Ingersoll-Rand HC-103 User manual

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SERIES HC

Heat-of-Compression

Compressed Air Dryer

Models HC-3 – HC-239

IMPORTANT! BEFORE INSTALLING AND

OPERATING THE DRYER, IT IS

RECOMMENDED THAT THIS

MANUAL BE STUDIED AND

CLEARLY UNDERSTOOD.

THIS DRYER IS DESIGNED TO BE

USED ONLY WITH A NON-

LUBRICATED COMPRESSOR.

USE WITH A LUBRICATED

COMPRESSOR WILL VOID ALL

WARRANTIES AND MAY CAUSE

SEVERE DAMAGE.

 Information

When making inquiries,

please provide the following

information:

1) Equipment Model Number

2) Equipment Serial Number

3) Equipment Operating

Pressure

4) Equipment Operating

Temperature

5) Approximate time in

service

6) Nature of Problem

For information, parts,

or service, contact your

local

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Service provider or

reach us at

www.air.irco.com

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 2 10/17/2013

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 3 10/17/2013

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 a pre and afterfilter

SECTION 2: INSTALLATION

2.1 Set-up and installation

2.1.1 Mechanical installation

2.1.2 Preventative maintenance prior to start-up

2.1.3 Filter installation

2.1.4 Electrical installation

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 4 10/17/2013

SECTION 3: START UP AND OPERATION

3.1 Start-up

3.1.1 Pressurizing dryer

3.2 Operator interface

SECTION 4: MAINTENANCE

4.1 Suggested preventive maintenance schedule

4.1.1 Introduction

4.1.2 Periodic maintenance schedule

4.2 Replacement / Disposal of the desiccant

4.2.1 For first time fill-up

4.2.2 To replace used desiccant

4.3 Dew point meter maintenance (DPDS Option only)

4.4 Afterfilter

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 afterfilter elements

4.5 Filter Accessories

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 5 10/17/2013

SECTION 5: TROUBLESHOOTING AND FAULTS

5.1 Introduction

5.2 High Dew Point

5.2.1 Changed operating conditions

5.2.2 Old desiccant

5.2.3 Towers not reversing

5.2.4 Cooler discharge air temperature too high

5.2.5 Dew point indication in error

5.2.6 Two-way valve leakage

5.3 Fail-to-shift

5.3.1 Solenoid valve failed to operate

5.3.2 Pilot air tubing leakage

5.3.3 Two-way switching valve actuator leakage

5.4 Primary Drain Failure

5.4.1 Plugging or sticking due to foreign matter

5.5 Secondary Drain Failure

5.5.1 Solenoid valve failure

5.5.2 Liquid level probe failure

5.6 Short-term shut-down

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

SECTION 6: SPECIFICATIONS, PARTS LIST(S), & DATA REPORTS

SECTION 7: AUXILIARY MANUALS (IF APPLICABLE)

SECTION 8: CUT SHEETS

SECTION 9: DRAWINGS

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 6 10/17/2013

PREFACE:

This technical manual from

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® 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 IR - 222 Rev 3

Page 7 10/17/2013

SECTION 1

INTRODUCTION

Prior to installation and start-up of this dryer,

please read and implement this section.

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 8 10/17/2013

SECTION 1:

INTRODUCTION

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.

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malfunctions caused by aggressive media.

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

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® and confirmed in writing.

In the interest of further development,

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® 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 IR - 222 Rev 3

Page 9 10/17/2013

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.

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 10 10/17/2013

SECTION 1: (Continued)

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:

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 8 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.

Danger!

Do not attempt to service or maintain dryer while system is hot!

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 11 10/17/2013

SECTION 1: (Continued)

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.

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 (Dew Point Demand System) is optional equipment and may or may

not be present on this particular air dryer. If the dryer is equipped with the DPDS,

see the associated DPDS Instruction Manual included in Section 7 for more

operational details.

The regeneration cycle is split up into three functions.

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 12 10/17/2013

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

dew point. The heating cycle lasts 90 minutes.

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 13 10/17/2013

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. If dryer is equipped with optional trim heater,

reference operational instructions in Addendum at back of manual.

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 14 10/17/2013

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 IR - 222 Rev 3

Page 15 10/17/2013

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

10.34 Bar(g)

Operating temperature

Max.

Min.

