ingersoll rand dryer o&m manual 80442833-en

8/10/2019 Ingersoll Rand Dryer O&M Manual 80442833-En

1/48

Manual Del OperadorES

Manual do OperadorPTManuel De LoprateurFR

Operators ManualEN

80442833Revision F

October 2012

Save These Instructions

HL Series Desiccant DryerMODELS 90-5000

Operators Manual

PRINT LANGUAGE

ENGLISH

FRENCH

PORTUGUESES

SPANISH


2/48

2 HL Series Desiccant Dryer Models 90-5000

ingersollrandproducts.com

1.0 CONTENTSCONTENTS PAGE1.0 CONTENTS 32.0 INTRODUCTION 43.0 WARRANTY 44.0 HEATLESS DRYER NOMENCLATURE 45.0 RECEIVING AND INSPECTION 55.1 INSPECTION 55.2 UNPACKING AND HANDLING 56.0 SAFETY AND OPERATION

PRECAUTIONS 57.0 PRINCIPLES OF OPERATION 67.1 INTRODUCTION 67.2 DRYING CYCLE 67.3 REGENERATION CYCLE 67.4 SETTING THE REGENERATION AIR FLOW 6

7.5 TOWER REPRESSURIZATION 67.6 VALVES 77.7 TIMING SEQUENCE 77.7.1 TIMING CYCLE FOR 40F DEW POINT

DRYERS 77.7.2 TIMING CYCLE FOR 100F DEW POINT

DRYERS 77.8 CONTROLS 77.8.1 BASIC USER INTERFACE 77.8.2 MICROPROCESSOR CONTROL

DISPLAY PARAMETERS 97.8.3 ALARMS AND THEIR FUNCTIONS 97.8.4 RESTART MODES AND OPERATING

DISPLAYS 117.8.4.1 RESTART MODE 117.8.4.2 OPERATION HOURS 118.0 ALARMS AND INDICATORS 128.1 MOISTURE INDICATOR 128.2 FAILURE TO SHIFT ALARM OPTIONAL 128.3 ENERGY MANAGEMENT SYSTEM

EMS OPTIONAL 128.4 HIGH DEW POINT ALARM INCLUDED

WITH EMS 128.5 COMPRESSOR INTERLOCK 129.0 INSTALLATION AND INITIAL

START UP 139.1 APPLICATION AND CHECK ANALYSIS 139.2 LOCATING AND MOUNTING 13

CONTENTS PAGE9.3 PIPING 139.4 FILTRATION 139.5 DEW POINT TRANSMITTER

INSTALLATION OPTIONAL 139.6 ELECTRICAL CONNECTION 149.7 DESICCANT LEVEL VERIFICATION 149.8 START UP 149.9 SHUT DOWN SEQUENCE 1510.0 TECHNICIAN MODE 1610.1 ENTERING TECHNICIAN MODE 1610.2 DEW POINT ADJUSTER

40 F DRYERS ONLY 1610.4 RESTART MODE 1710.5 PURGE FLOW ADJUSTER 18

10.6 COMPRESSOR INTERLOCK 1810.7 HIGH DEW POINT ALARMINCLUDED WITH EMS OPTION 18

10.7.1 DESCRIPTION AND ACTIVATION 1810.7.2 SETPOINT ADJUSTMENT 1911.1 SCHEDULED MAINTENANCE 2011.2 PRE FILTERS AND POST FILTERS 2011.2.1 THREADED FILTERS: 2011.2.2 FLANGED FILTERS: 2111.3 PILOT AIR CONTROL NO LOSS

DRAIN VALVES 2111.4 MUFFLER CHANGEOUT PROCEDURE 2111.5 PURGE AND SWITCHING

DIAPHRAGM VALVESHL90 HL 2700 21

11.6 PILOT OPERATED ACTUATORHL3300 HL5000 21

11.7 OUTLET CHECK VALVES 2111.8 DESICCANT CHANGEOUT PROCEDURE 2212.0 TROUBLESHOOTING 24

13.0 PURGE CHARTS 2514.0 GENERAL ARRANGEMENT 2815.0 WIRING DIAGRAM 3916.0 FLOW DIAGRAM 4017.0 REPLACEMENT PARTS 4218.0 ENGINEERING SPECIFICATIONS 47


3/48

HL Series Desiccant Dryer Models 90-5000 3ingersollrandproducts.com

2.0 INTRODUCTION

The Company warrants that the equipment manufactured byit and delivered hereunder will be free of defects in materialand workmanship for a period of twelve months from thedate of placing the Equipment in operation or eighteenmonths from the date of shipment from the factory,whichever shall rst occur. The Purchaser shall be obligatedto promptly report any failure to conform to this warranty,in writing to the Company in said period, whereupon theCompany shall, at its option, correct such nonconformity, bysuitable repair to such equipment or, furnish a replacementpart F.O.B. point of shipment, provided the Purchaser hasstored, installed, maintained and operated such Equipmentin accordance with good industry practices and hascomplied with specic recommendations of the Company.Accessories or equipment furnished by the Company, butmanufactured by others, shall carry whatever warranty themanufacturers have conveyed to the Company and whichcan be passed on to the Purchaser. The Company shallnot be liable for any repairs, replacements, or adjustmentsto the Equipment or any costs of labour performed bythe Purchaser or others without Companys prior writtenapproval.

The effects of corrosion, erosion and normal wear and tearare specically excluded. Performance warranties are limitedto those specically stated within the Companys proposal.Unless responsibility for meeting such performance

warranties are limited to specied tests, the Companysobligation shall be to correct in the manner and for theperiod of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY ORREPRESENTATION OF ANY KIND WHATSOEVER, EXPRES

OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIEDWARRANTIES OF MERCHANT ABILITY AND FITNESS FOPARTICULAR PURPOSE, ARE HERBY DISCLAIMED.

Correction by the Company of non conformities whetherpatent or latent, in the manner and for the period of timeprovided above, shall constitute fullment of all liabilities ofthe Company for such non conformities whether based oncontract, warranty negligence, indemnity, strict liability orotherwise with respect to or arising out of such Equipment.

The Purchaser shall not operate Equipment which isconsidered to be defective, without rst notifying theCompany in writing of its intention to do so. Any such use of

Equipment will be at Purchasers sole risk and liability.Note that this is Ingersoll Rand standard warranty. Anywarranty in force at the time of purchase of the equipmentor negotiated as part of the purchase order may take prec-edence over this warranty.

4.0 HEATLESS DRYER NOMENCLATUREPREFIX NOMINAL*

FLOW (m /hr)POWER /

DEW POINTNEMA/ MAWP ELECTRICAL

OPTIONELECTRICAL

OPTIONMECHANICAL

OPTIONFILTERS

HL 90-5000 1 = 115 / -40B = 115/ -1003=200-1-50/-40

E=220-1-50/-100

H = NEMA 4 /150 psig MAWP 0 = StandardF = EMS forHeatless Dryers

0 = Standard A = DownstreamPurge (Standard) A = Filters AttachedL = Filters Loose

* Nominal Flows indicated are for 100F inlet temperature, 100F ambient temperature and 100 psig compressed air pressure.

NOTICENomenclature shown above represents standard price sheet options. Other options are available, refer tonomenclature insert specic to your dryer for details.

The Ingersoll Rand Heatless Desiccant Dryers are designedto adsorb moisture from compressed air. The dryers areconstructed with two towers, each containing desiccantbeads, that alternate between online (drying) and offline(regenerating) modes, yielding a continuous stream of dryair at the dryers outlet.

During normal operation, wet air passes through the on linetower and water vapor from the air is adsorbed (collected)on the desiccant beads. While air is being adsorbed inthe online tower, the moisture on the desiccant in theoffline tower is removed by a process called desorption

(regeneration). After an initial rapid depressurization, aportion of dried air from the online tower passes over thedesiccant bed and carries the moisture off the bed and outthe dryers exhaust.

The continuous, alternating process of adsorption anddesorption is controlled using a timer that switches thetowers in a specic timed sequence. Very dry compressed airdew points are achieved through the continuous switchingand operation of this dryer. Ingersoll Rand offers dryers toprovide either -40F or -100F pressure dew point outlet air.

3.0 WARRANTY


4/48



Because an air dryer is pressurized and contains rotatingparts, the same precautions should be observed as withany piece of machinery of this type where carelessness inoperation or maintenance could be hazardous to personnel.In addition to obvious safety rules that should be followedwith this type of machinery, safety precautions as listedbelow must be observed:

Only qualied personnel shall be permitted to adjust,perform maintenance or repair this air dryer.

Read all instructions completely before operatingunit.

Pull main electrical disconnect switch and disconnectany separate control lines, if used, before attemptingto work or perform maintenance on the unit.

Do not attempt to service any part while machine is inan operational mode.

Do not attempt to remove any parts without rstrelieving the entire air system of pressure.Do not operate the dryer at pressures in excess of itsrating.

Do not operate the dryer without guards, shields andscreen in place.

Inspect unit daily to observe and correct any unsafeoperating conditions.

1.

2.

3.

4.

5.

6.

7.

8.

OSHAHeading Descriptions

WARNING

Warning is used to indicate a hazardous situationwhich has some probability of death or severe injury.Warning should not be considered for propertydamage accidents unless personal injury risk is present.

ATTENTION

Caution is used to indicate a hazardous situationwhich may result in minor or moderate injury.

NOTICENotice is used to indicate a statement of companypolicy as the message relates directly or indirectlyto the safety of personnel or protection of property.Notice should not be associated directly with a hazardor hazardous situation and must not be used in placeof Danger, Warning, or Caution.

