Ingersoll-Rand HC-3 User manual

Brand: Ingersoll-Rand

Model: HC-3

Category: Electric laundry dryers

Type: User manual

This manual is also suitable for

HC-239

SERIES HC

Heat-of-Compression

Compressed Air Dryer

Models HC-3 – HC-239

IMPORTANT! BEFORE INSTALLING AND

OPERATING THE DRYER, IT IS

RECOMMENDED THAT THIS

MANUAL BE STUDIED AND

CLEARLY UNDERSTOOD.

THIS DRYER IS DESIGNED TO BE

USED ONLY WITH A NON-

LUBRICATED COMPRESSOR. USE

WITH A LUBRICATED

COMPRESSOR WILL VOID ALL

WARRANTIES AND MAY CAUSE

SEVERE DAMAGE.

 Information

When making inquiries,

please provide the following

information:

1) Equipment Model Number

2) Equipment Serial Number

3) Equipment Operating

Pressure

4) Equipment Operating

Temperature

5) Approximate time in

service

6) Nature of Problem

For information, parts,

or service, contact your

local

Service

provider or

reach us at

www.air.irco.com

AIR COMPRESSOR GROUP

BONDED WARRANTY & REGISTERED START UP

Warranty

The Company warrants that the equipment manufactured by it and delivered hereunder will be free of defects in

material and workmanship for a period of twelve months from the date of placing the Equipment in operation

or eighteen months from the date of shipment from the factory, whichever shall first occur. The Purchaser shall be

obligated to promptly report any failure to conform to this warranty, in writing to the Company in said period,

whereupon the Company shall, at its option, correct such nonconformity, by suitable repair to such equipment or,

furnish a replacement part F.O.B. point of shipment, provided the Purchaser has stored, installed, maintained and

operated such Equipment in accordance with good industry practices and has complied with specific

recommendations of the Company. Accessories or equipment furnished by the Company, but manufactured by

others, shall carry whatever warranty the manufacturers have conveyed to the Company and which can be passed

on to the Purchaser. The Company shall not be liable for any repairs, replacements, or adjustments to the

Equipment or any costs of labor performed by the Purchaser or others without Company‘s prior written approval.

The effects of corrosion, erosion and normal wear and tear are specifically excluded. Performance warranties are

limited to those specifically stated within the Company‘s proposal. Unless responsibility for meeting such performance

warranties are limited to specified tests, the Company‘s obligation shall be to correct in the manner and for the period

of time provided above.

THE COMPANY MAKES NO OTHER WARRANTY OR REPRESENTATION OF ANY KIND WHATSOEVER,

EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES OF MERCHANTABILITY

AND FITNESS FOR A PARTICULAR PURPOSE, ARE HEREBY DISCLAIMED.

Correction by the Company of nonconformities whether patent or latent, in the manner and for the period of time

provided above, shall constitute fulfillment of all liabilities of the Company for such nonconformities whether based on

contract, warranty negligence, indemnity, strict liability or otherwise with respect to or arising out of such Equipment.

The purchaser shall not operate Equipment which is considered to be defective, without first notifying the Company

in writing of its intention to do so. Any such use of Equipment will be at Purchaser‘s sole risk and liability.

Note that this is Ingersoll–Rand standard warranty. Any warranty in force at the time of purchase of the equipment or

negotiated as part of the purchase order may take precedence over this warranty.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 2 September 2004