500°F

260°C

20°F

-6.67°C

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 IR - 222 Rev 3

Page 16 10/17/2013

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

(m3/hr) @ 6.89Bar(g)

37.8°C Drying Temperature

301

511

535

909

677

1150

836

1420

Vessel OD 12”

30.48 cm

16”

40.64 cm

18”

45.72 cm

20”

50.8 cm

Desiccant type IR Activated Alumina

Desiccant / Vessel 223 lbs

101 kgs

397 lbs

180 kgs

502 lbs

228 kgs

620 lbs

281 kgs

Inlet connection 2 NPT 2 NPT 3 FLG 3 FLG

Outlet connection 2 NPT 2 NPT 3 FLG 3 FLG

Afterfilter

(* Option)

AF-350

or AFH-350*

AF-550

or HAF-550*

AF-1000

or HAF-1000*

AF-1000

or HAF-1000*

Voltage 115/1/60 Standard

Consult Factory for other voltages

Cooling Water 9 GPM

34 LPM

16 GPM

61 LPM

20 GPM

76 LPM

25 GPM

95 LPM

Stripping Flow 6 SCFM

10 m3/hr

11 SCFM

19 m3/hr

14 SCFM

24 m3/hr

17 SCFM

29 m3/hr

Cycle time 8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dew Point Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoints 10 PSI Fail to Shift 60 PSI Initiate Cooling

.7 Bar Fail to Shift 4 Bar Initiate Cooling

Cooler outlet high temperature

alarm

105F

40.6°C

Low regeneration temperature

alarm

Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 17 10/17/2013

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

(m3/hr) @ 6.89Bar(g)

37.8°C Drying Temperature

1204

2046

1880

3194

2708

4601

3686

6263

Vessel OD 24”

60.96 cm

30”

76.2 cm

36”

91.44 cm

42”

106.7 cm

Desiccant type IR Activated Alumina

Desiccant / Vessel 893 lbs

405 kgs

1395 lbs

633 kgs

2009 lbs

911 kgs

2735 lbs

1241 kgs

Inlet connection 3 FLG 4 FLG 4 FLG 6 FLG

Outlet connection 3 FLG 4 FLG 4 FLG 6 FLG

Afterfilter

(* Option)

AF-1400

or HAF-1400*

AF-2400

or HAF-2400*

AF-3600

or HAF-3600*

AF-7200

or HAF-7200*

Voltage 115/1/60 Standard

Consult Factory for other voltages

Cooling Water 36 GPM

136 LPM

56 GPM

212 LPM

80 GPM

303 LPM

110 GPM

416 LPM

Stripping Flow 24 SCFM

41 m3/hr

38 SCFM

65 m3/hr

54 SCFM

92 m3/hr

74 SCFM

126 m3/hr

Cycle time 8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dew Point Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling

.7 Bar Fail to Shift 4 Bar Initiate Cooling

Cooler outlet high temperature

alarm

105F

40.6°C

Low regeneration temperature

alarm

Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 18 10/17/2013

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

(m3/hr) @ 6.89Bar(g)

37.8°C Drying Temperature

4814

8179

6093

10352

7522

12780

9101

15463

Vessel OD 48”

121.9 cm

54”

137.2 cm

60”

152.4 cm

66”

167.6 cm

Desiccant type IR Activated Alumina

Desiccant / Vessel 3572 lbs

1620 kgs

4521 lbs

2051 kgs

5581 lbs

2531 kgs

6753 lbs

3063 kgs

Inlet connection 6 FLG 6 FLG 8 FLG 8 FLG

Outlet connection 6 FLG 6 FLG 8 FLG 8 FLG

Afterfilter

(* Option)

AF-7200

or HAF-7200*

AF-7200

or HAF-7200*

AF-7200

or HAF-7200*

AF-10000

or HAF-10000*

Voltage 115/1/60 Standard

Consult Factory for other voltages

Cooling Water 143 GPM

541 LPM

138 GPM

572 LPM

172 GPM

651 LPM

208 GPM

787 LPM

Stripping Flow 96 SCFM

163 m3/hr

122 SCFM

207 m3/hr

150 SCFM

255 m3/hr

182 SCFM

309 m3/hr

Cycle time 8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dew Point Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling

.7 Bar Fail to Shift 4 Bar Initiate Cooling

Cooler outlet high temperature

alarm

105F

40.6°C

Low regeneration temperature

alarm

Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 19 10/17/2013

SECTION 1: (Continued)

1.4.5 Technical data sheet

MODEL HC-122 HC-143 HC-166

Flow:

(SCFM) @ 100 PSIG

100°F Drying Temperature

(m3/hr) @ 6.89Bar(g)

37.8°C Drying Temperature

10832

18404

12712

21598

14742

25047

Vessel OD 72”

182.9 cm

78”

198.12 cm

84”

