Manual EHDB1200-12000 - May 1996 PDF
Manual EHDB1200-12000 - May 1996 PDF
Manual EHDB1200-12000 - May 1996 PDF
OPERATORS/
INSTRUCTION MANUAL
Warranty
Ingersoll-Rand warrants that this product shall, when properly installed, operated, applied and maintained in accordance with
procedures and recommendations outlined in owner's manuals published by Ingersoll-Rand, be free from defect in materials and
workmanship for a period of one year from the date of installation, or eighteen (18) months from the date of shipment from the
factory, whichever occurs first, provided such defect is discovered and brought to Ingersoll-Rand's attention within the aforesaid
warranty period.
During the warranty period, Ingersoll-Rand will repair or replace any product or part determined by Ingersoll-Rand to be defective
within such warranty period, provided such defect occurred in normal service and not as a result of misuse, abuse, neglect or
accident. Repair or replacement shall be made at the factory or the installation site, as elected by Ingersoll-Rand. Any service
performed on the product by anyone other than Ingersoll-Rand, must first be authorized by Ingersoll-Rand. Unauthorized service
voids the warranty, and any resulting charge or subsequent claim will not be paid by Ingersoll-Rand.
Ingersoll-Rand products repaired or replaced under warranty shall be warranted for the unexpired portion of the warranty applying
to the original product.
THE LIMITED WARRANTY AND LIMITED REMEDY PROVIDED HEREIN ARE IN LIEU OF ANY OTHER EXPRESS OR IMPLIED
WARRANTY OR REMEDY, INCLUDING ANY IMPLIED WARRANTY OR MERCHANTABILITY AND WARRANTY OF FITNESS
FOR A PARTICULAR PURPOSE. INGERSOLL-RAND MAKES NO WARRANTY, EXPRESS OR IMPLIED, OF ANY NATURE
WHATSOEVER WITH RESPECT TO THIS PRODUCT OR THE USE THEREOF EXCEPT AS IS SPECIFICALLY SET FORTH
HEREIN. INGERSOLL-RAND SHALL IN NO EVENT BE LIABLE FOR INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL OR
PENAL DAMAGES, OR FOR ANY OTHER DAMAGES EXCEPT AS PROVIDED IN THIS LIMITED REMEDY. IN ANY EVENT,
INGERSOLL-RAND'S MAXIMUM MONETARY LIABILITY HEREUNDER SHALL BE LIMITED TO THE PURCHASE PRICE PAID
FOR THAT PART OF THE PRODUCT WHICH IS FOUND TO BE DEFECTIVE WITHIN THE WARRANTY PERIOD.
INSTRUMENTATION ............................................... 4
Valve Switching Failure Alarm ............................ 4
Heater Temperature Alarm ................................. 4
High Humidity Alarm ........................................... 4
AIRSaver Control (Optional) ............................... 4
Dew Point Monitor (Optional) .............................. 4
Remote Alarm Contacts ..................................... 4
Color Moisture Indicator (Optional) ..................... 4
Vessel Temperature Gauges .............................. 5
Purge Inlet Temperature Gauge ......................... 5
Purge Outlet Temperature Gauge ...................... 5
Vessel Pressure Gauges ..................................... 5
Purge Pressure Gauge ....................................... 5
Purge Flow Meter ............................................... 5
OPERATION ............................................................. 5
How It Works ...................................................... 5
Start-Up .............................................................. 5
MAINTENANCE ........................................................ 6
Shutdown ............................................................ 6
Desiccant Dusting ............................................... 7
Maintenance Schedule ....................................... 7
Daily Maintenance .............................................. 7
Weekly Maintenance .......................................... 7
Monthly Maintenance .......................................... 7
3-Month Maintenance ......................................... 7
6-Month Maintenance ......................................... 7
Yearly Maintenance ............................................ 7
Returns To Manufacturer .................................... 8
Desiccant Replacement ...................................... 8
Dryer Models 1200 Through 5600 ................ 8
Dryer Models 7000 Through 12000 .............. 9
Color Change Moisture Indicator
Desiccant Replacement ...................................... 9
High Humidity Alarm Field Adjustment ............... 10
Temperature Switch Field Adjustment ................ 11
Heater Over Temperature Controller
Set-Up, Adjustment and Replacement ............... 11
AIRSaver Field Adjustment ................................ 14
42
control circuit may remain energized when the power
INTRODUCTION switch is turned off.
EHDB Series Externally Heated Blower Purge Dryers use 6. Use only genuine replacement parts from the manufac-
non-consumable desiccants to remove moisture from com- turer. The manufacturer is not liable for hazards caused
pressed air to achieve pressure dew points as low as -40F. by the use of unauthorized parts.
The dryer supplies a continuous flow of dry air through two
desiccant vessels, one adsorbing moisture from the inlet air Safety instructions in this manual are bold-faced for empha-
while the other is being reactivated. Reactivation is accom- sis. The signal words DANGER, WARNING and CAUTION
plished by an atmospheric blower which forces ambient air are used to indicate hazard seriousness levels as follows:
through a heater. The heated air is used to regenerate the
off-line vessel. The drying cycle is controlled by a micropro- DANGERUsed to indicate the presence of an immediate
cessor. hazard which WILL cause severe personal injury, death, or
substantial property damage if the warning is ignored.
To ensure continuing good dryer performance and safe op-
eration, everyone who installs, uses or maintains the dryer WARNINGUsed to indicate the presence of a hazard or
must read and carefully follow the instructions in this unsafe practice which COULD cause severe personal injury,
manual. Throughout the manual, the word dryer is used to death, or substantial property damage if the warning is ig-
refer to EHDB Series Externally Heated Blower Purge Dry- nored.
ers.
CAUTIONUsed to indicate the presence of a hazard or
unsafe practice which WILL or CAN cause minor personal
injury or property damage if the warning is ignored.
SAFETY The dryer data plate (Figure 1), attached to the electrical
control box, contains critical safety and identification infor-
EHDB Series dryers are designed and built with safety as a mation. If the data plate is missing or defaced, contact your
prime consideration with industry accepted safety factors local distributor for a replacement.
having been used in the design. Each dryer has been in-
spected and tested for safety and operation. All desiccant INGERSOLLrAND
vessels have been hydrostatically tested at 1 times the COMPRESSED AIR DRYER
design pressure in accordance with ASME code require-
ments. Safety relief valves are standard and are provided MODEL NO. SERIAL NO.
with each dryer.
