Ingersoll-Rand HC-41 User manual

Category
Electric laundry dryers
Type
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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® 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
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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
105F
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
105F
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
105F
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
105F
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 85F, 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-41 User manual

Category
Electric laundry dryers
Type
User manual

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