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SERIES HC Heat-of-Compression Compressed Air Dryer
Models HC-3 HC-239
IMPORTANT! BEFORE INSTALLING AND OPERATING THE DRYER, IT IS
RECOMMENDED THAT THIS MANUAL BE STUDIED AND CLEARLY UNDERSTOOD.
THIS DRYER IS DESIGNED TO BE USED ONLY WITH A NON-LUBRICATED
COMPRESSOR. USE WITH A LUBRICATED COMPRESSOR WILL VOID ALL
WARRANTIES AND MAY CAUSE SEVERE DAMAGE.
Information When making inquiries, please provide the following
information: 1) Equipment Model Number 2) Equipment Serial Number
3) Equipment Operating
Pressure 4) Equipment Operating
Temperature 5) Approximate time in
service 6) Nature of Problem For information, parts, or service,
contact your local IInnggeerrssoollll--RRaanndd Service provider or
reach us at www.air.irco.com
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 2 September 2004
INDEX PREFACE SECTION 1: INTRODUCTION 1.1 General Information
1.2 Safety Instructions
1.2.1 Identification of signs and symbols in this manual 1.2.2
Safety tips for maintenance, inspection & assembly work
1.3 Personnel Qualification 1.4 Product Information
1.4.1 Theory of Operation 1.4.2 Pressure vessel regulations
1.4.3 Airtightness test 1.4.4 Overloading 1.4.5 Technical data
sheet 1.4.6 Dryer Flow Capacities 1.4.7 Transport 1.4.8 Storage
1.4.9 Use of an afterfilter
SECTION 2: INSTALLATION 2.1 Set-up and installation
2.1.1 Mechanical installation 2.1.2 Filter installation 2.1.3
Electrical installation
SECTION 3: START UP AND OPERATION 3.1 Start-up / Shut down
3.1.1 Pressurizing dryer 3.1.2 Energizing dryer controls
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 3 September 2004
3.2 Operator interface
3.2.1 Main screen 3.2.2 Dryer status 3.2.3 Settings 3.2.4
Alarms
3.3 Program Steps SECTION 4: MAINTENANCE 4.1 Suggested
preventive maintenance schedule 4.2 Replacement / Disposal of the
desiccant 4.3 Dewpoint meter maintenance (DPDS Option only) 4.4
Filters
4.4.1 General comments and use 4.4.2 Function 4.4.3 Assembly and
installation 4.4.4 Maintenance 4.4.5 Changing of filter elements
4.4.6 Accessories
SECTION 5: SPARE PARTS LIST 5.1 Recommended spares for HC-3 TO
HC-239 SECTION 6: TROUBLESHOOTING AND FAULTS 6.1 Introduction 6.2
High Dewpoint 6.3 Fail-to-shift 6.4 Primary Drain Failure 6.5
Secondary Drain Failure 6.6 Short-term shut-down 6.7 Shut-down in
case of a fault or for maintenance
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 4 September 2004
SECTION 7: I-R ACTIVATED ALUMINA MSDS 7.1 Company Description
7.2 Material Description 7.3 Ingredients 7.4 Physical Data 7.5 Fire
and Explosion Data 7.6 Reactivity Data 7.7 Health Hazard
Information 7.8 Spill, Leak, and Disposal Procedures 7.9 Special
Protection Information 7.10 Special Precautions and Comments 7.11
References SECTION 8: AUXILIARY MANUALS & DRAWINGS
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 5 September 2004
PREFACE:
This technical manual from IInnggeerrssoollll--RRaanndd is an
aid in getting to know the adsorption dryer better and in utilizing
its possibilities for application in accordance with its intended
use. Furthermore, this manual contains important information for
safe, proper and economic operation. All instructions must be
followed as written in order to avoid danger and damages which
could cause downtime and premature wear and tear on the adsorption
dryer. In addition to the technical manual and the accident
prevention regulations which are valid in the particular location
where the dryer is being used, the recognized special rules for
safe and proper working procedures must also be followed.
Each person involved with the set-up, start-up, operation,
maintenance and repair of the adsorption dryer in the User Company
must have first read and understood the technical manual and
especially the safety tips.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 6 September 2004
SECTION 1: 1.1 GENERAL INFORMATION
The adsorption dryer of the HC-3 HC-239 series is built
according to the latest technological developments and recognized
safety rules. Its use, however, can endanger life and limb of the
user or of third parties and can lead to considerable damage to the
adsorption dryer and other material assets if:
it is operated by personnel not trained or instructed in its
use, it is improperly used, It is improperly maintained or
serviced. This can result in the loss of all damage claims. This
adsorption dryer is designed for neutral media (gas) free of
aggressive water, oil and solid elements.
IInnggeerrssoollll--RRaanndd accepts no liability for corrosion
damage and malfunctions caused by aggressive media.
Applications other than those mentioned in this manual must be
agreed to by IInnggeerrssoollll--RRaanndd and confirmed in
writing.
In the interest of further development,
IInnggeerrssoollll--RRaanndd reserves the right to make changes at
any time, which, in keeping with the essential characteristics of
the adsorption dryer described here, may be necessary for
increasing efficiency or for reasons relating to safety or to
normal business practice.
1.2 SAFETY INSTRUCTIONS
This technical manual contains basic tips, which must be
followed during set-up, operation and servicing. It is of utmost
importance that it be read by the assembly technician before
installation and start-up, as well as by the specialist / operator
in charge, and it must always be within reach at the place where
the adsorption dryer is being used.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 7 September 2004
SECTION 1: (Continued) 1.2.1 Identification of signs and symbols
in this technical manual
The safety tips contained in this technical manual, whose
disregard could endanger people and machines, are indicated by a
general danger sign and the additional markings Danger! Or
Attention!
Danger! / Attention!
Warning against electrical voltage!
Safety tips printed directly on the adsorption dryer must also
be followed at all times and must be kept completely legible.
Advice: This sign refers to a procedure or sequence of
particular interest or importance. All tips must be followed to
ensure proper use of this adsorption dryer.
This dot refers to working or operational steps. The steps are
to be carried out in the order of their appearance from top to
bottom.
- The sign of a hyphen marks enumerations.
1.2.2 Safety tips for maintenance, inspection and assembly
work
The operator is to make sure that all maintenance, inspection
and assembly work is carried out by special personnel who are
authorized and qualified, and who are adequately informed through
careful study of the technical manual. For this reason, special
attention should be paid to the following attention and danger
sign:
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 8 September 2004
SECTION 1: (Continued) 1.2.2 Safety tips for maintenance,
inspection and assembly work (Continued)
Attention!
Never make structural changes to the adsorption dryer that are
not specifically authorized by Ingersoll-Rand!
Only use original spare and accessory parts! Carry out
maintenance work only when the
adsorption dryer is switched off, depressurized, and
disconnected from the electric power supply!
Attention!
Multiple power sources may exist in the electrical panel. All
possible power sources must be disconnected before servicing
dryer.
Advice: Refer to the desiccant material safety data sheet (MSDS)
when installing or disposing of desiccant, which can be found in
Section 7 of this User Manual.
Danger!
Wear protective goggles and mask when working with the
desiccant!
