONNECTIONS

(CYCLE SAVER / FAILURE TO SWITCH)

4.6 ELECTRICAL CONNECTIONS

WARNING

SERIOUS PERSONAL INJURY AND DAMAGE TO THE DRYER
WILL OCCUR IF THE DRYER IS CONNECTED TO A POWER
SOURCE OTHER THAN THE VOLTAGE LISTED ON THE DATA
TAG.

WHEN INSTALLING THE ELECTRICAL CONNECTIONS FOR
THIS DRYER, COMPLY WITH NATIONAL ELECTRICAL CODE
AND ALL APPLICABLE FEDERAL, STATE AND LOCAL
CODES

Control Power: 115V /1PH/50-60Hz; 230V/1PH/50-60Hz
Max amp draw: 1 AMPS; 0.5 AMPS
General Alarm Contacts: 115V-230V/1Ph/60Hz, 3 amps

PAGE 9

INSTALLING THE DRYER SECTION 4

4.6-3 EMCON II (115 VOLT)

The electrical controls for the Emcon II dryers are
housed in a NEMA 4 rated fiberglass enclosure.

Reference Figure 4E to locate the power input
terminals. Access into the enclosure for wiring and
conduit can be made by carefully drilling a hole in
the bottom of the enclosure.

FIGURE 4E ELECTRICAL CONNECTIONS EMCON II (115 VOLT)

Do NOT wire the power supply directly to the

IMPORTANT

PLC. Wire the power supply to the input
terminals as shown in Figure 4E.

Connect the proper conduit and wiring as required
for this installation by all applicable codes.

Make the necessary connections to the power input
terminals.

4.6-4 EMCON II (230 VOLT)

The main electrical controls for the Emcon II dryers are
housed in a NEMA 4 rated fiberglass enclosure.

Dryers rated for 230V/1PH/60Hz are equipped with a
power transformer located in a separate enclosure on
the dryer. All main power supply (230V) connections
will be made in the transformer enclosure.

Reference Figure 4F for connection details. Connect
to the enclosure using the proper conduit and wiring as
required for this installation by all applicable codes.

Control Power: 115V/1PH/60Hz
Max amp draw: 2 AMPS
General Alarm Contacts: 115V-230V/1PH/60Hz, 2 amps

FIGURE 4F ELECTRICAL CONNECTIONS EMCON II (230 VOLT)

General Alarm Contacts: 115V-230V/1PH/60Hz, 2 amps

PAGE 10

START UP SECTION 5

5.1 START UP

WARNING

BEFORE STARTING THIS DRYER, FOLLOW THE INSTALLATION
INSTRUCTIONS AND PROCEDURES COMPLETELY. SERIOUS
PERSONAL INJURY CAN RESULT IF INSTRUCTIONS ARE NOT
CAREFULLY AND COMPLETELY FOLLOWED.

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS
DRYER WHILE IT IS PRESSURIZED.

For the Standard Control Box, make sure the Stop button is pressed.
For the Cycle Saver and Emcon II Control Boxes, make sure that the
Power switch is in the OFF position.

If the dryer is being started up for the first time or after the
desiccant has been changed, the purge mufflers must be removed.
The dryer should be operated until no desiccant dust is visible at
the purge valves. Then the mufflers can be reinstalled. See
Section 2.2 for safety precautions concerning the desiccant dust.

WARNING

WHEN OPERATING THIS DRYER WITHOUT THE MUFFLERS
INSTALLED, USE HEARING PROTECTION.

If bypass piping was installed on this dryer as outlined in SECTION 4.2,
close the inlet and outlet isolation valves. Open the bypass valve.

Pressurize the air system. Once the air system is pressurized, slowly
open the inlet isolation valve. DO NOT open the outlet isolation valve.

To start the dryer with a Standard Control Box, press the Run button
which will light the Run LED. For Cycle Saver and Emcon II Control
Boxes, place the Power switch in the ON position. One tower will
already be pressurized. The other tower will depressurize. The purge
valve on the tower that is not pressurized will be open, air should be
exhausting from the muffler.

Dryers equipped with CYCLE SAVER or EMCON II controls will begin a
20 minute start up cycle. While in the start up cycle the dryer will
operate for 5 minutes on each tower to allow the humistat(s) to reach
equilibrium. Any time the dryer is restarted after a loss of power or
pressure in both towers, it will restart in the start up cycle.

The dryer is equipped with a purge metering valve. The setting should
be checked before placing the dryer on stream.