MAX PRESSURE (PSIG) MAX INLET AIR TEMP (F)
WARNING
VOLTS HZ PH AMPS
The following safety rules must be observed to en-
sure safe dryer operation. Failure to follow these
rules may void the warranty or result in dryer dam- Figure 1
age or personal injury. DRYER DATA PLATE
1
If concealed loss or damage is discovered, notify the carrier PIPING AND CONNECTIONS
at once and request an inspection. The carrier will make an
inspection and grant a concealed damage notation. The All external piping must be supplied by the user unless oth-
carrier will not consider any claim for loss or damage unless erwise specified. Piping must be rated for the maximum op-
an inspection has been made. If you give the carrier a clear erating pressure and temperature given on the dryer name-
receipt for goods that have been damaged or been lost in plate, and must conform to applicable codes. Support all
transit, you do so at your own risk and expense. piping. Do not allow the weight of the piping to stress the
dryer connections.
HANDLING All inlet and outlet piping MUST be of the same size as the
The dryer is designed to be moved by means of lifting lugs dryer inlet connection or larger. Undersized or incorrectly in-
supplied on the desiccant vessels. Use appropriate, load- stalled piping and/or piping components will increase pres-
rated lifting equipment and observe safe lifting procedures sure drop and reduce capacity. Refer to the Dimension and
during all moves. The dryer should be carefully unloaded as Connection Drawing which accompanies this manual for the
close as possible to the final installation site to minimize correct inlet and outlet connection sizes.
chances of equipment damage.
If the purge exhaust piping must be extended outside the
dryer area, the piping must be sized so that it will cause no
AMBIENT AIR TEMPERATURE back pressure (Note: Vertical piping runs must include drip
Locate the dryer under cover in an area where the ambient legs). BACK PRESSURE WILL CAUSE DRYER MAL-
air temperature will remain between 35F and 115F. If am- FUNCTION. Consult your local distributor for piping details
bient temperatures below 35F cannot be avoided, contact if required.
your local distributor.
Inlet and outlet manual shut off valves are recommended so
the dryer can be easily isolated and depressurized for ser-
LOCATION AND CLEARANCE vicing. Bypass piping may be installed around the dryer to
Install the dryer on a solid, level foundation. Utilizing the allow for uninterrupted air flow during servicing. If the down-
base-plate mounting holes provided, anchor the dryer to the stream application cannot tolerate unprocessed air for short
floor with four 3/4-inch diameter bolts with a minimum 4 inch periods, install a second dryer in the bypass line.
thread engagement. Allow a minimum of 4 feet clearance
for servicing of all components. Above each dryer chamber, CAUTION
allow sufficient overhead clearance for heater removal and Do not hydrostatically test the piping with the dryer
replacement. Provide suitable protective barriers to reduce installed in the air system. Hydrostatic testing will
the possibility of accidental damage if the dryer is located in damage the dryer's desiccant charge.
an open area or in close proximity to heavy vehicular and
pedestrian traffic.
CHAMBER DEPRESSURIZATION PIPING
Remove all mounting bolts from Blower base which MAY
have been used for shipping purposes. The Blower is de- The chamber depressurization piping is connected to the
signed to vibrate freely on its vibration pad during operation. Purge Exhaust manifold piping. The dryer should be
equipped with Purge Exhaust piping extended to a safe
Note: The Blower manufacturer cautions that the blower place.
should not be bolted down during operation.
DESICCANT
SYSTEM ARRANGEMENT
EHDB Series dryers use activated alumina as the desiccant
The dryer should be installed downstream of an aftercooler in the dryer vessels.
and moisture separator so dryer inlet air is within design
temperature specifications and contains no liquid water. Liq- Desiccant is not normally installed prior to shipment, and
uid water or inlet temperatures above design specifications must be added to the dryer vessels before the dryer is put
can reduce drying capacity. Contact your local distributor into service.
for information on proper dryer sizing at elevated inlet air
temperatures. CAUTION
Pouring desiccant creates a fine dust; safety
Oil contaminates the desiccant, reducing drying efficiency goggles, gloves and dust mask should be worn by
and desiccant life. A high efficiency oil removing filter must personnel installing desiccant. Refer to the Mate-
be installed at the dryer inlet. A particulate filter should be rial Safety Data Sheet (MSDS) for more complete
installed at the dryer outlet to capture desiccant particles. information.
2
Table 1 3. Utilizing an appropriately sized funnel (with nozzle long
DESICCANT REQUIREMENTS enough to extend below manifolds), fill each desiccant
vessel as follows:
Layer
Model 1 2 3 4
a) Install the specified quantity of tabular support in
1200 71# 845# ____ ____
1/4" Bead 1/8" Bead layer one of each vessel.
1600 144# 1071# ____ ____
1/4" Bead 1/8" Bead b) Level layer 1 and each subsequent layer of desic-
cant as added to each chamber.
1900 144# 1299# ____ ____
1/4" Bead 1/8" Bead
c) Finish filling each chamber with desiccant until all
2200 144# 1527# ____ ____ desiccant has been installed. LIGHT tapping on
1/4" Bead 1/8" Bead
chamber sides with a soft-face mallet should yield
2700 324# 106# 1969# ____ additional free space to allow installation of all des-
1/2" Bead 1/4" Bead 1/8" Bead
iccant required. DO NOT TAMP OR RAM DES-
3700 630# 143# 2678# ____ ICCANT.
1/2" Bead 1/4" Bead 1/8" Bead
4300 630# 143# 3124# ____ Note: Do not be alarmed if the specified quantity
1/2" Bead 1/4" Bead 1/8" Bead of desiccant cannot be installed in each chamber.
5600 729# 360# 191# 4095# Desiccant levels will settle after two to three weeks
1" Bead 1/2" Bead 1/4" Bead 1/8" Bead of normal operation. Following this 'settling' pe-
7000 5332# ____ ____ ____
riod, desiccant should be added as necessary to
1/8" Bead bring the levels up to the bottom of each
7500 5696#
chamber's retaining screen (when installed).
____ ____ ____
1/8" Bead
4. Clean fill port closure. Reinstall the desiccant retaining
8700 6607# ____ ____ ____
1/8" Bead screen and fill port closure in each desiccant vessel.