NOTICEThe user of any air dryer manufactured by IngersollRand, is hereby warned that failure to follow theabove Safety and Operation Precautions may resultin personal injury or equipment damage. However,Ingersoll Rand does not state as fact, nor does itmean to imply, that the preceding list of Safety andOperating Precautions is all inclusive, and further, thatthe observance of this list will prevent all personalinjury or equipment damage.

6.0 SAFETY AND OPERATION PRECAUTIONS

5.1 INSPECTION

Upon receiving your Ingersoll Rand air dryer, please inspectthe unit closely. If rough handling has been detected, pleasenote it on your delivery receipt, especially if the dryer will notbe immediately uncrated. Obtaining the delivery personssigned agreement to any noted damages will facilitate anyinsurance claims

5.2 UNPACKING AND HANDLING

WARNING

Under no circumstances should any person attemptto lift heavy objects without proper lifting equipment(i.e., crane, hoist, slings or fork truck). Lifting any unitwithout proper lifting equipment, can cause serious

injury.Refer to labels on the dryer for the appropriate means forlifting or moving the dryer. When lifting the dryer, ensure thatno stress is applied to the piping or valving. Refer to Section9.2 for locating and mounting of dryer.

5.0 RECEIVING AND INSPECTION


5/48


7.1 INTRODUCTION

As described in Section 2, water vapor is removed fromcompressed air by diverting air ow alternately between twotowers lled with desiccant. While one tower processes thecompressed air stream, adsorbing water vapor, the oppositetower is regenerated by desorbing the water vapor and

venting it to atmosphere. Refer to the Flow Diagram for avisual representation of the drying and regenerating cycles.

7.2 DRYING CYCLE

Saturated compressed air enters the dryer and is divertedto the appropriate tower by the Inlet Flow Valves. Referringto the Flow Diagram (Section 16.0), the Left Inlet Flow Valveis actuated to a closed position to prevent air ow fromentering the regenerating tower. Simultaneously, the RightInlet Flow Valve is actuated to an open position, allowingair ow to the right hand tower. During this time, theRight Tower Purge Valve is actuated to a closed position,

preventing the compressed air from venting to atmosphere.As the compressed air ows through the desiccant materialat pressure, removal of water vapor from the air streambegins to occur through adsorption. In the adsorptionprocess, the desiccant material draws water vapor out of thecompressed air and holds it until the right tower dryingcycle is complete. Compressed air ows out of the tower fordelivery to the process use. The Outlet Flow Check Valvesprovide air ow diversion to the outlet air connection of thedryer. The Right Outlet Flow Check Valve allows air owthrough to the outlet connection of the dryer while The LeftOutlet Flow Check Valve checks off to prevent ow back tothe regenerating tower.

7.3 REGENERATION CYCLE

Previously adsorbed moisture, removed from the processstream, gets stripped or desorbed from the desiccantmaterial in the regeneration process. The rst stage ofregeneration is tower depressurization. After the InletFlow Valves are switched to divert air ow away from theregenerating tower, the appropriate Purge Valve will beopened and the tower will be depressurized. Through rapiddepressurization, a signicant portion of the previouslyadsorbed water vapor is stripped off of the desiccantmaterial and exhausted to atmosphere.

The second stage of regeneration uses a portion of thedry, compressed air, expanded to atmospheric pressure tocomplete the desorption process. As shown on the FLowDiagram, the compressed air exits the drying tower and aportion of the air ows through the Purge Adjustment Valveand the Purge Orice. Once the air has passed throughPurge Orice, it expands to atmospheric pressure andcontinues the regeneration process. Desorption occurs asthe desiccant releases water vapor into the regeneration airand is exhausted through the Purge Muffler.

Heatless dryers are equipped with the ability to use air froma downstream source to purge the regenerating towers. This feature is useful for applications with downstream (dry)storage tanks, as pulling air from a downstream source canminimize cycling of the air compressor.

7.4 SETTING THE REGENERATION AIR FLOW

Proper setting of the purge is necessary to achieve properdryer performance. Setting the purge ow too high willwaste compressed air and if set too low, the dryer will notachieve proper dew point performance.

The purge adjustment manifold consists of the PurgeAdjustment Valve, the Purge Pressure Gauge and the PurgeOrice. Manually adjust the Purge Adjustment Valve untilthe gauge reading on the purge pressure gauge matchesthe Purge Pressure Gauge setting listed on the laminated tagaffixed to the Orice Plate Assembly.

NOTICEOn dryers equipped with the optional EMS feature,the purge valve MUST be set to the factory set point toensure proper operation of this feature.

7.5 TOWER REPRESSURIZATION

Upon completion of tower regeneration, and prior to theInlet Flow Valves changing position to switch towers, theregenerated tower must be repressurized.

NOTICEFailure to re-pressurize prior to tower switchover willresult in shocking the desiccant material and causepremature desiccant dusting.

Repressurization is accomplished by closing the appropriatePurge Valve. Closing the Purge Valve allows the regenerationair to begin to pressurize the tower. In addition to theregeneration air, the Repressurization Valve, (standard on-100F dew point and high pressure dryers) opens allowingsome additional air from the outlet of the dryer to ensureadequate pressurization. During normal tower regeneration,the Repressurization Valve is held closed so that the onlysource of air for regeneration passes through the purgeadjustment assembly.

7.6 VALVES

Solenoid control valves are used to actuate the Flow Valves,Purge Valves and the optional Repressurization Valveon Heatless Dryers. The Inlet Flow Valves and optionalRepressurization Valve are normally open valves, while thePurge Valves are connected as normally closed valves. Thisarrangement permits air to ow through the dryer duringperiods of loss of power.

Outlet Check Valves are single direction check valves that will

7.0 PRINCIPLES OF OPERATION


6/48



allow ow in the direction shown on the Flow Diagram, butnot allow ow in the opposite direction.

7.7 TIMING SEQUENCE

All timing functions are controlled by the MicroprocessorController. Timing for HL Series dryers is as follows:

7.7.1 TIMING CYCLE FOR -40F DEW POINT DRYERS

The standard timing cycle for -40F operationswitches the Inlet Flow Valve position every veminutes which alternates the drying tower. Atthe same time as a tower Inlet Valve opens,the appropriate tower Purge Valve opens todepressurize the regenerating tower. Towerregeneration occurs for 4 minutes and 15 seconds,at which time the Purge Valve closes to initiaterepressurization.

7.7.2 TIMING CYCLE FOR -100F DEW POINT DRYERS

The standard timing cycle for -100F operationswitches the Inlet Flow Valve position every 2minutes which alternates the drying tower. Atthe same time as a tower Inlet Valve opens,the appropriate tower Purge Valve opens todepressurize the regenerating tower. Towerregeneration occurs for 1 minute and 50 seconds,at which time the Purge Valve closes to initiaterepressurization. The Repressurization Valve opensto assist tower repressurization for the last 10seconds prior to Inlet Flow Valve switching.

7.8 CONTROLS

The Microprocessor Controller controls all pneumatic valveoperation and dryer functions as well as communicatesdryer alarms. The Microprocessor Controller stores the last 20alarm conditions, displaying the alarm and the time and datethe alarm occurred. This useful feature can greatly facilitate

troubleshooting of the dryer. The Microprocessor Controller features three levels ofaccess. The default level CUSTOMER MODE permits viewingof various drying parameters. A protected TECHNICIANMODE permits access to and manipulation of additionalparameters. A password protected FACTORY MODE is alsoincluded for use with Ingersoll Rand Service Personnel fortroubleshooting the dryer.

7.8.1 BASIC USER INTERFACE

The Microprocessor Control display providesthe user with the operating parameters and theircorresponding values. When power is supplied tothe dryer, the Microprocessor Control will illuminateand default to the Standby mode, displaying thePress ON prompt.

The following illustration summarizes the keypadfunctions.

FIGURE 1 MICROPROCESSOR CONTROLLER



7/48


BUTTONS

ONInitiates PLC program. Begins system monitoringand valve switching functions.

OFFStops PLC program. Stops valve switchingfunctions. Initiates shutdown sequence. OpensInlet Flow Valves. Closes Purge Valves.

SELECT DISPLAYAllows the user to scroll through the availabledisplays. The last display selected will remaindisplayed as the default display.

+ / -Allows user to modify set point values. Set pointvalues cycle through a xed range. Also allowsentering negative numbers in Factory Modes.

or blank button

Allows user to step backwards to the previouslevel of the menu.

RESETPressing once clears the local alarm indicationand de-energizes the remote alarm contactfor many alarm conditions. Should the alarmcondition persist, the alarm will return after thealarm inhibit time has expired.

SETPermits the adjustment of parameters inFACTORY MODES.

ENTERUsed to accept changed parameters and set pointvalues.

TESTNot used in Desiccant Dryer applications

iRestricted Level access for factory use only.

The status panel provides clear indication of dryer status via

bright LED indicators. The following illustration summarizes the panels features:

FIGURE 2 STATUS PANEL

Dryer ON (Green)

Left Tower Regeneration(Yellow)

Left Tower Drying(Yellow)

Dryer OFF / Alarm(Red)

Right Tower Regeneration(Yellow)

Right Tower Drying(Yellow)



8/48



7.8.2 MICROPROCESSOR CONTROL DISPLAYPARAMETERS

The Microprocessor Controller is capable ofdisplaying a number of system parameters. Thefollowing summarizes the parameters that can beaccessed by depressing the SELECT DISPLAY buttonfrom the Microprocessor Controller. (Note that somedisplays are optional and may not appear on allmodels):

Tower Status {LT DRY / RT REGEN or LT REGEN /RT DRY}: Provides visual conrmation of towerdrying and regenerating status.

Step Timer {ie STEP 4 TIME 120}: Informationscreen displaying the current step in the programand the time remaining for the displayed step.