Advice for protection: If desiccant comes into contact with the
eyes, rinse eyes immediately with large
amounts of clear water. If the desiccant is spilled, clean up
with effort to minimize the formation of dust. In case of fire,
there is no restriction on the use of fire extinguishing material.
A small dust mask must be worn.
1.3 PERSONNEL QUALIFICATION The personnel involved in operation,
maintenance, inspection, and assembly must have the corresponding
qualifications to do this work. Areas of responsibility and
supervision of the personnel must be precisely established by the
operator. Should the personnel not possess the necessary knowledge,
then they must be trained and instructed. If need be, this training
may be carried out by the manufacturer / supplier at the request of
the operator of the adsorption dryer. Further, the operator is to
make sure that the personnel completely understand the contents of
the technical manual.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 9 September 2004
SECTION 1: (Continued) 1.4 PRODUCT INFORMATION
The adsorption dryer is used for the purpose of drying
compressed air and other gases according to its respective design.
As a "standard model" the adsorption dryer is equipped with two
desiccant vessels and, depending on certain conditions, provides
pure, dry and oil-free compressed air or gases.
1.4.1 Theory of Operation The HC heat-of-compression dryer uses
the hot air from the compressor to regenerate the desiccant. Each
tower is sized for a minimum of 4 hours online, but may be extended
by use of the optional DPDS which will allow the dryer to switch
towers based on water load rather than time. The DPDS (Dewpoint
Demand System) is optional equipment and may or may not be present
on your particular air dryer. If your dryer is equipped with the
DPDS, see the associated DPDS Installation and Operating Guide for
more operational details. The regeneration cycle is split up into
three functions.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 10 September 2004
SECTION 1: (Continued)
A. Regeneration Cycles
1. Heating. Hot air directly from the compressor enters the
inlet of the HC and is directed by the inlet 2-way valves into the
regenerating tower. This hot, thirsty air regenerates the bulk of
the water from the desiccant. The air is then directed into the
aftercooler where it is cooled, the coalescing separator where
liquid water is removed through the drain trap system, then into
the drying tower where the air is actually dried to its final low
dewpoint. The heating cycle lasts 90 minutes.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 11 September 2004
SECTION 1: (Continued)
2. Stripping. At the end of heating, the inlet valves shift
position, directing the hot inlet air directly into the
aftercooler, separator, and drying tower. We now begin stripping.
The stripping phase of regeneration lasts 90 minutes. At the
beginning of stripping, the regenerating tower is depressurized
through a muffler. During stripping, a small adjustable flow of dry
air is used to remove the last little bit of moisture from the
regenerating tower.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 12 September 2004
SECTION 1: (Continued)
3. Cooling. At the end of stripping, the regenerating tower is
repressurized. The cooling cycle valves open and cooling begins.
The cooling cycle lasts 60 minutes. During cooling, a portion of
the dry outlet air is directed into the regenerating tower to
reduce the temperature of the bed prior to tower shift.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 13 September 2004
SECTION 1: (Continued)
1.4.2 Pressure vessel regulations
The pressure vessels are designed according to the standard
technical requirements. They fulfill the test of the certifying
procedure and carry the U, UM ASME Symbol.
Range of Application:
Type HC-3 HC-239
Operating overpressure Max. 150 PSIG
Operating Temperature Max.Min.
500F 20F
Attention! Never weld on or alter a pressure vessel in any
way!
1.4.3 Airtightness test
All adsorption dryers are subjected to an airtightness test
prior to shipment using compressed air.
1.4.4 Overloading
Attention! Protect the adsorption dryer from overloads! The
adsorption dryer can become overloaded, if: The inlet flow is too
high, The temperature of the air at the discharge of the
aftercooler is too high, The min. operating pressure is too low,
The temperature of the air at the discharge of the
compressor is too low.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 14 September 2004
SECTION 1: (Continued) 1.4.5 Technical data sheet
MODEL HC-3 HC-6 HC-7 HC-9 Flow (SCFM) @ 100 PSIG 100F Drying
Temperature
301 535 677 836
Vessel OD Inches 12 16 18 20
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 223 397 502 620
Inlet connection 2 NPT 2 NPT 3 FLG 3 FLG
Outlet connection 2 NPT 2 NPT 3 FLG 3 FLG
FILTER Afterfilter AF-350 AF-550 AF-1000 AF-1000 Voltage
115/1/60 Standard -
Consult Factory for other voltages
Cooling Water GPM 9 16 20 25
Stripping Flow SCFM 6 11 14 17
Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours
Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoints 10 PSI Fail to Shift 60 PSI Initiate
Cooling Cooler outlet high temperature alarm 105F Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 15 September 2004
SECTION 1: (Continued) 1.4.5 Technical data sheet
MODEL HC-14 HC-21 HC-30 HC-41 Flow (SCFM) @ 100 PSIG 100F Drying
Temperature
1204 1880 2708 3686
Vessel OD Inches 24 30 36 42
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 893 1395 2009 2735
Inlet connection 3 FLG 4 FLG 4 FLG 6 FLG
Outlet connection 3 FLG 4 FLG 4 FLG 6 FLG
FILTER Afterfilter AF-1400 AF-2400 AF-3600 AF-7200 Voltage
115/1/60 Standard -
Consult Factory for other voltages
Cooling Water GPM 36 56 80 110
Stripping Flow SCFM 24 38 54 74
Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours
Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate
Cooling Cooler outlet high temperature alarm 105F Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 16 September 2004
SECTION 1: (Continued) 1.4.5 Technical data sheet
MODEL HC-54 HC-69 HC-85 HC-103 Flow (SCFM) @ 100 PSIG 100F
Drying Temperature
4814 6093 7522 9101
Vessel OD Inches 48 54 60 66
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 3572 4521 5581 6753
Inlet connection 6 FLG 6 FLG 8 FLG 8 FLG
Outlet connection 6 FLG 6 FLG 8 FLG 8 FLG
FILTER Afterfilter AF-7200 AF-7200 AF-7200 AF-10000 Voltage
115/1/60 Standard -
Consult Factory for other voltages
Cooling Water GPM 143 138 172 208
Stripping Flow SCFM 96 122 150 182
Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours
Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate
Cooling Cooler outlet high temperature alarm 105F Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 17 September 2004
SECTION 1: (Continued) 1.4.4 Technical data sheet
MODEL HC-122 HC-143 HC-166 Flow (SCFM) @ 100 PSIG 100F Drying
Temperature
10832 12712 14742
Vessel OD Inches 72 78 84
Desiccant type IR Activated Alumina
Lbs. Desiccant / Vessel 8037 9432 10939
Inlet connection 8 FLG 8 FLG 10 FLG
Outlet connection 8 FLG 8 FLG 10 FLG
FILTER Afterfilter AF-16000 AF-16000 AF-16000 Voltage 115/1/60
Standard -
Consult Factory for other voltages
Cooling Water GPM 247 289 335
Stripping Flow SCFM 217 254 295
Cycle time 8 Hour NEMA Cycle 4 Hours drying/ 4 Hours
Regeneration
Outlet Dewpoint Variable
DPDS Control Adjustable
High Humidity Alarm Adjustable
Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate
Cooling Cooler outlet high temperature alarm 105F Low regeneration
temperature alarm Adjustable
Process flow Downward Regeneration / Upward Drying
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 18 September 2004
SECTION 1: (Continued) 1.4.6 Dryer Flow Capacities
Model Selection Chart:
MODEL 85 PSI 90 PSI 95 PSI 100 PSI 105 PSI 110 PSI 115 PSI
HC-3 262 274 287 301 313 327 342 HC-6 465 486 509 535 557 581
608 HC-7 588 615 645 677 705 735 769 HC-9 726 760 796 836 870 908
950 HC-14 1046 1094 1146 1204 1253 1308 1368 HC-21 1634 1709 1790
1880 1957 2042 2136 HC-30 2353 2462 2578 2708 2819 2941 3076 HC-41
3203 3351 3509 3686 3837 4003 4187 HC- 54 4183 4376 4583 4814 5011
5228 5469 HC-69 5295 5539 5801 6093 6343 6617 6922 HC-85 6537 6837
7161 7522 7830 8169 8545 HC-103 7909 8273 8664 9101 9474 9884 10339
HC-122 9413 9846 10312 10832 11276 11764 12305 HC-143 11047 11555
12102 12712 13233 13805 14441 HC-166 12812 13401 14035 14743 15347
16011 16748
Note: Maximum operating pressure is 150 PSIG; higher pressures
available as an option. Consult factory.