INDEX

PREFACE

SECTION 1: INTRODUCTION

1.1 General Information

1.2 Safety Instructions

1.2.1 Identification of signs and symbols in this manual

1.2.2 Safety tips for maintenance, inspection & assembly work

1.3 Personnel Qualification

1.4 Product Information

1.4.1 Theory of Operation

1.4.2 Pressure vessel regulations

1.4.3 Airtightness test

1.4.4 Overloading

1.4.5 Technical data sheet

1.4.6 Dryer Flow Capacities

1.4.7 Transport

1.4.8 Storage

1.4.9 Use of an afterfilter

SECTION 2: INSTALLATION

2.1 Set-up and installation

2.1.1 Mechanical installation

2.1.2 Filter installation

2.1.3 Electrical installation

SECTION 3: START UP AND OPERATION

3.1 Start-up / Shut down

3.1.1 Pressurizing dryer

3.1.2 Energizing dryer controls

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 3 September 2004

3.2 Operator interface

3.2.1 Main screen

3.2.2 Dryer status

3.2.3 Settings

3.2.4 Alarms

3.3 Program Steps

SECTION 4: MAINTENANCE

4.1 Suggested preventive maintenance schedule

4.2 Replacement / Disposal of the desiccant

4.3 Dewpoint meter maintenance (DPDS Option only)

4.4 Filters

4.4.1 General comments and use

4.4.2 Function

4.4.3 Assembly and installation

4.4.4 Maintenance

4.4.5 Changing of filter elements

4.4.6 Accessories

SECTION 5: SPARE PARTS LIST

5.1 Recommended spares for HC-3 TO HC-239

SECTION 6: TROUBLESHOOTING AND FAULTS

6.1 Introduction

6.2 High Dewpoint

6.3 Fail-to-shift

6.4 Primary Drain Failure

6.5 Secondary Drain Failure

6.6 Short-term shut-down

6.7 Shut-down in case of a fault or for maintenance

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 4 September 2004

SECTION 7: I-R ACTIVATED ALUMINA MSDS

7.1 Company Description

7.2 Material Description

7.3 Ingredients

7.4 Physical Data

7.5 Fire and Explosion Data

7.6 Reactivity Data

7.7 Health Hazard Information

7.8 Spill, Leak, and Disposal Procedures

7.9 Special Protection Information

7.10 Special Precautions and Comments

7.11 References

SECTION 8: AUXILIARY MANUALS & DRAWINGS

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 5 September 2004

PREFACE:

This technical manual from

® is an aid in getting to know the adsorption

dryer better and in utilizing its possibilities for application in accordance with its

intended use. Furthermore, this manual contains important information for safe,

proper and economic operation.

All instructions must be followed as written in order to avoid danger and damages

which could cause downtime and premature wear and tear on the adsorption dryer.

In addition to the technical manual and the accident prevention regulations which are

valid in the particular location where the dryer is being used, the recognized special

rules for safe and proper working procedures must also be followed.

Each person involved with the set-up, start-up, operation, maintenance and repair of

the adsorption dryer in the User Company must have first read and understood the

technical manual and especially the safety tips.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 6 September 2004

SECTION 1:

1.1 GENERAL INFORMATION

The adsorption dryer of the HC-3 – HC-239 series is built according to the latest

technological developments and recognized safety rules. Its use, however, can

endanger life and limb of the user or of third parties and can lead to considerable

damage to the adsorption dryer and other material assets if:

• it is operated by personnel not trained or instructed in its use,

• it is improperly used,

• It is improperly maintained or serviced.

This can result in the loss of all damage claims.

This adsorption dryer is designed for neutral media (gas) free of aggressive water,

oil and solid elements.

® accepts no liability for corrosion damage and

malfunctions caused by aggressive media.

Applications other than those mentioned in this manual must be agreed to by

® and confirmed in writing.

In the interest of further development,

® reserves the right to make

changes at any time, which, in keeping with the essential characteristics of the

adsorption dryer described here, may be necessary for increasing efficiency or for

reasons relating to safety or to normal business practice.

1.2 SAFETY INSTRUCTIONS

This technical manual contains basic tips, which must be followed during set-up,

operation and servicing. It is of utmost importance that it be read by the assembly

technician before installation and start-up, as well as by the specialist / operator in

charge, and it must always be within reach at the place where the adsorption dryer

is being used.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 7 September 2004

SECTION 1: (Continued)

1.2.1 Identification of signs and symbols in this technical manual

The safety tips contained in this technical manual, whose disregard could endanger

people and machines, are indicated by a general danger sign and the additional

markings Danger! Or Attention!

Danger! / Attention!

Warning against electrical voltage!