Dew Point Temperature (OPTIONAL) - {DEWPOINT TEMP: XX}: When equipped with the

Energy Management System (EMS) feature,provides accurate display of dryeroutlet pressure dew point.

Purge Status (OPTIONAL) - {PURGE / NO PURGE}:Indicates whether unit is currently consumingpurging air. Requires EMS.

Alarms {ALARM LIST - PRESS ENTER}: Depressing at this prompt permits viewing of currentalarm status and alarm history.

Operating & Purge Times - {OPERATING TIMES -PRESS ENTER}: Depressing at this prompt

provides access to the operating and purgehours of operation.

Operating Mode {OPERATING MODE: HEATLESS}:Indicates mode of operation for dryer.

7.8.3 ALARMS AND THEIR FUNCTIONS

There are several alarms detected by theMicroprocessor Control to alert the user of anout of tolerance condition. Once each alarm isdetected, a description of the alarm will appear inthe screen and the remote alarm contact will close.Note that during the alarm condition, the SELECT

DISPLAY button may be depressed to scroll throughthe available parameters. After approximately 30seconds, the alarm screen will reappear, providedthe alarm condition persists.

Fail to Shift Alarm (OPTIONAL) - (FAIL TO SHIFT)Pressure switches are provided to detect thepressure within each tower. At 0 psig the switchesare normally closed which sends a signal to thecontroller. When the towers pressurize, the switches

open, thus removing the signal to the controller.During the cycle, the Microprocessor Controllerinterrogates the pressure switches to determinetheir current position. The Microprocessor Controllercompares their position to a look-up table withinthe program. If the position of either switch differsfrom the switchs proper position, the dryer willinitiate the Fail to Shift Alarm.

High Dew Point Alarm (OPTIONAL) - (HIGH DEWPOINT) When the heatless dryer is equipped withthe optional EMS feature, a sensor is providedthat senses the outlet pressure dew point of theair and displays the value on the MicroprocessorController. For dryers equipped with the optionalEMS feature, the sensor is used to detect a high dewpoint condition and displays the alarm as High DewPoint.

Alarm List

The Microprocessor Controller stores the 20 mostrecent alarm conditions. These alarms are storedwith the type of alarm as well as the date and timethe alarm occurred. This list can greatly facilitatetroubleshooting the dryer and provide an indicationof dryer operation during unattended service. Thefollowing describe the method to access and reviewthe alarms stored in the Microprocessor Controller:

Depressing the SELECT DISPLAY button will reveal theprevious alarm condition(s), as well as the remainingavailable alarm placeholders for alarms. To EXIT the ALARMLIST, perform the following:

SELECT DISPLAY

ALARM LISTPRESS ENTER

Depress the SELECT DISPLAY button until theALARM LIST display appears.

ENTER BEGIN ALARMS

Depressing the ENTER button enters the ALARM

LIST menu.

SELECT DISPLAY ALARM OFF

Depressing the SELECT DISPLAY button advancesthe menu to the current alarm status.



9/48


SELECT DISPLAY

HIGH DEW POINTTM 1635 DATE 1104

Depressing the SELECT DISPLAY list displaysthe most recent of the alarms stored by the

Microprocessor Control. Refer to the diagram at theend of this section for an explanation of the ALARMLIST Display.

BEGIN ALARMS

Depressing the button returns the controller to

the top of the ALARM LIST.

ALARM LISTPRESS ENTER

Depressing the button again returns the

controller to the CUSTOMER MODE.

HIGH DEW POINTTM 1635 DATE 1104

FIGURE 3 ALARM SCREEN DETAILS

Time of Alarm(Military Time)

Date of Alarm(Date-Month)

Example shows April 11

Alarm Condition



10/48



7.8.4 RESTART MODES AND OPERATING DISPLAYS

7.8.4.1 Restart Mode

The Microprocessor Controller includes a ShutdownSequence that is activated when the dryer OFFbutton is depressed. This feature positions the

valves to their failsafe position and resets theprogram and is the recommended methodof shutting down the dryer. When the dryer issubsequently energized, the dryer is ready to run atthe start of the program. Should the Desiccant dryerpower fail unexpectedly, the dryer may be set torestart in one of two start modes.

Manual Mode (ZERO)

Ingersoll Rand dryers are shipped from the factoryin the Manual Mode. After power is supplied tothe dryer after a loss of power, the PRESS ONdisplay will appear. The valve switching and timing

operations will only start once the ON button isdepressed. In this conguration, to restart the dryer,the user must manually depress the ON button onthe Microprocessor Control panel.

Auto Restart Mode (LAST)

In this mode, the dryer will start automatically oncepower is re-applied to the dryer. The MicroprocessorControl will pick up where it left off in the programonce power is applied.

7.8.4.2 Operation Hours

In the CUSTOMER MODE, the MicroprocessorController provides access to the operating hoursof the dryer. The following describe the method toaccess and review the operating and purge hoursfor the dryer:

SELECT DISPLAY

OPERATING TIMESPRESS ENTER

Depress the SELECT DISPLAY button until the OPERATING TIMES display appears.

ENTER BEGIN TIMES

Depressing the ENTER button enters the OPERATING TIMESmenu.

SELECT DISPLAY

OPERATING HOURS000000065

Depressing the SELECT DISPLAY button displays thecumulative operating hours of the dryer.

SELECT DISPLAY

PURGE HOURS000000009

Depressing the SELECT DISPLAY button displays thecumulative hours the dryer has used purge air.

ENTER BEGIN TIMES

Depressing the ENTER button returns the display to the topof the OPERATING TIMES menu.

OPERATING TIMESPRESS ENTER

Depressing the button returns the controller to theCUSTOMER MODE



11/48


8.1 MOISTURE INDICATOR

The moisture indicator senses a sample of the control airwhich is taken from the dryer outlet. The indicator providesa gross indication of dew point deterioration at the outlet ofthe dryer. Under normal operating conditions, the indicatoris blue. In the event of a dryer malfunction or prolongeddryer shut down, it will turn gray in the presence of moisture.

8.2 FAILURE TO SHIFT ALARM (OPTIONAL)

The Failure to Shift Alarm provides an indication of switchingfailure in one of the dryer switching valves. The Fail to ShiftAlarm uses a pressure switch to monitor the pressure in eachtower. At 0 PSIG the switches are normally closed whichsends a signal to the controller. When the towers pressurize,the switches open, thus removing the signal to thecontroller. The controller anticipates the appropriate openand closed switch position based on its timing sequence. Ifeither switch is in an incorrect position, the alarm light willilluminate.

8.3 ENERGY MANAGEMENT SYSTEM (EMS) -(OPTIONAL)

Ingersoll Rand s EMS system is designed to minimizethe loss of purge air during low ow or low water loadingconditions. A digital dew point sensor is used to detectthe actual outlet pressure dew point of the process air. Thesensor communicates the pressure dew point reading to theMicroprocessor Controller. The Microprocessor Controllerinterprets whether the outlet pressure dew point is aboveor at the EMS set point. As long as the outlet pressuredew point is dryer than the set point, the MicroprocessorController will not allow the Purge Valves to open. Thedryer will however, continue to cycle back and forthbetween towers. Once the EMS threshold is reached, theMicroprocessor Controller will initiate the regeneration cycleand the appropriate Purge Valve will open.

NOTICEAt initial start-up or after desiccant changeout, thenew desiccant has a moisture holding capacity higherthan the dryers design regeneration capabilities. Thedesiccant stabilizes to an aged state after three to sixmonths of use. Ingersoll Rand recommends keepingthe EMS feature off for one to two weeks from initialstart-up or desiccant replacement. Activating the EMSafter this period will insure proper operation of theEMS.

8.4 HIGH DEW POINT ALARM (INCLUDED WEMS)

The purpose of the High Dew Point Alarm is to provide theoperator an alarm indication should the equipment fail tosupply air at its designed pressure dew point. The EMS dewpoint sensor communicates the pressure dew point readingto the Microprocessor Controller. Should the pressure dewpoint rise above the alarm set point, the MicroprocessorController will display the alarm condition on the controllerscreen.

8.5 COMPRESSOR INTERLOCK

Compressor Interlock adjusts the operation of the dryer touse purge air only when the air compressor is LOADING orON. For installations with signicant downstream air storage,this feature closes the purge valves if the compressor is notdelivering ow after completion of the current tower purgecycle. This feature requires a relay (supplied by others) onthe air compressor to indicate whether the air compressoris LOADING or ON vs. UNLOADING or OFF. Prior to using thisfeature, the relay must be wired to the 5V DC terminal stripin the dryers electrical enclosure (refer to the appropriatewiring diagram). The dryer will provide the 5V DC power.For proper operation, the air compressor ON or LOAD signalshould correspond with the relay being closed. The OFF orUNLOAD signal must correspond to the relay being open.

Adjusting the purge cycle to correlate with the operationof the air compressor minimizes the potential for the aircompressor to cycle and saves the energy associated withgenerating unnecessary purge air.

8.0 ALARMS AND INDICATORS


12/48



9.1 APPLICATION AND CHECK ANALYSIS

To achieve the best dryer performance, you should carefullycheck that the design and installation requirements outlinedbelow are satised.

NOTICE

The standard dryer is not rated for any gas other thanair.

Operating pressure of Ingersoll Rand dryers can rangefrom 75 -150 PSIG. Air available for your usage will vary withoperating pressure. The maximum design pressure of theIngersoll Rand Heatless Dryer is 150 PSIG. For units requiredfor higher operating pressures, consult your Ingersoll Randrepresentative.

The dryer must never be installed where air and/or ambienttemperature exceeds 120F or drops below +50F. Locatedryer to avoid extremes of heat and cold from ambient or

other conditions. Avoid locating dryer outside or where it isexposed to the elements.