Minimum Inlet Pressure (PSIG) 85 90 95 100 105 110 115
Correction Factor 1.15 1.1 1.05 1 .96 .92 .88
CORRECTION FACTOR FOR COOLING WATER TEMPERATURE
TEMPERATURE F 75 80 85 90 Correction Factor .85 .9 1.0 1.2
To correct for a cooling water temperature other than 85F, or an
operating pressure other than 100 psig, multiply dryer capacity by
the correction factors listed above. Example: To size for an inlet
flow of 1300 SCFM @ 90 Psig, using 90F cooling water:
Multiply 1300 * (1.1) * (1.2) = 1716 Use model HC-21
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 19 September 2004
SECTION 1: (Continued) 1.4.7 Transport
After the adsorption dryer has been delivered, it must be
checked for damage that may have occurred during transport. The
Transport Company must be informed to register any damage. Shipping
damage is not covered by any warranty.
1.4.8 Storage If the adsorption dryer is to be stored for a
prolonged period of time, it should be stored in a dry place,
preferably indoors; protected from the elements including freezing
or extremely warm temperatures.
1.4.9 Use of a pre and afterfilter Use of a prefilter is not
necessary with a heat-of-compression dryer. An afterfilter should
be provided to prevent desiccant dust from migrating
downstream.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 20 September 2004
SECTION 2:
INSTALLATION 2.1 SET-UP AND INSTALLATION
Once at the installation location, the adsorption dryers of the
series HC-3 HC-239, which are supplied with a base frame, must be
positioned so that all sides are easily accessible. Should
vibrations occur on the installation location, the adsorption dryer
is to be placed onto vibration dampeners. Since the adsorption
dryer has already been completely wired at our factory, the
customer only has to connect the power supply cable to the terminal
strip according to the supplied wiring diagrams.
Advice Should you still have questions regarding installation,
you can request installation blueprints separately from
IInnggeerrssoollll--RRaanndd Davidson NC.
Warning! Use the appropriate, load-rated lifting equipment and
observe safe lifting procedures during all operations of
installation. The equipment should be unloaded as close as possible
to the installation site to minimize any chances of equipment
damage.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 21 September 2004
SECTION 2: (Continued) 2.1.1 Mechanical installation
The equipment should be located in an area as practically
possible with
adequate clearances for service. An overhead clearance of not
less than three feet above each adsorber tower is required for
loading of the desiccant. Access clearance of three feet in front
of the control panel should be provided. Insulate the pipe between
the compressor and dryer to minimize heat loss. Remove all
protective shipping crates, flange covers, etc.
Utilizing the mounting holes provided on the skid, anchor the
IInnggeerrssoollll--RRaanndd type HC Dryer to a solid, level
foundation designed to support the dryer.
Do not hydrostatically test the pressure vessels. All HC dryers
pressure vessels are hydrostatically tested at one and one-half
times the design pressure after fabrication and before
assembly.
Desiccant is shipped loose (HC-41 and above) and must be
installed. Refer to section 4.2 for installation of desiccant.
If the equipment is installed in a high traffic area, protective
barriers may be required to prevent possible damage of equipment
and to prevent contact with hot surfaces.
Because of vibration during shipping, some tube fittings may
have loosened; therefore, inspect all connections and tighten if
required. Also, flange connections may have loosened; therefore
tighten all flange bolts.
Ensure that the inlet and outlet connections to and from the
IInnggeerrssoollll--RRaanndd type HC Dryer are made using the
correct rated fittings and piping to meet the design
conditions.
System isolation and by-pass valves should be installed. If not
supplied as part of the equipment package by
IInnggeerrssoollll--RRaanndd, they should be supplied and installed
by others. It must be verified that these exist, so that future
servicing of the Dryer System may take place.
Full flow relief valves to protect the system from over-pressure
must be provided by others in accordance with local
regulations.
The purge exhaust connection on the HC larger dryers may be
connected to a vent header. To ensure satisfactory regeneration of
the desiccant chambers is achieved, the purge exhaust piping should
be sized as follows to prevent "back pressure" build up.
Installed length of exhaust pipe Pipe size required
Up to 10 Ft Same size as the dryer exhaust Up to 25 Ft One size
larger than dryer exhaust Up to 50 Ft Two sizes larger than dryer
exhaust Up to 100 Ft Three sizes larger than dryer exhaust
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 22 September 2004
SECTION 2: (Continued) 2.1.2 Filter installation
Series HC dryers are shipped with the afterfilter loose or with
the filter skid mounted on a separate steel frame. The following
installation applies to all models that are shipped with filters
loose. Afterfilter Installation Mount afterfilter in such a way as
to allow clearance for the element
installation and removal. The filter must be piped so that the
correct flow direction indicated on the
filter is followed. Ensure that all piping and valves are
equivalent or larger in size to the dryer
inlet connection. Filter Skid with 3-Valve Bypass Installation
Filters skid should be located as close to dryer as possible. Use
the skid bolt
holes to secure the assembly. Ensure that the skid is located
such that the 3-valve bypass will bypass the
dryer and filters when in use. Check the flow direction of each
filter to ensure the after filter is connected to
the outlet pipe of the dryer. Connect the filter skid piping and
dryer skid piping using materials and
fabrication procedures that are suitable for compressed air
pressure piping. All flanges are ANSI B16.5 Class 150 Raised Face
flanges.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 23 September 2004
SECTION 2: (Continued) 2.1.3 Electrical installation
Connect the dryer to a correctly sized power supply. The dryer
requires a 115V 60 cycle connection. A disconnect switch is not
provided with the dryer and must be supplied by end user in
accordance with the recognized electrical codes.
Ground the frame of the dryer in accordance with the recognized
electrical codes.