213.36 cm

Desiccant type IR Activated Alumina

Desiccant / Vessel 8037 lbs

3646 kgs

9432 lbs

4278 kgs

10939 lbs

4962 kgs

Inlet connection 8 FLG 8 FLG 10 FLG

Outlet connection 8 FLG 8 FLG 10 FLG

Afterfilter

(* Option)

AF-16000

or HAF-16000*

AF-16000

or HAF-16000*

AF-16000

or HAF-16000*

Voltage 115/1/60 Standard

Consult Factory for other voltages

Cooling Water 247 GPM

935 LPM

289 GPM

1094 LPM

335 GPM

1268 LPM

Stripping Flow 217 SCFM

627 m3/hr

254 SCFM

734 m3/hr

295 SCFM

851 m3/hr

8 Hour NEMA Cycle –

4 Hours drying/ 4 Hours Regeneration

Outlet Dew Point Variable

DPDS Control Adjustable

High Humidity Alarm Adjustable

Pressure Switch Setpoint 10 PSI Fail to Shift 60 PSI Initiate Cooling

.7 Bar Fail to Shift 4 Bar Initiate Cooling

Cooler outlet high temperature

alarm

105F

40.6°C

Low regeneration temperature

alarm

Adjustable

Process flow Downward Regeneration / Upward Drying

USER MANUAL

Series HC

Reference IR - 222 Rev 3

Page 20 10/17/2013

SECTION 1: (Continued)

1.4.6 Dryer Flow Capacities

Model Selection Chart:

MODEL

PSI:

Bar:

85

5.86

90

6.2

95

6.55

100

6.9

105

7.24

110

7.58

115

7.93

HC-3

SCFM:

Nm3/h:

262

421

274

441

287

461

301

484

313

503

327

526

342

550

HC-6

SCFM:

Nm3/h:

465

748

486

781

509

818

535

860

557

896

581

934

608

978

HC-7

SCFM:

Nm3/h:

588

945

615

989

645

1037

677

1088

705

1133

735

1182

769

1236

HC-9

SCFM:

Nm3/h:

726

1167

760

1222

796

1280

836

1344

870

1399

908

1460

950

1527

HC-14

SCFM:

Nm3/h:

1046

1682

1094

1759

1146

1842

1204

1936

1253

2014

1308

2103

1368

2199

HC-21

SCFM:

Nm3/h:

1634

2627

1709

2748

1790

2878

1880

3023

1957

3146

2042

3283

2136

3434

HC-30

SCFM:

Nm3/h:

2353

3783

2462

3958

2578

4145

2708

4354

2819

4532

2941

4728

3076

4945

HC-41

SCFM:

Nm3/h:

3203

5150

3351

5388

3509

5642

3686

5926

3837

6169

4003

6436

4187

6732

HC- 54

SCFM:

Nm3/h:

4183

6725

4376

7035

4583

7368

4814

7740

5011

8056

5228

8405

5469

8793

HC-69

SCFM:

Nm3/h:

5295

8513

5539

8905

5801

9326

6093

9796

6343

10198

6617

10638

6922

11129

HC-85

SCFM:

Nm3/h:

6537

10510

6837

10992

7161

11513

7522

12093

7830

12589

8169

13134

8545

13738

HC-103

SCFM:

Nm3/h:

7909

12716

8273

13301

8664

13929

9101

14632

9474

15232

9884

15891

10339

16622

HC-122

SCFM:

Nm3/h:

9413

15134

9846

15830

10312

16579

10832

17415

11276

18129

11764

18913

12305

19783

HC-143

SCFM:

Nm3/h:

11047

17761

11555

18577

12102

19457

12712

20438

13233

21275

13805

22195

14441

23217

HC-166

SCFM:

Nm3/h:

12812

20598

13401

21545

14035

22565

14743

23703

15347

24674

16011

25741

16748

26926

Note: Maximum operating pressure is 150 PSIG (10.34 Bar);

higher pressures available as an option. Consult factory.

Minimum Inlet Pressure

PSIG:

Bar:

85

5.86

90

6.2

95

6.55

100

6.9

105

7.24

110

7.58

115

7.93

Correction Factor

1.15 1.1 1.05 1 .96 .92 .88

CORRECTION FACTOR FOR COOLING WATER TEMPERATURE

Temperature

°F

ºC

75

24

80

27

85

29

90

32

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 2208 m^3/hr @ 6.2 Bar, using 32



C cooling water:

Multiply 2208 * (1.1) * (1.2) = 2914 Use Model HC-21

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Ingersoll-Rand HC-103 User manual

Ingersoll-Rand HC-103 User manual

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