NOTICEIngersoll Rand recommends that the mufflers becleaned after initial start-up to remove any desiccantdust generated during shipment. After running dryerfor initial 30 minute period, de-energize / depressurizedryer and remove mufflers. Disassemble and cleanthe removable insert inside the muffler core. Reinstallmufflers prior to operating dryer.

9.2 LOCATING AND MOUNTINGLift the dryer only by the lifting points indicated by thelifting labels on the dryer.

If the dryer has been shipped with desiccant packagedseparately, install the desiccant after locating and mounting.Desiccant has been provided separate to minimize handlingdifficulty and placing unnecessary stress on the dryerassembly

Bolt the dryer to the foundation using the bolt holesprovided in the base frame. Anchor bolts should projecta minimum of 3.5 inches above the foundation. Refer toGeneral Arrangement drawing for details.

9.3 PIPING

Pipe the compressed air lines to the inlet and outletconnections. Locate the pre-lters as close as possible to thedryer. Ensure the positioning allows for ease of servicing.Refer to the General Arrangement drawing.

Note that the wet air inlet is at the dryers lower manifold,while the dry air outlet is at the dryers upper manifold. Insituations where air supply is required 24 hours a day (it is

undesirable to interrupt the airow), a three valve by-passsystem is recommended to bypass the dryer. Use the fewestelbows necessary to keep pressure drop at a minimum.

Once all piping has been connected, all joints includingthose on the dryer, should be soap bubble tested at linepressure to ensure no joints have been damaged in transitand site placement.

9.4 FILTRATION

It is important that a pre-lter and an post-lter be providedin your dryer installation. All dryers are supplied with a pre-lter and post-lter as standard. They are mounted on theHL1200 and smaller. They are shipped loose on the HL1500and larger.

NOTICEAll dryers must have proper ltration. A .3 microncoalescing lter with automatic drain & particulateafter lter must be used as a minimum. Failure toprovide proper ltration for dryer will void warranty.

Coalescing pre-lters, located before the dryer, protectdesiccant beds from contamination by oil, entrained water,pipe scale, etc., thereby, extending dryer desiccant life.Locate pre-lters as close to dryer as possible.

It is recommended that a mechanical separator be installedimmediately preceding the pre-lter to remove the bulkliquid and entrained water.

Particulate post-lters, located after the dryer, help eliminatethe possibility of desiccant dusting and carryover into the air

system.9.5 DEW POINT TRANSMITTER INSTALLATION

(OPTIONAL)

On dryers equipped with EMS, the dew point transmitteris shipped in a separate container within the electricalenclosure to protect the transmitter during shipment. Priorto using the EMS feature, the transmitter must be installedin the sensor block located on the side of or behind theelectrical enclosure and the transmitter cable fastened tothe sensor. Note that the transmitter should only be installedwhen the dryer is ready to be commissioned.

To install the Dew Point Transmitter:Remove Transmitter from original packaging.

Verify that Washer is placed below Transmitter hex.

Thread the Transmitter into the Sensor Block asshown.

Attach the Transmitter Cable to the Transmitter. Besure to fully engage the Transmitter Cable SecuringScrew into the mating thread in the Transmitter.

9.0 INSTALLATION AND INITIAL START UP


13/48


TRANSMITTER CABLE

SECURING SCREW

TRANSMITTER CABLE

TRANSMITTER

WASHER

SENSING BLOCK

9.6 ELECTRICAL CONNECTION

Make all electrical connections to the dryer as shown onthe wiring diagram. Care must be taken in connecting theproper voltages.

NOTICEDryer must be grounded with the full sized groundwire connected to an earth ground.

NOTICEDryer must be fused according to NEC with thesize fuse listed on the dryer serial nameplate, or onspecication sheet in technical manual.

Size eld connection knock-out for the conduit ttingrequired by the NEC.

9.7 DESICCANT LEVEL VERIFICATION

Remove desiccant ll port and the top of the desiccant vessel

and check desiccant level. The level should be consistentwith the level depicted on the Desiccant Fill Chart at the endof the manual. The initial charge of desiccant is installed inthe dryers at the factory on models HL 2700 and smaller.

9.8 START-UP

Slowly pressurize the dryer. When the dryer reachesfull operating pressure, check the system for airleaks. Soap test all joints and tting. To maintain

desired dew point, any leaks detected must be xed,especially those on the outlet side of the dryer.

Make sure that the purge adjustment valve is openand air outlet shut off valve (if equipped) is closed .

For dryers equipped with EMS, remove the dewpoint monitor sensor from the electrical enclosureand install in the sensing block, located beside theenclosure and attach the sensor cable to the sensor.



14/48



Turn on dryer disconnect switch (supplied bycustomer) to apply power to the dryer. The LCDdisplay on the Microprocessor Controller willilluminate.

Start dryer by depressing the ON button on theMicroprocessor Controller.

For the rst 30 seconds that the dryer is energized,both purge valves will remain closed. After 30seconds, the left tower purge valve will be openedand depressurization of the left tower will occur.

With a voltmeter, check the power connections for thecorrect voltage shown on the dryer serial nameplate.

Close and secure all electrical panel covers.

The Microprocessor Controller will indicate that theleft tower is drying. The dryer will operate in thesequence described in Section 7.

Following depressurization, adjust purge valve asdescribed in Section 7.4

NOTICEAt initial start-up, check the dryer operation for oneor two cycles, especially at the time of the tower shift.Verify that all systems are operating in their properorder and sequence. If the dryer is not functioningproperly, contact distributor or Ingersoll RandTechnical Service.

If the dryer has been in storage or off for an extendedperiod of time, the Blue Moisture Indicator may begray, the High Dew Point Alarm (if equipped) maybe activated and the dew point display (if equipped)may indicate a high dew point. Depending upon theduration of idle time, it may take anywhere from oneto twelve hours for the alarm condition to go out, theBMI to return to its normal blue state and the dewpoint to drop.

Slowly open the outlet valve to gradually pressurizethe down stream piping.

NOTICEWhen opening the outlet valve, insure drying towergauge maintains line pressure. Allowing pressure todrop in the dryer will result in an overow condition.

NOTICE-100 F dryers require ow through the dryer to lowerthe pressure dew point to design levels. Failure topermit air ow through dryer (deadheading) will resultin elevated outlet dew points. Once air is permittedto ow through the dryer, the pressure dew point willgradually reduce to design levels.

9.9 SHUT-DOWN SEQUENCE

NOTICEPrior to removing power or compressed air from thedryer, depress the OFF button on the MicroprocessorControl This initiates the Shutdown Sequence, whichcloses the purge valves, repressurizes the off-linetower and opens the ow valves. DO NOT REMOVEPOWER OR COMPRESSED AIR FROM THE DRYERDURING THE SHUTDOWN SEQUENCE.

Maintain a compressed air source to the dryer and asupply of power to the Microprocessor Controller.

OFF SHUTDOWNSEQEUNCE

Depress the OFF button to initiate the SHUTDOWNSEQUENCE.

Permit the dryer to complete the full SHUTDOWNSEQUENCE (30 seconds)

PRESS ON

Once the PRESS ON Prompt is displayed, the dryer hascompleted the SHUTDOWN SEQUENCE. Power and air maybe safely removed from the dryer.

De-energize the dryer

Shut down air compressor or bypass dryer

Close Isolation Valves (if equipped)

Note: On the subsequent Start-up, the outlet isolationvalve should be in the closed position. Slowly open thevalve to build pressure downstream.



15/48


The Microprocessor Control provides a protected TECHNICIAN MODE to manipulate several parametersnot accessible by the casual operator. Below is a list ofparameters that can be accessed and manipulated bythe technician in the TECHNICIAN MODE:

Parameter Display Set Point

DEW POINT ADJUSTERSETTING PDP ADJUSTER -40, -4, +38

ENERGY MANAGEMENTSYSTEM (OPTIONAL)

EMS OFF , ON

ENERGY MANAGEMENTSYSTEMSETPOINT (OPTIONAL) *

EMS SET POINT -76 - +68

RESTART MODE RESTART LAST, ZEROPURGE FLOW ADJUSTERSETTING

PURGEADJUSTER

30% - 100%

COMPRESSOR INTERLOCK SETTING

COMPINTERLOCK

OFF , ON

HIGH DEW POINT ALARMACTIVATION (OPTIONAL)

HIGH DEWPOINT

OFF , ON

In TECHNICIAN MODE, the following parameters can beviewed but not changed:

Parameter DisplayOPERATION MODE HEATLESS

* NOTE: Setpoints indicated are adjustable ONLY when dryeris equipped with the EMS. Setpoints are non-adjustable ondryers without this option

10.1 ENTERING TECHNICIAN MODE

WARNING

TECHNICIAN MODE should only be entered byqualied service personnel. Altering the set points inTECHNICIAN MODE will have a signicant effect onthe operation of the dryer. Incorrect set points maydamage dryer and cause potential serious injury.

To enter the TECHNICIAN MODE, perform the followingkeystrokes:

2 3BEGIN

TECHNICIAN MODE

Pressing the 2 and 3 buttons simultaneously entersthe TECHNICIAN MODE.

SELECT DISPLAY

SET OPMODEHEATLESS

Depressing SELECT DISPLAY scrolls through the availableparameters.

10.2 DEW POINT ADJUSTER (-40 F DRYERS O

Dew point adjuster allows the user to select between -40F, -4 F and +38F pressure dew points. Selecting a higher(wetter) pressure dew point lengthens the drying cycle,making the regeneration process commence less frequentlythan at lower (dryer) dew points. This results in energysavings by depressurizing the system less times per hour. The chart below describes the available outlet pressure dewpoints that may be selected along with their respective cycletimes.