It is recommended that the common alarm relay, located in the
dryer control panel, be connected to the control room or operator
station so that an immediate response to the dryer alarm may be
given when required.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 24 September 2004
SECTION 3:
START UP AND OPERATION 3.1 START UP
Attention! All pipes and wire connections are to be tightened!
Furthermore, before start-up: The pipes must be checked for the
presence of scale,
abraded material from the threading, or other similar
impurities.
All shut off valves on the adsorption dryer, after-filter and on
the bypass line should be closed.
The ambient temperature must not be less than 33F.Breakdowns
resulting from faulty installation do not fall under
IInnggeerrssoollll--RRaanndd's warranty obligation.
3.1.1 Pressurizing dryer
Prior to pressurizing the IInnggeerrssoollll--RRaanndd Series HC
Dryer system, verify the following:
- Dryer On Off switch is in the off position. - System outlet
block valve is closed. - Cooling water is turned on to the
aftercooler.
Slightly open the inlet isolation valve slowly admitting
compressed air to the
system. When full system operating pressure has been reached all
connections should be soap bubble tested for leaks. Any leaks
should be repaired and retested prior to placing the equipment in
service. If some gas other than the process air will be used for
leak testing, consult IInnggeerrssoollll--RRaanndd for its
compatibility with system components before proceeding. Fully open
the inlet isolation valve.
When the system is filled with process air, is leak tight and
start-up is
completed, then slowly open the system outlet valve to
pressurize the downstream piping. During the procedure, ensure that
the dryer system pressure does not fall below 95% of its reading
prior to opening the system outlet valve. This will protect the
equipment internal components (i.e. filter elements, desiccant)
from gas velocities above design conditions.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 25 September 2004
SECTION 3: (Continued) 3.1.1 Pressurizing dryer (Continued)
When pressurizing is complete then fully open the system outlet
valve to place the equipment in service.
Verify the system inlet pressure and temperature are at the
design operating
levels. 3.1.2 Energizing dryer controls
Turn ON-OFF switch to the ON position. A Micrologix programmable
controller with individual input/output modules
controls the dryer cycle. A copy of the program complete with a
full listing of inputs, outputs, internal coils, timers and
counters is included later in this manual. This should be used as a
reference guide to ensure dryer is cycling. A manual mode is
included in the dryer program to allow for fast cycling to verify
the operation of the dryer.
While dryer is in the stripping mode for either chamber, the
regeneration flow
setting should be checked. The stripping flow valve should be
set at 1.5 turns open at start-up and adjusted as necessary to
maintain the specified dewpoint. The pressure gauge on the
regenerating tower should not exceed 10 psig.
Warning! Failure to correctly set the stripping flow can lead to
improper regeneration of the desiccant bed, resulting in a dewpoint
failure when that chamber is returned to service.
It is recommended that the operational program of the dryer and
the wiring schematic be studied before operating the dryer.
NOTE : If the DPDS (Dewpoint Demand System) option is
purchased,
reference the DPDS Installation and Operating Guide for
instructions.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 26 September 2004
SECTION 3: (Continued) 3.2 OPERATOR INTERFACE
Function keys F1 through F4 perform the function displayed on
the screen.
ARROWS ALLOW USER TO SCROLL UP OR DOWN INSIDE OF THE SCREEN LIST
SELECTOR. AN ARROW ON THE RIGHT SIDE OF THE SCREEN NAMES INDICATES
WHICH SCREEN IS BEING SELECTED.
ENTER=> SELECTS THE SCREEN IN WHICH THE ARROW IS POINTING AND
DISPLAYS THAT SCREEN.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 27 September 2004
SECTION 3: (Continued)
3.2.1 Main Screen
This is the main screen. This screen will be displayed upon
initial startup or after an alarm has been cleared. Using the up or
down arrow keys and the enter key you may select a screen to
view.
3.2.2 Status
This screen will give you the dryers current status. The top
line will tell you which tower is onstream. The second line is the
regeneration cycle in which the opposite tower (regenerating) is
in. This will toggle from HEATING to STRIPPING to REPRESSURIZATION
to COOLING. If the optional dewpoint demand system (DPDS) is
installed, you may also see STANDBY below the current tower status.
The lower left hand corner gives the time remaining in the current
regeneration cycle. This starts counting down from 240 minutes
(four hours). Note: When the dryer is in DPDS Standby, the time
remaining will read zero. The lower right hand corner is another
screen selector list. This list is the same as the one on the MAIN
screen, except it only displays one screen name at a time. Use the
up or down arrow key to select the screen name you would like to go
to then press the enter key.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 28 September 2004
SECTION 3: (Continued) 3.2.3 Settings
The settings screen allows you to toggle between Dewpoint Demand
and straight Time cycle. While in Time cycle, the dryer will shift
towers every four hours. When utilizing the optional DPDS, the
dryer will complete its four hour regeneration and go into a
standby mode until the outlet dewpoint has reached the dewpoint
monitors set point. When dewpoint demand is not purchased, this
screen will not be available. 3.2.4 Alarms
The alarm screen will display any and all alarms. Alarms are
displayed in the order in which they occur, for instance the top
alarm is always the most recent one. When an alarm situation
occurs, this screen will automatically be displayed. When an alarm
clears, the operator interface will automatically return to the
MAIN screen. The optional fail-to-shift alarm comes with an alarm
horn. The F4 key will allow an operator to disable this horn while
they are in the area to fix the alarm condition. When fail-to-shift
is not purchased, this function will not be present. Using the
other function keys, per the above designations, you may toggle to
any other screen.
