Ingersoll-Rand HB series Troubleshooting Manual

Brand: Ingersoll-Rand

Model: HB series

Type: Troubleshooting Manual

This manual is also suitable for

Rev 3, November 2011

The following manual contains various guides for IR technical personnel troubleshooting the IR desiccant dryers models HL-EH-HB.

SAFETY AND OPERATION PRECAUTIONS

Because an air dryer is pressurized and contains rotating parts, the same precautions should be observed as with any piece of machinery

of this type where carelessness in operation or maintenance could be hazardous to personnel. In addition to obvious safety rules that

should be followed with this type of machinery, safety precautions as listed below must be observed:

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

2. Read all instructions completely before operating unit.

3. Pull main electrical disconnect switch and disconnect any separate control lines, if used, before attempting to work or perform

maintenance on the unit.

4. Do not attempt to service any part while machine is in an operational mode.

5. Do not attempt to remove any parts without first relieving the entire air system of pressure.

6. Do not operate the dryer at pressures in excess of its rating.

7. Do not operate the dryer without guards, shields and screen in place.

8. Inspect unit daily to observe and correct any unsafe operating conditions.

The following warnings are located on the dryer to warn of various hazards.

OSHA

Heading Descriptions

WARNING

“Warning” is used to indicate a hazardous situation which has some probability of death or severe injury. Warning should not be

considered for property damage accidents unless personal injury risk is present.

“Caution” is used to indicate a hazardous situation which may result in minor or moderate injury.

“Notice” is used to indicate a statement of company policy as the message relates directly or indirectly to the safety of personnel or

protection of property. Notice should not be associated directly with a hazard or hazardous situation and must not be used in place of

“Danger,” “Warning,” or “Caution.”

NOTICE

The user of any air dryer manufactured by Ingersoll Rand, is hereby warned that failure to follow the above Safety and Operation

Precautions may result in personal injury or equipment damage. However, Ingersoll Rand does not state as fact, nor does it mean to

imply, that the preceding list of Safety and Operating Precautions is all inclusive, and further, that the observance of this list will prevent

all personal injury or equipment damage.

Desiccant DPC Controller

Checking Inputs/Outputs

The DPC controller used on the HL, EH and HB Desiccant dryers communicates with an Expansion

Adapter so the controller can have more inputs and outputs. If you experience problems with an output

that goes to a component on the dryer you can press and hold the i button on the controller for 5 seconds

and this will allow you to access the software data table in the controller. By using the following

instructions you can see which inputs or outputs are on or off. Example: the blower output is on in the

data table but the expansion module is output is off (blower not running but should be), this indicates that

either the cable or the expansion module is bad. The expansion adapter when operating normally should

show a green power led light and a green communication led. The expansion module will show a green

led light when operating normally, and any outputs will show red. The expansion module uses relays to

output a signal, if the red indicator light is on but no output to the terminal strip is ON then the module is

bad.

Press and hold i button for five seconds, then press Enter.

Display will show Inputs/Outputs. Press Enter

Display will show I (Inputs)

To toggle between Inputs and Outputs press Set button. When you have made your selection press Enter.

Display will show 000-007, this is the Input or Output addresses inside the controller software. To scroll

up or down press the arrow or set button, there are a total of 255 addresses. Below are the Input and

Output addresses being used in the Desiccant DPC controller that are the most used by service

technicians. When the Input/Output is ON it is indicated by a black block, OFF is indicated by a _ .To exit

this mode press the i button until you return to the main menu. Note: Due to variations in software and

dryer configurations some of these addresses may vary

Controller Inputs

Software Address Physical Address on Controller

0 LT Pressure Switch I0

1 RT Pressure Switch I1

2 Heater HI Temp Switch I2

Controller Outputs

Software Address Physical Address on Controller

0 RT Inlet Valve O0

1 LT Inlet Valve O1

2 RT Purge Valve O2

3 LT Purge Valve O3

4 Heater Contactor O4

5 Remote Alarm O5

Expansion Module Outputs

Software Address Physical Address on Expansion Module

32 Blower 0

33 RT Depress Valve 1

34 LT Depress Valve 2

35 Repress Valve 3

Controller Analog Inputs

Physical inputs (Depends on various options (see machine specific wiring schematic))

AI0 Heater Output Temperature

AI1 Purge Temperature (monitors the purge air out the exhaust to turn the heater off at 190 deg F on

dryers with EMS option).

