HHE-HHL-HHS IM Base (rev B_10Apr07draft).indd

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HHE-HHL-HHS IM Base (rev B_10Apr07draft).indd | Manualzz

3162258 Rev. B 4/07

XX-XXX-X

Internal Use Only

3162258b / 070417

INSTRUCTION MANUAL

HHE, HHL and HHS SERIES

with AccuShift™ Switching Valves

MODELS

HHE

SERIES w/ Timer

Controller

HHE-40

HHE-60

HHE-90

HHE-115

HHE-165

HHE-260

HHE-370

HHE-450

HHE-590

HHE-750

HHE-930

HHE-1130

HHE-1350

HHE-1550

HHE-2100

HHE-3000

HHE-4100

HHE-5400

HHL

SERIES w/ Level 1

Controller

HHS

SERIES w/ Level 2

Controller

HHL-40

HHL-60

HHL-90

HHL-115

HHL-165

HHL-260

HHL-370

HHL-450

HHL-590

HHL-750

HHL-930

HHL-1130

HHL-1350

HHL-1550

HHL-2100

HHL-3000

HHL-4100

HHL-5400

HHS-40

HHS-60

HHS-90

HHS-115

HHS-165

HHS-260

HHS-370

HHS-450

HHS-590

HHS-750

HHS-930

HHS-1130

HHS-1350

HHS-1550

HHS-2100

HHS-3000

HHS-4100

HHS-5400

RATED

FLOW

40 SCFM

60 SCFM

90 SCFM

115 SCFM

165 SCFM

260 SCFM

370 SCFM

450 SCFM

590 SCFM

750 SCFM

930 SCFM

1130 SCFM

1350 SCFM

1550 SCFM

2100 SCFM

3000 SCFM

4100 SCFM

5400 SCFM

REFER

AS

MODELS

40

60

90

750

930

1130

1350

1550

2100

115

165

260

370

450

590

3000

4100

5400

Contents

1. GENERAL SAFETY INFORMATION ................................ 2

2. RECEIVING, MOVING, UNPACKING .............................. 2

3. DESCRIPTION ................................................................. 3

4. INSTALLATION ................................................................. 8

5. CONTROLLERS – GENERAL .......................................... 16

6. CONTROLLER – TIMER BASED ..................................... 18

7. CONTROLLER – LEVEL 1 ............................................... 20

8. CONTROLLER – LEVEL 2 ............................................... 31

9. OPERATION ..................................................................... 48

10. MAINTENANCE ............................................................... 54

11. TROUBLESHOOTING ..................................................... 55

12. NOTES ............................................................................. 56

WARRANTY ..................................................................... 60

PRESSURE-SWING

DESICCANT TYPE

COMPRESSED

AIR DRYERS

®

SERVICE DEPARTMENT : (724) 746-1100

1. General Safety Information

1.1 Pressurized Devices

• This equipment is a pressure-containing device.

• Do not exceed maximum operating pressure as shown on the equipment serial number tag.

• Verify that equipment is fully de-pressurized before performing service or maintenance functions.

1.2 Electrical:

• This equipment requires electricity to operate.

• Install equipment in compliance with national and local electrical codes.

• Standard equipment is supplied with NEMA 4,4X electrical enclosures and is not intended for installation in hazardous environments.

• Disconnect power supply to equipment when performing any electrical service work.

1.3 Breathing Air:

Air treated by this equipment may not be suitable for breathing without further purification.

Refer to OSHA standard 1910.134 for the requirements for breathing quality air.

1.4 Noise:

CAUTION: Do not operate dryer without mufflers installed.

1.5 High Velocity Air:

CAUTION: Do not stand near mufflers during tower depressurization.

2. Receiving, Moving, Unpacking

2.1 Receiving:

• This shipment has been thoroughly checked, packed and inspected before leaving our plant.

• It was received in good condition by the carrier and was so acknowledged.

• Check for visible loss or damage. If this shipment shows evidence of loss or damage at time of delivery to you, insist that the carrier’s agent make a notation of this loss or damage on the delivery receipt.

2.2 Moving:

CAUTION: Use lifting lugs or forklift. Do not lift equipment by piping.

2.3 Unpacking:

Check for concealed loss or damage. When a shipment has been delivered to you in apparent good order, but concealed damage is found upon unpacking, notify the carrier immediately and insist that his agent inspects the shipment.

Fifteen days from receipt of shipment is the maximum time limit for requesting such inspection.

Concealed damage claims are not our responsibility as our terms are F.O.B. point of shipment.

— 2 —

3. Description

3.1 Dryer Function

• Dual tower regenerative desiccant dryers are an economical and reliable way to dry compressed air to dew points below the freezing point of water (dew points as low as -150°F (101°C)

[1 ppb @100 psig, 7.0 kgf/cm

2

] are possible) or reduce the moisture content of compressed air when used in critical process applications.

• These dryers continuously dry compressed air by using two identical towers, each containing a desiccant bed. While one tower is on-stream drying, the other tower is off-stream being regenerated (reactivated, i.e., dried out). The towers are alternated on- and off-stream so that dry desiccant is always in contact with the wet compressed air. In this way a continuous supply of dry air downstream of the dryer is possible.

• Desiccant dryers lower the dew point of compressed air by adsorbing the water vapor present in the compressed air onto the surface of the desiccant. Desiccant is a highly porous solid containing extensive surface area.

• Adsorption occurs until the partial pressure of the water vapor in the air and that on the surface of the desiccant come into equilibrium. As adsorption occurs, heat is released (referred to as the heat of adsorption) and is stored in the bed for use during regeneration.

• Desiccant is regenerated by driving off (desorbing) the water collected on its surface. Pressure-swing (also called heatless or heater-less because no outside heat is added) dryers regenerate by expanding a portion (approximately 14 -15% at 100 psig, 7 kgf/ cm

2

) of the dried air to atmospheric pressure. This “swing in pressure ” causes the expanded air to become very dry (have a very low vapor pressure). This very dry air (called purge air) plus the stored heat of adsorption allows the moisture to desorb from the desiccant. The purge air then carries the desorbed water out of the dryer.

3.2 Automatic Purge Saving System

Featured with the Level 2 Controller, the Automatic Purge Saving

System is designed to save energy (purge air) when pressure-swing dryers are operated at reduced loads.

The patented Purge Saving System operates by monitoring the changes in temperature within the desiccant beds. These changes in temperature are the result of heat (thermal energy) that is released when a bed is on-line drying (heat of adsorption), and the heat that is used when a bed is off-line being regenerated (heat of desorption). The magnitude of these changes in temperature is an indirect measure of the water vapor content in the air being dried.

This information is used to determine the time a tower stays on line during the drying cycle.

— 3 —

3.3 Description of Operation – Dryer

3.3.1 Models 40 to 3000 w/ Shuttle Valve

(Refer to Fig. 3-1a.) Compressed air flows through inlet shuttle valve ( 3) to tower (4A) where the air is dried. After the air is dried it flows through outlet shuttle valve (5) and then to the dryer outlet. A portion of the dry air, the purge stream, branches off from the main air stream prior to the outlet. The purge stream flow rate is controlled by the adjustable purge rate valve (6) and the two purge orifices (7).

The purge flow, which has been throttled to near atmospheric pressure, is directed to tower (4B). As the purge flow passes over the desiccant in tower (4B), it removes the water vapor, which was deposited there while the tower was on-line drying. The purge air then passes through purge and repressurization valve (9B) (normally closed) and purge muffler (10B) to the atmosphere.

After regeneration, purge and repressurization valve (9B) (normally closed) closes allowing tower (4B) to repressurize slowly. Adequate repressurization time is allowed so that tower (4B) is fully repressurized before tower switchover. After a controlled time period, purge and repressurization valve (9A) (normally closed) then opens. This causes the inlet and outlet shuttle valves to shift, directing the air flow through tower (4B).

(Refer to Fig. 3-1b.) Tower ( 4B) is now drying the main air stream while tower (4A) is being regenerated by the purge air stream. The operation of the purge and repressurization (normally closed) valves is sequenced by the control system located in the electrical enclosure.

OUTLET

11

5

1

8

7 6 2 7

1

TOWER

4A

3

9A 9B

INLET

10A 10B

FIGURE 3-1a

TOWER 4A DRYING

TOWER 4B REGENERATING

TOWER

4B

OUTLET

11

5

1

8

7 6

2 7

1

TOWER

4A

TOWER

4B

3

9A 9B

INLET

10A 10B

FIGURE 3-1b

TOWER 4A REGENERATING

TOWER 4B DRYING

1. Tower Pressure Gauges

2. Purge Pressure Gauge

3. Inlet Shuttle Valve

4. Desiccant Drying Towers

5. Outlet Shuttle Valve

6. Adjustable Purge Rate Valve

7. Purge Orifices

8. Safety Valve

9. Purge and Repres-

surization Valves

10. Purge Mufflers

11. Moisture Indicator

A Left Tower Suffix

B Right Tower Suffix

Process Stream

Purge Stream

— 4 —

3.3.2 Models 4100 to 5400 w/ Check Valves

(Refer to Fig. 3-2a.) Compressed air flows through inlet switching valve (3A) (normally open) to tower (4A) where the air is dried. After the air is dried it flows through outlet check valve (5A) and then to the dryer outlet. A portion of the dry air, the purge stream, branches off from the main air stream prior to the outlet. The purge stream flow rate is controlled by the adjustable purge rate valve (6) and the single purge orifice (7).

The purge flow, which has been throttled to near atmospheric pressure, is directed through purge check valve (5D) to tower (4B). As the purge flow passes over the desiccant in tower (4B), it removes the water vapor which was deposited while the tower was on-line drying. The purge air then passes through purge and repressurization valve (9B)

(normally closed) and purge muffler (10B) to the atmosphere.

After regeneration, purge and repressurization valve (9B) (normally closed) closes allowing tower (4B) to re-pressurize slowly. Adequate repressurization time is allowed so that tower (4B) is fully repressurized before switchover. After a controlled time period, air inlet switching valve (3B) (normally open) opens and inlet-switching valve

(3A) (normally open) closes, purge and repressurization valve (9A)

(normally closed) then opens.

(Refer to Fig. 3-2b.) Tower (4B) is now drying the main air stream while tower (4A) is being regenerated by the purge air stream. The operation of the inlet switching (normally open) and purge and repressurization

(normally closed) valves is sequenced by the control system located in the electrical enclosure.

8

1

5A

5C

OUTLET

11

6

7

2

5B

5D

8

1

TOWER

4A

TOWER

4B

10A

9A 3A 3B

INLET

FIGURE 3-2a

TOWER 4A DRYING

TOWER 4B REGENERATING

9B

10B

8

1

5A

5C

OUTLET

11 5B

6

7

2

5D

8

1

TOWER

4A

TOWER

4B

10A

9A 3A 3B

INLET

FIGURE 3-2b

TOWER 4A REGENERATING

TOWER 4B DRYING

9B

10B

1. Tower Pressure Gauges

2. Purge Pressure Gauge

3. Inlet Switching Valves

4. Desiccant Drying Towers

5. Check Valves

6. Adjustable Purge Rate Valve

7. Purge Orifice

8. Safety Valves

9. Purge and Repres-

surization Valves

10. Purge Mufflers

11. Moisture Indicator

A & C Left Tower Suffixes

B & D Right Tower Suffixes

Process Stream

Purge Stream

— 5 —

3.3.3 Models 40 to 450 (High Pressure Option)

(Refer to Fig. 3-3a.) Compressed air flows through inlet switching valve

(3A) (normally open) to tower (4A) where the air is dried. After the air is dried it flows through shuttle valve (5) and then to the dryer outlet. A portion of the dry air, the purge stream, branches off from the main air stream prior to the outlet. The purge stream flow rate is controlled by the adjustable purge rate valve (6) and the two purge orifices (7).