5.2 ADJUSTING THE PURGE FLOW

IMPORTANT

NEVER OPERATE THE DRYER WITH THE PURGE METERING
VALVE CLOSED. IF THE VALVE IS CLOSED, THE TOWERS WILL
NOT REPRESSURIZE AND SWITCHING FAILURE WILL OCCUR.

DO NOT ADJUST THE PURGE METERING VALVE ABOVE OR
BELOW THE RECOMMENDED SETTING FOR THE OPERATING
CONDITIONS OF THIS INSTALLATION. IMPROPER SETTING MAY
CAUSE POOR DRYER PERFORMANCE AND/OR EXCESSIVE USE
OF PROCESS AIR.

conditions, the purge metering valve must be adjusted to maintain the
required purge flow rate listed in Figure 5B.

Determine the dryer minimum operating pressure. Using the chart in Figure
5A, find the valve setting for that pressure. The valve is equipped with a set
screw which must be loosened before the valve is adjusted. Adjust the needle
valve to the desired setting. Tighten the set screw to prevent tampering.

FIGURE 5A PURGE METERING VALVE SETTINGS

1/2" & 3/4" VALVES used on
models HL-200 THROUGH HL-500

1" VALVE used on
models HL-650 through HL-2000

FACTORY

SETTING

MODEL

HL-200
HL-250
HL-375
HL-500
HL-650

HL-800
HL-1000
HL-1250
HL-1500
HL-1750
HL-2000

60 PSIG

3.5 turns

3.6 turns

4.5 turns

5.6 turns

2.7 turns

2.8 turns

3.0 turns

3.4 turns

3.8 turns

4.0 turns

4.2 turns

80 PSIG

3.3 turns

3.4 turns

4.0 turns

4.6 turns

2.6 turns

2.7 turns

2.8 turns

3.0 turns

3.3 turns

3.5 turns

3.9 turns

100 PSIG

3.2 turns

3.3 turns

3.8 turns

4.2 turns

2.5 turns

2.6 turns

2.7 turns

2.9 turns

3.0 turns

3.2 turns

3.4 turns

120 PSIG

3.1 turns

3.2 turns

3.7 turns

4.0 turns

2.3 turns

2.5 turns

2.6 turns

2.7 turns

2.9 turns

3.0 turns

3.2 turns

150 PSIG

3.0 turns

3.1 turns

3.5 turns

3.8 turns

2.2 turns

2.3 turns

2.5 turns

2.6 turns

2.7 turns

2.8 turns

3.0 turns

FIGURE 5B REQUIRED PURGE FLOW

DRYER

MODEL

HL-200
HL-250
HL-375
HL-500
HL-650
HL-800

PURGE

FLOW

36.0 SCFM

45.0 SCFM

67.5 SCFM

90.0 SCFM

117.0 SCFM

144.0 SCFM

DRYER

MODEL
HL-1000
HL-1250
HL-1500
HL-1750
HL-2000

PURGE

FLOW

180.0 SCFM

225.0 SCFM

270.0 SCFM

315.0 SCFM

360.0 SCFM

5.3 CONDITIONING THE DESICCANT BED

To condition the desiccant bed, the dryer is operated without any outlet flow,
while the towers regenerate with purge air.

To start the dryer with a Standard Control Box, press the Run button which
will light the Run LED. For Cycle Saver and Emcon II Control Boxes, place
the Power switch in the ON position.

The purge flow can be adjusted for the operating conditions. Standard
dryers are equipped with a micrometer type needle valve. The valve can
be adjusted to the desired setting.

This dryer was shipped with the purge flow set for the rated inlet flow at
100 PSIG. Reference Section 3.1 for rated flow. This setting should be
correct for most installations. Before placing the dryer on stream, check
the purge metering valve setting.

Figure 5B shows the purge flow required for each model. This flow is
required to properly regenerate the desiccant beds.

If the dryer is being operated at a pressure other than inlet rated

Dryers equipped with the Standard Contol Box should be set on the 10 minute
time cycle. Dryers equipped with Emcon II and Cycle Saver should be set in
the Fixed Mode. Observe the dryer for several cycles. Make sure that it is
operating properly.

At initial start up or after extended shutdowns (over one month), the dryer may
take 24 to 48 hours of continuous operation for the bed to be conditioned.
Moisture that has accumulated on the desiccant bed should be removed
before the dryer is placed on stream.

Once the moisture indicator on the dryer turns blue, the desiccant bed is
ready. Place the dryer on stream by opening the outlet isolation valve. Make
sure that the by-pass valve is closed.

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