AI2 Dew Point Transmitter

AI3 Compressor Interlock (used on HL dryers to cycle the dryer on and off with the air compressor)

or Hi Tout (High air Temp Out of dryer (Option))

Setting Date Time on DPC

To set the Date and Time on the DPC press and hold the i button for 5 seconds, then press the set button.

System will appear in the display, press enter. Date and time will appear in the display Press enter to show

the current military time, press enter to set time and enter the current time using the number keys on the

key pad, when through press enter. Press set next to set the date, then enter to change the date using the

keypad numbers, when through press enter to save you selection. To return to the main menu keep

pressing the i button.

How the Dew point sensor works with the DPC

The EMS system has a dew point sensor that is powered by the dual voltage DC power supply located in

the control panel. The sensor power supply voltage should be 24 VDC + or - .05 VDC for proper

operation of the sensor. The sensor “reads” the dew point and sends a 4-20 DC Ma signal to terminal

TB2-18; at this point it is converted to a 0-5 VDC voltage signal because of a 250 Ohm precision resistor

that is grounded through TB2-17 (Note: refer to the model specific wiring for exact terminal numbers).

Troubleshooting Dew Point Problems

The best way to troubleshoot a problem with the dew point sensor is to first remove the probe from the

sample port and observe the reading on the DPC controller. It should start to rise as it is exposed to moist

ambient air, If not check the wiring connections. Most of the time problems with the EMS is either a lose

connections or a bad probe. The best way to determine if the controller is working properly is to source a

0-5 VDC signal to the controller (AN2 + and 0 volt (always refer to machine specific wiring schematic

for correct terminal)) and watch the DPC readout change. If the display does not change then the problem

is in the controller, if it does then check the wiring; resistor or probe because this is where the problem is.

The dew point meter reading can be compared with a known good dew point meter and the reading should

be within 2 or 3 degrees of the reading you are getting on the suspect meter to determine if the probe is

bad. Also Note: The air flow across the dew point probe should be very low, almost to the point that you

can’t feel the air flow out of the sample port. This air flow should be adjusted at the outlet of the sample

port; the inlet valve (if equipped) should be fully open. The tubing going to the sample port should be

stainless steel although copper can be used, never use polymer tubing. See the dew point scaling chart in

this document for more information concerning the dew point probe input to the DPC.

Various Resistors used with the DPC

There are 3 types of resisters used on the DPC controllers and they are as follows.

R1= 10K Ohm resister ¼ watt 1%, This resistor is used as a "pull up" resistor for the thermistors, one for

each temp sensor, installed from signal to ground.

R2 = 200 Ohm ½ watt .5 %, This resistor is used to put a base load on the power supply to ensure that it is

stable and in the regulation range, installed 5v to ground. Power supply voltage should be 5 VDC + or -

.05 volts DC.

R3 = 250 Ohm ¼ watt .01%, This resistor is used to convert the 4-20 Ma signal from the dew point sensor

to a 0-5 VDC signal for the DPC.

The following chart will help convert voltage coming back to the controller from the dew point probe to the dew point that

is displayed on the DPC controller. The DPC will issue alarm (Dew point Sensor Failure) if the voltage is less than

approximately 1.003 since this is the program set point for the alarm (Scaling range for the probe is +68 F to -148 F) . The

controller expects to see a voltage signal from approximately 1.025 VDC to 5 VDC. You will normally see the dew point

sensors fail to the extremely low side -148 and lower so this is why the alarm is setup this way. When checking the DCV

signal from the dew point sensor with your meter, always place your negative lead back the power supply ground and not

the equipment ground.

DESICCANT CONTROLLER OPTIONS

1 On POWERUP shows program version (DD01v01) for 10 sec then shows PRESS ON .

2 Enter TECH MODE (TM) anytime. Press 2+3. To turn enabled optional features ON or OFF.

3 Enter FACTORY MODE (FM) only when OFF. Press 2 then 5 then 3. To enable option features . New controls (July, 2009 and newer) press 2&5 in order to enter FACTORY MODE.