The purge flow, which has been throttled to near atmospheric pressure, is directed to tower (4B). As the purge flow passes over the desiccant in tower (4B), it removes the water vapor which was deposited while the tower was on-line drying. The purge air then passes through purge and repressurization valve (9B) (normally closed) and purge muffler

(10B) to the atmosphere.

After regeneration, purge and repressurization valve (9B) (normally closed) closes allowing tower (4B) to re-pressurize slowly. Adequate repressurization time is allowed so that tower (4B) is fully repressurized before switchover. After a controlled time period, air inlet switching valve (3B) (normally open) opens and inlet-switching valve

(3A) (normally open) closes, purge and repressurization valve (9A)

(normally closed) then opens.

(Refer to Fig. 3-3b.) Tower (4B) is now drying the main air stream while tower (4A) is being regenerated by the purge air stream. The operation of the inlet switching (normally open) and purge and repressurization

(normally closed) valves is sequenced by the control system located in the electrical enclosure.

TOWER

4A

OUTLET

11 5

1

8

7 6 2 7

1

TOWER

4B

9A

3A 3B

9B

INLET

10A 10B

FIGURE 3-3a

TOWER 4A DRYING

TOWER 4B REGENERATING

TOWER

4A

OUTLET

11

5

1

8

7 6

2 7

1

TOWER

4B

3A 3B

9A 9B

INLET

10A 10B

FIGURE 3-3b

TOWER 4A REGENERATING

TOWER 4B DRYING

1. Tower Pressure Gauges

2. Purge Pressure Gauge

3. Inlet Switching Valves

4. Desiccant Drying Towers

5. Shuttle Valve

6. Adjustable Purge Rate Valve

7. Purge Orifices

8. Safety Valve

9. Purge and Repres-

surization Valves

10. Purge Mufflers

11. Moisture Indicator

A Left Tower Suffix

B Right Tower Suffix

Process Stream

Purge Stream

— 6 —

3.4 Automatic Purge Saving System

(Refer to Figure 3-4a for Models 40 through 3000 and Figure 3-4b for

Models 4100 through 5400.)

Assume tower A is on-line drying while tower B has just gone off-line to be regenerated. At the beginning of tower B’s regeneration cycle a thermistor temperature measurement is made at position B1. After the tower has been regenerated, another measurement is made at B1. The drop in temperature sensed during regeneration is an indirect measure of the water vapor content of the inlet air. The Automatic Purge Saving

System’s microprocessor then uses this information to calculate an allowable temperature rise in the bed during the drying cycle.

When tower B goes back on-line, a temperature probe at position B2 measures the initial bed temperature at this point and then monitors the bed until the calculated temperature rise occurs. The temperature rise occurs as heat of adsorption is released during the drying process.

The time for the temperature rise to occur depends on flow rate. At

100% flow the temperature rise takes 5 minutes, at 50% flow it takes

10 minutes.

NOTE: If after 30 minutes, the bed temperature has not risen to

the calculated value, the dryer will automatically switch towers.

When the calculated temperature rise is reached, the towers switch with tower A now drying and tower B being regenerated. Tower B regenerates for 3.9 minutes, re-pressurizes, and remains idle until it is called upon for the next drying cycle.

TOWER

4A

A2

1

7

OUTLET

11 5

8

1

6 2

7

B2

A1

3

B1

TOWER

4B

9A 9B

INLET

10A

FIGURE 3-4a

10B

Models 40 through 3000

TOWER 4A DRYING

TOWER 4B REGENERATING

8

1

5A

5C

OUTLET

11

6

7

5B

2 5D

8

1

TOWER

4A

A2

A1

B2

TOWER

4B

B1

10A

9A 3A 3B

INLET

FIGURE 3-4b

Models 4100 through 5400

TOWER 4A DRYING

TOWER 4B REGENERATING

9B

10B

1. Tower Pressure Gauges

2. Purge Pressure Gauge

3. Inlet Shuttle or Switching

Valves

4. Desiccant Drying Towers

5. Shuttle or Check Valve(s)

6. Adjustable Purge Rate Valve

7. Purge Orifice(s)

8. Safety Valve(s)

9. Purge and Repres-

surization Valves

10. Purge Mufflers

11. Moisture Indicator

A & C Left Tower Suffix(es)

B & D Right Tower Suffix(es)

Process Stream

Purge Stream

— 7 —

4. Installation

4.1 Location in the compressed air system

NOTE: The air compressor should be adequately sized to handle air system demands as well as purge loss. Failure to take this into account could result in overloading air compressors and/or insufficient air supply downstream. It is desirable to install the dryer where the compressed air is at the lowest possible temperature (downstream of aftercoolers) and the highest possible pressure (upstream of pressure reducing valves) without exceeding the maximum operating pressure of the equipment. (Refer to Figure 4-1)

4.1.4 Heatless Pressure-Swing Desiccant Air Dryer

4.1.5 Afterfilter(s) –

To ensure downstream air purity (prevent desiccant dust from traveling downstream) adequate filtration downstream of the dryer is required.

First Afterfilter - Particulate Removal -Typically 1-micron filtration is specified although finer filtration is available.

Second Afterfilter - Oil Vapor Adsorption -This filter is used to remove oil vapor and its subsequent taste and odor and to protect down-stream components from solid particles 0.01 micron and larger.

NOTE: By-pass lines and isolation valves are recommended so that maintenance work can be performed without shutting off the air supply.

Compressor Aftercooler Separator Receiver Prefilters

Figure 4-1

Desiccant Dryer Afterfilters Receiver

4.1.1 Aftercooler/Separator –

Compressed air entering dryer must be cooled to a temperature of

140°F (60°C) or lower. Use of an aftercooler and condensate separator may be necessary to reduce inlet air temperature to an acceptable level.

NOTE: Installation of a refrigerated dryer ahead of a pressure-swing desiccant dryer does not increase desiccant dryer capacity or reduce purge flow requirements.

4.1.2 Receiver(s) –

Air receivers dampen pulsations from the compressor discharge line and can eliminate some of the condensed moisture that is carried over from the aftercooler and separator. They also provide a reservoir of stored air for response to system demands in excess of compressor capacity. Size and location of receivers in the compressed air system need to be considered carefully. Flows must not exceed the adjusted maximum inlet capacity of the desiccant air dryer.

4.1.3 Prefilter(s) –

Adequate filtration is required upstream of the dryer in order to protect the desiccant bed from contamination. The following filtration, equipped with automatic condensate drains, is recommended:

First Prefilter - Particulate/Gross Liquid Removal - On heavily contaminated systems, a gross contaminant filter to remove solids and high inlet liquid concentrations should be used.

Second Prefilter - Oil Aerosol Removal - On systems with lubricated compressors, an oil removal filter to remove oil aerosols and protect the desiccant beds from oil contamination is required.

4.2 Physical Location

The dryer must be installed with suitable overhead protection as well as clearance to change desiccant. Sufficient clearance around the periphery of the dryer should be provided to allow maintenance personnel access to all areas for routine inspections and adjustments.

4.3 Minimum & Maximum Operating Conditions

The compressed air supply to the dryer inlet should be checked periodically to ensure that dryer design specifications are not exceeded. Normally the compressor installation includes intercoolers, aftercoolers, separators, receivers, or similar equipment, which adequately pretreat the compressed air supply in order to avoid excessively high air temperatures and liquid slugging of downstream equipment.

4.4 Maximum Operating Pressure (MOP):

150 psig (10.5 kgf/cm

2

) is standard.

250 psig (17.6 kgf/cm

2

) is optional.

Refer to Dryer Serial Number Tag.

WARNING - Do not operate the dryer at pressures above the maximum operating pressure shown on the serial number tag.

NOTE: Consult factory for applications requiring higher maximum operating pressures.

— 8 —

4.5 Minimum Operating Pressures:

4.5.1 For 150 psig (17.6 kgf/cm

2

) MOP models -

60 psig (4.2 kgf/cm

2

) is the minimum operating pressure for dryers operated on ISO classes 1, 2, 3, and 4.

4.5.2 For 250 psig (17.6 kgf/cm

2

) MOP models -

120 psig (8.44 kgf/cm

2

) is the minimum operating pressure for dryers operated on ISO classes 1, 2, 3, and 4.

Refer to Dryer Serial Number Tag.

WARNING - Do not operate the dryer at pressures below the minimum operating pressure shown on the serial number tag.

NOTE: Consult factory for applications requiring lower minimum operating pressures.

4.6 Maximum Compressed Air Temperature at Dryer

Inlet:

• 140°F (60°C) for all models.

4.7 Ambient Temperatures:

4.7.1 Minimum Ambient Temperature

Standard units: 35°F (2°C)

Units with optional low ambient package: -20°F ( -29°C)

4.7.2 Maximum Ambient Temperature

120°F (49°C)

NOTE: If dryer is installed in ambients below 35°F (2°C), low ambient protection requiring heat tracing and insulation of the prefilter bowls, auto drains and/or sumps, and lower piping with inlet switching and purge/repressurization valves is necessary to prevent condensate from freezing. If installing heat tracing, observe electrical class code requirements for type of duty specified. Purge mufflers and their relief mechanisms must be kept clear from snow and ice buildup that could prevent proper discharge of compressed air.

4.8 Mounting

Install dryer on a level pad. Holes are provided in the dryer base members for floor anchors.

NOTE: Floor anchors must be used if area is subject to vibration.

4.9 Piping

Inlet and Outlet connections

Observe locations of inlet and outlet connections as shown in Figures

4-2 or 4-3 and connect inlet and outlet piping as indicated.

NOTE: All piping must be supported so as not to bear on the dryers or filters.

4.10 Isolation Valves

If isolation or bypass valves are installed, care must be used to ensure that equipment is pressurized slowly. This is particularly true if isolation valves are placed before and after pre and afterfilters where rapid pressurization could cause excessive pressure drop across filter elements.

— 9 —

NOTE: When quarter-turn valves (e.g. ball or butterfly valves) are used for isolation of pressure components, care should be taken to open or close valves slowly.

4.11 Electrical Connections

Refer to the appropriate controller sections for detailed information on connections, ratings, and operation of the Level 1 or Level 2

Controller.

NOTE: Refer to the dryer serial number tag for allowable voltages, frequency and power rating.

4.12 Provisions for Purge Exhaust

Purge exhaust must be routed through the factory supplied mufflers or piped to a remote location.

Purge mufflers - If shipped separately, install purge exhaust mufflers in the locations shown in Figures 4-2 or 4-3.

If purge exhaust is piped to a muffler located in a remote location, choose a combination of diameters, lengths, and turns that limits the additional pressure drop to 1 psid or less.

WARNING - Do not operate dryer without installed mufflers. Exhausting compressed air directly to atmosphere will result in noise levels above

OSHA permissible levels and rapidly expanding gas could potentially cause harm to persons or property.

4.13 Initial Desiccant Charge

The dryer is shipped complete with desiccant and is ready to operate after piping and electrical connections are made and controller settings are established.

4.14 Icon Identification

P

Left Tower

Pressure Gauge

P

P

Right Tower

Pressure Gauge

Air Outlet

Air Inlet

Purge

Pressure Gauge

Electrical

Inlet

J

M

(MAX)

D

E

C

LIFTING LUG

DESICCANT FILL PORT

LEFT CHAMBER

PRESSURE GAUGE

MOISTURE INDICATOR

RIGHT CHAMBER

PRESSURE GAUGE

CONTROL ENCLOSURE

B

L

(MAX)

A

TOP VIEW

WARNING: Disconnect the main power supply before removing this cover.