ISO8573.1Class

PressureDew Point CycleLength Regenerationsper hour

2 -40 F -40 C 10 min 12

3 -4 F -20 C 16 min 7.5

4 +38 F +3 C 24 min 5

The following illustrates the method of accessing andadjusting the dew point adjuster feature

SELECT DISPLAY

PDP ADJUSTERDEW POINT: -40

Depress the SELECT DISPLAY button until the DEW POINTADJUSTER screen is displayed.

+

-

PDP ADJUSTERDEW POINT: -4

Depress the +/- button until the desired dew point isdisplayed. Pressing SELECT DISPLAY saves the current

selection.

10.3 ENERGY MANAGEMENT SYSTEM (OPTIO

10.3.1 DESCRIPTION AND ACTIVATION

The optional Energy Management System (EMS)feature is designed to minimize the loss of purgeair during low ow or low water loading conditions.A digital dew point sensor detects the actualoutlet air pressure dew point of the process air.

10.0 TECHNICIAN MODE


16/48



The sensor communicates the pressure dew pointreading to the Microprocessor Controller. Shouldthe pressure dew point be below the EMS set point,the Microprocessor Controller will keep the purgevalves closed while the dryer continues to cycleback and forth between towers, thereby savingpurge air.

The following illustrates the method of accessingand adjusting the Energy Management Systemfeature:

SELECT DISPLAY EMS: OFF

Depress the SELECT DISPLAY button until the ENERGYMANAGEMENT SYSTEM screen is displayed.

+

- EMS: ON

Depress the +/- button until the desired set point isdisplayed. Pressing SELECT DISPLAY saves the currentselection.

10.3.2 SETPOINT ADJUSTMENT

On dryers equipped with the optional EMS, theEnergy Management System setpoint can beadjusted to match the dryers requirements to thedesired pressure dew point.

The following illustrates the method of adjustingthe setpoint for the Energy Management Systemfeature:

SELECT DISPLAY

EMS SET POINT-43

Depress the SELECT DISPLAY button until the EMS SET POINTscreen is displayed.

SET EMS SET POINT___

Pressing the SET button permits the value of the EMSSETPOINT to be changed

+

-

EMS SET POINT-___

To enter a negative number, depress the +/- button.Otherwise, proceed to the next step.

4 EMS SET POINT-4__

Use the numbers on the keypad to enter the desiredpressure dew point temperature for the EMS setpoint.

1 EMS SET POINT-41_

Use the numbers on the keypad to enter the desiredpressure dew point temperature for the EMS setpoint.

ENTER EMS SET POINT-41

Depressing ENTER saves the selected set point.

NOTICEThe Energy Management System set point should notbe lower (wetter) than the dew point adjuster setting.Failure to do so will prevent the Energy ManagementSystem feature from operating. In addition, whenoperating in EMS, the purge ow adjuster should beset to 100%.

10.4 RESTART MODE

HL Dryers can be congured to restart in one of twooperating modes. As described in Section 5, the dryer maybe congured for Manual operation (factory default) or AutoRestart, which permits the dryer to restart automaticallyonce power is re-applied to the dryer. The followingillustrates the method of accessing and adjusting thedifferent start modes for the dryer:

SELECT DISPLAY

RESTART ZERO

Depress the SELECT DISPLAY button until the START MODEscreen is displayed.

+

-

RESTART

LAST To change the start mode from its current selection to thealternate setting, depress the +/- button until the desiredset point is displayed. Pressing SELECT DISPLAY saves thecurrent selection.

10.5 PURGE FLOW ADJUSTER

Purge ow adjuster allows the user to reduce the duration ofthe purge cycle to more closely match the inlet conditions



17/48


to the dryer. This feature is well suited for applicationswhere the dryer is consistently underowed, allowing onlythe required amount of purge air to be used. The purgeow adjuster feature allows the user to select the relativeduration of the purge cycle, from 30% to 100%, in 10%increments.

The following illustrates the method of accessing and

adjusting the purge ow adjuster feature

SELECT DISPLAY

PURGE ADJUST% PRG SELECT 100

Depress the SELECT DISPLAY button until the PURGE FLOWADJUSTER screen is displayed.

+

-

PURGE ADJUST% PRG SELECT 70

Depress the +/- button until the desired percent purge

is displayed. Pressing SELECT DISPLAY saves the currentselection.

NOTICEOn dryers equipped with the optional EnergyManagement System feature, the purge owadjuster MUST be set to 100% in order for the EnergyManagement System to operate properly.

10.6 COMPRESSOR INTERLOCK

Compressor Interlock adjusts the operation of dryer topurge only when the air compressor is LOADING or ON. This feature requires the customer to provide a relay on theair compressor to indicate whether the air compressor isLOADING or ON vs. UNLOADING or OFF. Prior to using thisfeature, the user must wire the relay to the 5V DC terminalstrip in the dryers electrical enclosure. The dryer will providethe 5V DC power. The air compressor ON or LOAD signalshould correspond with the relay being open. The OFF orUNLOAD signal must correspond to the relay being closed.

With the Compressor Interlock properly set-up andactivated, the dryers purge valves will close when the aircompressor is not making air, as indicated by the OFF orUNLOAD condition. With the purge cycle corresponding to

the demands of the air dryer, cycling of the air compressoris minimized and energy savings is realized by only purgingwhen the air system requires.

The following illustrates the method of accessing andadjusting the Compressor Interlock feature:

SELECT DISPLAY

COMP INTERLOCKOFF

Depress the SELECT DISPLAY button until the COMPRESSOR

INTERLOCK screen is displayed.

+

-

COMP INTERLOCKON

Depress the +/- button until the desired set point isdisplayed. Pressing SELECT DISPLAY saves the current

selection.10.7 HIGH DEW POINT ALARM (INCLUDED W

EMS OPTION)

10.7.1 DESCRIPTION AND ACTIVATION

The purpose of the High Dew Point Alarm is toprovide the operator an alarm indication shouldthe equipment fail to supply air at its designedpressure dew point. The EMS dew point sensorcommunicates the pressure dew point reading tothe Microprocessor Controller. Should the pressure

dew point rise above the alarm set point, theMicroprocessor Controller will display the alarmcondition on the controller screen.

The following illustrates the method of activatingthe High Dew Point Alarm feature:

SELECT DISPLAY

HIGH DEW PTOFF

Depress the SELECT DISPLAY button until the HIGH DEWPOINT screen is displayed.

+

- HIGH DEW PTON

Depress the +/- button until the desired set point isdisplayed. Pressing SELECT DISPLAY saves the currentselection.

10.7.2 SETPOINT ADJUSTMENT

On dryers equipped with the optional EMS, the HighDew Point Alarm setpoint can be adjusted.

The following illustrates the method of adjustingthe setpoint for the High Dew Point Alarm feature:

SELECT DISPLAY

HI PDP SETPOINT-10

Depress the SELECT DISPLAY button until the HIGH DEWPOINT ALARM SET POINT screen is displayed.



18/48



SET HI PDP SETPOINT___

Pressing the SET button permits the value of the HIGH DEWPOINT ALARM SET POINT to be changed.

+

-

HI PDP SETPOINT-___

To enter a negative number, depress the +/- button.Otherwise, proceed to the next step.

2 HI PDP SETPOINT-2__

Use the numbers on the keypad to enter the desiredpressure dew point temperature for the HIGH DEW POINTALARM setpoint.

1 HI PDP SETPOINT-21_

Use the numbers on the keypad to enter the desiredpressure dew point temperature for the HIGH DEW POINTALARM setpoint.

ENTER HI PDP SETPOINNT-21

Depressing ENTER saves the selected set point.

NOTICE

The High Dew Point Alarm set point should not begreater than the Energy Management System setpoint or the dew point adjuster setting. Failure to doso will result in an alarm indication. Ingersoll Randrecommends setting the High Dew Point Alarm at least10F wetter than the Energy Management System ordew point adjuster setpoints.

NOTICETo exit the TECHNICIAN MODE, press the + / - key tothe initial SETOPMODE screen and depress thebutton to return to the CUSTOMER MODE.

Ingersoll Rand desiccant dryers are capable of remotecommunications via MODBUS. Refer to the documententitled, Microprocessor Control Modbus CommunicationsGuide for details on communicating with the Controller viaMODBUS.



19/48


11.1 SCHEDULED MAINTENANCE

DAILY MAINTENANCE FUNCTIONS:

Check and record inlet pressure, temperature andow. Verify that it is within specications.

Check tower pressure gauge readings withinoperating tolerance.

Check operation for proper dryer cycling,depressurization and repressurization.

Check that the pre-lter drain is operating properlyand that there is no condensate discharged frompurge mufflers. Replace cartridges sooner if necessaryas required by differential pressure indicator.

Verify that pressure in purging tower is 10 PSIG orless. If higher, muffler replacement is recommended.(Section 11.4)

Verify that pre-lter and post-lter differentialpressure is within operating limits. Change asrequired. (Section 11.2). Replace cartridges soonerif necessary as required by differential pressureindicator.

Check the Blue Moisture Indicator. Make sure air isbleeding through the indicator. The indicator will beblue when air is dry.

SEMI-ANNUAL MAINTENANCE FUNCTIONS:

Check outlet dew point.

Check pilot air lter element and clean or replace asrequired.

Replace pre-lter and post-lter elements and / orcartridges. Replace cartridges sooner if necessary asrequired by differential pressure indicator.

ANNUAL MAINTENANCE FUNCTIONS:

Check desiccant and replace if necessary.

Inspect and clean pilot air control no-loss drain valves,check valves and diaphragm valves. Rebuild and / orreplace as required.

Test lights and switches, replace as necessary.