Safety tips printed directly on the adsorption dryer must also be followed at all times

and must be kept completely legible.

 Advice: This sign refers to a procedure or sequence of particular

interest or importance. All tips must be followed to ensure

proper use of this adsorption dryer.

• This dot refers to working or operational steps. The steps are to be carried out in

the order of their appearance from top to bottom.

- The sign of a hyphen marks enumerations.

1.2.2 Safety tips for maintenance, inspection and assembly work

The operator is to make sure that all maintenance, inspection and assembly work is

carried out by special personnel who are authorized and qualified, and who are

adequately informed through careful study of the technical manual. For this reason,

special attention should be paid to the following attention and danger sign:

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 8 September 2004

SECTION 1: (Continued)

1.2.2 Safety tips for maintenance, inspection and assembly work

(Continued)

Attention!

− Never make structural changes to the adsorption

dryer that are not specifically authorized by

Ingersoll-Rand!

− Only use original spare and accessory parts!

− Carry out maintenance work only when the

adsorption dryer is switched off, depressurized,

and disconnected from the electric power supply!

Attention!

− Multiple power sources may exist in the electrical

panel. All possible power sources must be

disconnected before servicing dryer.

 Advice: Refer to the desiccant material safety data sheet (MSDS) when

installing or disposing of desiccant, which can be found in

Section 7 of this User Manual.

Danger!

Wear protective goggles and mask when working with the desiccant!

 Advice for protection:

− If desiccant comes into contact with the eyes, rinse eyes immediately with large

amounts of clear water.

− If the desiccant is spilled, clean up with effort to minimize the formation of dust.

− In case of fire, there is no restriction on the use of fire extinguishing material.

− A small dust mask must be worn.

1.3 PERSONNEL QUALIFICATION

The personnel involved in operation, maintenance, inspection, and assembly must

have the corresponding qualifications to do this work. Areas of responsibility and

supervision of the personnel must be precisely established by the operator. Should

the personnel not possess the necessary knowledge, then they must be trained and

instructed. If need be, this training may be carried out by the manufacturer / supplier

at the request of the operator of the adsorption dryer. Further, the operator is to

make sure that the personnel completely understand the contents of the technical

manual.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 9 September 2004

SECTION 1: (Continued)

1.4 PRODUCT INFORMATION

The adsorption dryer is used for the purpose of drying compressed air and other

gases according to its respective design. As a "standard model" the adsorption dryer

is equipped with two desiccant vessels and, depending on certain conditions,

provides pure, dry and oil-free compressed air or gases.

1.4.1 Theory of Operation

The HC heat-of-compression dryer uses the hot air from the compressor to

regenerate the desiccant. Each tower is sized for a minimum of 4 hours online,

but may be extended by use of the optional DPDS which will allow the dryer to

switch towers based on water load rather than time.

The DPDS (Dewpoint Demand System) is optional equipment and may or may

not be present on your particular air dryer. If your dryer is equipped with the

DPDS, see the associated DPDS Installation and Operating Guide for more

operational details.

The regeneration cycle is split up into three functions.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 10 September 2004

SECTION 1: (Continued)

A. Regeneration Cycles

1. Heating. Hot air directly from the compressor enters the inlet of the HC

and is directed by the inlet 2-way valves into the regenerating tower. This

hot, thirsty air regenerates the bulk of the water from the desiccant. The

air is then directed into the aftercooler where it is cooled, the coalescing

separator where liquid water is removed through the drain trap system,

then into the drying tower where the air is actually dried to its final low

dewpoint. The heating cycle lasts 90 minutes.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 11 September 2004

SECTION 1: (Continued)

2. Stripping. At the end of heating, the inlet valves shift position, directing

the hot inlet air directly into the aftercooler, separator, and drying tower.