When screen is switched with a pre-existing alarm, this alarm
screen will not automatically pop back up until all alarms are
cleared.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 29 September 2004
3.3 PROGRAM STEPS: (Continued)
Part numbers for the instrument abbreviations listed in the
program steps below (i.e. V1, V2, etc.) can be found in the Spare
Parts List in Section 5 of this User Manual. STEP TIME DESCRIPTION
OF ACTION
1 0 min. De-energize SV1-2 Energize SV1-1; Opens V3, 6, 8 &
9 Closes V4, 5, 7 & 10 Left Tower Onstream Start time delay of
60 seconds; When time delay times out if pressure switch PS2 is
greater than 10 Fail to Shift alarm
2 2 min. De-energize SV2-2 Energize SV2-1; Opens V1 & 15
Closes V2 Heating Right Tower
3 90 min. De-energize SV2-1 Energize SV2-2; Opens V2 Closes V1
& 15 Energize SV4-1; Opens V12 Energize SV3-1; Opens V11
Stripping Right Tower
4 180 min. De-energize SV4-1; Closes V12 Re-pressurizing Right
Tower When PS3 reaches setpoint of 60 PSI then, Energize SV5-1;
Opens V13 Cooling Right Tower
5 240 min. If dewpoint is below the analyzer set-point and the
Dewpoint/Timer selector switch is on Dewpoint then; Begin standby
Standby
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 30 September 2004
3.3 PROGRAM STEPS: (Continued)
6 240 min. If the dewpoint rises above the analyzer set-point or
the Dewpoint/ +stdby Timer selector switch is on Timer then;
De-energize SV5-1; Closes V13 De-energize SV1-1 Energize SV1-2
Opens V4, 5, 7 & 10 Closes V3, 6, 8 & 9 Right Tower
Onstream Start time delay of 60 seconds; When time delay times out
if pressure switch PS2 is greater than 10 Fail to Shift alarm
7 242 min. De-energize SV2-2 Energize SV2-1; Opens V1 & 15
Closes V2 Heating Left Tower
8 330 min. De-energize SV2-1 Energize SV2-2; Opens V2 Closes V1
& 15 Energize SV4-1; Opens V12 Energize SV3-1; Opens V11
Stripping Left Tower
9 420 min. De-energize SV4-1; Closes V12 Re-pressurizing Left
Tower When PS3 reaches setpoint of 60 PSI then, Energize SV5-1;
Opens V13 Cooling Left Tower
10 480 min. If dewpoint is below the analyzer set-point and the
Dewpoint/Timer selector switch is on Dewpoint then; Begin standby
Standby
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 31 September 2004
3.3 PROGRAM STEPS: (Continued)
11 480 min. If the dewpoint rises above the analyzer set-point
or the Dewpoint/ +stdby Timer selector switch is on Timer then;
De-energize SV5-1; Closes V13 GOTO STEP 1
NOTES: 1.) At any time during the cycle, if Inlet temperature
(TH1) drops below the
setpoint (240F) then; Low Regeneration Temperature Alarm 2.) At
any time during the cycle, if the cooler outlet temperature (TS1)
rises
above the setpoint (105F) then; High Cooler Outlet Temperature
Alarm 3.) At any time during the cycle, if the dewpoint (DPDS)
rises above the setpoint
(-20F) for more than five continuous minutes then; High Dewpoint
Alarm 4.) At any time during the cycle, if the compressor goes
unloaded (CR1) then
stop the timing cycle of the dryer until the compressor is
loaded.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 32 September 2004
SECTION 4: MAINTENANCE
Advice: In order to ensure continuous and trouble-free
operation, a maintenance contract with IInnggeerrssoollll--RRaanndd
is recommended.
4.1 SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE
4.1.1 Introduction
The Series HC compressed air dryer requires a minimum of
maintenance as most components are "maintenance-free". However, a
certain amount of "preventive maintenance" is recommended to assure
years of trouble-free, high-performance service.
4.1.2 Periodic Maintenance Schedule
Whereas it is recommended that the dryer be observed and
inspected as often as it is practical, the following is a minimum
requirement:
A. EVERY 2000 HOURS OR 3 MONTHS
1. Check the inlet air temperature; make adjustments, if
necessary. 2. Check the air temperature at intercooler outlet;
above 100F means:
a. Increase the cooling water flow. b. Lower the cooling water
temperature. c. Back flush and thoroughly clean the intercooler, to
restore efficiency.
3. "Blow off" the vessel relief valves to assure their
integrity. 4. Test the drain trap assembly and drain the sump at
the separator drain of
sludge that may have accumulated by closing off the primary
drain until the secondary valve actuates.
All of the above can be accomplished while the dryer is
operating.
B. EVERY 4000 HOURS OR 6 MONTHS
1. Perform steps 1 through 4 as outlined in "Every 2000 Hours or
3 Months".
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 33 September 2004
SECTION 4: (Continued)
2. Isolate and depressurize the dryer. 3. Disconnect power to
the dryer. 4. Replace afterfilter elements (the proper number and
quantity is indicated
on the filter and in the Spare Parts List in Section V of this
manual). 5. Make certain all air and electrical connections are
sound. 6. Repressurize the dryer and place "on stream". 7.
Reconnect power to the dryer.
C. EVERY 8000 HOURS OR 12 MONTHS
1. Perform steps 1 through 4 as outlined in "Every 4000 Hours or
6 Months".
DO NOT REPRESSURIZE DRYER OR RECONNECT POWER
TO THE DRYER YET! 2. Rebuild the actuators by installing repair
kits in the major switching valves.
(V1-V13 and V15)
3. Carefully disassemble and clean the solenoid valves in the
control group; rebuild with new parts only if damage or serious
wear is evident.
4. Carefully disassemble and clean the 3-way solenoid valve on
the
separator drain trap.
5. Rebuild the secondary drain valve by installing a valve
repair kit. (SD - P/N 38341285)
6. Disassemble and clean the primary drain. (FT)
7. It is recommended that the aftercooler be back-flushed and
thoroughly
cleaned, both tubeside and shellside, at 8,000 hours; but this
interval should be adjusted shorter or longer, based on water
quality and plant experience.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 34 September 2004
SECTION 4: (Continued)
8. If the DPDS option is purchased, refer to the DPDS
Installation and Operating Guide for instructions.
9. Make certain all air, electric, and water connections are
sound. 10. Open the cooling water supply valve and adjust as
required. 11. Repressurize the dryer and place "on-stream". 12.
Reconnect power to the dryer.
D. EVERY 16,000 HOURS OR 24 MONTHS
1. Perform steps 1 through 9 as outlined in "Every 8000 Hours or
12 Months.
DO NOT REPRESSURIZE DRYER OR RECONNECT POWER
TO THE DRYER YET!
2. Drain all the desiccant from both vessels through the drain
at the bottom of each vessel.
3. Refill both vessels with the proper amount of desiccant as
noted in the
specifications at the front of this manual.
NOTE: Desiccant can be purchased only through Ingersoll-Rand
distributors authorized to sell Series HC dryers and related
products.
4. Make certain all air, electric, and water connections are
sound. 5. Open the cooling water supply valve and adjust as
required. 6. Repressurize the dryer and place "on-stream". 7.
Reconnect power to the dryer.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 35 September 2004
SECTION 4: (Continued)
D. ADJUSTMENTS
The inlet air temperature (as indicated on the Instrument Panel)
should be adjusted to obtain the desired temperature/dewpoint
performance (reference the Regenerative Dryer Specification Sheet
in Section I). This can be accomplished through manipulation of the
inlet piping insulation and/or the compressor intercooling.
The temperature of the air leaving the dryer aftercooler should
be maintained at or below 90F. Adjust the cooling water supply as
required.
4.2 REPLACEMENT / DISPOSAL OF THE DESICCANT
NOTE : Refer to the desiccant MSDS in the appendix of this
manual for detailed information regarding material description and
ingredients.
The dryer is filled from the top and emptied from the bottom.
Refer to the General Arrangement drawing for location of fill and
drain ports. To drain the desiccant, remove the drain plug/cover
and catch the old
desiccant in a suitable container. Replace the desiccant drain
plug/cover. Remove the fill cap and refill the chamber with the
specified desiccant. Refer
to the spare parts section for desiccant quantity. Do not tamp
the desiccant. Replace the fill cap.
Soap test both fill and drain ports for leaks before returning
the dryer to service.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 36 September 2004
SECTION 4: (Continued) 4.3 DEWPOINT METER MAINTENANCE (DPDS
Option only)
NOTE: Refer to the Dewpoint Demand Installation & Operating
Guide included with this User Manual for information on dewpoint
meter maintenance and operation.
4.4 FILTERS 4.4.1 General comments and use
Filters of the series AF are suitable for filtering solids out
of compressed air and other neutral, compressed gases. This new
filtration concept is characterized by high flows at low
differential pressure.