4 Press OFF to execute 30 sec SHUTDOWN SEQUENCE, opens inlet valves, closes purge valves.

5 Press "i" 5 sec to set time, see inputs and outputs. Press "i" several times to exit.

6 Press SELECT DISPLAY to move to next screen.

7 Press ENT (if displayed) to move to alternate screen, such as ALARMS or % TIME.

8 Press BLANK KEY to go back one screen in Customer Mode.

9 Press BLANK KEY at BEGIN TECH MODE to go back to Customer Mode.

10 Press BLANK KEY at BEGIN FACTORY MODE to go back to Customer Mode.

11 Main Displays are RT DRY LT REGEN and STEP 4 TIME 10300 (sec)

12 ALARM LIST; ENT to see last 20 ALARMS, DATE (dd;mm) and TIMES (hh:mm)

13 OPERATING TIMES; ENT to see Operating Hours; No purge hours; Heater Hours

14 If OFF, hit OFF to get back to PRESS ON

Dryer Type DPC Display

FEATURE NAME HL EH HB CUSTOMER Tec Mode Factory Mode ADD HDWRE DESCRIPTION

1 PDP ADJUSTER : -40, -4, 40 std no yes no none Changes cycle length to

change dewpoint; 16 m for -4;

24 m for +40

2 Restart: ZERO or AT FAIL std std std no yes no none On power fail, restart at

beginning (zero) or where

failed.

3 PURGE ADJUST, % Purge Select std no Select % no none Match length of purge to

compressor output.

4 Fail To Shift (FTS) opt opt opt FTS Alarm no yes Pressure switches Alarm if incorrect pressures at

steps 1,4,15,18

5 Dewpoint Temp opt opt opt HH Alarm;

Dewpoint

On/Off; set Select DEW TRANS Dew trans: -100

only plus cell.

Display dewpoint and hi

humidity alarm

6 EMS opt opt opt NO PURGE On/Off; set BRD or DEW

TRANS

DEWTRANS HTLS - midpoint bed with

board; HTD - outlet with

DEWTRANS

7 Hi Humidity (HH) opt opt opt HH Alarm On/Off; set BRD or DEW

TRANS

DEWTRANS Measure outlet dewpoint;

alarm if high

8 COMPRESSOR INTERLOCK std NO PURGE On/Off Enable none Close purge valve when

compressor unloads and

current purge finishes

9 -100 opt opt opt no yes Enable Repress line;

25% Mol Sieve

4 minute NEMA Cycle

10 Primary Operating Mode: HTLS std no yes Select HTLS Heatless cycle

11 Primary Operating Mode: HTD std no yes Select HTD Heated Cycle

12 Primary Operating Mode: BLWR std no yes Select BLWR Blower Cycle

13 High Outlet Temp Alarm (HOT) opt opt On Alarm On/Off; set Enable Thermistor in outlet Display alalrm on high outlet

temp

14 Power Saver (PSV)

(EMS)

opt opt No Purge On/Off Enable; Set Purge out

connection,

thermistor

Terminate purge when heat

comes through bed

15 Cool Sweep opt no On/Off Enable Purge line Add 1 hour of dry purge to

cooldown

16 Dual Mode std std no Select mode Enable none Standard with HTD or BLWR

17 Extended Heating (EXT HTG) opt opt no On/Off Enable DP TRANS plus

PWR SAVER

Extends heating for new dryers

with MLC and PWR Saver

18 PID Heater Control std std HTR Temp HTR Temp

Setpoint

P=200; I = 50; D=

10; PWM = 120

none Smooth operating heater

control

Bergh Desiccant DPC

Cheatsheet_IR Data.xls

10/25/2007

Timing chart and IO TABLE

relay: O0 O2 O1 O3 EO3 E02 E01 O4 EO0

valve config: NO NC NO NC NC NC NC <---------------HL-------------------------------> HB EH/HB

Step function: Rtin RTprg Ltin LTprg Rprs Ltdep Rtdep -100 -40 -4 40 EH HB cool prg htls mode