Torque flanged fill port bolts per following:
10500 8019# ____ ____ ____
1/8" Bead
5/8" Bolts 55 ft-lbs.
12000 9125# ____ ____ ____ 3/4" & 1" Bolts 80 ft-lbs.
1/8" Bead
ELECTRICAL CONNECTIONS
CAUTION
The dryer is prewired, ready for use. Connect the dryer to
Do not tamp, ram or pneumatically convey desic-
the power supply specified on the data plate. Using the con-
cant in vessels. Tamping damages desiccant and
duit connection ports indicated, connect the electrical input
causes dusting.
and ground leads to the power input terminal blocks. Make
connections in accordance with the lead connection inscrip-
tions (GND, L4, L5, etc.). CONNECT GROUND LEAD
To add desiccant:
(GND) FIRST.
1. Remove desiccant fill port closure and desiccant re-
taining screen installed in the top of each chamber. CAUTION
See Dimension & Connection drawing for location. Do not make any additional wiring connections to
terminals GND, L4, L5, L6, L7, L8 and L9 on the
2. Refer to Table 1 for desiccant quantity per vessel. power input terminal blocks.
When using Table 1 you will find the desiccant quanti-
ties listed in layers. Each layer will vary in depth due CAUTION
to the type, quantity and purpose of the desiccant. The blower and motor have been completely
Layer one must be installed first at the bottom of the checked and operated prior to shipment from the
vessel followed by layer number 2 etc., until the com- factory. After connecting the power supply to the
plete charge of desiccant has been installed. motor, momentarily energize the blower motor
starter. Blower rotation should match the indicator
Note: A desiccant spreader is provided to level each arrow on the blower housing. If not, disconnect
layer of desiccant after it has been installed. power and reverse the wiring connections.
3
High Humidity Alarm
INSTRUMENTATION
A moisture sensor connected to the dryer outlet manifold
monitors the relative humidity of the outlet air. The sensor
The EHDB dryer is equipped with a microprocessor system triggers an alarm, labeled HIGH HUMIDITY WARNING, if
that controls the operation of all dryer functions. The con- the relative humidity of the outlet air exceeds the factory set-
troller is programmed to operate the dryer on an eight hour ting before regeneration is complete. A set-plug adjustment
cycle. The controller keeps the drying vessel on line for four bulb is included for use in calibrating the high humidity
hours while simultaneously regenerating the off-line vessel. alarm. Refer to the maintenance section of this manual for
Standard and optional indicators on the controller help in field adjustment instructions.
monitoring dryer operation and performance.
2) Pressure Switches. The drying tower pressure switch is 2. Locate the Flow Cell Block located near the dryer
monitored continuously during the drying cycle. The control box.
off-line tower pressure switch is ignored until the end of 3. Mount the probe into the Flow Cell Block. Tighten
depressurization to allow the off-line tower to reach at- the compression fitting by first hand-tightening the
mospheric pressure. The control checks the switch for nut. Using a wrench, tighten the nut one and one-
low pressure at the end of depressurization. The switch quarter turn.
is monitored continuously during the heating cycle. It is
ignored until the end of repressurization to allow the off-
line tower to reach line pressure. The control checks Dew Point Monitor (Optional)
the switch for high pressure at the end of repressuriza- The monitor continuously displays outlet pressure dew point.
tion. (Consult the owner's manual supplied with the monitor for
Should the alarm conditions correct themselves after the more information.)
alarm has activated, the alarm will reset itself and the dryer
will return to normal operation. Note: The dew point will spike at tower changeover.
4
quiring corrective action. The indicator is blue when dry, but Automatic purge air temperature control: A sensor
gradually changes to pink in color whenever a "wet" gas monitors the temperature of the purge air exiting the dryer.
sample is received. If the purge air temperature reaches 180F, the heater and
blower shut off and the regenerating vessel is cooled down,
Vessel Temperature Gauges repressurized and put in standby mode until the on line ves-
sel has completed its drying cycle.
A gauge mounted on each desiccant vessel to indicate the
temperature inside the vessel. INLET
AIR
V1
V2
Purge Inlet Temperature Gauge
A gauge mounted on the heater outlet piping to indicate the
temperature exiting the purge heater. V4
V3
RELIEF
VALVE
Purge Outlet Temperature Gauge
2TS
BLOWER
OPERATION FILTER
HEATER
SILENCER
5
2. Close the pilot air filter bleed valve.
MAINTENANCE
3. Ensure that all associated pipe and tubing connections,
flanges, unions, plugs, mounting bolts, pipe hangers, SHUTDOWN
etc., have been checked tight and/or properly secured.
If the dryer or air system is shut down, desiccant life can be
4. Open the pilot air service valve, located upstream of prolonged by venting the dryer internal pressure to the atmo-
the pilot air filter. sphere.
DANGER
SHOCK HAZARD
Portions of the electrical control circuit remain en-
ergized when the power switch is turned OFF. Dis-
connect the main power supply to the dryer before
performing maintenance on the electrical system.
6
Before performing electrical maintenance: c) Inlet Flow Rate
d) Inlet Temperature
1. De-energize the dryer's electrical supply after comple-
tion of switch over. 2. Check the pressure drop across the prefilters and after-
filters. Replace filter elements in accordance with
2. Disconnect the main power supply. manufacturers directions.
7
RETURNS TO MANUFACTURER For Dryer Models 1200 through 5600:
If the dryer or a component of the dryer must be returned to 1. Remove the desiccant fill port closure and desiccant
the manufacturer, first call your local distributor for a return retaining screen installed in the top of each desiccant
authorization number and a shipping address. Your distribu- vessel. Clean and inspect the desiccant fill port clo-
tor will inform you whether the dryer or only the component sure and desiccant retaining screen.
must be returned.
2. Place a container suitable for receiving the spent des-
iccant under the desiccant vessel.
DESICCANT REPLACEMENT
Periodic desiccant replacement is necessary to maintain 3. Remove the desiccant drain port flanges from the bot-
dryer performance. The frequency of desiccant replace- tom of each desiccant vessel. Desiccant will begin
ment is dependent on the operating conditions present. A draining when desiccant drain port flange is removed.
rising dew point at the dryer outlet is an indication that new
desiccant is needed 4. When the desiccant has stopped draining, open the
center drain port closure and remove the desiccant re-
taining screen from the bottom of each desiccant ves-
DANGER
sel.