4.4.2 Function
The soiled medium flows through the filter element "Series AF"
from the outside to the inside. Solids are filtered out by impact
or by the effect of inertia.
4.4.3 Assembly and installation
Advice The piping system must be cleaned before assembling
filter. The filter must always be installed vertically.
4.4.4 Maintenance
Advice The filter element should be replaced when a differential
pressure of
> 10 PSID has been reached or, at latest, after 6 months of
operation.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 37 September 2004
SECTION 4: (Continued) 4.4.5 Changing of filter elements
Danger! The soiled filter elements are changed only when the
housings are DEPRESSURIZED!
Filter elements are to be changed according to the following
steps:
Open the hand hole. Loosen and remove the element by hand.
Install the new element and make sure that the element seats
perfectly. Re-install hand hole cover. Elements of the AF series
can NOT be cleaned with compressed air.
4.4.6 Accessories
Advice Pressure differential gauge: Indicates the degree to
which the elements are soiled.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 38 September 2004
SECTION 5: RECOMMENDED SPARE PARTS LIST
5.1 RECOMMENDED SPARE PARTS FOR HC-3 TO HC-14 Part No.
Description ID HC-3 HC-6 HC-7 HC-9 HC-14
38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745
Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle
removal, miniature,
inline, , for DPDS option 1 1 1 1
38339370 SB350 filter element for AF-350 afterfilter
1
38335592 812-1B filter element 1 1 2 38335584 16D33 filter
element, high efficiency,
coalescing, for HEF-60 prefilter 1 1 1 1
38339610 Fuse, 3 amp 1 1 1 1 38338836 Muffler, 2 MNPT 1 1 2 2
38338844 Relay, DPDT, 115/1/60 1 1 1 1 38338851 Gasket, grafoil, 3,
150#, ring, 1/16 6 6 38338869 Gasket, grafoil, 6, 150#, ring, 1/16
2 2 38342556 Gasket, grafoil, 3, 150#, FF, 1/16 4 4 38338893
Switch, pressure, 30-300 PSIG 1 1 1 1 38338901 Switch, pressure,
3-30#, SPDT, for
Fail-to-shift Alarm option 1 1 1 1
38339750 Repair kit, actuator, CTD&S-020 V11-13 1 1 38337937
Repair kit, actuator, CTD&S-030 V11-13 1 1 38339735 Repair kit,
actuator, CTD&S-040 V1-10,15 2 2 38337960 Repair kit, actuator,
CTS-050 V12 1 1 38339768 Repair kit, ball valve, 1 V11-13 2 2
38337929 Repair kit, ball valve, 1 V11-13 2 2 38338018 Repair kit,
ball valve, 2 V1-10,15 1 1 38337986 Repair kit, butterfly valve, 3
V1-10,15 1 1 38335626 Repair kit, actuator, MX-60 V1-10,15 1 1
38341285 Repair kit, diaphragm valve, SD 1 1 1 1 38338943 Valve,
solenoid single coil 4-way,
aluminum SV3-5 1 1 1 1
38338950 Valve, solenoid dual coil 4-way, aluminum
SV1-2 1 1 1 1
Part No. Description
38004834 Alumina, 3/16" IR Activated 50 lbs bag
38340642 Alumina, 3/16" IR Activated 100 lbs drum
38340659 Alumina, 3/16" IR Activated 2000 lbs sack
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 39 September 2004
SECTION 5: (Continued)
RECOMMENDED SPARE PARTS LIST 5.1 RECOMMENDED SPARE PARTS FOR
HC-21 TO HC-54 Part No. Description ID HC-21 HC-30 HC-41 HC-54
38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745
Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle
removal, miniature,
inline, , for DPDS option 1 1 1 1
38335592 812-1B filter element 2 3 6 6 38335584 16D33 filter
element, high efficiency,
coalescing, for HEF-60 prefilter 1 1 1 1
38339610 Fuse, 3 amp 1 1 1 1 38341293 Seal, gasket, Manway,
11x15, PTFE 2 38342481 Seal, gasket, Manway, 12x16, PTFE 2 2
38338836 Muffler, 2 MNPT 4 4 8 8 38338844 Relay, DPDT, 115/1/60 1 1
1 1 38338851 Gasket, grafoil, 3, 150#, ring, 1/16 4 4 38342499
Gasket, grafoil, 4, 150#, ring, 1/16 6 6 38338869 Gasket, grafoil,
6, 150#, ring, 1/16 6 6 38342507 Gasket, grafoil, 8, 150#, ring,
1/16 2 38339222 Gasket, grafoil, 10, 150#, ring, 1/16 2 2 38338877
Gasket, grafoil, 12, 150#, ring, 1/16 2 38342564 Gasket, grafoil,
4, 150#, FF, 1/16 4 4 38338885 Gasket, grafoil, 6, 150#, FF, 1/16 4
4 38338893 Switch, pressure, 30-300 PSIG 1 1 1 1 38338901 Switch,
pressure, 3-30#, SPDT, for
Fail-to-shift Alarm option 1 1 1 1
38339735 Repair kit, actuator, CTD&S-040 V11-13 1 1 38337960
Repair kit, actuator, CTS-050 V12 1 1 38335634 Repair kit,
actuator, CTS-060 V12 1 1 38338018 Repair kit, ball valve, 2 V11-13
2 2 38337986 Repair kit, butterfly valve, 3 V11-13 2 2 38338927
Repair kit, actuator, MX-200 V1-10,15 1 1 38335626 Repair kit,
actuator, MX-60 V1-10,15 1 1 38335626 Repair kit, actuator, MX-60
V11-13 1 1 38339271 Repair kit, butterfly valve, 4 V1-10,15 1 1
38338919 Repair kit, butterfly valve, 6 V1-10,15 1 1 38338935 Check
valve, 3, CI, rebuilt CV1 1 1 38341285 Repair kit, diaphragm valve,
SD 1 1 1 1 38338943 Valve, solenoid single coil 4-way,
aluminum SV3-5 1 1 1 1
38338950 Valve, solenoid dual coil 4-way, aluminum
SV1-2 1 1 1 1
Part No. Description
38004834 Alumina, 3/16" IR Activated 50 lbs bag
38340642 Alumina, 3/16" IR Activated 100 lbs drum
38340659 Alumina, 3/16" IR Activated 2000 lbs sack
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 40 September 2004
SECTION 5: (Continued)
RECOMMENDED SPARE PARTS LIST 5.1 RECOMMENDED SPARE PARTS FOR
HC-69 TO HC-122
Part No. Description ID HC-69 HC-85 HC-103 HC-122
38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745
Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle
removal, miniature,
inline, , for DPDS option 1 1 1 1
38335592 812-1B filter element 6 6 10 16 38335584 16D33 filter
element, high efficiency,
coalescing, for HEF-60 prefilter 1 1 1 1