No Action Pltwr Prtwr V1 V2 V3 V4 V5 V6 V7 HTR BLWR Time Time Time Time Time Time Time Time

1 Open LT Inlet val hi hi O C O CCCCoffoff 333333 3 3

2 Close RT Inlet val hi hi C C O CCCCoffoff 333377 7 3

3 Open RT Depress val hi lo C C O C C C O off off 00001013013040

4 Open RT Purge val/Close RT depress val hi lo C O O CCCCoffoff101 249 429 669 30 9 9 209

5 Turn on blower hi lo C O O CCCCoffon 000001111 0

6 Enable heater (PID function) hi lo C O O CCCConon 000010710 13440 10640 0

7 Enabled: JOG, EMS, PwrSvr, ExtHtg,%prg hi lo C O O CCCConon 0000 - - - 0

8 Disable heater hi lo C O O CCCCoffon 00003420 600 600 0

9 Turn off blower hi lo C O O CCCCoffoff 00000200 0

10 Open RT purge val (Dry Purge - enable JOG) hi lo C O O CCCCoffoff 0000002870 0

11 Close RT purge val (%prg calc) hi hi C C O CCCCoffoff 1 44 44 44 10 10 2 2

12 Open Repress val hi hi C C O C O C C off off 11 0 0 0 169 169 127 44

13 Close Repress val hi hi C C O CCCCoffoff 000011 1 1

14 EMS Standby hi hi C C O CCCCoffoff 111111 1 0

15 Open RT inlet val hi hi O C O CCCCoffoff 333333 3 3

16 Close LT Inlet val hi hi O CCCCCCoffoff 333377 7 3

17 Open LT Depress val lo hi O CCCCOCoffoff 00001013013040

18 Open LT Purge val/Close LT depress val lo hi O C C O C C C off off 101 249 429 669 30 9 9 209

19 Turn on blower lo hi O C C O C C C off on 000001111 0

20 Enable heater (PID function) lo hi O C C O C C C on on 000010710 13440 10640 0

21 Enabled: JOG, EMS, PwrSvr, ExtHtg,%prg lo hi O C C O C C C on on 0000 - - - 0

22 Disable heater lo hi O C C O C C C off on 00003420 600 600 0

23 Turn off blower lo hi O C C O C C C off off 00000200 0

24 Open LT purge val (Dry Purge - enable JOG) lo hi O C C O C C C off off 0000002870 0

25 Close LT Purge val (%prg cal) hi hi O CCCCCCoffoff 1 44 44 44 10 10 2 0

26 Open Repress val hi hi O C C C O C C off off 11 0 0 0 169 169 127 44

27 Close repress val hi hi O C O CCCCoffoff 000011 1 1

28 EMS Standby hi hi O C O CCCCoffoff 111111 1 0

29 Repeat step 1 hi hi O C O CCCCoffoff 000000 0 0

PTLWR= Pressure left tower

PRTWR=Pressure Right Tower

RTin=Right Tower Air Input

RTprg=Right tower purging

Ltin=Left Tower Air Input

LTprg=Left tower purging

Rprs=Right Tower pressurizing

Lprs=Left Tower pressurizing

Ltdep=Left Tower de-pressurizing

Rtdep=Right tower de-pressurizing

EMS=Energy Management System

All times in Seconds

Bergh 10/24/07 Desiccant IR Data.xls

HL Desiccant Air Dryer Re-rate Chart

Dryer Air Flow in SCFM Pressure Correction Factor Temperature Correction Factor Rerated Dryer Capacity in SCFM

800 0.91 0.86 626

Pressure Correction

Inlet Pressure (PSIG)

70 80 90 100 110 120 130 140 150

Correction Factor

0.74 0.82 0.91 1 1.09 1.17 1.26 1.35 1.44

Temperature Correction

Inlet Temp (F)

60 70 80 90 100 105 110 115 120

Correction Factor

1.2 1.15 1.1 1.05 1 0.86 0.74 0.63 0.52

EH and HB Desiccant Air Dryer Re-rate Chart

Dryer Air Flow in SCFM Pressure Correction Factor Temperature Correction Factor Rerated Dryer Capacity in SCFM

800 0.88 0.85 598

Pressure Correction

Inlet Pressure (PSIG)

60 70 80 90 100 110 120 130 140 150

Correction Factor

0.55 0.66 0.79 0.88 1 1.09 1.18 1.26 1.35 1.44

Temperature Correction

Inlet Temp (F)

60 70 80 90 100 105 110 115 120

Correction Factor

1.2 1.15 1.1 1.05 1 0.85 0.69 0..57 0.46

Example:

What is the capacity of an

HL800

psig inlet, and

105°F

inlet?