DESICCANT DRAIN PORT

FRONT VIEW

CENTERLINE OF CUSTOMER

INLET/OUTLET CONNECTIONS

7/8” X 1 1/4” SLOT (TYP 4 PLCS)

[22mm] [32mm]

F

P

AIR OUTLET

N

(MAX)

RIGHT SIDE VIEW

RIGHT CHAMBER REMOVED FOR CLARITY

P

AIR INLET

H

G

REAR VIEW

OUTLET SHUTTLE

VALVE ASSY

PILOT AIR FILTER

PURGE PRESSURE GAUGE

& REGULATOR

PURGE ADJUSTING VALVE

ASME CODE TAG

ASME PRESSURE

RELIEF VALVE

INLET SHUTTLE

VALVE ASSY

PURGE EXHAUST

VALVE

PURGE EXHAUST

MUFFLER

Figure 4-2

(continued on next page)

40-450 SCFM General Arrangement

— 10 —

356

991

44

889

889

1235

1 NPT

166

40

702

351

32

749

375

71

39

1.3/4

35

35

49

1 NPT

365

40

27.5/8

13.13/16

1.1/4

29.1/2

14.3/4

2.13/16

14

MODEL

A

B

C

F

G

D

E

L

M

N

H

J

P

WT/KGS

MODEL

A

B

E

F

C

D

J

L

G

H

M

N

P

WT/LBS

356

1372

44

889

889

1616

1 NPT

202

60

702

351

32

749

375

71

54

1.3/4

35

35

64

1 NPT

445

60

27.5/8

13.13/16

1.1/4

29.1/2

14.3/4

2.13/16

14

356

1803

44

948

889

2047

1 NPT

261

DIMENSIONS IN INCHES

90

27.5/8

115

38.3/8

165

38.3/8

13.13/16

1.1/4

29.1/2

14.3/4

19.13/16

1.1/4

35.1/2

17.3/4

19.13/16

1.1/4

35.1/2

17.3/4

2.13/16

14

71

1.3/4

37

35

81

1 NPT

575

2.13/16

15

45

1.3/4

50

41

57

1 NPT

685

32

749

375

71

DIMENSIONS IN MILLIMETERS

90 115 165

702

351

975

487

975

487

32

902

451

71

32

902

451

71

2.13/16

15

45

1.3/4

50

41

57

1 NPT

685

381

1143

44

1264

1041

1437

1 NPT

311

381

1143

44

1264

1041

1437

1 NPT

311

406

1346

70

1470

1062

1658

2 NPT

551

370

1254

627

32

902

451

83

53

2.3/4

58

42

65

2 NPT

1215

370

49.3/8

24.11/16

1.1/4

35.1/2

17.3/4

3.1/4

16

381

1600

70

1305

1041

1894

2 NPT

458

260

1051

525

32

902

451

83

63

2.3/4

51

41

75

2 NPT

1010

260

41.3/8

20.11/16

1.1/4

35.1/2

17.3/4

3.1/4

15

406

1549

70

1470

1062

1861

2 NPT

612

450

1254

627

32

902

451

83

61

2.3/4

58

42

73

2 NPT

1350

450

49.3/8

24.11/16

1.1/4

35.1/2

17.3/4

3.1/4

16

Figure 4-2 (continued from previous page)

40-450 SCFM General Arrangement

— 11 —

M

(MAX)

D

E

C

B

A

L

(MAX)

TOP VIEW

PURGE PRESSURE

ADJUSTMENT VALVE

LIFTING LUG

LEFT CHAMBER

PRESSURE GAUGE supply before removing this cover.

WARNING: Disconnect the main power

FRONT VIEW

CENTERLINE OF CUSTOMER

INLET/OUTLET CONNECTIONS

H

7/8” X 1-1/4” SLOT (TYP 4 PLACES)

[22mm] [32mm]

G

F

BOTTOM RIGHT SIDE VIEW

(Models 1550, 2100 and 3000)

RIGHT CHAMBER REMOVED FOR CLARITY

P

AIR INLET

F

P

AIR OUTLET

DESICCANT FILL PORT

MOISTURE INDICATOR

PURGE PRESSURE GAUGE

RIGHT CHAMBER

PRESSURE GAUGE

CONTROL

ENCLOSURE

N

(MAX)

DESICCANT DRAIN PORT

G

H

PURGE

EXHAUST

MUFFLER

ASME CODE TAG

P

AIR INLET

PILOT AIR

FILTER

ASME PRESSURE

RELIEF VALVE

RIGHT SIDE VIEW

(Models 590 through 1350)

RIGHT CHAMBER REMOVED FOR CLARITY

REAR VIEW

Figure 4-3

(continued on next page)

590-3000 SCFM General Arrangement

— 12 —

MODEL

A

B

E

F

C

D

L

M

G

H

N

P

WT/KGS

MODEL

A

B

C

D

G

H

E

F

N

P

L

M

WT/LBS

83

234

2472

1387

1295

2631

2 NPT

668

590

1187

594

32

1156

578

590

46.3/4

23.3/8

1.1/4

45.1/2

22.3/4

3.1/4

9.3/16

97.5/16

55

51

104

2 NPT

1473

83

247

2561

1438

1295

2720

2 NPT

968

750

1208

604

32

1156

578

750

47.9/16

23.13/16

1.1/4

45.1/2

22.3/4

3.1/4

9.11/16

100.13/16

57

51

107

2 NPT

2134

1338

669

32

1359

679

83

291

930

52.11/16

26.5/16

1.1/4

53.1/2

26.3/4

3.1/4

11.7/16

105.9/16

63

59

112

DIMENSIONS IN INCHES

1130

56.7/16

28.1/4

1.1/4

53.1/2

26.3/4

5.1/8

11

107.1/8

66

59

115

1350

57.5/16

28.11/16

1.1/4

53.1/2

26.3/4

5.1/8

11

112.1/8

68

59

120

1550

63.1/8

31.9/16

1.1/4

53.1/2

26.3/4

5.9/16

5.1/4

109.1/2

74

59

117

2100

69.13/16

34.7/8

1.1/4

53.1/2

26.3/4

5.9/16

6.3/16

111.5/16

82

59

119

3000

73.3/8

36.11/16

1.1/4

59.1/2

29.3/4

5.9/16

8.1/2

117.3/8

86

67

125

2 NPT

2414

3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE

2875 3722 4167 4417 9010

DIMENSIONS IN MILLIMETERS

930 1130 1350 1550 2100 3000

2681

1603

1499

2841

2 NPT

1095

1434

717

32

1359

679

130

279

2721

1673

1499

2924

1456

728

32

1359

679

130

279

2848

1724

1499

3051

1604

802

32

1359

679

141

133

2781

1876

1499

2980

1773

886

32

1359

679

141

157

2827

2080

1499

3026

1864

932

32

1511

756

141

216

2981

2172

1693

3180

3 FLANGE 3 FLANGE 4 FLANGE 4 FLANGE 4 FLANGE

1304 1688 1890 2004 4087

Figure 4-3 (continued from previous page)

590-3000 SCFM General Arrangement

— 13 —

CENTERLINE OF CUSTOMER

INLET/OUTLET CONNECTIONS

ASME PRESSURE

RELIEF VALVE

FLOW FLOW

M

(MAX)

D

E

C

FLOW FLOW

B

A

L

(MAX)

TOP VIEW

FLOW FLOW

LIFTING LUG

PURGE PRESSURE

ADJUSTMENT VALVE

LEFT CHAMBER

PRESSURE GAUGE

FRONT VIEW

7/8” X 1-1/4” SLOT (TYP 4 PLACES)

[22mm] [32mm]

F

P

AIR OUTLET

DESICCANT FILL PORT

MOISTURE INDICATOR

PURGE PRESSURE GAUGE

RIGHT CHAMBER

PRESSURE GAUGE

CONTROL

ENCLOSURE

N

OVERALL

LENGTH

PURGE EXHAUST MUFFLER

DESICCANT DRAIN PORT

J

RIGHT SIDE VIEW

RIGHT CHAMBER REMOVED FOR CLARITY

G

H

PILOT AIR FILTER

P

AIR INLET

FLOW FLOW

REAR VIEW

Figure 4-4

(continued on next page)

4100-5400 SCFM General Arrangement

— 14 —

MODEL

A

B

C

D

E

F

G

H

J

L

M

N

DIMENSIONS IN INCHES

4100

82.7/8

41.7/16

1.1/4

59.1/2

29.3/4

33.3/16

13.13/16

115.13/16

36.3/16

100

88

5400

93.3/8

46.11/16

1.1/4

63.1/2

31.3/4

35.7/8

19.7/16

116.3/16

38.7/8

105

89

P

WT/LBS

124 124

6 FLANGE 6 FLANGE

9900 12000

DIMENSIONS IN MILLIMETERS

MODEL 4100 5400

A

B

C

D

E

F

G

H

J

L

M

2106

1053

32

1511

756

843

351

2942

919

2537

2227

2372

1186

32

1613

806

911

494

2951

988

2667

2253

N

P

WT/KGS

3158

6 FLANGE 6 FLANGE

4500

3158

5445

Figure 4-4 (continued from previous page)

4100-5400 SCFM General Arrangement

— 15 —

5. Controllers – General

5.1 Overview

The solid-state dryer controller is located in a polycarbonate, NEMA

Class 4/4X, IP66 rated electrical enclosure mounted to a center panel located between the two desiccant towers. Controls are available in three functional levels. The Timer Controller offers a fixed-time cycle that provides a dew point corresponding to ISO compressed air quality class 2. Both the Level 1 and Level 2 controls offer four fixed-time cycles that provide dew points corresponding to ISO compressed air quality classes 1 through 4. A key difference between the Level 1 and

Level 2 controls is the way in which they address energy savings. When inlet flow is less than the adjusted rated capacity of the dryer, average purge air requirements are reduced. This reduction can translate to energy savings at the air compressor.

The Level 1 Controller offers 8 selectable fixed-cycle Energy (purge)

Saver modes (0% to 70% in 10 % increments) to reduce purge time to match the load on the dryer.

Level 2 Controllers feature the Automatic Purge Saving System

(APSS) as described in Sections 3.2 and 3.4. When Level 2 Controllers are operated in demand rather than fixed cycle modes, the APSS automatically adjusts to dryer loading and extends drying time when possible. Average purge use is thus automatically reduced.

A feature-by-feature comparison of each controller can be found in

Table 5-1

.