Test electrical components, replace as necessary.

EVERY TWO YEARS:Replace diaphragm and seal kits on purge andswitching diaphragm valves.

EVERY THREE - TO - FIVE YEARS:

Replace desiccant.

Rebuild purge and switching diaphragm valves(Preventative)

Replace Check Valves (Preventative)

11.2 PRE-FILTERS AND POST-FILTERSPre-lters - The cartridges of the pre-lter mustbe changed as often as required to preventcontamination of the regenerative dryers desiccantbed.

The pre-lter and automatic drain must be checked daily. To prolong lter cartridge life, it is recommended that amechanical air / moisture separator be placed immediatelybefore the pre-lter.

NOTICEShould the drying system be overloaded and/ormalfunctioning, causing high pressure drop, post-lters will prematurely plug. This problem canbe avoided by frequent inspection and proactivereplacement of cartridges.

Post-lters - The purpose of the post-lter is toremove residual desiccant dust. Depending uponequipment application and usage, frequency oflter element change will vary. It is recommended tochange lter element every six months as a minimum.

WARNING

To avoid injury, depressurize dryer before performingany service.

11.2.1 THREADED FILTERS:

Refer to F35 - F2378 (G, H, A, D) Operators Manual(CCN 85566024) for element change-out procedures forthreaded lters.

11.0 MAINTENANCE AND SYSTEM CHECK


20/48



11.2.2 FLANGED FILTERS:STEP 1 - Usinga 2" socket withan extension,carefully loosenelement.

STEP 2 -Remove oldelement fromfilter housing.

STEP 3 - Installnew element bycarefullyinsertingelement in topplate.

STEP 4 - Handtighten elementin place untilelement o-ringcontacts topplate.

STEP 5 - Usinga 2" socket withan extension,tighten elementone half turn.DO NOT OVER-TIGHTEN.

STEP 6 -Repeatprocedure asrequired toreplace allelements.

11.3 PILOT AIR CONTROL NO-LOSS DRAIN VALVES

The length of time the pilot air valves can reliably operatewithout replacing is dependent upon the type of dryerand the dryers operation. On Ingersoll Rand -40F dewpoint dryers, replacing the valves is recommended every 60months. Given the difference in cycle times for -100F units,these dryers should have their pilot valves replaced every 30months.

11.4 MUFFLER CHANGEOUT PROCEDURE

WARNING


Depressurize the dryer turn control power off.

Replace muffler.

Follow Start-up procedure described in Section 9.7.

Turn control power back on.

11.5 PURGE AND SWITCHING DIAPHRAGMVALVES (HL90 - HL 2700)

These valves have two control ports; one on top and theother on the back side.

Normally Open (N.O.) Valves: For N.O. inlet orrepressurization valves, control air is supplied to thetop port. The back side port exhausts out the bottomside of the diaphragm. If air leaks continuously whencontrol air is supplied to the valve, the internal sealsare leaking and must be replaced.

Normally Closed (N.C.) Valves: For N.C. purge valves,the top port is plugged. Control air is supplied

to the back port. If air vents out of the back portcontinuously when the solenoid is de-energized, itwill exhaust through the top of the solenoid. If thiscondition is observed, the internal seals are leakingand must be replaced.

11.6 PILOT OPERATED ACTUATOR (HL3300 -HL5000)

Should the actuator fail to rotate, disconnect the pilot linesto check if the actuator is receiving pilot pressure.

If the actuator is receiving pressur e:

Verify that control pressure is 75 psig min.

Ensure the inlet valve is not plugged.

11.7 OUTLET CHECK VALVES

Outlet check valves sealing can be veried by depressurizingthe dryer and slowly applying pressure to the outlet. Thevalves should seal and prevent air from pressurizing thetowers. If a tower begins to pressurize, the check valve onthat side requires replacement.



21/48


11.8 DESICCANT CHANGEOUT PROCEDURE

When it becomes necessary to replace the desiccant in thetowers, observe the following procedure:

WARNING


CAUTION

Be sure to wear respiratory protection during thedraining and lling process to minimize inhalation ofdesiccant, as desiccant will produce dust during thisprocedure.

NOTICEEach dryer is shipped with a desiccant sample kit to

allow the desiccant to be sent for analysis. This kit canbe used to have the condition of the desiccant veriedby laboratory analysis. Please follow the instructionsfound in the kit.

The standard units are furnished with ll and drainports on each desiccant tower. Remove the caps onboth ports.

To assist in getting the desiccant to ow from thetower, insert a small rod in to the drain port asnecessary. This may be required as the desiccant ispacked into the towers which may interfere with thedesiccant ow from the towers.

Retainer screens, located at the inlet and outlet

piping connections of the tower, are removable on allmodels. It is suggested that these screens be removedand cleaned at the time of desiccant changeout. These screens can be accessed by disconnecting theupper and lower manifolds from the dryer towers.

After cleaning the retainer screens, replace screensand reattach the outlet port plug.

With the ll port plug removed, ll the dryer towerwith the appropriate grade and size desiccant. The level of the desiccant should be below the topretainer screen as shown on the Desiccant Fill Chartbelow.

Once the towers have been lled, replace the ll portplug on each tower.

Any connections disturbed in the desiccantchangeout process should be leak tested prior to re-commissioning the dryer.



22/48



Model No. A BHL90 20 30

HL120 7 20.38HL160 18 29.75HL200 7 21.50HL250 16 28HL300 7 21.25HL400 8 22.25HL500 20 34.75HL600 10 27.50HL800 27 41

Model No. A BHL1000 14.5 31.5

HL1200 4 23.75HL1500 6 23.25HL1800 31.50 45.75HL2100 22 38.5HL2700 6 26HL3300 16.25 5.25HL4000 7.75 29HL5000 9 28

Tolerance = +/- .50

MODEL

No.

LB. AA -40C

DRYERS

LB. AA -100C

DRYERS

LB. MS -100C

DRYERS

HL90 100 75 25HL120 134 101 34HL160 192 144 48HL200 236 177 59HL250 290 218 73HL300 344 258 86HL400 470 353 118HL500 638 479 160HL600 748 561 187HL800 900 675 225

HL1000 1100 825 275

HL1200 1270 953 318HL1500 1600 1200 400HL1800 2000 1500 500HL2100 2340 1755 585HL2700 2928 2196 732HL3300 3800 2850 950HL4000 4226 3200 1026HL5000 5138 3850 1288

AA = ACTIVATED ALUMINA NOTE: Qty. is per dryerMS = MOLECULAR SIEVE

DESCRIPTION PART #ACTIVATED ALUMINA QTY. (1) 50 LB. BAG 38004834ACTIVATED ALUMINA QTY. (42) 50 LB. BAGS 38004933ACTIVATED ALUMINA QTY. (1) 2000 LB. SACK 38340659MOLECULAR SIEVE QTY. (1) 275 LB. DRUM 38449971

DESICCANT FILL CHART



23/48


Refer to maintenance descriptions in Section 11as required for trouble shooting procedures.

PROBLEM PROBABLE CAUSE CORRECTIVE ACTIONElevated dew point Insufficient purge rate Check purge ow settings.

Check purge piping for obstruction.Clean purge piping and muffler.

Inlet air pressure below design condition. Check pressure source and system for leakage.Flow rate higher than design condition. Check ow rate and cause for increased demand.

Correct ow rate condition.Inlet temperature above design condition(120F).

Check aftercooler, clean and service as necessary.

Entrained water entering desiccant bed. Check air/moisture separator and pre-lter. Replace dryerdesiccant if necessary.

Desiccant contaminated by oil. Install suitable pre-lter. Replace dryer desiccant.Blue Moisture Indicator(BMI) indicates highmoisture level.

Elevated dew point Refer to Elevated Dew Point corrective actions above.BMI wet Depending on degree of saturation of the desiccant, the BMI may

take a week or more of continuous use to switch back to its blue(dry) state.

Excessive pressure dropin dryer

Excessive ow rate. Check ow rate and cause for increased air demand.

Inlet pressure below design condition . Check pressure source.

Failure to Shift (SwitchingFailure)

No input power Check power input.Defective solenoid valve Check solenoid valve.No pilot air Check pilot air line. Check that control air line lter is clean.Pilot-operated diaphragm valve seal failure Inspect and replace seals as required.

Dryer fails to pressurize. Faulty purge valve Check that repressurization circuit is sending controlsignal.Check purge valve and its solenoid valve.

Dryer depressurizes toorapidly.

Purge valve does not close; dryerrepressurizing through inlet valve.

Check purge valve and its solenoid valve.

Dryer fails to purge. Purge valve does not open. Purge valve stuck

in closed position.

Check purge valve and its solenoid valve. Repair and

replace if necessary.Check that repressurization circuit is sending control signal.Excessive back pressurein regenerating tower(above 5 psig)

Purge muffler does not pass air. Purge muffler is dirty; replace.

Purge muffler passes too much air. Air isleaking across valve.

Check inlet valve and outlet check valves. Verify inlet valve isclosed to purging tower (0 psig tower).

Right tower excessivelyhigh pressure at the purgegauge.

Improper calibration. Reset when right tower is on line.