EXPLOSION HAZARD
Ensure that the dryer is valve isolated, and fully de-
5. Use a flashlight to inspect each vessel through its re-
pressurized before attempting to remove or disas-
spective ports to ensure that all desiccant has been
semble any component or disassembly. Failure to
drained. LIGHT tapping on the vessel side with a soft-
do so may result in serious personal injury and/or
faced mallet will remove any desiccant that may have
equipment damage.
lodged in the desiccant retaining screen slotting.
DANGER
6. Remove any blockage which may have lodged in the
SHOCK HAZARD
desiccant retaining screen slotting.
Portions of the electrical control circuit remain en-
ergized when the power switch is turned OFF. Dis-
7. Reinstall drain port flanges, bottom desiccant retaining
connect the main power supply to the dryer before
screens, and center drain closures. Torque flanged
performing maintenance on the electrical system.
drain port bolts per following:
WARNING
5/8" Bolts 55 ft-lbs.
Used desiccant material must be handled with spe-
3/4" & 1" Bolts 80 ft-lbs.
cial care. Desiccant is an adsorbent material. Used
desiccant may contain chemicals and/or gases that
8. Refer to Table 1 for the quantity of desiccant and tabu-
are hazardous, toxic and/or flammable. It is recom-
lar support required for each desiccant vessel.
mended that all used desiccant be analyzed to de-
termine content before disposal. Exercise proper
care and procedures during handling and storage When using Table 1 you will find the desiccant quanti-
of used materials. All containers must be properly ties listed in layers. Each layer will vary in depth due
labelled and disposed of in accordance with local, to the type, quantity and purpose of the desiccant.
state, and federal regulations. Layer one must be installed first at the bottom of the
vessel followed by layer number two etc., until the
CAUTION complete charge of desiccant has been installed.
Pouring desiccant creates a fine dust; safety
goggles, gloves and dust mask should be worn by CAUTION
personnel installing desiccant. Refer to the Mate- Before beginning any desiccant installation, verify
rial Safety Data Sheet (MSDS) for more complete in- the existence of the desiccant retaining screens lo-
formation. cated at the bottom of each desiccant chamber.
CAUTION
Do not tamp, ram or pneumatically convey desic- 9. Utilizing an appropriately sized funnel (with nozzle long
cant in vessels. Tamping damages desiccant and enough to extend below manifolds), fill each desiccant
causes dusting. vessel as follows:
8
b) Level layer 1 and each subsequent layer of desic- 5. Reinstall drain port flanges. Torque drain port flange
cant as added to each vessel. bolts per following.
c) Finish filling each vessel with desiccant until all 5/8" Bolts 55 ft-lbs.
desiccant has been installed. LIGHT tapping on 3/4" & 1" Bolts 80 ft-lbs.
vessel sides with a soft-face mallet should yield
additional free space to allow installation of all des- 6. Refer to the Table 1 for the quantity of desiccant re-
iccant required. quired for each desiccant chamber.
10. Clean fill port closure. Reinstall the desiccant retaining 7. Utilizing an appropriately sized funnel (with nozzle long
screen and fill port closure in each desiccant chamber. enough to extend below manifolds), fill each desiccant
Torque flanged fill port bolts per following. chamber with desiccant until all desiccant has been in-
stalled. LIGHT tapping on chamber sides with a soft-
5/8" Bolts 55 ft-lbs. faced mallet should yield additional free space to allow
3/4" & 1" Bolts 80 ft-lbs. installation of all desiccant required. DO NOT TAMP
OR RAM DESICCANT.
Figure 4
4. Use a flashlight to inspect each chamber through its
MOISTURE INDICATOR
respective fill port to ensure that all desiccant has been
drained. LIGHT tapping on the chamber side with a
soft-faced mallet will remove any desiccant that may
have remained in each chamber.
9
2. Open the door of the electrical control box.
CAUTION
Dryer shutdown is not necessary to perform the
3. Locate the high-humidity circuit board (refer to
following procedure and can be accomplished
Figure 5).
without removing the entire assembly from the
gauge panel.
4. A calibrated set plug (refer to Figure 6) is shipped loose
inside the electrical box. The set plug is used to select
1. Close the Moisture Indicator Supply Valve, and ensure the setting at which the high-humidity alarm sounds.
that the moisture indicator has fully depressurized To insert the set plug, unplug the flat brown 2-wire rib-
through bleed valve before proceeding to next step. bon cable in the electrical box. Insert the set plug into
the ribbon cable socket.
DANGER
To avoid serious injury and/or equipment damage,
ensure that the moisture indicator is fully depres-
surized before attempting disassembly. +
OFF
3. Remove screw from sight dome by exerting pres-
ON
sure on screw's threaded end. Drain granular indicator.
P3
4. Remove porous disc and clean sight dome.
CAUTION P2
The sight dome is an acrylic plastic. Do not P1
clean with any type of solvent.
DANGER
SHOCK HAZARD
Portions of the electrical control circuit remain
energized when the power switch is turned OFF.
Disconnect the main power supply to the dryer
Figure 6
before performing maintenance on the electrical SET PLUG
system.
10
7. Put a drop of lacquer or nail polish on potentiometer P1 2. To adjust solid state temperature switch.
to prevent vibrations from altering the setting.
Turn small brass screw incorporated in the blue rect-
8. Turn the power switch to OFF. angular 25 turn potentiometer located at the upper left
hand side of the printed circuit board.
9. Remove the set plug and reinsert the ribbon cable.
The high humidity alarm is now set. Turn clockwise to increase set point
P1
(10 to 12F / turn)
To put the dryer back into service, follow the start-up instruc-
tions.
U1
P1
LED1
TEMPERATURE SWITCH FIELD ADJUSTMENT
K1
TB1
DANGER
EXPLOSION HAZARD
Ensure that the dryer is de-energized, valve iso-
lated, and fully depressurized before attempting to
remove or disassemble any dryer component or
subassembly. Failure to do so may result in seri-
ous personal injury and/or equipment damage.
Figure 6
Temperature Switch
11
1. To set the Heater Over Temperature setting: the value for the Lower Limit of the temperature
setting range. This value is arbitrary, and may be
Press the Up and Down keys until the required set to zero as shown.
set value appears in the SV window.