Desiccant Dryer Controllers

Category Feature

General

AC Input Voltage: 85-264 VAC, 47-63 Hz (See Note 1)

DC Input Voltage: 11.5-28 VDC (See Note 1)

Auxiliary power terminals (See Note 2)

Solenoid valve coil voltage

NEMA 4/4X, IP 66 electrical enclosure rating

Soft on/off switch with two power recovery modes (See Note 3)

Tower status LEDs (amber=drying)

Tower status LEDs (green=drying, amber=regenerating)

Process valve status LEDs (on=valve open, off=valve closed)

Operating mode LEDs (see next category for number of modes)

Alarm LED (red)

Operating Modes

(See Note 5)

Digital I/O

Analog I/O

(12 bit accuracy)

Voltage-free alarm contacts, 5A rating

Alarm reset switch (mounted on front panel)

Service reminder LEDs (See Note 4)

Vacuum fluorescent text display

60-150 or 120-250 psig MOP (selectable via jumper on circuit board)

ISO Class 1 (-100°F/-73°C PDP) - fixed cycle (4 minute)

ISO Class 2 (-40°F/-40°C PDP) - fixed cycle (10 minute)

ISO Class 3 (-4°F/-20°C PDP) - fixed cycle (16 minute)

ISO Class 4 (+38°F/+3°C PDP) - fixed cycle (24 minute)

Fixed Cycle Energy (purge) Saver (See Note 6)

Manual Cycle (test mode)

ISO Class 2 (-40°F/-40°C PDP) - demand cycle

ISO Class 3 (-4°F/-20°C PDP) - demand cycle

ISO Class 4 (+38°F/+3°C PDP) - demand cycle

Controlled shutdown and restart (upon user supplied contact closure)

Tower pressure switches (2)

High Humidity or Dew Point Alarm

Filter monitor alarm (1 or 2 filters)

Electric drain alarm (1 or 2 filters)

Electric drain test (1 or 2 filters)

Thermistors (4)

Analog input #1 (0-5 VDC) Dew point transmitter

Analog input #2 (0-5 VDC) Pressure transducer

Analog input #3 (0-5 VDC) Temperature sensor

Communication

RS232 communication port

Table 5-1 (continued on next page)

Feature Comparison – Level 1 and 2 Controllers

— 16 —

Timer

Controller

12 VDC

Level 1

Fixed Cycle Only

12 VDC

Optional

Optional

Optional

Optional

Optional

Optional

Optional

Level 2

Fixed Cycle and APSS

12 VDC

Table 5-1 (continued from previous page)

Notes:

1. The Timer Controller will accept AC (Alternating Current) input power. The Level 1 and Level 2 Controllers will accept either AC

(Alternating Current) or DC (Direct Current) input power.

2. (Level 1 & Level 2 Controllers) The auxiliary power terminals are in parallel with the input power terminals (i.e., there are two common terminals for each input power connection point, L, N, and PE. The auxiliary power terminals provide a connection point for another device that operates on the same voltage as the Desiccant Dryer Controller.

3. (Level 1 & Level 2 Controllers) The controller has two power recovery modes. For Level 1 the selection is made using a jumper on the circuit board. For Level 2 the selection is made using the switches on the front panel. In one mode, the controller remembers its state (on or off) prior to a power interruption and returns to that state when power is restored. In the other mode, the controller always returns to the off state when power is restored after an interruption.

4. (Level 1 & Level 2 Controllers) The service reminder LEDs indicate that it is time to perform preventive maintenance on the (a) filters and drains, (b) valves, or (c) desiccant. The user selects between Normal and Severe service intervals. For Level 1 the selection is made using a jumper on the circuit board. For Level 2 the selection is made using the switches on the front panel.

5. (Level 1 & Level 2 Controllers) For Level 1 and Level 2, the operating mode (with exception of the MOP) is selected via switches on the front panel.

6. (Level 1 Controllers) The Level 1 Energy (purge) Saver feature has eight settings, 0% to 70% in 10% increments. Energy Saver setting

= 100% – (percentage of adjusted allowable inlet flow). (e.g. if the maximum adjusted allowable inlet flow to a dryer was 1000 SCFM, but the actual flow to the inlet was only 300 SCFM, then the Energy Saving setting would be 100%-((300/1000)*100%)=70%. At 300 SCFM, only 30% of the dryer capacity is being utilized. Average purge requirements and the related energy needed to compress that purge air can be reduced by 70%.) The selection is made using a switch on the front panel.

7. PDP - Pressure Dew Point

MOP - Maximum Operating Pressure

— 17 —

6. Controller – Timer Based

This section provides connection, adjustment and operational information for the Timer Based – Fixed Cycle Controller. Similar information for the Level 1 – Fixed Cycle Controller and Level 2

Controller featuring the APSS, Automatic Purge Saving System, can be found in Sections 7 and 8 respectively.

6.1 Reference Figures – Timer Based Controller

Figure 6-1, Front Panel Overlay – Timer Controller

Figure 6.-2, Electrical Schematic – Timer Controller

6.2 Connections – Timer Based Controller

See Figure 6-2, Electrical Schematic for the location and function of the various cable and cord connectors that are provided on the bottom of the Timer Based enclosure.

6.2.1 Connections - Input Power

6.2.1.1 VAC Input Power Connections

Single-phase, alternating current (AC) input power connection of 110-

120 VAC / 1 ph / 50-60 Hz. can be made at terminals mounted within the control enclosure. See reference figures for proper polarity.

Program Step

Left tower status

Right tower status

Left purge solenoid

Right purge solenoid

Left purge valve

Right purge valve

1

drying regen off off closed closed

2

drying regen off off closed closed

3

drying regen off on closed open

4

drying regen off off closed closed

5

regen drying off off closed closed

Table 6-1

Cycle Sequence Steps –Timer Based Controller

6

regen drying off off closed closed

7

regen drying on off open closed

8

regen drying off off closed closed

Dryer MOP

ISO Class

Dew Point

Cycle Time (minutes)

Time t4 t5 t6 t0 t1 t2 t3 t7 t8

Purge time (min:sec)

Repress. time (min:sec)

60-150 psig

2

-40°C

-40°F

10

Time from start of cycle

(minutes:seconds)

00:00

00:02

00:06

04:12

05:00

05:02

05:06

09:12

10:00

Reference Data

04:12

00:48

120-250 psig

2

-40°C

-40°F

10

Time from start of cycle

(minutes:seconds)

00:00

00:02

00:06

04:12

05:00

05:02

05:06

09:12

10:00

Table 6-2

Fixed Cycle Timing –Timer Based Controller

04:12

00:48

— 18 —

Power ON Light

Right Tower

DRYING Light

Left Tower

DRYING Light

WARNING: Disconnect the main power supply before removing this cover.

Figure 6-1

Front Panel Overlay –Timer Based Controller

(Note: Figure is representative of Models 40 through 3000.)

TIMER

CONTROLLER

12 VDC

DIN 43650

FORM-B

PLUG

(LEFT) (POWER) (RIGHT)

LEFT TOWER

SOLENOID

LIVE

NEUTRAL

EARTH

CUSTOMER CONNECTION

120V / 1PH / 60Hz

12 VDC

RIGHT TOWER

SOLENOID

Figure 6-2

Electrical Schematic –Timer Based Controller

(Note: Figure is representative of Models 40 through 3000.)

— 19 —

7. Controller – Level 1

This section provides connection, adjustment and operational information for the Level 1 – Fixed Cycle Controller. Similar information for the Level 2 Controller featuring the APSS, Automatic Purge Saving

System, can be found in Section 8.

7.1 Reference Figures – Level 1 Controller

Figure 7-1, Front Panel Overlay – Level 1 Controller

Figure 7.-2, Electrical Schematic – Level 1 Controller

Figure 7-3, Point-to-Point Diagram – Level 1 Controller

Figure 7-4, Panel Layouts – Level 1 Controller

Figure 7-5, Enclosure Penetrations – Level 1 Controller

7.2 Connections – Level 1 Controller

See Figure 7-5, Enclosure Penetrations for the location, size and function of the various cable and cord connectors that are provided on the bottom of the Level 1 enclosure.

7.2.1 Connections - Input Power

7.2.1.1 VAC Input Power Connections

Single-phase, alternating current (AC) input power connections ranging from 85-264 VAC and 47 to 63 Hz. can be made at terminals TB5-20,

-22, and –24. See reference figures for proper polarity. These terminals are connected to accessory output terminals TB5-21, -23, and –25 respectively. Accessory output terminals can be used to direct power at the same voltage and frequency to external devices.

CAUTION: Accessory output terminals are NOT controlled by the power on/off switch and are always energized when power is provided to terminals TB –20, -22, and -24.

7.2.1.2 VDC Power Connections

• The control and display boards operate on low-voltage direct current. The controller is provided pre-wired with an AC to 12

VDC power supply board. For users with AC power as described in Section 7.2.1.1, their AC input is directed to the power supply board where it is conditioned and returned to the control board as 12 VDC at terminals TB4-18 and –19.

• For users with direct current (DC) input power ranging from 11.5 to 28 VDC, use of the AC to DC power supply board is not needed and their connections can be made at terminals TB4-18 and –19 by first removing the black and red leads coming from the power supply board. See reference figures for proper polarity.

7.2.2 Connections – Common Alarm Contacts

Connections to voltage-free common alarm contacts with a minimum

5-amp rating can be made at terminals TB2-7 through –9.

• Terminal TB2-9 is the common contact connection.

• Terminal TB2-7 is the N.O. (normally open) contact connection.

• Terminal TB2-8 is the N.C. (normally closed) contact connection.

• The alarm relay coil is energized when power is supplied to the controller input terminals and there are no alarms.

• The coil is de-energized when power is removed or when an alarm condition exists.

• Additional information on the common alarm relay logic appears in Table 7-1.

— 20 —

Power

To

Controller

Controller

On or

Off?

No

Yes

Yes

Yes

N/A

Off

On

On

Alarm or

Service

Reminder

N/A

N/A

No

Yes

Alarm

Relay

Coil

Alarm

N.O.

Contact

(TB2-7)

De-Energized Open

Energized Closed

Energized Closed

De-Energized Open

Table 7-1

Common Alarm Relay Logic –Level 1 Controller

Alarm

N.C.

Contact

(TB2-8)

Closed

Open

Open

Closed

7.2.3 Connections – Remote Start / Stop

Terminals TB1-1 and –2 are used to provide a 5 VDC output to a remote switch or volt free contacts that when closed will stop the dryer at the end of the current half cycle. The dryer will resume running at the beginning of the new half cycle when the remote switch or contacts are reopened. When dryer operation is in the remote stop state, all four tower drying (green) and regenerating (amber) LEDs flash simultaneously.

Note: Remote start / stop is disabled when the dryer is in the

Manual cycle operation mode. When the dryer is in the remote stop state, the only front panel and remote selector switches

(see Section 7.2.4) that remain enabled are the power on/off switches.

7.2.4 Connections – Remote Switches

The controller door is equipped with four momentary-contact, push button switches. Pressing the appropriate icon printed on the display overlay actuates these switches. The display board containing the switches, display LEDs and the J2 terminal strip is mounted on the inside of the enclosure door. The terminal strip provides connection points for remotely mounted, NO (normally open), momentary-contact push buttons that provide the same function as the board mounted switches. The terminal – switch combinations are:

Terminals J2-1 and –2 (remote switch to select ISO dew point class or manual cycle / test mode)

Terminals J2-3 and –4 (remote switch to select % energy savings mode)

Terminals J2-5 and –6 (remote power on / off switch) N O T E :

Care must be exercised in using this remote switch to stop a dryer. Closing this switch will affect the same response as a loss of power. Both purge-repressurization valves will close. On standard pressure models 4100 & 5400 and high pressure models 40 through 450, both inlet-switching valves will open. A tower that is actively purging when the power on/off button is actuated will be subjected to a rapid repressurization that can lead to fluidization and subsequent abrasion of the desiccant bed. Ideally, dryers should only be powered off during those portions of the drying cycle when both desiccant towers are at full operating pressure. Use of the remote start/stop connections as described in Section

7.2.3 would be preferable in most cases.

Terminals J2-7 and –8 (remote alarm reset and manual cycle increment switch)

7.2.5 Connections – RS232

RS232 connections can be made at the 3-pin connector labeled J5 and located at the upper left-hand corner of the control board. A cable for this connection can be purchased through your distributor.

Press and hold the on/off button.

Release the on/off button.

Release the alarm reset button. The service interval time is now reset; the maintenance LED flashes three times to acknowledge the action.