12.0 TROUBLESHOOTING


24/48



Purge Orifice - 5/32"HL120 Setting - 53 psig @ 19 SCFM

02

46

810

1214

16182022

0 10 20 30 40 50 60 70

Purge Meter Setting - psig

P u r g e

A i r F l o w -

S C F M


0

5

10

15

20

25

30

35

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w

- S C F M


0

5

10

15

20

2530

35

40

45

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w - S

C F M


05

1015202530354045505560

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F M


05

10152025303540455055606570

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F M

P u r g e

A i r F l o w

S C F M


0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F M

0

2

4

6

8

10

12

14

16

0 10 20 30 40 50 60 70

Purge Orifice -9/64"HL90 Set t ing - 65 ps ig @ 14 SCFM


13.0 PURGE CHARTS


25/48


Purge Orifice - 3/8" HL500 Setting - 35 psig @ 81 SCFM

0102030405060708090

100110120130

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F

M


0102030405060708090

100110120130

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F

M

Purge Orifice - 7/16"

HL800 Setting - 46 psig @ 130 SCFM

0

20

40

60

80

100

120

140

160

180

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F M


0

20

40

60

80

100

120

140

160

180

200

220

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F M


0

30

60

90

120

150

180

210

240

270

300

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F M


0306090

120150180

210240270300330360

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w -

S C F M

13.0 PURGE CHARTS


26/48




0306090

120150180210240

270300330360

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w - S

C F M


0

50

100

150

200

250

300350

400

450

500

0 10 20 30 40 50 60 70


P u r g e

A i r F l o w - S

C F M


0

50

100

150

200

250

300

350

400

450

500

0 10 20 30 40 50 60 70



P u r g e

A i r F l o w -

S C F M

P u r g e

A i r F l o w -

S C F M

P u r g e

A i r F l o w -

S C F M

0

10 0

20 0

30 0

40 0

50 0

60 0

70 0

0 10 20 30 40 50 60 70

Purge Orifice- 7/8"HL3300 Set ting- 4 7 p s ig @ 5 3 5 SC F M

0

10 0

20 0

30 0

40 0

50 0

60 0

70 0

80 0

90 0

0 10 20 30 40 50 60 70

Purge Or i f i ce -1"HL4000 Sett ing - 4 4 p s ig @ 6 4 9 SC F M

0

10 0

20 0

30 0

40 0

50 0

60 0

70 0

80 0

90 0

0 10 20 30 40 50 60 70

P u r g e

A i r

F l o w -

S C F M

Purge Or i f ice -1"HL5000Se t ti ng -56 p s ig @ 811 SCFM



13.0 PURGE CHARTS


27/48


G E N E R A L A R R A N G E M E N T

H L 9 0 - H L 1 2 0

5 8 0 0 0 0

- G

14.0 GENERAL ARRANGEMENT


28/48




H L 1 6 0

- H L 2 0 0

5 8 0 0 0 1

- E



29/48



H L 2 5 0

- H L 3 0 0

5 8 0 0 0 2

- F



30/48




H L 4 0 0

5 8 0 0 0 3

- E



31/48



H L 5 0 0

- H L 6 0 0

5 8 0 0 0 4

- E



32/48




H L 8 0 0

- H L 1 2 0 0

5 8 0 0 0 5

- G



33/48



H L 1 5 0 0

5 8 0 0 0 6

- F



34/48



G E N E R A L A R R A N

G E M E N T

H L 1 8 0 0 - H L 2 1 0 0

5 8 0 0 2 9

- E



35/48



H L 2 7 0 0

5 8 0 0 0 7

- F



36/48




H L 3 3 0 0 - H L 4 0 0 0

5 8 0 0 9 2

- F



37/48


G E N E R A L A R R A N

G E M E N T

H L 5 0 0 0

5 8 0 3 0 6

- C



38/48



W I R I N G D I A G R A M

H L 9 0 - H L 5 0 0 0

T M - 5

8 0 0 7 8 - C

15.0 WIRING DIAGRAM


39/48


F L O W

D I A G R A M

H L 9 0 - H L 2 7 0 0

5 8 0 0 2 2

- E

16.0 FLOW DIAGRAM


40/48


41/48


DESCRIPTION HL901H00AAHL1201H00

AAHL1601H00

AAHL2001H00

AAHL2501H00

AAQTY/UNIT

SPARES1 2 3

BLUE MOISTURE INDICATOR 705001-SP 705001-SP 705001-SP 705001-SP 705001-SP 1DESICCANT, 4-8mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1DISPLAY BOARD, PANEL 633653 633653 633653 633653 633653 1DRYER CONTROLLER, TYPE 4 WITHDESICCANT PROGRAM (Dryermodel and serial number mustbe provided with order to ensureproper conguration.)

800030 800030 800030 800030 800030

ELEMENT, PILOT AIR FILTER Refer to page 45 for Pilot Air Filter Element Section 1 1 1 2ELEMENT, PRE-FILTER 105 SCFM 85565679 - - - -ELEMENT, PRE-FILTER 125 SCFM - 85565711 - - - 1 1 1ELEMENT, PRE-FILTER 233 SCFM - - 85565752 85565752 - 1 1 1 2ELEMENT, PRE-FILTER 250 SCFM - - - - 85565794 1 1 1ELEMENT, POST-FILTER 105 SCFM 85565661 - - - - 1 1 1ELEMENT, POST-FILTER 125 SCFM - 85565703 - - - 1 1 1ELEMENT, POST-FILTER 233 SCFM - - 85565745 85565745 - 1 1 1 2ELEMENT, POST-FILTER 250 SCFM - - - - 85565786 1 1 1

GAUGE, PURGE/TOWER PRESSURE2 1/2 680572 680572 680572 680572 680572 3

MUFFLER, PURGE, 1/2 680619 680619 - - - 2MUFFLER, PURGE, 1 - - 680454 680454 680454 2OVERLAY, CONTROLLER 634086 634086 634086 634086 634086 1POWER SUPPLY, 5V/24VDC 633665-SP 633665-SP 633665-SP 633665-SP 633665-SP 1 1 1 1RESISTOR, 5V LOAD, 200 OHM 683968 683968 683968 683968 683968 1RETAINER, DESICCANT SCREENASSEMBLY 705604-SP 705604-SP 705604-SP 705180-SP 705180-SP 4

VALVE, DIAPHRAGM, 1 P.O.N.O. 630721 630721 - - - 2VALVE, DIAPHRAGM, 1 1/2 P.O.N.O. - - 630725 630725 630725 2VALVE, DIAPHRAGM, 2 P.O.N.O. - - - - - 2VALVE, DIAPHRAGM, 3/4 P.O.N.C 630569 630569 - - - 2VALVE, DIAPHRAGM, 1 P.O.N.C. - - 630725 630725 630725 2VALVE, BALL, CONTROL AIR, 1/4 681621 681621 681621 681621 681621 1VALVE, BALL, PURGE, 1/2 680029 680029 680029 680029 - 1VALVE, BALL PURGE, 3/4 - - - - 680429 1VALVE, CHECK, PURGE, 1/2 AD0510 AD0510 AD0510 AD0510 - 2VALVE, CHECK, PURGE, 3/4 - - - - AD0515 2VALVE, CHECK, FLOW, 1 632790 632790 632790 - - 2VALVE, CHECK, FLOW, 1 1/2 - - - 632791 632791 2VALVE, SAFETY/RELIEF 1/4 630730 630730 630730 630730 630730 2VALVE, SOLENOID, CONTROL AIR,24VDC MINI 633658 633658 633658 633658 633658 1

NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.

Spare. Quantities under this heading reect the number of each item which we recommend be kept on hand formaintenance or repair. The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.

Class Quantity Suggested for

1 Minimum Domestic service where interruptions in service are acceptable.2 Average Domestic service where some interruptions in service are acceptable.3 Maximum Export service or for domestic service where interruptions in service are unacceptable.

17.0 REPLACEMENT PARTS


42/48



DESCRIPTIONHL3001H00

AAHL4001H00

AAHL5001H00

AAHL6001H00

AAHL8001H00

AAQTY/UNIT

SPARES1 2 3

BLUE MOISTURE INDICATOR 705001-SP 705001-SP 705001-SP 705001-SP 705001-SP 1DESICCANT, 4-8mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1DISPLAY BOARD, PANEL 633653 633653 633653 633653 633653 1DRYER CONTROLLER, TYPE 4 WITHDESICCANT PROGRAM (Dryermodel and serial number must beprovided with order to ensure properconguration.)

800030 800030 800030 800030 800030 1

ELEMENT, PILOT AIR FILTER Refer to page 45 for Pilot Air Filter Element Section 1 1 1 1ELEMENT, PRE-FILTER 339 SCFM 85565836 - - - - 1 1 1 1ELEMENT, PRE-FILTER 466 SCFM - 85565877 - - - 1 1 1 1ELEMENT, PRE-FILTER 580 SCFM - - 85565919 - - 1 1 1 1ELEMENT, PRE-FILTER 680 SCFM - - - 85565968 - 1 1 1 1ELEMENT, PRE-FILTER 900 SCFM - - - - 85565992 1 1 1 1ELEMENT, POST-FILTER 339 SCFM 85565828 - - - - 1 1 1 1ELEMENT, POST-FILTER 466 SCFM - 85565869 - - - 1 1 1 1ELEMENT, POST-FILTER 580 SCFM - - 85565901 - - 1 1 1 1ELEMENT, POST-FILTER 680 SCFM - - - 85565950 - 1 1 1 1ELEMENT, POST-FILTER 900 SCFM - - - - 85565984 1 1 1 1GAUGE, PURGE/TOWER PRESSURE 2 1/2 680572 680572 680572 680572 - 3GAUGE, PURGE/TOWER PRESSURE 3 1/2 - - - - 631324 3MUFFLER, PURGE, 1 MPT 680454 680454 680454 680454 - 2 2 2 2MUFFLER, PURGE, 1 1/2 - - - - 680711 2 2 2 2OVERLAY, CONTROLLER 634086 634086 634086 634086 634086 1POWER SUPPLY, 5V/24VDC 633665-SP 633665-SP 633665-SP 633665-SP 633665-SP 1 1 1 1RESISTOR, 5V LOAD, 200 OHM 683968 683968 683968 683968 683968 1RETAINER, DESICCANT SCREENASSEMBLY 705180-SP - 705180-SP 705180-SP - 4RETAINER, DESICCANT SCREENASSEMBLY 2 - 704972-SP - - - 4RETAINER, DESICCANT SCREENASSEMBLY 3 X 2 - - 725195-SP 725195-SP - 4RETAINER, DESICCANT SCREENASSEMBLY 3 - - - - 725139-SP 4