Dryer Capacity @

I00

psig,

100°F

multiplied by the correction actors

re-rated capacity.

800

scfm

0.91

0.86 = 626

scfm

The

HL800

is suitable for

626

scfm @ 90 psig inlet and

105°F

inlet.

Example:

What is the capacity of an EH800 @ 90 psig inlet, and 105°F inlet

Dryer Capacity @ 100 psig, 100°F multiplied by the correction factors = re-rated capacity

800 scfm x 0.88 x 0.85 = 598 scfm

The EH800 is suitable for 598 scfm @ 90 psig inlet and 105°F inlet.

DPC Control for Heated Dryers

Temperature Probe Resistance Chart

Temp Rnom Temp Rnom Temp Rnom Temp Rnom Temp Rnom Temp Rnom Temp Rnom Temp Rnom Temp Rnom

(°F) (Ohms) (°F) (Ohms) (°F) (Ohms) (°F) (Ohms) (°F) (Ohms) (°F) (Ohms) (°F) (Ohms) (°F) (Ohms) (°F) (Ohms)

100 131,102 145 47,549 192 18,737 231 9,407 271 4,964 317 2,560 364 1,395 411 806.9 458 491.7

101 127,992 146 46,557 193 18,392 232 9,251 272 4,890 318 2,526 365 1,378 412 798 459 486.8

102 124,965 147 45,588 194 18,055 233 9,097 273 4,816 319 2,491 366 1,361 413 789.3 460 481.9

103 122,018 148 44,642 195 17,725 234 8,947 274 4,744 320 2,458 367 1,345 414 780.6 461 477.1

104 119,149 149 43,718 196 17,402 235 8,799 275 4,673 321 2,425 368 1,328 415 772.1 462 472.4

105 116,355 150 42,815 197 17,085 236 8,654 276 4,603 322 2,392 369 1,312 416 763.7 463 467.7

106 113,635 151 41,934 198 16,775 237 8,512 277 4,535 323 2,360 370 1,297 417 755.4 464 463.1

107 110,986 152 41,073 199 16,471 238 8,373 278 4,467 324 2,329 371 1,281 418 747.2 465 458.5

108 108,406 153 40,232 200 16,174 239 8,236 279 4,401 325 2,298 372 1,266 419 739.1 466 454

109 105,894 154 39,411 201 15,883 240 8,102 280 4,336 326 2,267 373 1,250 420 731.1 467 449.6

110 103,447 155 38,608 202 15,597 241 7,970 281 4,272 327 2,237 374 1,236 421 723.2 468 445.2

111 101,063 156 37,824 203 15,318 242 7,841 282 4,209 328 2,208 375 1,221 422 715.4 469 440.8

112 98,741 157 37,058 204 15,044 243 7,714 283 4,147 329 2,179 376 1,206 423 707.7 470 436.5

113 96,479 158 36,310 205 14,776 244 7,589 284 4,087 330 2,150 377 1,192 424 700.2 471 432.3

114 94,275 159 35,579 206 14,514 245 7,467 285 4,027 331 2,122 378 1,178 425 692.7 472 428

115 92,127 160 34,864 207 14,256 246 7,347 286 3,968 332 2,094 379 1,164 426 685.3 473 423.9

116 90,035 161 34,166 208 14,004 247 7,229 287 3,911 333 2,067 380 1,150 427 678 474 419.8

117 87,995 162 33,483 209 13,757 248 7,114 288 3,854 334 2,040 381 1,137 428 670.8 475 415.7