7.3 Control Board Jumpers – Level 1

Refer to Figure 7-3, Point to Point Connection Diagram – Level 1

Controller. In the upper left hand corner of the control board there are four two-pin jumpers labeled J1 through J4. Only three of the four jumper pairs are utilized. Pair J2 is not used. The jumper is a removable bridge that is used to make or break continuity between the two pins that form a pair. When installed in the ON position, the jumper is placed on both pins of the pair and continuity between the pins is established. When installed in the OFF position, the jumper is removed or stored on a single pin and continuity is broken. Jumper functions are as follows:

7.3.1 Jumper J1 – Maximum Operating Pressure

Jumper J1 is used to select the maximum operating pressure. Installed in the OFF position when operating at inlet pressures of 60 to 150 psig

(4.2 to 10.5 kgf/cm

2

). Installed in the ON position when operating at inlet pressures of 120 to 250 psig (8.4 to 17.6 kgf/cm

2

). This setting will affect tower purge and repressurization times. (Refer to serial number tag.)

7.3.2 Jumper J2 – Unused.

Service Item

(Customer check points are listed for each item)

Filters

1. Check prefilter Delta-P

2. Ensure prefilter drain is discharging

3. Check afterfilter Delta-P

Desiccant

1. Check moisture indicator

2. Check dryer outlet dew point

3. Inspect mufflers for excessive dusting

Valves

1. Ensure valves are cycling properly

2. Check for switching failure alarms

3. Inspect valves for leaks - adjust purge valve as needed

Table 7-2

Normal

Service

Interval

(J3 OFF)

4,000

Hours

8,000

Hours

4,000

Hours

Jumper J3 – Service Reminder Intervals

Severe

Service

Interval

(J3 ON)

2,000

Hours

4,000

Hours

2,000

Hours

7.3.3 Jumper J3 – Service Reminder Interval

Jumper J3 is used to select the service reminder interval. Installed in the OFF position when the Normal service reminder interval is desired.

Installed in the ON position when the Severe service reminder interval is desired. Service items, check points and time intervals appear in

Table 7-2.

7.3.3.1 Filter Service

When the service interval for filters has expired the following LEDs will blink:

Service LED (amber)

Three filter LEDs (amber)

7.3.3.2 Desiccant Service

When the service interval for desiccant has expired, the following

LEDs will blink:

Service LED (amber)

Both tower regenerating LEDs (amber). The service function overrides the normal display of the tower regenerating LEDs.

7.3.3.3 Valve Service

When the service interval for valves has expired, the following LEDs will blink:

Service LED (amber)

Valve LEDs (green) The service function overrides the normal display of the valve LEDs.

To extinguish the blinking LEDs and restart the timer for a new service interval, press the alarm reset button. NOTE: Time continues to

accumulate as long as power is supplied to the controller, whether

the controller is switched on or off. Use the following sequence to manually reset the accumulated service interval time for all timers.

Pause for about 1 second at each instruction. If the sequence is executed too quickly it will not work.

With the controller already on, press and hold the alarm reset button.

— 21 —

7.3.4 Jumper J4 – Power Recovery Mode

Jumper J4 is used to select the power recovery mode. When power to the controller is interrupted, the position of this jumper controls the recovery mode of the dryer when power is restored. Installed in the

OFF position when automatic power recovery is not desired. Installed in the ON position when automatic power recovery is desired.

Jumper J4 installed in the OFF position – Automatic power recovery is turned off. The controller returns to the off state when interrupted power to the controller is restored.

Jumper J4 installed in the ON position – Automatic power recovery is turned on. The controller remembers its state (on or off) prior to a power interruption and returns to that state (at the beginning of the prior ISO operating cycle) when power is restored. If power is interrupted while the controller is in the Manual cycle mode, the controller will return to the prior ISO operating cycle and not the Manual cycle when power is restored.

7.4 Front Panel Overlay – Level 1 Controller

Left tower pressure switch LED:

On=switch closed

Off=switch open

Left tower drying LED

Left purge valve LED

On=valve open

Off=valve closed

Left tower regenerating

LED

Filter service / maintenance LED

Operating mode LEDs

ISO Class 1 – 4

Operating mode selector switch

Operating mode LED

Manual (test) mode

Communications icon

Power On LED

Power On / Off Switch

-100°F/-73°C

-40°F/-40°C

-4°F/-20°C

+38°F/+3°C

Figure 7-1

Front Panel Overlay – Level 1 Controller

(Note: Figure is representative of Standard Pressure Models 40 through 3000.)

(Note: Overlay for Standard Pressure Models 4100 & 5400 depicts a different inlet valve and outlet/purge circuit. Overlay for High Pressure Models 40 through 450 depicts a different inlet valve circuit.)

Filter service / maintenance LED

Filter service / maintenance LED

Right tower pressure switch LED:

On=switch closed

Off=switch open

Right tower drying LED

Right purge valve LED

On=valve open

Off=valve closed

Right tower regenerating LED

Energy (purge) savings

LEDs

Energy savings icon

Energy/purge savings selector switch

Maintenance / service reminder LED

Alarm LED

Reset switch for alarm and maintenance reminder – Advance switch for manual cycle

— 22 —

7.4.1 Front Panel LEDs

Power on - green

Alarm – red

Service / maintenance reminder – amber

Filters (pre, after, and pilot) service / maintenance reminders

- amber

Operating mode (ISO class / manual (test) mode) – green

Energy (purge) savings % – green

Purge / repressurization valve status (On = valve open; Off = valve closed) – green

Left and right tower status (regenerating) - amber

Left and right tower status (drying) - green

Left and right tower pressure switch status (On = switch closed;

Off = switch open) - green

7.4.2 Front Panel Switches

The front panel contains four momentary-contact push button switches.

Refer to Figure 7-1, Front panel Overlay – Level 1 Controller for the appropriate icon associated with each switch. Pushing on the overlay icon actuates the switch. Switching can be affected remotely by wiring external pushbuttons to the J2 terminals located on the rear of the display board. Refer to Section 7.2.4.

7.4.2.1 Dryer On / Off Switch

This switch is used to turn the dryer on (run) or off (stop).

Caution: In the event of a loss of power, either intentional or unintentional, both purge-repressurization valves will close. On standard pressure models 4100 & 5400 and high pressure models

40 through 450, both inlet-switching valves will open. A tower that is actively purging when the power off button is actuated will be subjected to a rapid repressurization that can lead to fluidization and subsequent abrasion of the desiccant bed. Ideally, dryers should be powered off at the end of any half cycle when both desiccant towers are at full operating pressure.

Power recovery after an external loss of power is affected by the position of control board jumper J4 (power recovery mode). Refer to

Section 7.3.4 for additional information.

7.4.2.2 Operating Mode Selector Switch

Four fixed-time cycles provide varying degrees of dryness corresponding to ISO Classes 1, 2, 3, and 4.

Manual cycle (test mode) is used for troubleshooting and startup.

The operating mode can be changed at any time. Press the switch repeatedly until the desired mode’s LED is blinking. The

LED for the current mode remains illuminated until the end of the current half-cycle, at which time the new selection becomes active. At this time, the LED for the new selection switches from blinking to illuminated, and the LED for the previous selection is extinguished.

To select Manual (test) cycle, press and hold the switch for approximately 2 seconds. The current ISO Class LED will remain illuminated and the Manual cycle mode LED will illuminate. When in the Manual cycle mode, the dyer can be advanced one step at a time using the reset/manual advance switch. Refer to section

7.4.2.4.

Note: Button function is disabled when the remote start /

stop feature has placed the dryer in the cycle interrupted

(stop) mode. Refer to section 7.2.3.

7.4.2.3 Percent Energy / Purge Savings Selector Switch

If dryer is operated at less than maximum flow capacity a reduction in purge air usage may be possible. Eight settings (0% to 70% in 10% increments) reduce the purge time to match the load on the dryer. Refer to the Operation Section to determine maximum inlet flow capacity at operating pressure. The Energy savings selection can be changed at any time. Press the switch repeatedly until the desired selection’s LED is blinking. The LED for the current selection remains illuminated until the end of the current half-cycle, at which time the new selection becomes active. At this time, the LED for the new selection switches from blinking to illuminated, and the LED for the previous selection is extinguished.

Example: If the maximum adjusted allowable inlet flow to a

dryer was 1000 SCFM, but the actual flow to the inlet was only

300 SCFM, then the Energy Saving setting would be 100%-

((300/1000)*100%)=70%. At 300 SCFM, only 30% of the dryer capacity is being utilized. Average purge requirements and the related energy needed to compress that purge air can be reduced by 70%.

Note: Button function is disabled when the remote start /

stop feature has placed the dryer in the cycle interrupted

(stop) mode. Refer to section 7.2.3.

7.4.2.4 Reset / Manual Advance Switch

This switch is normally used to reset an alarm or service reminder.

When the Manual cycle (test) mode is selected, this switch is used to advance through the operating cycle one step at a time. Note:

Allow towers to fully repressurize before advancing to tower switchover.

7.4.3 Switching Failure Alarms

When a tower does not de-pressurize, the Alarm LED, Pressure

Switch LED, and Tower Regenerating LED will blink.

When a tower does not re-pressurize, the Alarm LED, Pressure

Switch LED, and Tower Drying LED will blink.

To extinguish the blinking LEDs, correct the fault condition and press the alarm-reset button.

Refer to Table 7-4.

7.5 Fixed Cycle Timing

Refer to Table 7-3 for the fixed cycle timing for the Level 1

Controller.

7.6 Event Sequence and Component Status

Refer to Table 7-4 for the event sequence and component status for the Level 1 Controller.

— 23 —

Dryer MOP

ISO Class

Dew Point

Cycle Time (minutes)

Time

Energy (Purge)

Savings Settings t0 t1 t2 all all all t3 t4 t5 t6

70%

60%

50%

40%

30%

20%

10%

0% all all t7 t8 all

70%

60%

50%

40%

30%

20%

10%

0% all

Purge time (min:sec) at 0% Energy Savings settings [(t3-t2) or (t7-t6)]

Purge time (min:sec) at 0% Energy Savings settings [(t3-t2) or (t7-t6)]

1

-73°C

-100°F

4

01:06

00:48

00:00

00:02

00:06

00:26

00:32

00:39

00:46

00:52

00:59

01:05

01:12

02:00

02:02

02:06

02:26

02:32

02:39

02:46

02:52

02:59

03:05

03:12

04:00

05:06

06:16

06:40

07:03

07:26

07:50

08:13

08:37

09:00

10:00

01:16

01:40

02:03

02:26

02:50

03:13

03:37

04:00

05:00

05:02

60-150 psig

2

-40°C

3

-20°C

-40°F

10

-4°F

16

Time from start of cycle

(minutes : seconds)

00:00

00:02

00:06

00:00

00:02

00:06

4

+3°C

+38°F

24

08:06

10:09

10:50

11:31

12:11

12:52

13:33

14:14

14:55

16:00

02:09

02:50

03:31

04:11

04:52

05:33

06:14

06:55

08:00

08:02

Reference Data

12:06

15:19

16:24

17:28

18:32

19:37

20:41

21:46

22:50

24:00

00:00

00:02

00:06

03:19

04:24

05:28

06:32

07:37

08:41

09:46

10:50

12:00

12:02

03:54 06:49 10:44

01:00 01:05 01:10

00:42

01:12

Table 7-3

Fixed Cycle Timing – Level 1 Controller

00:00

00:02

00:06

00:19

00:23

00:27

00:31

00:35

00:40

00:44

00:48

02:00

02:02

02:06

02:19

02:23

02:27

02:31

02:35

02:40

02:44

02:48

04:00

1

-73°C

-100°F

4

05:06

05:58

06:16

06:33

06:50

07:08

07:25

07:43

08:00

10:00

00:58

01:16

01:33

01:50

02:08

02:25

02:43

03:00

05:00

05:02

2

120-250 psig

3

-40°C -20°C

-40°F

10

-4°F

16

Time from start of cycle

(minutes : seconds)