PV
PV PV
Process Process SV
Value Value
SV SV
OUT AT HB ALM
12
d) The electrical connections for the controller are Note: The factory uses Type K temperature
located at the bottom of the mounting bracket. sensors as standard for the Heater Over
Unless there was damage to the existing wiring or Temperature Alarm. If a different tempera-
connections, no re-wiring is required. ture sensor has been used, adjust the setting
as follows:
In the event re-wiring is required, wire the control-
ler per the following diagram. No. Sensor Type No. Sensor Type
0 R 5 E
Logic Common 5 10 Heater Over Temperature 1 S 6 B
from MCPU Signal to MCPU 2 K 7 N
4 9
3 J 8 L
3 8 4 T 9 U
2 7
120 VAC THERMOCOUPLE
1 6 +
3) The Key Protect Switch, located on the right
side of the temperature controller should be
set to the OFF position as illustrated.
WARNING
PROTECT ON
The sensor input must be connected to the con-
troller prior to power-up, otherwise the controller
output will remain on and cause an uncontrolled
upscale reaction.
DANGER
SHOCK HAZARD After completion of all setting adjustments,
Portions of the electrical control circuit remain set the Key Protect Switch to the ON position
energized when the power switch is turned OFF. to disable all key functions (Up, Down, AT
Disconnect the main power supply to the unit be- and Level) except the Mode key.
fore performing maintenance on the electrical
system. f) Carefully re-insert temperature controller back
into its mounting case.
e) Ensure function selector switches are set as fol- g) Turn the power switch to ON.
lows:
h) Proceed to step 1 to set Heater Over Tempera-
1) Ensure DIP switches, located on the top side ture settings.
of the temperature controller are set as illus-
trated. These DIP switch settings will display
temperature readings in degrees Fahrenheit.
ON
1 2 3 4 5 6
0
9 1
8 2
7 3
6 4
5
13
AIRSAVER FIELD ADJUSTMENT In the DISPLAY window, temperature and dew point
are indicated with the (degree) symbol appearing in
Note: Excerpts from the HydroGuard 2550 Installation and the upper right hand corner.
Operation Manual make up the following discussion of the
AIRSAVER moisture analyzer. The SELECT button is always the entry into a pro-
gramming sequence or Page. It primarily functions as
1. System Description: an enter key.
The AIRSAVER is a microprocessor controlled trace
moisture analyzer. It consists of a ONDYNE gold/alu- The Arrow Left (!) button is used to select Pages
minum oxide probe and an electronics module (ana- and to enter numbers in the Pages.
lyzer). The analyzer provides the alarm set point, dis-
plays the dew point (DP) temperature (F or C), and The Arrow Up (") button combines 2 functions.
sample temperature (F or C) on a four digit LCD dis- (#1) When a number in a page is to be changed,
play. press the " button once, and the existing value will
reset. (#2) Holding the " button down causes the
Dryer switch over is obtained with the first alarm relay. numbers to increase sequentially (from 0 to 9).
The second alarm relay switches the dryer to fixed
cycle operation in the event of a sensor or analyzer 3. Programming:
failure. IMPORTANT considerations before getting
started:
2. Basic Functions of the Push Buttons:
Note: Output and alarm status of the AirSaver are not Prior to programming the AirSaver, decide which engi-
updated while the user is manipulating the push but- neering units will be used in your application, because
tons (i.e., unit is in programming mode). set points and output range set-up must correspond to
the selected unit.
Page 1 (P1) Page 2 (P2) Page 3 (P3) Page 4 (P4) Page 5 (P5) Page 6 (P6)
(Calibration) (Calibration)
First Mode Code N/A N/A Alarm DP N/A N/A
Second Mode Code N/A N/A Alarm DP N/A (not used)
First Code Engineering Units of Display, Moisture Alarm and Current Output
0062 Dew Point [F] and Temperature [F]
0063 Dew Point [C] and Temperature [C]
Second Code Engineering Units of Display, Moisture Alarm and Current Output
0000 Returns program to First Mode Code and normal operation
0001 Edit Enable (Allows user to make changes in a selected page)
0024 N/A Refer to HydroGuard 2550 Installation and Operation Manual for explanation.
0064 N/A Refer to HydroGuard 2550 Installation and Operation Manual for explanation.
0415 General Reset to factory program (Moisture alarm set points, output ranges, etc.)
14
Example: Alarm is programmed to 30C. Switching To change code choice, press " button to set
to F, the alarm would be 30F. Changing previous code to zero.
the engineering unit requires changing the
set point(s) and the output range, respec- Press " button to increase digit value. Repeat-
tively. edly pressing " button increases digit value by
one (i.e., 0001 - 0002, etc.).
Utilizing the three push buttons on the front panel, the
following functions can be programmed with six short Press ! button to shift cursor to second digit.
sequences called "pages." Page 1 has a First and Then press " button to increase second digit
Second Mode Code. Pages 2 through 6 contain a value by one with each pressing until the desired
First and Second Value (i.e., set point, calibration code is programmed.
point, etc.).
Press SELECT button twice to return to the nor-
Page 1: Selection of Units and Special Functions mal Dew Point temperature display.
The moisture unit dew point (DP) in C or F.
The temperature unit (C or F). c. To change the Alarm Set Point(s).
Pages 2 and 3: Temperature Calibration Data Note: Alarm activates when its corresponding set
(refer to HydroGuard 2550 Installation and Operation point value is exceeded.
Manual for further discussion.)
Press the SELECT button repeatedly (twice) until
Page 4: Alarm Set Point* P1 is indicated in the DISPLAY window.
Alarm 1 set point for the moisture units (selected
on page 1). Press the SELECT button twice more until 0000 is
displayed.
Note: Alarm activates when its corresponding set
point is exceeded. The alarm relays are en- Press the " button twice to increase first digit
ergized on power-up (fail-safe mode). value to 0001, which activates the edit enable
function.
Page 5: Output range selection
(refer to HydroGuard 2550 Installation and Operation Press the SELECT button to return display to P1.
Manual for further discussion.)
Press the ! button 3 times to advance display in-
Page 6: Pressure Constant dication to P4.
(not utilized - refer to HydroGuard 2550 Installation
and Operation Manual for further discussion.) Press SELECT button to display existing set point.