VALVE, DIAPHRAGM, 1 P.O.N.C. 630575 630575 630575 630575 - 2VALVE, DIAPHRAGM, 1 1/2 P.O.N.C. - - - - 630572 2VALVE, DIAPHRAGM, 2 P.O.N.O. 633667 633667 633667 633667 - 2VALVE, DIAPHRAGM, 3 P.O.N.O. - - - - 631478 2VALVE, BALL, CONTROL AIR, 1/4 681621 681621 681621 681621 681621 1VALVE, BALL, PURGE ADJUST, 3/4 680429 680429 680429 680429 - 1VALVE, BALL, PURGE ADJUST, 1 1/2 - - - - 680712 1VALVE, CHECK, PURGE, 3/4 AD0515 AD0515 AD0515 AD0515 - 2VALVE, CHECK, PURGE, 1 1/2 - - - - 683983 2VALVE, CHECK, FLOW, 1 1/2 632791 - - - -VALVE, CHECK, FLOW, 2 - 632792 632792 632792 - 2VALVE, CHECK, FLOW, 3 - - - - 632794 2VALVE, SAFETY/RELIEF 1/4 630730 630730 630730 630730 - 2VALVE, SAFETY/RELIEF 1/2 - - - - 680896 2VALVE, SOLENOID 24VDC MINI 633658 633658 633658 633658 633658 1NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.Spare . Quantities under this heading reect the number of each item which we recommend be kept on hand formaintenance or repair. The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.





43/48



AAHL15001H00

AAHL18001H00

AAHL21001H00

AAQTY/UNIT

SPARES1 2 3

BLUE MOISTURE INDICATOR 705001-SP 705001-SP 705001-SP 705001-SP 705001-SP 1DESICCANT, 4-8mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1DISPLAY BOARD, PANEL 633653 633653 633653 633653 633653 1DRYER CONTROLLER, TYPE 4 WITHDESICCANT PROGRAM (Dryermodel and serial number mustbe provided with order to ensureproper conguration.)

800030 800030 800030 800030 800030 1

ELEMENT, PILOT AIR FILTER Refer to page 45 for Pilot Air Filter Element Section 1 1 1ELEMENT, PRE-FILTER 1070 SCFM 85566230 - - - - 1 1 1ELEMENT, PRE-FILTER 1250 SCFM - 85566248 - - - 1 1 1ELEMENTS, PRE-FILTER 1800 SCFM - - 38446357 38446357 - 3 3 3ELEMENTS, PRE-FILTER 2400 SCFM - - - - 38446357 4 4 4ELEMENT, POST-FILTER 1070 SCFM 85566214 - - - - 1 1 1ELEMENT, POST-FILTER 1250 SCFM - 85566222 - - - 1 1 1ELEMENT, POST-FILTER 1800 SCFM - - 23553357 23553357 3 3 3ELEMENT, POST-FILTER 2400 SCFM - - 23553357 4 4 4GAUGE, PURGE/TOWER PRESSURE3 1/2 631324 631324 631324 631324 631324 3

MUFFLER, PURGE, 1 1/2 680711 680711 - - - 2 2 2 2MUFFLER, PURGE, 2 - - 680455 680455 680455 2 2 2 2OVERLAY, CONTROLLER 634086 634086 634086 634086 634086 1POWER SUPPLY, 5V/24VDC 633665-SP 633665-SP 633665-SP 633665-SP 633665-SP 1 1 1 1RESISTOR, 5V LOAD, 200 OHM 683968 683968 683968 683968 683968 1RETAINER, SCREEN ASSEMBLY 3 725139-SP 725139-SP - - - 4RETAINER, SCREEN ASSEMBLY 4 - - 725140-SP 725269-SP 725269-SP 4VALVE, DIAPHRAGM,1 1/2 P.O.N.C. 630572 630572 - - - 2VALVE, DIAPHRAGM, 2 P.O.N.C. - - 633701 633701 633701 2VALVE, DIAPHRAGM, 3 P.O.N.O. 631478 631478 - - - 2VALVE, DIAPHRAGM, 4 P.O.N.O. - - 630406 630406 630406 2VALVE, BALL, CONTROL AIR, 1/4 681621 681621 681621 681621 681621 1VALVE, BALL, PURGE ADJUST, 11/2 680712 680712 680712 680712 680712 1

VALVE, BALL, PURGE ADJUST, 2 - - - - - 1VALVE, CHECK, PURGE, 1 1/2 683983 683983 683983 683983 683983 2VALVE, CHECK, FLOW, 3 632794 632794 632794 632794 632794 2VALVE, SAFETY/RELIEF 1/2 680896 680896 680896 - - 2VALVE, SAFETY/RELIEF 3/4 - - - AD1415 AD1415 2

VALVE, SOLENOID 24VDC MINI 633658 633658 633658 633658 633658 1NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.Spare . Quantities under this heading reect the number of each item which we recommend be kept on hand formaintenance or repair. The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.





44/48




AAHL40001H00

AAHL50001H00

AAQTY/UNIT

SPARES1 2 3

BLUE MOISTURE INDICATOR 705001-SP 705001-SP 705001-SP 705001-SP 1DESICCANT, 4-8mm GRADE D NOTE 1 NOTE 1 NOTE 1 NOTE 1 NOTE 1DISPLAY BOARD, PANEL 633653 633653 633653 633653 1DRYER CONTROLLER, TYPE 4 WITHDESICCANT PROGRAM (Dryer model and

serial number must be provided withorder to ensure proper conguration.)

800030 800030 800030 800030 1

ELEMENT, PILOT AIR FILTER Refer to page 45 for Pilot Air Filter Element Section 1 1 1 1ELEMENT, PRE-FILTER 3000 SCFM 38446357 - - - 5 5 5 5ELEMENT, PRE-FILTER 3600 SCFM - 38446357 - - 6 6 6 6ELEMENT, PRE-FILTER 4200 SCFM - - 38446357 - 7 7 7 7ELEMENT, PRE-FILTER 6000 SCFM - - - 38446357 10 10 10 10ELEMENT, POST-FILTER 3000 SCFM 23553357 - - - 5 5 5 5ELEMENT, POST-FILTER 3600 SCFM - 23553357 - - 6 6 6 6ELEMENT, POST-FILTER 4200 SCFM - - 23553357 - 7 7 7 7ELEMENT, POST-FILTER 6000 SCFM - - - 23553357 10 10 10 10GAUGE, PURGE/TOWER PRESSURE 3 1/2 631324 631324 631324 631324 3MUFFLER, PURGE, 2 680455 680455 680455 680455 2 2 2 2OVERLAY, CONTROLLER 634086 634086 634086 634086 1POWER SUPPLY, 5V/24VDC 633665-SP 633665-SP 633665-SP 633665-SP 1 1 1 1RESISTOR, 5V LOAD, 200 OHM 683968 683968 683968 683968 1RETAINER, SCREEN ASSEMBLY 4 725269-SP - - - 4RETAINER, SCREEN ASSEMBLY 6 - 725151-SP 725151-SP 725151-SP 4VALVE, DIAPHRAGM, 2 P.O.N.C. 633701 - - - 2VALVE, DIAPHRAGM, 3/ 4 P.O.N.O. - 630622 630622 - 2VALVE, DIAPHRAGM, 1 P.O.N.O. - - - 630721 2VALVE, DIAPHRAGM, 4 P.O.N.O. 630406 - - - 2VALVE, BUTTERFLY, 3 - 632170 632170 632170 2VALVE, BUTTERFLY, 6 - 632172 632172 632172 2VALVE, BALL, CONTROL AIR, 1/4 681621 681621 681621 681621 1VALVE, BALL, PURGE ADJUST, 2 680466 680466 680466 680466 1VALVE, CHECK, PURGE, 2 633943 633943 633943 - 2VALVE, CHECK, PURGE, 3 - - - 634098 2VALVE, CHECK, FLOW, 4 633364 633364 633364 - 2VALVE, CHECK, FLOW, 6 - - - 633365 2VALVE, SAFETY/RELIEF 3/4 AD1415 AD1415 AD1415 AD1415 2VALVE, SOLENOID 24VDC MINI 633658 - - - 4VALVE, SOLENOID 24VDC MINI - 633604 633604 633604 4

NOTE 1: Refer to the Desiccant Fill Chart in the Maintenance section.Spare . Quantities under this heading reect the number of each item which we recommend be kept on hand formaintenance or repair. The appropriate quantity for your application will depend on how critical interruptions in service are to your operation.

Class Quantity Suggested for1 Minimum Domestic service where interruptions in service are acceptable.2 Average Domestic service where some interruptions in service are acceptable.3 Maximum Export service or for domestic service where interruptions in service are unacceptable.



45/48


DIAPHRAGM VALVE REBUILD KITSVALVE DESCRIPTION VALVE PART # * SEAL KIT PART # HARDWARE K

VALVE, DIAPHRAGM, 3/4 P.O.N.C. 630569 630391 631762VALVE, DIAPHRAGM, 1 P.O.N.C. 630575 630391 631762VALVE, DIAPHRAGM, 1-1/2 P.O.N.C. 630572 630392 631763

VALVE, DIAPHRAGM, 2 P.O.N.C. 63370

ingersoll rand dryer o&m manual 80442833-en

Documents