00:00

00:02

00:06

00:00

00:02

00:06

08:06

09:46

10:20

10:53

11:26

12:00

12:33

13:07

13:40

16:00

01:46

02:20

02:53

03:26

04:00

04:33

05:07

05:40

08:00

08:02

02:54

02:00

05:34

02:20

4

+3°C

+38°F

24

09:14

02:40

00:00

00:02

00:06

02:52

03:48

04:43

05:38

06:34

07:29

08:25

09:20

12:00

12:02

12:06

14:52

15:48

16:43

17:38

18:34

19:29

20:25

21:20

24:00

— 24 —

Process valve name

(Process valve state w/ de-energized pilot solenoid valve)

Left purge valve (normally closed) t0 t1 t2

Left Tower Drying

Right Tower Regenerating

Half Cycle

t3

Time (refer to Table 7-3) t4 t5 t6

Right Tower Drying

Left Tower Regenerating

Half Cycle

Pilot Energized

(open)

t7

Left inlet valve (normally open)

(See NOTE 1)

Right inlet valve (normally open)

(See NOTE 1)

Pilot Energized (closed)

Pilot Energized (closed)

Right purge valve (normally closed)

Pilot Energized

(open)

Normal status of pressure switches

Left tower pressure switch

Right tower pressure switch

closed closed closed closed closed closed closed closed closed for < 5 sec. then open open at t3, closed before t4 closed

Pressure switch status that causes an alarm

closed closed for < 5 sec. then open closed open at t7, closed before t8 closed

Left tower drying

Low tower pressure a

Left tower regenerating

Fail to de-pressurize b

Left tower regenerating

Fail to re-pressurize c

Right tower drying

Low tower pressure d

Right tower regenerating

Fail to de-pressurize e

Right tower regenerating

Fail to re-pressurize f

open closed

1

1 open open

1

2 closed open

1

1 open open

2

1

Note

Stop cycle on fault

Comments

1: Check for fault condition at 15, 25,

35,... seconds into half-cycle

no

If the fault condition is clear for 2 cycles: the alarm LED stays on (without blinking); the tower and pressure switch LEDs stop blinking (return to normal operation). Once the fault condition is clear, pressing the reset button will clear the alarm LED (and the tower and pressure switch LEDs if they are still blinking).

2: Check for fault condition just before the end of the half-cycle

yes

If the fault condition clears: resume cycling; the alarm LED stays on (without blinking); the pressure switch LED stops blinking

(returns to normal operation). Once the fault condition is clear, pressing the reset button will clear the alarm LED.

a: Blink the following LEDs: Alarm + P1 + Left tower drying b: Blink the following LEDs: Alarm + P1 + Left tower regenerating c: Blink the following LEDs: Alarm + P1 d: Blink the following LEDs: Alarm + P2 + Right tower drying e: Blink the following LEDs: Alarm + P2 + Right tower regenerating f: Blink the following LEDs: Alarm + P2

NOTE 1: Standard Pressure Models 4100 & 5400 ONLY. High Pressure Models 40 through 450 ONLY

t8

Table 7-4

Event Sequence and Component Status – Level 1 Controller

— 25 —

09

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

01

02

03

04

05

06

07

08

27

28

29

30

31

32

33

34

35

36

37

38

39

40

CUSTOMER

AC POWER

CONNECTIONS

85-264 VAC

47-440 HZ

SEE NOTE 1

CUSTOMER

DC POWER

CONNECTIONS

11.5-28 VDC

SEE NOTE 2

COMMOM

ALARM

CONNECTIONS

SEE NOTE 5

PE

GRN/YEL

NEUTRAL

WHT

HOT

BLK

POS.

NEG.

+

+

+

+

TB5-20

TB5-21

TB5-22

TB5-23

TB5-24

TB5-25

NEG.

BLACK

-

+

TB4-18

TB4-19

TB3-10

DC INPUT

TB3-11

TB3-12

TB3-13

TB3-14

TB3-15

TB3-16

TB3-17

+5

HOT

RED

AC TO DC

POWER SUPPLY

+12

+12

RIGHT INLET VALVE

(SEE NOTE 6)

RIGHT PURGE VALVE

+12

+12

LEFT INLET VALVE

(SEE NOTE 6)

LEFT PURGE VALVE

TB1-1

TB1-2

+5

EXT. CONTACT

TB1-3

TB1-4

+5

PRESSURE SW. 1

LEFT TOWER

TB1-5

TB1-6

TB2-7

TB2-9

TB2-8

PRESSURE SW. 2

RIGHT TOWER

CONTROL BOARD

52

53

54

55

56

57

49

50

51

58

59

60

61

62

63

64

65

66

41

42

43

44

45

46

47

48

67

68

69

70

71

72

73

74

75

76

77

78

79

80

Y

G

G

Y

Y

Y

G

Y

G

G

G

Y

G

G

G

G

G

G

G

G

G

G

G

Y

Y

Y

G

G

G

J2-1

J2-3

J2-5

J2-7

SERVICE REMINDER 3 (PRE FILTERS)

LEFT INLET VALVE OPEN (SEE NOTE 6)

LEFT TOWER REGENERATING

LEFT PURGE VALVE OPEN

LEFT TOWER DRYING

PRESSURE SW. 1 (LEFT TOWER) CLOSED

SERVICE REMINDER 1 (PILOT AIR FILTER)

SERVICE REMINDER 2 (AFTER FILTERS)

RIGHT INLET VALVE OPEN (SEE NOTE 6)

RIGHT TOWER REGENERATING

RIGHT PURGE VALVE OPEN

RIGHT TOWER DRYING

POWER ON

MAIN SERVICE REMINDER

COMMON ALARM

PRESSURE SW. 2 (RIGHT TOWER) CLOSED

ENERGY SAVINGS 70%

ENERGY SAVINGS 60%

ENERGY SAVINGS 50%

ENERGY SAVINGS 40%

ENERGY SAVINGS 30%

ENERGY SAVINGS 20%

ENERGY SAVINGS 10%

ENERGY SAVINGS 0%

ISO CLASS 1 (-100°F/-70°C DEW POINT) CYCLE

ISO CLASS 2 (-40°F/-40°C DEW POINT) CYCLE

ISO CLASS 3 (-4°F/-20°C DEW POINT) CYCLE

ISO CLASS 4 (+37°F/+3°C DEW POINT) CYCLE

MANUAL CYCLE (TEST MODE)

MULTIPLEXED LED BUS

+5

+5

+5

+5

ISO CLASS/MANUAL CYCLE

J2-2

ENERGY SAVINGS %

J2-4

POWER ON/OFF

J2-6

ALARM RESET/MANUAL INCREMENT

J2-8

REMOTE SW. CONNECTIONS = J2

DISPLAY BOARD

NOTES:

1. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS AC (ALTERNATING CURRENT). TERMINALS TB5-21, TB5-23 AND TB5-25 CAN BE USED TO PROVIDE ACCESSORY POWER AT THE SAME VOLTAGE AND

FREQUENCY. AC POWER IS DIRECTED TO POWER SUPPLY BOARD WHERE IT IS CONVERTED TO 12 VDC AND RETURNED TO THE CONTROL BOARD.

2. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS DC (DIRECT CURRENT). RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER SHOULD

MAKE THEIR POWER CONNECTIONS AT TERMINALS TB4-18 AND TB4-19.

3. VOLTAGE RATING OF VALVES IS 12 VDC.

4. VOLTAGE RATING OF SWITCHES IS 5 VDC.

5. WITH UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB2-7 AND TB2-9.

6. STANDARD PRESSURE MODELS 4100 & 5400 ONLY. HIGH PRESSURE MODELS 40 THROUGH 450 ONLY.

Figure 7-2

Electrical Schematic – Level 1 Controller

— 26 —

JUMPERS

(SEE NOTE 3)

JUMPER NO. &

FUNCTION

J1 - MAXIMUM OPERATING PRESSURE

J2 - UNUSED

J3 - SERVICE INTERVAL

J4 - POWER RECOVERY MODE

ENCLOSURE

DOOR

INTERIOR

JUMPER

OFF

150 PSIG

-

NORMAL

OFF

JUMPER

ON

250 PSIG

-

SEVERE

AUTO

JUMPER

JUMPER PINS

JUMPER BASE

ENCLOSURE

INTERIOR

JUMPER

OFF

JUMPER

ON

AC TO DC

POWER SUPPLY

RED WIRE

TO TB4-18

J1 J2 J3 J4

BLK WIRE

TO TB4-19

CONTROL BOARD

TB5

TB1 TB2 TB3 TB4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

DISPLAY BOARD

ALARM RESET/MANUAL CYCLE INCREMENT SWITCH

POWER ON/OFF SWITCH

ENERGY SAVINGS % SELECTOR SWITCH

ISO CLASS/MANUAL CYCLE SELECTOR SWITCH

4

4

+5

EXT. CONTACT

1

+5

PRESSURE SWITCH 1

(LEFT TOWER)

1 +5

PRESSURE SWITCH 2

(RIGHT TOWER)

RIGHT INLET VALVE

(SEE NOTE 5)

NO NC COM

ALARM

CONTACT

+12

+ –

DC

POWER

INPUT

11.5-28 VDC

AC

POWER

INPUT

85-264 VAC

1 PHASE

47-63 HZ

LEFT PURGE VALVE

+12

+12

RIGHT PURGE VALVE LEFT INLET VALVE

(SEE NOTE 5)

+12

NOTES:

1. SEE FIGURE 7-5 FOR RECOMMENDED AWG CONDUCTOR SIZES.

2. CUSTOMER SUPPLIED AC (ALTERNATING CURRENT) INPUT POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB5-21, TB5-23, AND TB5-25. FOR CUSTOMER SUPPLIED DC (DIRECT CURRENT) POWER, THE

RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB4-18 AND TB4-19.

3. IN THE “JUMPER OFF” POSITION, THE JUMPER CAN BE COMPLETELY REMOVED OR STORED ON A SINGLE PIN. IN THE “JUMPER ON” POSITION, THE JUMPER IS INSTALLED ACROSS BOTH PINS TO PROVIDE

CONTINUITY.

4. WITH THE UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB2-7 AND TB2-9.

5. STANDARD PRESSURE MODELS 4100 & 5400 ONLY. HIGH PRESSURE MODELS 40 THROUGH 450 ONLY.

Figure 7-3

Point-to-Point Connection Diagram - Level 1 Controller

— 27 —

7L 8L

6L

5L

4L

3L

16L

12L

11L

10L

1L

18L

1PB

19L

17L

4PB

3PB

2PB

13L

14L

15L

ENCLOSURE DOOR EXTERIOR

LEGEND

CR COMMON ALARM RELAY

1L SERVICE REMINDER 3 - PREFILTERS (AMBER)

3L LEFT TOWER REGEN. (AMBER)

4L LEFT PURGE VALVE OPEN (GREEN)

5L LEFT TOWER DRYING (GREEN)

6L PRESS. SWITCH 1 - L. TWR. CLOSED (GREEN)

7L SERVICE REMINDER 1 - PILOT AIR FILTER (AMBER)

8L SERVICE REMINDER 2 - AFTERFILTERS (AMBER)

10L R. TWR REGEN. (AMBER)

11L RIGHT PURGE VALVE OPEN (GREEN)

12L RIGHT TWR. DRYING (GREEN)

13L POWER ON LED (GREEN)

14L MAIN SERVICE REMINDER (AMBER)

15L COMMON ALARM (RED)

16L PRESS. SWITCH 2 - R. TWR. CLOSED (GREEN)

17L ENERGY SAVINGS % LEDS (GREEN)

18L ISO CLASS (DEW POINT) CYCLE LEDS (GREEN)

19L MANUAL CYCLE (TEST MODE) LED (GREEN)

CNTRLPCB CONTROL BOARD

DISPCB DISPLAY BOARD

JMP CONFIGURATION JUMPERS (MAX. OPER. PRESS.,

SERVICE INTERVAL, & POWER RECOVERY MODE)

1PB ISO CLAS/MANAUL CYCLE SELECTOR SWITCH

2PB POWER ON/OFF SWITCH

3PB ALARM RESET/MANUAL CYCLE INCREMENT SWITCH

4PB ENERGY SAVINGS % SELECTOR SWITCH

RS232 SERIAL I/O CONNECTION

PS AC TO DC POWER SUPPLY

J2 REMOTE SWITCH TERMINALS

TB1 EXTERNAL CONTROL INPUT TERMINALS

TB2 COMMON ALARM CONTACT TERMINALS

TB3 VALVE OUTPUT TERMINALS

TB4 DC POWER INPUT TERMINALS

TB5 AC POWER INPUT TERMINALS

Figure 7-4

(continued on next page)

Panel Layouts - Level 1 Controller

(Note: Figure is representative of Standard Pressure Models 40 through 3000.)