Press " button to reset alarm set point. The
Refer to Table 1 and Table 2 during the programming display indication should be -202 (DP).
procedure.
Press " and ! buttons to select and program the
a. To display the probe temperature: alarm set point.
Press the SELECT button. The DISPLAY window Press SELECT button twice to return to the nor-
will either show temperature in C or F (depend- mal Dew Point temperature display.
ing on program selection). After 5 seconds, the
display returns to the actual dew point (DP) tem- 4. Recalibration:
perature value.
A routine factory recalibration and inspection of
ONDYNE moisture sensors is recommended every six
b. To select the Dew Point temperature units:
(6) to twelve (12) months. Contact your local Ingersoll-
Rand Distributor for details.
Press the SELECT button repeatedly (twice) until
P1 is indicated in the DISPLAY window.
15
FIELD SERVICE GUIDE
WARNING
Compressed air can be dangerous unless safety
precautions are observed in the use of compressed
air and compressed air equipment. Completely
vent the internal air pressure to the atmosphere
before diassembling any subassemblies or com-
ponents and before doing any work on compressed
air equipment. To vent internal air pressure, follow
the shutdown instructions.
Purge air contaminated at blower intake. Check purge air at blower intake and eliminate the cause
of the contamination. Check desiccant and make certain
it has not been contaminated by contaminated purge air.
Inlet air temperature is above dryer's design inlet tem- Check the compressor aftercooler and cooling system.
perature. Adjust as necessary to bring the dryer inlet temperature
to design specification.
Inlet air pressure is below design pressure. Check dryer inlet pressure. Correct if necessary.
Inlet air flow rate (in SCFM) is above the dryer's de- Verify actual flow rate (in SCFM) through dryer. Reduce
sign flow rate. flow rate if operating above design flow rate.
Liquids entering the dryer inlet. Isolate and depressurize prefilter assembly. Inspect
prefilter cartridges and seals for loosening and/or dam-
age. Tighten or replace as necessary.
Heater temperature switch set too low or temperature Adjust cautiously or replace as required.
switch failure.
Purge exhaust temperature switch set too low or tem- Adjust cautiously or replace as required.
perature switch failure.
Desiccant is badly broken or is contaminated with oil Shutdown and Depressurize Dryer. Inspect desiccant
or other contaminant. The normally white desiccant through fill ports and replace if badly broken or fouled.
will appear tan or brown if oil contamination has oc- Inspect prefilter if fouling is noted.
curred.
Union or other piping/component leaks at dryer outlet Soap test dryer outlet manifold and piping downstream of
manifold or downstream of dryer outlet. dryer. Repair ALL leaks.
16
PROBLEM POSSIBLE CAUSE REMEDY
Color Change Moisture Indicator Moisture Indicator's bleed valve is closed. Open bleed valve installed moisture indicator body until a
has changed from BLUE (dry) to SLIGHT continuous air bleed is felt exhausting from
PINK (wet) indication. bleed valve's exhaust port. Granular indicator MUST re-
main motionless after final adjustment.
Moisture Indicator's supply valve is closed. Fully open moisture indicator supply valve. Adjust
indicator's bleed valve as instructed in previous step.
Moisture indicator is internally clogged, preventing air Refer to Color Change Moisture Indicator Recharging
from exiting through indicator's bleed valve. Procedure section for disassembly instructions. Clean
or replace components as necessary.
Sample tubing to Moisture Indicator is leaking permit- Perform a soap bubble leak test indicator's tubing and
ting "wet" atmospheric air to enter tubing and contami- fittings. Tighten or repair.
nate dry air sample.
If after previous items have been checked and the Refer to "Dew Point too high or too low" section of this
Moisture Indicator fails to return to blue within 3 to 5 Field Service Guide. Determine cause and correct.
hours, a dew point problem may exist.
Excessive pressure drop across Badly broken, dusted or fouled desiccant. Shutdown and Depressurize. Inspect desiccant
dryer. through fill ports. Replace if badly broken, dusted or
fouled.
Inlet flow rate (scfm) exceeds the dryer's design flow Reduce inlet flow rate as necessary to meet dryer's de-
rate. sign flow rate.
Desiccant retaining screens are clogged or fouled. Shutdown and Depressurize. Remove desiccant re-
taining screens from each chamber's fill and drain (mod-
els 1200 through 5600 only) ports and clean if fouling is
noted. Investigate and correct source of fouling.
Inlet and/or outlet pressure gauges are out of calibra- Shutdown and Depressurize. Replace gauges.
tion or damaged.
Loss of power to operating status Loss of power supply to dryer's customer supplied Check disconnect switch or breaker is closed. If tripped
and alarm indicators. electrical disconnect switch or breaker. breaker or blown fuse. Iinvestigate and remedy cause.
Control system's power fuse is blown. De-energize dryer power supply. Replace fuse if
blown. Investigate and remedy cause.
Loose connections at power input. De-energize dryer power supply. Check power supply
input wiring connections.
Damaged solid state components and/or circuit Contact local Ingersoll Rand distributor for assistance.
boards.
Valve Switching Failure Alarm Off-line chamber's Inlet Switching Valve has failed to Check pneumatic output indicators on solenoid valves B
close due to the associated solenoid valve's (B or C) and C to determine whether energized.
failure to energize. up position - energized
down position - de-energized
Note:
LC Drying RC Drying:
Sol C is energized Sol B is energized
Sol B is de-energized Sol C is de-energized
Off-line chamber's Inlet Switching Valve has failed to Check for pilot air at off-line Inlet Switching Valve's pilot
close due to fouled or worn valve internals. gas tubing connections.
17
PROBLEM POSSIBLE CAUSE REMEDY
Valve Switching Failure Alarm Off-line Exhaust Valve has failed to open due to the Check red pneumatic output indicators on solenoid
associated solenoid valve's (A or D) failure to ener- valves A and D to determine whether energized.
gize. up position - energized
down position - de-energized
Note:
LC Drying RC Drying:
Sol D is energized Sol A is energized
Sol A is de-energized Sol D is de-energized
Off-line Exhaust Valve has failed to close due to Check for pilot air at off-line Exhaust Valve's pilot air tub-
fouled or worn valve internals. ing connections.
Repressurization Valve has failed to close due to Check for pilot air pressure at Repressurization Valve's
fouled or worn valve internals. pilot gas tubing connection.