38339610 Fuse, 3 amp 1 1 1 1 38342481 Seal, gasket, Manway,
12x16, PTFE 2 2 2 2 38338836 Muffler, 2 MNPT 8 1 1 1 38338844
Relay, DPDT, 115/1/60 1 1 1 1 38338851 Gasket, grafoil, 3, 150#,
ring, 1/16 4 38342499 Gasket, grafoil, 4, 150#, ring, 1/16 4 4 4
38338869 Gasket, grafoil, 6, 150#, ring, 1/16 6 38342507 Gasket,
grafoil, 8, 150#, ring, 1/16 6 6 6 38338877 Gasket, grafoil, 12,
150#, ring,
1/16 2
38342515 Gasket, grafoil, 14, 150#, ring, 1/16
2
38342523 Gasket, grafoil, 16, 150#, ring, 1/16
2 2
38338885 Gasket, grafoil, 6, 150#, FF, 1/16 4 38342572 Gasket,
grafoil, 8, 150#, FF, 1/16 4 4 4 38338893 Switch, pressure, 30-300
PSIG 1 1 1 1 38338901 Switch, pressure, 3-30#, SPDT, for
Fail-to-shift Alarm option 1 1 1 1
38337960 Repair kit, actuator, CTS-050 V12 1 1 1 1 38335634
Repair kit, actuator, CTS-060 V22 1 1 1 38337929 Repair kit, ball
valve, 1 V12 1 1 1 38337986 Repair kit, butterfly valve, 3 V11-13 2
38338927 Repair kit, actuator, MX-200 V1-10,15 1 38335626 Repair
kit, actuator, MX-60 V11-13 1 1 1 1 38339818 Repair kit, actuator,
MX-450 V1-10,15 1 1 1 38339271 Repair kit, butterfly valve, 4
V11,13,22 2 2 2 38338919 Repair kit, butterfly valve, 6 V1-10,15 1
38339248 Repair kit, butterfly valve, 8 V1-10,15 1 1 1 38338935
Check valve, 3, CI, rebuilt CV1 1 38339545 Check valve, 4, CI,
rebuilt CV1 1 1 1 38341285 Repair kit, diaphragm valve, SD 1 1 1 1
38338943 Valve, solenoid single coil 4-way,
aluminum SV3-5 1 1 1 1
38338950 Valve, solenoid dual coil 4-way, aluminum
SV1-2 1 1 1 1
Part No. Description
38004834 Alumina, 3/16" IR Activated 50 lbs bag
38340642 Alumina, 3/16" IR Activated 100 lbs drum
38340659 Alumina, 3/16" IR Activated 2000 lbs sack
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 41 September 2004
SECTION 5: (Continued)
RECOMMENDED SPARE PARTS LIST 5.1 RECOMMENDED SPARE PARTS FOR
HC-143 TO HC-239
Part No. Description ID HC-143 HC-166 HC-186 HC-211 HC-239
38338737 Probe, for Dewpoint Demand option 1 1 1 1 38338745
Thermocouple, armoured, 12 1 1 1 1 38335600 Filter, particle
removal, miniature,
inline, , for DPDS option 1 1 1 1
38335592 812-1B filter element 16 16 20 30 38335584 16D33 filter
element, high efficiency,
coalescing, for HEF-60 prefilter 1 1 1 1
38339610 Fuse, 3 amp 1 1 1 1 38342481 Seal, gasket, Manway,
12x16, PTFE 2 2 2 2 38338836 Muffler, 2 MNPT 1 1 1 1 38338844
Relay, DPDT, 115/1/60 1 1 1 1 38342499 Gasket, grafoil, 4, 150#,
ring, 1/16 4 38338869 Gasket, grafoil, 6, 150#, ring, 1/16 4 4 4
38342507 Gasket, grafoil, 8, 150#, ring, 1/16 6 38339222 Gasket,
grafoil, 10, 150#, ring, 1/16 6 6 6 38342531 Gasket, grafoil, 18,
150#, ring, 1/16 2 38342549 Gasket, grafoil, 20, 150#, ring, 1/16 2
38342572 Gasket, grafoil, 8, 150#, FF, 1/16 4 38342580 Gasket,
grafoil, 10, 150#, FF, 1/16 4 4 4 38338893 Switch, pressure, 30-300
PSIG 1 1 1 1 38338901 Switch, pressure, 3-30#, SPDT, for
Fail-to-shift Alarm option 1 1 1 1
38337960 Repair kit, actuator, CTS-050 V12 1 38335634 Repair
kit, actuator, CTS-060 V22 1 38335634 Repair kit, actuator, CTS-060
V12 1 1 1 38339693 Repair kit, actuator, CTS-065 V22 1 1 1 38337929
Repair kit, ball valve, 1 V12 1 38338018 Repair kit, ball valve, 2
V12 1 1 1 38338927 Repair kit, actuator, MX-200 V11-13 1 1 1
38335626 Repair kit, actuator, MX-60 V11-13 1 38335618 Repair kit,
actuator, MX-750 V1-10,15 1 1 1 38339818 Repair kit, actuator,
MX-450 V1-10,15 1 38339271 Repair kit, butterfly valve, 4 V11,13,22
2 38338919 Repair kit, butterfly valve, 6 V11,13,22 2 2 2 38339248
Repair kit, butterfly valve, 8 V1-10,15 1 38338000 Repair kit,
butterfly valve, 10 V1-10,15 1 1 1 38339545 Check valve, 4, CI,
rebuilt CV1 1 38339719 Check valve, 6, CI, rebuilt CV1 1 1 1
38341285 Repair kit, diaphragm valve, SD 1 1 1 1 38338943 Valve,
solenoid single coil 4-way,
aluminum SV3-5 1 1 1 1
38338950 Valve, solenoid dual coil 4-way, aluminum
SV1-2 1 1 1 1
Part No. Description
38004834 Alumina, 3/16" IR Activated 50 lbs bag
38340642 Alumina, 3/16" IR Activated 100 lbs drum
38340659 Alumina, 3/16" IR Activated 2000 lbs sack
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 42 September 2004
SECTION 5: (Continued)
I-R Series HC Theory of Operation Illustration
Legend: BE = visual moisture indicator CS = separator F = filter
FS = float switch FT = primary float trap P = pressure gauge PRV =
pressure relief valve SD = secondary drain SV = solenoid valve T =
temperature gauge TW = thermowell V = valve
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 43 September 2004
SECTION 6: TROUBLESHOOTING & FAULTS
6.1 INTRODUCTION
Following proper preventive maintenance procedures will go far
toward assuring trouble-free dryer performance; however, failures
will still occur. This troubleshooting part will help to identify
the source of the problem and to effect a remedy.
6.2 HIGH DEWPOINT 6.2.1 Changed Operating Conditions
Check to see that flow rate, pressure, and temperature are still
within specification.
6.2.2 Old Desiccant
If the dryer is not able to maintain dewpoint for a sufficiently
long period, the desiccant may have aged to the point where its
capacity is inadequate. Replace the desiccant with the appropriate
quantity and type of desiccant.
6.2.3 Towers Not Reversing
Check PLC, solenoid valve, inlet switching valves, and, if
supplied, Dewpoint Demand System meter.
6.2.4 Cooler Discharge Air Temperature Too High
Check cooling water flow rate and temperature. Fouled or dirty
cooler may require cleaning on air and/or water side.