(Note: Overlay for Standard Pressure Models 4100 & 5400 depicts a different inlet valve and outlet/purge circuit. Overlay for High Pressure Models 40 through 450 depicts a different inlet valve circuit.)

— 28 —

Figure 7-4 (continued from previous page)

Panel Layouts - Level 1 Controller

11.5-28 VDC 85-264 VAC

47-63 HZ

— 29 —

LOCATION FUNCTION

# OF

CONDUCTORS

AWG

SIZE

CABLE DIAMETER RANGE

MIN. DIA. in.

mm

MAX. DIA.

in.

mm

1

2

3

6

7

4

5

8

FACTORY

CONNECTIONS

STANDARD

DEVICES

PRESSURE SWITCH - RIGHT TOWER

PRESSURE SWITCH - LEFT TOWER

SOLENOID - LEFT PURGE VALVE

SOLENOID - LEFT INLET VALVE*

SOLENOID - RIGHT PURGE VALVE

SOLENOID - RIGHT INLET VALVE*

ALARM CONTACTS

REMOTE STOP / START

2

2

2

2

2

2

2

2

18

18

18

0.181

0.181

0.181

4.6

4.6

4.6

0.312

0.312

0.312

7.9

7.9

7.9

18 0.181

4.6

0.312

7.9

18 0.181

4.6

0.312

7.9

18 0.181

4.6

0.312

7.9

16 0.181

4.6

0.312

7.9

16 0.181

4.6

0.312

7.9

9

10

USER

CONNECTIONS

RS232

INPUT POWER

3

3

22

14

0.114

0.230

* STANDARD PRESSURE MODELS 4100 & 5400 ONLY. HIGH PRESSURE MODELS 40 THROUGH 450 ONLY.

2.9

5.8

0.250

0.395

6.4

10.0

PG-9

PG-9

PG-9

PG-9

PG-9

PG-9

PG-9

PG-9

PG-7

PG-11

CONNECTOR

SIZE

ENCLOSURE

HOLE DIA.

in.

mm

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.492

12.5

0.733

18.6

0.87" [22 mm]

1.97" [50 mm]

4.17" [106 mm]

5.35" [136 mm]

6.54" [166 mm]

7.72" [196 mm]

8.90" [226 mm]

10.00" [254 mm]

Figure 7-5

Enclosure Penetrations - Level 1 Controller

2.74" [70 mm]

3.45" [88 mm]

— 30 —

8. Controller – Level 2

This section provides connection, adjustment and operational information for the Level 2 Controller featuring the Automatic Purge

Saving System (APSS). Similar information can be found in Section

7 for the Level 1, Fixed Cycle Controller.

8.1 Reference Figures – Level 2 Controller

Figure 8-1, Front Panel Overlay – Level 2 Controller

Figure 8-2, Electrical Schematic – Level 2 Controller

Figure 8-3, Point-to-Point Diagram – Level 2 Controller

Figure 8-4, Panel Layouts – Level 2 Controller

Figure 8-5, Enclosure Penetrations – Level 2 Controller

8.2 Connections – Level 2 Controller

See Figure 8-5, Enclosure Penetrations for the location, size and function of the various cable and cord connectors that are provided on the bottom of the Level 2 enclosure.

8.2.1 Connections - Input Power

8.2.1.1 VAC Input Power Connections

Single-phase, alternating current (AC) input power connections ranging from 85-264 VAC and 47 to 63 Hz. can be made at terminals TB6-45,

-47, and –49. See reference figures for proper polarity. These terminals are connected to accessory output terminals TB6-44, -46, and –48 respectively. Accessory output terminals can be used to direct power at the same voltage and frequency to external devices.

CAUTION: Accessory output terminals are NOT controlled by the power on/off switch and are always energized when power is provided to terminals TB6–45, -47, and -49.

8.2.1.2 VDC Power Connections

• The control and display boards operate on low-voltage direct current. The controller is provided pre-wired with an AC to 12

VDC power supply board. For users with AC power as described in Section 8.2.1.1, their AC input is directed to the power supply board where it is conditioned and returned to the control board as 12 VDC at terminals TB5-42 and –43.

• For users with direct current (DC) input power ranging from 11.5 to 28 VDC, use of the AC to DC power supply board is not needed and their connections can be made at terminals TB5-42 and –43 by first removing the black and red leads coming from the power supply board. See reference figures for proper polarity.

8.2.2 Connections – Common Alarm Contacts

Connections to voltage-free common alarm contacts with a minimum

5-amp rating can be made at terminals TB4-39 through –41.

• Terminal TB4-41 is the common contact connection.

• Terminal TB4-39 is the N.O. (normally open) contact connection.

• Terminal TB4-40 is the N.C. (normally closed) contact connection.

• The alarm relay coil is energized when power is supplied to the controller input terminals and there are no alarms.

• The coil is de-energized when power is removed or when an alarm condition exists.

• Additional information on the common alarm relay logic appears in Table 8-1.

Power

To

Controller?

No

Yes

Yes

Yes

Controller

On or

Off?

N/A

Off

On

On

Alarm or

Service

Reminder

N/A

N/A

No

Yes

Alarm

Relay

Coil

Alarm

N.O.

Contact

(TB4-39)

De-Energized Open

Energized Closed

Energized Closed

De-Energized Open

Alarm

N.C.

Contact

(TB4-40)

Closed

Open

Open

Closed

Table 8-1

Common Alarm Relay Logic –Level 2 Controller

8.2.3 Connections – Remote Start / Stop

Terminals TB2-17 and –18 are used to provide a 5 VDC output to a remote switch or volt free contacts that when closed will stop the dryer at the end of the current half cycle. The dryer will resume running at the beginning of the new half cycle when the remote switch or contacts are reopened. When dryer operation is in the remote stop state, all four tower drying (green) and regenerating (amber) LEDs flash simultaneously.

Note: Remote start / stop is disabled when the dryer is in the

Manual cycle operation mode. When the dryer is in the remote stop state, the only front panel and remote selector switches

(see Section 8.2.4) that remain enabled are the power on/off switches.

8.2.4 Connections – Remote Switches

The controller door is equipped with four momentary-contact, push button switches. Pressing on the appropriate icon printed on the display overlay actuates these switches. The display board containing the switches, display LEDs, text display, and the RPB (J2) terminal strip is mounted on the inside of the enclosure door. The terminal strip provides connection points for remotely mounted, NO (normally open), momentary-contact push buttons that provide the same function as the board mounted switches. The terminal – switch combinations are:

Terminals J2-1 and –2 (Remote “SELECT” switch)

Terminals J2-3 and –4 (Remote “ENTER” switch)

Terminals J2-5 and –6 (Remote Power On / Off Switch)

NOTE: Care must be exercised in using this remote switch to stop a dryer. Closing this switch will affect the same response as a loss of power. Both purge-repressurization valves will close. On standard pressure models 4100 &

5400 and high pressure models 40 through 450, both inletswitching valves will open. A tower that is actively purging when the power on/off button is actuated will be subjected to a rapid repressurization that can lead to fluidization and subsequent abrasion of the desiccant bed. Ideally, dryers should only be powered off during those portions of the drying cycle when both desiccant towers are at full operating pressure. Use of the remote start/stop connections as described in Section 8.2.3 would be preferable in most cases.

Terminals J2-7 and –8 (Remote Alarm Reset Switch)

— 31 —

8.2.5 Connections – RS232

RS232 connections can be made at the 3-pin connector labeled J3 and located at the upper left-hand corner of the control board. A cable for this connection can be purchased through your distributor.

8.2.6 Connections – High humidity or dew point alarm

The normally closed dry contacts from a high humidity or dew point alarm device can be wired to AUX 1 terminals TB1-7 and TB1-8. A shorting jumper that connects the two terminals must be installed if an alarm device is not wired to the terminals. When continuity between the terminals is broken, the controller displays an outlet dew point alarm

(refer to Section 8.9, screens 17 and 18). If the AUX1 terminals are in use, then the optional dew point sensor cannot be used (see 8.3.3).

8.3 Control Board Jumpers – Level 2

Refer to Figure 8-3, Point to Point Connection Diagram – Level 2

Controller. In the upper left hand corner of the control board there are eight two-pin jumpers labeled JP1 through JP8. Only two of the eight jumper pairs are utilized. Pairs JP3-JP8 are not used. NOTE: Do not

install jumpers in the ON position on pairs JP3 through JP8. The jumper is a removable bridge that is used to make or break continuity between the two pins that form a pair. When installed in the ON position, the jumper is placed on both pins of the pair and continuity between the pins is established. When installed in the OFF position, the jumper is removed or stored on a single pin and continuity is broken. Jumper functions are as follows:

8.3.1 Jumper JP1 – Maximum Operating Pressure

Jumper JP1 is used to select the maximum operating pressure.

Installed in the OFF position when operating at inlet pressures of

60 to 150 psig (4.2 to 10.5 kgf/cm

2

). Installed in the ON position when operating at inlet pressures of 120 to 250 psig (8.4 to 17.6 kgf/cm

2

).

This setting will affect tower purge and repressurization times.

8.3.2 Jumper JP2 – Electric Drains

Jumper JP2 is installed in the ON position if one or two electric demand drains are installed. It is installed in the OFF position when no electric drains are installed.

The drains can be manually tested through the Level 2 controller

Setup Mode.

The drains provide a digital alarm signal to the Level 2 controller, which then displays an alarm message.

If the dryer has only 1 drain, then the alarm input terminals for

Drain 2 (TB2-25 and TB2-26) must be shorted.

8.4 Front Panel Overlay – Level 2 Controller

Refer to Figure 8-1, Front Panel Overlay – Level 2 Controller for information regarding the location and function of the LEDs, switches, and text display.

8.4.1 Front Panel LEDs

• Power on – green (constant when controller is switched on; flashing when controller is energized but switched off.)

• Alarm – red

• Service / maintenance reminder – amber

• Filters (pre, after, and pilot) service / maintenance reminders

- amber

— 32 —

• Purge / repressurization valve status (On = valve open; Off = valve closed) – green

• Left and right tower status (regenerating) - amber

• Left and right tower status (drying) - green

• Left and right tower pressure switch status (On = switch closed;

Off = switch open) – green

8.4.2 Front Panel Switches

The front panel contains four momentary-contact push button switches.

Refer to Figure 8-1, Front panel Overlay – Level 2 Controller for the appropriate icon associated with each switch. Pushing on the overlay icon actuates the switch. Switching can be affected remotely by wiring external pushbuttons to the RPB (J2) terminals located on the rear of the display board. Refer to Section 8.2.4.

8.4.2.1 Dryer On / Off Switch

This switch is used to turn the dryer on (run) or off (stop).