Repressurization Valve has failed to open due to the Check yellow pneumatic output indicator on solenoid
associated solenoid valve's (E) failure to energize. valve E to determine whether energized.
up position - de-energized
down position - energized
Check Valve internals are worn, damaged or fouled, Shutdown and Depressurize Dryer. Repair or replace
permitting "blow-by" of on-line chamber's pressure valve.
(through faulty check valve) to the off-line chamber.
Damaged or out-of-calibration pressure sensor. Shutdown and Depressurize Dryer. Replace pressure
sensor.
Valve position limit switch failure. Check the appropriate terminal blocks prior to the limit
switches and make certain that the required input signals
are present. There are two limit switches per Switching
Valve. The top limit switch on each valve, identified by LS1,
actuates when the Switching Valve is "CLOSED". The
lower limit switch on each valve, Identified by LS2, actuates
when the Switching Valve is "OPENED".
HIGH HUMIDITY or AirSaver Excessive moisture or temperature on sensor. Check tubing or sensor isolation valve. If problem per-
Sensor Failure. sists, a dew point problem may exist.
18
19
Material Safety Data Sheet DRIOUT DESICCANT (1/ 8" Dia.), (3/ 16" Dia.), (1/ 4" Dia.)
(3/ 8" Dia.), (1/ 2" Dia.)
Revision Date: 96-01-25 Original Date: 81-01-23
COMPANY IDENTIFICATION
3. HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
Off-white crystalline or gelatinous granules, pellets, or powder. No unusual fire or spill hazard. Dust may be irritating to eyes and upper
respiratory tract.
This product contains total silicon at <1% by weight. Total silicon content includes metal silicates, amorphous and crystalline silica.
No analytical method exists to detect and differentiate between amorphous and crystalline silica and other silicates at <1% by weight.
Based on the chemistry of bauxite-derived products, crystalline silica is not expected to be present in this product. Amorphous silica
is a low health risk by inhalation.
Alumina is a low health risk by inhalation and should be treated as a nuisance dust as specified by the American Conference of
Government Industrial Hygienists (ACGIH).
Medical conditions aggravated by exposure to the product: Skin rashes, chronic lung disease, asthma.
EYES: Flush eyes with plenty of water or saline for at least 15 minutes. If irritation persists, consult a physician.
SKIN: Wash with soap and water for 15 minutes. If irritation develops, consult a physician.
INHALATION: Remove victim to fresh air. Check for clear airway, breathing, and pressure of pulse. Provide CPR for persons without
pulse or respirations. Consult a physician.
INGESTION: If swallowed, dilute by drinking large amounts of water. Never give anything by mouth to a convulsing or unconscious
person. Do not induce vomiting. Consult a physician.
Material Safety Data Sheet DRIOUT DESICCANT (1/ 8" Dia.), (3/ 16" Dia.), (1/ 4" Dia.)
(3/ 8" Dia.), (1/ 2" Dia.)
Revision Date: 96-01-25 Original Date: 81-01-23
PRODUCT NAME: DRIOUT DESICCANT
ENGINEERING CONTROLS: Use with adequate ventilation to meet exposure limits listed in Section 2.
RESPIRATORY PROTECTION: NIOSH-approved dust respirator if overexposure potential exists.
SKIN PROTECTION: Wear appropriate gloves to avoid direct skin contact.
EYE PROTECTION: Safety glasses recommended.
CHEMICAL STABILITY (CONDITIONS TO AVOID): A rise in temperature may result from contact with water
INCOMPATIBILITY: None.
HAZARDOUS DECOMPOSITION PRODUCTS: None.
HAZARDOUS POLYMERIZATION: None.
Non-corrosive.
Collect in containers, bags, or covered dumpster boxes. If reuse or recycling is not possible, material may be disposed of at an industrial
landfill.
TCLP data are available.
SPECIAL CAUTION
When disposing of used desiccant, material must be handled with special precautions. Desiccant is an adsorbent ma-
terial. Following contact with typical petrochemicals or gases, the combination of desiccant and retained material can be
hazardous, toxic and/or flammable. It is highly recommended that all used desiccant be analyzed to determine content
before disposal. Appropriate care and procedures should be followed in handling and storage of used materials. Once
content is determined, containers should be properly labeled and disposed of in accordance with Federal, State and Local
Regulations.
U.S.A. DOT: Not Regulated - Enter the proper freight classification, "MSDS Number," and "Product Name" on the shipping paperwork.
Canadian TDG Hazard Class & PIN: - Not regulated.
For inventory reporting purposes, CAS No. 1344-28-1 was assigned for aluminum hydroxide and activated alumina products instead
of the CAS number 1333-84-2 as indicated in Section 2.
In reference to Title VI of the Clean Air Act of 1990, this material does not contain nor was it manufactured using ozone-depleting
chemicals.
INTERNATIONAL REGULATIONS:
CANADIAN DOMESTIC SUBSTANCES LIST: All components of this product are listed on Domestic Substances List.
EUROPEAN COMMUNITY: All components of this product are listed on the ECOIN, the European Core Inventory.
JAPAN: All components of this product are listed on MITI, the Ministry of International Trade Industry.
AUSTRALIA: All components of this product are listed on the AICS inventory.
MSDS Status: Changes in all Sections 1, 3, 4, 8, 13, 15, 16, and Legend.
Product Use: Adsorbent; dehydration agent; catalyst support.
REFERENCES:
Guide to Occupational Exposure Values - 1995, Compiled by the American Conference of Governmental Industrial Hygienists
(ACGIH)
Documentation of the Threshold Limit Values and Biological Exposure Indices, Sixth Edition, 1991, Compiled by the American
Conference of Governmental Industrial Hygienists, Inc. (ACGIH).
NIOSH Pocket Guide to Chemical Hazards, U.S. Department of Health and Human Services, June 1994.
Dangerous Properties of Industrial Materials, Sax, N. Irving, Van Nostrand Reinhold Co., Inc., 1984.
Quick Identifier
DRIOUT DESICCANT (1/ 8" Dia.), (3/ 16" Dia.), (1/ 4" Dia.)
(3/ 8" Dia.), (1/ 2" Dia.)
This MSDS supersedes all prior data sheets received for this
product. We urge you to study it carefully. This provided with
each container as our way of communicating Health, Safety, and
Environmental Protection information to our customers.