6.2.5 Dewpoint Indication In Error
Check calibration/operation of dewpoint measuring
instrument.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 44 September 2004
SECTION 6: (Continued) 6.2.6 Two-way Valve Leakage
Valve leakage here will allow relatively wet inlet air to leak
into the dry outlet air stream, thereby raising the dewpoint of the
composite air. Compare the dewpoint of the air at the dryer outlet
to the dewpoint measured at the top (outlet) of the drying tower
(i.e., at the relief valve location). If there is a significant
difference in dewpoint, one or both closed 2-way valves is leaking.
Check actuator operation and check for seat wear.
6.3 FAIL-TO-SHIFT 6.3.1 Solenoid Valve Failed To Operate
Check electrical connection, coil, and valve seat.
6.3.2 Pilot Air Tubing Leakage
Check tubing fittings for leakage.
6.3.3 Two-way Switching Valve Actuator Leakage
A leaking actuator can cause the switching valve to malfunction;
low pilot pressure due to leakage (or solenoid valve failure) will
cause the FAIL-TO-SHIFT ALARM to activate. Check for leakage.
6.4 PRIMARY DRAIN FAILURE 6.4.1 Plugging Or Sticking Due To
Foreign Matter
If the PRIMARY DRAIN FAILURE ALARM activates, the probable cause
is sediment plugging the orifice or impeding the proper operation
of the float. Disassemble, inspect, and clean as necessary.
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 45 September 2004
SECTION 6: (Continued) 6.5 SECONDARY DRAIN FAILURE 6.5.1
Solenoid Valve Failure
When the liquid level rises above the primary float valve
elevation and contacts the liquid level probe, a circuit is
completed energizing the 3-way normally open solenoid valve
depressurizing the secondary drain valve actuator. The system
pressure should open the secondary drain valve. If the PRIMARY
DRAIN FAILURE ALARM activates, but the secondary drain valve fails
to open, check the 3-way normally open solenoid valve. Clean,
repair, or replace as necessary.
6.5.2 Liquid Level Probe Failure
If the PRIMARY DRAIN FAILURE ALARM does not activate after or
during failure of the float operated drain, check the liquid level
probe for proper operation.
6.6 SHORT-TERM SHUT-DOWN
Advice
The following sequence is to be heeded when switching off the
adsorption dryer: First close all the shut off valves up and
downstream of dryer Then immediately switch off the adsorption
dryer.
Attention! Dryer will remain pressurized.
6.7 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE
Danger! Before any kind of maintenance or repair work is done,
the adsorption dryer must be depressurized and disconnected from
the power source. Apply the general safety regulations!
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USER MANUAL Series HC
Reference No. 145 Final Rev 5 Page 46 September 2004
SECTION 7:
IR ACTIVATED ALUMINA MSDS 7.1 COMPANY DESCRIPTION
Ingersoll-Rand Company Heavy Industrial Air Solutions 800-B
Beaty Street, Davidson, NC 28036 For Product Information: Tel:
(800) 247-8640
7.2 MATERIAL DESCRIPTION Chemical Name & Formula: Aluminum
Oxide; A1203 xH20 Other Designation: Activated Alumina F-1, F-20,
F-200, HF-200, S-100, F-1(E), S-100, CG-20, OF-2000, Active bed
supports, SRU Product Use: Absorbent; dehydration agent; catalyst
support
7.3 INGREDIENTS
Component & by weight typical Occupational Exposure Limits
A1203 90.0 95.0 TWA I mg/m3 *Na20 0.3 0.6 ACGIH TLV *Si02 0.01 0.2
Alumina Dust: *Fe203 0.03 0.1 Total fraction - 10 Loss on ignition
(water) 4.0 7.0 PEL Respirable fraction - 5 * Expressed as oxide
equivalent No LD50 or LC50 found for oral, dermal, or inhalation
routes of administration.
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7.4 PHYSICAL DATA Physical Form: Crystalline or gelatinous
granules, pellets, or powder Boiling Temperature: NA Freeze-Melt
Temperature: 3700F (2038C) Vapor Pressure (mm): NA Vapor Density
(air = 1): NA Evaporation Rate: NA Specific Gravity: 3.2 Density:
Loose bulk: 39 52 lb./ft.3 (0.62 0.83 g/CM3) Water Solubility:
Insoluble; soluble in concentrated acids and alkalies pH: -10 (20%
slurry solution) Color: Off-white Odor: None; Odor Threshold (ppm):
NA Coefficient of water/oil distribution: NA
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7.5 FIRE AND EXPLOSION DATA
Flashpoint: NA Auto-Ignition Temp.: NA Flammability Limits in
Air: Upper/Lower: NA Product is non-flammable; not an explosion
hazard.
7.6 REACTIVITY DATA
With water: Generates heat With air: None With heat: None With
strong oxidizers: None Non-corrosive
7.7 HEALTH HAZARD INFORMATION
The desiccant properties of Activated Alumina may cause
irritation to the eyes and upper respiratory tract. Alumina is a
low health risk by inhalation. Alumina should be treated as a
nuisance dust, as specified by the American Conference of
Governmental Industrial Hygienists (ACGIH). According to AIHA
Hygienic Guide, Alumina:
Toxicity by ingestion: None expected Skin and eyes: Not an
irritant
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7.8 SPILL, LEAK, & DISPOSAL PROCEDURES
Clean up using dry procedures; avoid dusting. Waste may be
considered as inert material, suitable for landfill. RCRA Hazardous
Waste No.: Not federally regulated
7.9 SPECIAL PROTECTION INFORMATION
Use with adequate ventilation to meet the exposure limits as
listed in Section 7.3. Where the exposure limit is or may be
exceeded, use NIOSH approved respiratory protection. Select the
appropriate respirator (dust respirator, etc.) based on the actual
or potential airborne contaminants and their concentrations
present.
7.10 SPECIAL PRECAUTIONS & COMMENTS
Chemical substance components have been reported to the EPA
Office of Toxic Substances in accordance with the requirements of
the Toxic Substances Control Act (Title 40 CFR 710). None of the
materials in this mixture are on the EPA list of extremely
hazardous substances (Section 302 of SARA). Aluminum oxide is on
the toxic chemical list (Section 313 of SARA). The reportable
chemical substances in this product are regulated by the OSHA
Hazard Communication Standard (29 CFR 1910.1200) solely because
they are listed by ACGIH. However, they do not fit any of the five
proposed hazard categories under Section 311 and 312 of SARA.
D.O.T. Shipping Name, Hazard Class, I.D. No. (if applicable): Not
regulated Canadian TDG Hazard Class & PIN: Not regulated
7.11 REFERENCES
American Industrial Hygiene Association (AIHA) Hygienic Guide
Series (Revised June 1978). U.S. Dept. of Health and Human
Services, NIOSH: Registry of Toxic Effects of Chemical Substances.
1985-86 Edition. Sax, N. Irving: Dangerous Properties of Industrial
Materials. Van Nostrand Reinhold Co., Inc., 1984. Information
herein is given in good faith as authoritative and valid; however,
no warranty, express or implied, can be made.
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SECTION 8:
AUXILIARY MANUALS & DRAWINGS