118 86,008 163 32,816 210 13,515 249 7,000 289 3,798 335 2,013 382 1,124 429 663.6 476 411.7

119 84,071 164 32,164 211 13,278 250 6,889 290 3,743 336 1,987 383 1,110 430 656.6 477 407.8

120 82,183 165 31,527 212 13,046 251 6,780 291 3,689 337 1,961 384 1,097 431 649.7 478 403.8

121 80,343 166 30,904 213 12,818 252 6,672 292 3,636 338 1,936 385 1,085 432 642.8 479 400

122 78,549 167 30,295 214 12,595 253 6,567 293 3,584 339 1,911 386 1,072 433 636.1 480 396.1

123 76,801 168 29,700 215 12,376 254 6,464 294 3,533 340 1,887 387 1,060 434 629.4 481 392.4

124 75,096 169 29,117 216 12,162 255 6,362 295 3,483 341 1,862 388 1,047 435 622.8 482 388.6

125 73,433 170 28,548 217 11,951 256 6,263 296 3,433 342 1,839 389 1,035 436 616.3 483 384.9

126 71,812 171 27,992 218 11,746 257 6,165 297 3,384 343 1,815 390 1,023 437 609.8 484 381.3

127 70,231 172 27,448 219 11,544 258 6,069 298 3,336 344 1,792 391 1,012 438 603.5 485 377.7

128 68,690 173 26,915 220 11,346 259 5,974 299 3,289 345 1,769 392 1,000 439 597.2 486 374.1

129 67,186 174 26,395 221 11,152 260 5,881 300 3,243 346 1,747 393 988.6 440 591 487 370.6

130 65,720 175 25,886 222 10,961 261 5,790 301 3,197 347 1,725 394 977.3 441 584.9 488 367.1

131 64,289 176 25,388 223 10,775 262 5,701 302 3,152 348 1,703 395 966.1 442 578.9 489 363.6

132 62,894 177 24,901 224 10,592 263 5,613 303 3,108 349 1,681 396 955.1 443 572.9 490 360.2

133 61,533 178 24,424 225 10,413 264 5,527 304 3,065 350 1,660 397 944.3 444 567 491 356.8

134 60,205 179 23,958 226 10,237 265 5,442 305 3,022 351 1,639 398 933.6 445 561.2 492 353.5

135 58,909 180 23,502 227 10,064 266 5,359 306 2,980 352 1,619 399 923.1 446 555.4 493 350.2

136 57,645 181 23,056 228 9,895 267 5,277 307 2,939 353 1,599 400 912.6 447 549.8 494 346.9

137 56,411 182 22,620 229 9,729 268 5,197 308 2,898 354 1,579 401 902.4 448 544.2 495 343.7

138 55,207 183 22,193 230 9,567 269 5,118 309 2,858 355 1,559 402 892.2 449 538.6 496 340.5

139 54,032 184 21,775 231 9,407 270 5,041 310 2,819 356 1,540 403 882.3 450 533.1 497 337.4

140 52,885 185 21,366 232 9,251 271 4,964 311 2,780 357 1,521 404 872.4 451 527.7 498 334.3

141 51,766 186 20,966 233 9,097 272 4,890 312 2,742 358 1,502 405 862.7 452 522.4 499 331.2

142 50,674 187 20,574 234 8,947 273 4,816 313 2,704 359 1,483 406 853 453 517.1 500 328.1

143 49,607 188 20,191 235 8,799 274 4,744 314 2,667 360 1,465 407 843.6 454 511.9

144 48,566 189 19,816 236 8,654 275 4,673 315 2,631 361 1,447 408 834.2 455 506.8

190 19,448 237 8,512 276 4,603 316 2,595 362 1,429 409 825 456 501.7

191 19,089 238 8,373 277 4,535 317 2,560 363 1,412 410 815.9 457 496.6

Ingersoll-Rand HB series Troubleshooting Manual

Brand: Ingersoll-Rand

Model: HB series

Type: Troubleshooting Manual

This manual is also suitable for

Download PDF

report

Ingersoll-Rand HB series Troubleshooting Manual

This manual is also suitable for

Ingersoll-Rand HB series Troubleshooting Manual

Related papers

Other documents