LEGEND:
ACGIH American Conference of Governmental Industrial Hygienists atm atmosphere
AICS Australian Inventory of Chemical Substances cm centimeter
CAS Chemical Abstract Services g, gm gram
CERCLA Comprehensive Environmental Response, Compensation, and Liability Act in inch
CFR Code of Federal Regulations kg kilogram
DOT Department of Transportation lb pound
DSL Domestic Substances List (Canada) m meter
ECOIN European Core Inventory mg milligram
EPA Environmental Protection Agency ml, ML milliliter
IARC International Agency for Research on Cancer mm millimeter
LC50 Lethal concentration (50 percent kill) n.o.s. not otherwise specified
LCLo Lowest published lethal concentration ppb parts per billion
LD50 Lethal dose (50 percent kill) ppm parts per million
LDLo Lowest published lethal dose psia pounds per square inch
NFPA National Fire Protection Agency , u micron
NIOSH National Institute for Occupational Safety and Health g microgram
NTP National Toxicology Program
OSHA Occupational Safety and Health Administration
PEL Permissible Exposure Limit
PIN Product Identification Number
RCRA Resource Conservation and Recovery Act
SARA Superfund Amendments and Reauthorization Act
STEL Short Term Exposure Limit
TCLP Toxic Chemicals Leachate Program
TDG Transportation of Dangerous Goods
TLV Threshold Limit Value
TSCA Toxic Substances Control Act
TWA Time Weighted Average
The information contained herein is based upon data considered true and accurate. However, Flair Corporation makes no warranties (express or implied) as
to the accuracy or adequacy of the information contained herein or the results to be obtained from the use thereof. This information is offered solely for the
user's consideration, investigation and verification. Since the use and conditions of use of this information and the material described herein are not within
the control of Flair Corporation, Flair Corporation assumes no responsibility for injury to the user or third persons. The material described herein is sold only
pursuant to Flair Corporation Terms and Conditions of Sale, including those limiting warranties and remedies contained therein. It is the responsibility of the
user to determine whether any use of this data and information is in accordance with applicable Federal, State or Local Laws and Regulations.
Material Safety Data Sheet DRIOUT BED SUPPORT (1/ 8" Dia.), (1/ 4" Dia.)
(1/ 2" Dia.), (1" Dia.)
Revision Date: 95-02-08 Original Date: 81-01-23
Flair Corporation
4647 S.W. 40th Avenue
Ocala, Florida 34474
Product Information: 904-237-1220
CHEMICAL FORMULA: 38% Aluminum Oxide Al2O3, 51% Silicon Dioxide SiO2, 11% other inorganic oxides
2. HAZARDOUS INGREDIENTS
4. PHYSICAL HAZARDS
5. HEALTH HAZARDS
THRESHOLD LIMIT VALUE: Use nuisance dust limits as maximum workplace dust load.
10 mg/m Total (TWA) and 20 mg/m (STEL); 5 mg/m respirable dust
ENGINEERING CONTROLS: Use with adequate ventilation to meet exposure limits listed in Section 2.
RESPIRATORY PROTECTION: NIOSH-approved dust respirator where exposure limit is or may be exceeded.
HANDLING and STORAGE: Desiccant should be handled so as to avoid generation of dusty conditions in the
workplace. Use adequate ventilation. If dust develops, use a NIOSH approved respirator
to avoid drying of mucous membranes in nose and throat.
OTHER PRECAUTIONS: In dusty conditions, prolonged contact may cause irritation of skin. If contact with skin is
unavoidable, wear close-weave gloves with tight fitting wristlets. These should be washed
frequently.
STEPS TO BE TAKEN IN
CASE MATERIAL IS
RELEASED OR SPILLED: Vacuum or sweep up immediately. Spilled material can be slippery. This will minimize
chance of injury due to falls.
WASTE DISPOSAL
METHODS: Dispose of unused desiccant in accordance with Federal, State, and Local Regulations.
Material Safety Data Sheet DRIOUT BED SUPPORT (1/ 8" Dia.), (1/ 4" Dia.)
(1/ 2" Dia.), (1" Dia.)
Revision Date: 95-02-08 Original Date: 81-01-23
8. HANDLING CAUTIONS
As with all desiccants or dry powders, a static electric charge can build up when pouring. Proper grounding should
be observed when pouring from a bag or drum in the presence of flammable vapors.
When transferring desiccant with high pressure, wear goggles. Malfunction of equipment can propel bead with
enough velocity to penetrate skin. Make sure that both the transfer system and receiving vessels are properly grounded.
Follow standard operating procedures.
SPECIAL CAUTION
When disposing of used desiccant, material must be handled with special precautions. Desiccant is an
adsorbent material. Following contact with typical petrochemicals or gases, the combination of desiccant and
retained material can be hazardous, toxic and/or flammable. It is highly recommended that all used desiccant
be analyzed to determine content before disposal. Appropriate care and procedures should be followed in
handling and storage of used materials. Once content is determined, containers should be properly labeled
and disposed of in accordance with Federal, State and Local Regulations.
Chemical substance components have been reported to the EPA Office of Toxic Substances in accordance with
the requirements of the Toxic Substance Control Act (Title 40 CFR Part 710).
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 or 312 of SARA.
For purposes of SARA III reporting, this substance contains no ingredients listed on the Extremely Hazardous,
CERCLA, or Section 313 Lists.
D.O.T. Shipping Name, Hazard Class, I.D. No. (if applicable) - Not Regulated.
This MSDS supersedes all prior data sheets received for this
product. We urge you to study it carefully. This provided with
each container as our way of communicating Health, Safety, and
Environmental Protection information to our customers.
The information contained herein is based upon data considered true and accurate. However, Flair Corporation makes no warranties (express or implied) as
to the accuracy or adequacy of the information contained herein or the results to be obtained from the use thereof. This information is offered solely for the
user's consideration, investigation and verification. Since the use and conditions of use of this information and the material described herein are not within
the control of Flair Corporation, Flair Corporation assumes no responsibility for injury to the user or third persons. The material described herein is sold only
pursuant to Flair Corporation Terms and Conditions of Sale, including those limiting warranties and remedies contained therein. It is the responsibility of the
user to determine whether any use of this data and information is in accordance with applicable Federal, State or Local Laws and Regulations.
MAINTENANCE RECORD