We now begin stripping. The stripping phase of regeneration lasts 90

minutes. At the beginning of stripping, the regenerating tower is

depressurized through a muffler. During stripping, a small adjustable flow

of dry air is used to remove the last little bit of moisture from the

regenerating tower.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 12 September 2004

SECTION 1: (Continued)

3. Cooling. At the end of stripping, the regenerating tower is repressurized.

The cooling cycle valves open and cooling begins. The cooling cycle lasts

60 minutes. During cooling, a portion of the dry outlet air is directed into

the regenerating tower to reduce the temperature of the bed prior to

tower shift.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 13 September 2004

SECTION 1: (Continued)

1.4.2 Pressure vessel regulations

The pressure vessels are designed according to the standard technical

requirements. They fulfill the test of the certifying procedure and carry the “U”,

“UM” ASME Symbol.

Range of Application:

Type HC-3 – HC-239

Operating overpressure

Max. 150 PSIG

Operating Temperature

Max.

Min.

500°F

20°F

Attention!

Never weld on or alter a pressure vessel in any

way!

1.4.3 Airtightness test

All adsorption dryers are subjected to an airtightness test prior to shipment using

compressed air.

1.4.4 Overloading

Attention!

Protect the adsorption dryer from overloads!

The adsorption dryer can become overloaded, if:

− The inlet flow is too high,

− The temperature of the air at the discharge of the

aftercooler is too high,

− The min. operating pressure is too low,

− The temperature of the air at the discharge of the

compressor is too low.

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 14 September 2004

SECTION 1: (Continued)

1.4.5 Technical data sheet

MODEL HC-3 HC-6 HC-7 HC-9

Flow (SCFM) @ 100 PSIG

100°F Drying Temperature

301 535 677 836

Vessel OD – Inches 12 16 18 20

Desiccant type IR Activated Alumina

Lbs. Desiccant / Vessel 223 397 502 620

Inlet connection 2 NPT 2 NPT 3 FLG 3 FLG

Outlet connection 2 NPT 2 NPT 3 FLG 3 FLG

FILTER

• Afterfilter AF-350 AF-550 AF-1000 AF-1000

Voltage 115/1/60 Standard -

Consult Factory for other voltages

Cooling Water GPM 9 16 20 25

Stripping Flow SCFM 6 11 14 17

Cycle time

8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dewpoint Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoints

10 PSI Fail to Shift 60 PSI Initiate Cooling

Cooler outlet high

temperature alarm 105°F

Low regeneration

temperature alarm Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 15 September 2004

SECTION 1: (Continued)

1.4.5 Technical data sheet

MODEL HC-14 HC-21 HC-30 HC-41

Flow (SCFM) @ 100 PSIG

100°F Drying Temperature

1204 1880 2708 3686

Vessel OD – Inches 24 30 36 42

Desiccant type IR Activated Alumina

Lbs. Desiccant / Vessel 893 1395 2009 2735

Inlet connection 3 FLG 4 FLG 4 FLG 6 FLG

Outlet connection 3 FLG 4 FLG 4 FLG 6 FLG

FILTER

• Afterfilter AF-1400 AF-2400 AF-3600 AF-7200

Voltage 115/1/60 Standard -

Consult Factory for other voltages

Cooling Water GPM 36 56 80 110

Stripping Flow SCFM 24 38 54 74

Cycle time

8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dewpoint Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoint

10 PSI Fail to Shift 60 PSI Initiate Cooling

Cooler outlet high

temperature alarm 105°F

Low regeneration

temperature alarm Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 16 September 2004

SECTION 1: (Continued)

1.4.5 Technical data sheet

MODEL HC-54 HC-69 HC-85 HC-103

Flow (SCFM) @ 100 PSIG

100°F Drying Temperature

4814 6093 7522 9101

Vessel OD – Inches 48 54 60 66

Desiccant type IR Activated Alumina

Lbs. Desiccant / Vessel 3572 4521 5581 6753

Inlet connection 6 FLG 6 FLG 8 FLG 8 FLG

Outlet connection 6 FLG 6 FLG 8 FLG 8 FLG

FILTER

• Afterfilter AF-7200 AF-7200 AF-7200 AF-10000

Voltage 115/1/60 Standard -

Consult Factory for other voltages

Cooling Water GPM 143 138 172 208

Stripping Flow SCFM 96 122 150 182

Cycle time

8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dewpoint Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoint

10 PSI Fail to Shift 60 PSI Initiate Cooling

Cooler outlet high

temperature alarm 105°F

Low regeneration

temperature alarm Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 17 September 2004

SECTION 1: (Continued)

1.4.4 Technical data sheet

MODEL HC-122 HC-143 HC-166

Flow (SCFM) @ 100 PSIG

100°F Drying Temperature

10832 12712 14742

Vessel OD – Inches 72 78 84

Desiccant type IR Activated Alumina

Lbs. Desiccant / Vessel 8037 9432 10939

Inlet connection 8 FLG 8 FLG 10 FLG

Outlet connection 8 FLG 8 FLG 10 FLG

FILTER

• Afterfilter AF-16000 AF-16000 AF-16000

Voltage 115/1/60 Standard -

Consult Factory for other voltages

Cooling Water GPM 247 289 335

Stripping Flow SCFM 217 254 295

Cycle time

8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dewpoint Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoint

10 PSI Fail to Shift 60 PSI Initiate Cooling

Cooler outlet high

temperature alarm 105°F

Low regeneration

temperature alarm Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 18 September 2004

SECTION 1: (Continued)

1.4.6 Dryer Flow Capacities

Model Selection Chart:

MODEL 85 PSI 90 PSI 95 PSI 100 PSI 105 PSI 110 PSI 115 PSI

HC-3

262 274 287 301 313 327 342

HC-6

465 486 509 535 557 581 608

HC-7

588 615 645 677 705 735 769

HC-9

726 760 796 836 870 908 950

HC-14

1046 1094 1146 1204 1253 1308 1368

HC-21

1634 1709 1790 1880 1957 2042 2136

HC-30

2353 2462 2578 2708 2819 2941 3076

HC-41

3203 3351 3509 3686 3837 4003 4187

HC- 54

4183 4376 4583 4814 5011 5228 5469

HC-69

5295 5539 5801 6093 6343 6617 6922

HC-85

6537 6837 7161 7522 7830 8169 8545

HC-103

7909 8273 8664 9101 9474 9884 10339

HC-122

9413 9846 10312 10832 11276 11764 12305

HC-143

11047 11555 12102 12712 13233 13805 14441

HC-166

12812 13401 14035 14743 15347 16011 16748

Note: Maximum operating pressure is 150 PSIG; higher pressures available as an option. Consult factory.

Minimum Inlet Pressure (PSIG)

85 90 95 100 105 110 115

Correction Factor

1.15 1.1 1.05 1 .96 .92 .88

CORRECTION FACTOR FOR COOLING WATER TEMPERATURE

TEMPERATURE ºF

75 80 85 90

Correction Factor

.85 .9 1.0 1.2

To correct for a cooling water temperature other than 85°F, or an operating pressure

other than 100 psig, multiply dryer capacity by the correction factors listed above.

Example: To size for an inlet flow of 1300 SCFM @ 90 Psig, using 90

F cooling water:

Multiply 1300 * (1.1) * (1.2) = 1716 Use model HC-21

USER MANUAL

Series HC

Reference No. 145 Final Rev 5 Page 19 September 2004

SECTION 1: (Continued)

1.4.7 Transport

After the adsorption dryer has been delivered, it must be checked for damage that

may have occurred during transport. The Transport Company must be informed to

1.4.8 Storage

If the adsorption dryer is to be stored for a prolonged period of time, it should be

stored in a dry place, preferably indoors; protected from the elements including

freezing or extremely warm temperatures.

1.4.9 Use of a pre and afterfilter

Use of a prefilter is not necessary with a heat-of-compression dryer. An afterfilter

should be provided to prevent desiccant dust from migrating downstream.

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Ingersoll-Rand HC-3 User manual

Brand: Ingersoll-Rand

Model: HC-3

Category: Electric laundry dryers

Type: User manual

This manual is also suitable for

HC-239

Download PDF

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Ingersoll-Rand HC-3 User manual

This manual is also suitable for

Ingersoll-Rand HC-3 User manual

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