Caution: In the event of a loss of power, either intentional or unintentional, both purge-repressurization valves will close. On standard pressure models 4100 & 5400 and high pressure models

40 through 450, both inlet-switching valves will open. A tower that is actively purging when the power off button is actuated will be subjected to a rapid repressurization that can lead to fluidization and subsequent abrasion of the desiccant bed. Ideally, dryers should be powered off at the end of any half cycle when both desiccant towers are at full operating pressure.

Power recovery after an external loss of power is affected by the programming of the auto restart mode (Program Mode – Screen 2).

Refer to Section 8.7 for additional information.

8.4.2.2 SELECT Switch

This button is located to the left of the text display window.

Refer to Section 8.6 for additional information.

8.4.2.3 ENTER Switch

This button is located to the right of the text display window.

Refer to Section 8.6 for additional information.

8.4.2.4 Alarm Reset Switch

This switch is normally used to reset an alarm or service reminder.

Refer to Section 8.9 for additional information.

8.5 Event Sequence and Component Status

Refer to Tables 8-2, 8-4, and 8-5 for the event sequence, timing and component status for the Level 2 Controller.

8.6 Front Panel Operation

1. There are five operating modes for the Level 2 Desiccant

Dryer Controller.

a. Program Mode b. Setup Mode c. Alarm & Service Mode d. Display Mode e. Test Mode

2. Each mode is described below.

Left tower pressure switch LED:

On=switch closed

Off=switch open

Left tower drying LED

Left purge valve LED

On=valve open

Off=valve closed

Left tower regenerating

LED

Filter service / maintenance LED

Vacuum Fluorescent

Text Display

Select switch

Power On LED

Communications icon

Power On / Off Switch

Figure 8-1

Front Panel Overlay – Level 2 Controller

(Note: Figure is representative of Standard Pressure Models 40 through 3000.)

(Note: Overlay for Standard Pressure Models 4100 & 5400 depicts a different inlet valve and outlet/purge circuit. Overlay for High Pressure Models 40 through 450 depicts a different inlet valve circuit.)

Filter service / maintenance LED

Filter service / maintenance LED

Right tower pressure switch LED:

On=switch closed

Off=switch open

Right tower drying LED

Right purge valve LED

On=valve open

Off=valve closed

Right tower regenerating LED

Enter switch

Maintenance / service reminder LED

Alarm LED

Reset switch for alarm

Also see 7.7.3, setting dew point alarm.

— 33 —

8.7 Program Mode

1. Press and hold and simultaneously for 3 seconds to enter Program Mode.

2. Program Mode is comprised of the screens that are described below.

3. There are three ways to exit Program Mode.

a. Press after making the selection in the final screen.

b. At any screen, press and hold for 3 seconds.

c. The controller automatically exits Program Mode if no button is pressed within 60 seconds.

4. Upon exiting Program Mode the controller will switch to

Display Mode.

8.7.1 Program Mode Screen 1 – Select the language.

ENGLISH

Press to scroll through the available language choices: ENGLISH, DEUTSCH, FRANCAIS, ESPANOL, and

ITALIANO.

• When finished, press to save the selection and move to

Screen 2.

8.7.2 Program Mode Screen 2 – Select the auto restart mode.

AUTO RESTART

DISABLED

Press to toggle between DISABLED and ENABLED.

When finished, press to save the selection and move to Screen 3 (if a dew point sensor is connected to AUX2) or

Screen 4 (if one is not).

8.7.3 Program Mode Screen 3 – Set the alarm point for the dew point sensor (AUX2, analog input).

DEWPOINT ALARM

±XX°C ±XXX°F

Press to increase or the ALARM RESET button to decrease the setting to the desired value. a. The default is –20°C ( –4°F) .

b. The allowable range of values is from

–5°C (–103°F) to +10°C (+50°F) .

When finished, press to save the selection and move to

Screen 4.

8.7.4 Program Mode Screen 4 – Select the service level.

SERVICE LEVEL

NORMAL

Press to toggle between NORMAL and SEVERE.

a. NORMAL service intervals are: i. 4000 hours for filters ii. 8000 hours for desiccant iii. 4000 hours for valves b. SEVERE service intervals are: i. 2000 hours for filters ii. 4000 hours for desiccant iii. 2000 hours for valves

NOTE: Time continues to accumulate as long as power

is supplied to the controller, whether the controller is switched on or off.

When finished Press to save the selection and move to

Screen 5 (if no filter monitors are detected) or Screen 6 (if 1 or 2 filter monitors are detected).

8.7.5 Program Mode Screen 5 – Reset the timer for filter service.

FILTER SERVICE

RESET? NO

Press to toggle between NO and YES.

• When finished, press to acknowledge the selection and move to Screen 6.

8.7.6 Program Mode Screen 6 – Reset the timer for desiccant service.

DESICCANT SERVICE

RESET? NO

• Press to toggle between NO and YES.

When finished, press to acknowledge the selection and move to Screen 7.

8.7.7 Program Mode Screen 7 – Reset the timer for valve service.

VALVE SERVICE

RESET? NO

Press to toggle between NO and YES.

When finished, press to acknowledge the selection and move to Screen 8.

8.7.8 Program Mode Screen 8 – Reset the valve cycle counter.

CYCLE COUNTER

RESET? NO

Press to toggle between NO and YES.

When finished, press to acknowledge the selection and exit Program Mode.

8.8 Setup Mode

Press and hold for 3 seconds to enter Setup Mode.

Setup Mode is comprised of the screens that are described below.

There are three ways to exit Setup Mode.

1. Press after making the selection in Screen 2 (if the dryer does not have electric drains) or Screen 4 (if the dryer has electric drains).

2. At any screen, press and hold for 3 seconds.

— 34 —

3. The controller automatically exits Setup Mode if no button is pressed within 60 seconds.

• One of two things will happen upon exiting Setup Mode.

1. The controller will switch to Display Mode if DEMAND

CYCLE or FIXED CYCLE was selected.

2. The controller will switch to Test Mode if MANUAL

CYCLE was selected.

8.8.1 Setup Mode Screen 1 – Select the dew point class.

ISO 8573 DEW PT

2: -40°C/-40°F

Press to scroll through the choices:

1: -73°C/-100°F

2: -40°C/-40°F

3: -20°C/-4°F

4: +3°C/+38°F

• When finished, press to save the selection and move to

Screen 2.

8.8.2 Setup Mode Screen 2 – Select the cycle type.

CYCLE TYPE

DEMAND CYCLE

• Press to scroll through the choices: DEMAND CYCLE,

FIXED CYCLE, and MANUAL CYCLE. Note: DEMAND CYCLE is not available if Class 1 was selected in the previous screen.

When finished, press to save the selection and move to

Screen 3 (if the dryer has electric drains) or exit Setup Mode

(if the dryer does not have electric drains).

8.8.3 Setup Mode Screen 3 – Test the drains.

TEST DRAIN ?

NO

Press to toggle between NO and YES.

Press to continue.

a. If NO was selected, the controller immediately exits

Setup Mode.

b. If YES was selected, the controller energizes Drain 1 and Drain 2 for 4 seconds before exiting Setup Mode.

8.9 Alarm & Service Mode

Alarm & Service Mode is active when the controller is in Display Mode.

It is not active in Program Mode, Setup Mode, or Test Mode.

NOTE: Alarm messages have priority over Service messages. Service messages have priority over Display messages. When an alarm occurs,

Display Mode is disabled and only the alarm message is shown. When a service message is active, it takes the place of the corresponding service reminder in the Display Mode (e.g. “HOURS TO SERVICE FILTERS:

XXXX” would be replaced by “SERVICE DRYER FILTERS”).

8.9.1 Alarm messages

Alarm messages are displayed on a first-out basis with one exception.

The alarm caused by an open pressure switch at the end of the regeneration cycle, takes precedence over existing alarms. See

8.9.1.1 (3).

— 35 —

8.9.1.1 Pressure Switch Alarms

There are three alarms for each tower that are triggered by the tower pressure switches. These alarms can occur in either the fixed or demand cycle. Following is a brief description of each alarm.

1. Left or right tower, drying, low pressure

Pressure switch open during drying cycle

2. Left or right tower, regenerating, high pressure

Pressure switch closed while purge valve is open (after an initial time delay)

3. Left or right tower, regenerating, low pressure

Pressure switch open at the end of the regenerating cycle

8.9.1.2 Thermistor Alarms

There are two alarms for each of the four thermistors. These alarms can only occur in the demand cycle. Following is a brief description of each alarm.

1. Left or right tower, upper or lower sensor, over-range

Temperature above 150°F (66°C)

Thermistor circuit shorted

2. Left or right tower, upper or lower sensor, under-range one cycle

Temperature below 40°F (4°C)

Thermistor circuit open

8.9.1.3 Optional Device Alarms

1. Electric Drains with Alarm Contacts

Each drain has alarm contacts that connect to the Level 2

Controller.

If the contacts open, then a drain alarm is indicated.

2. Humistat (humidity sensor) - AUX 1 input

The humistat has alarm contacts that connect to the Level

2 controller.

If the contacts open, the outlet dew point alarm is indicated.

3. Dew point sensor - AUX 2 analog input

The Level 2 Controller scales the DC analog input signal to dew point.

The user enters an alarm value through the Level 2

Controller Program Mode.

If the measured dew point exceeds the alarm value, the outlet dew point alarm is indicated.

When an alarm condition occurs, the controller operates as follows.

The alarm LED blinks and the appropriate alarm message is shown on the text display.

The dryer continues to cycle normally (see below for exception).

NOTE: The LEDs for the valves, pressure switches, and

desiccant towers are not used for alarm indication (as in the

Level 1 Controller).

If the alarm condition clears for one cycle, then the alarm LED stops blinking (LED on); the alarm message continues to be displayed.

Exception: If the alarm is caused by the condition in

Section 8.9.1, then the cycle stops. Once the alarm condition is corrected, the alarm LED stops blinking (LED on) and the cycle continues normally; the alarm message continues to be displayed.

In the demand cycle, the control switches to a fixed 10 minute cycle when the alarm LED begins blinking. Control switches back to the selected demand cycle after the alarm condition clears. This applies to pressure switch, thermistor, and outlet dew point alarms, but not to drain alarms.

When the alarm condition is corrected, press the reset button to extinguish the alarm LED and to clear the alarm message from the text display.

The following text display is shown for each alarm. The second line of the alarm screens contains up to three messages, which are scrolled through, displaying each one for 3 after the alarm condition clears seconds.

8.9.1.4 Alarm Mode Screen 1 – Left Tower Drying – Low

Pressure (Open Pressure Switch Circuit)

ALARM

LEFT TOWER

DRYING

LOW PRESSURE

8.9.1.5 Alarm Mode Screen 2 – Left Tower Regenerating – High

Pressure (Closed Pressure Switch Circuit)

ALARM

LEFT TOWER

REGENERATING

HIGH PRESSURE

8.9.1.6 Alarm Mode Screen 3 – Left Tower Regenerating- Low

Pressure (Open Pressure Switch Circuit)

ALARM

LEFT TOWER

REGENERATING

LOW PRESSURE

8.9.1.7 Alarm Mode Screen 4 – Left Tower, Upper Sensor

(Thermistor) Under-Range

ALARM

LEFT TOWER

UPPER SENSOR

UNDER-RANGE

8.9.1.8 Alarm Mode Screen 5 – Left Tower, Upper Sensor

(Thermistor) Over-Range

ALARM

LEFT TOWER

UPPER SENSOR

OVER-RANGE

8.9.1.9 Alarm Mode Screen – Left Tower, Lower Sensor

(Thermistor) Under-Range

ALARM

LEFT TOWER

LOWER SENSOR

UNDER-RANGE

8.9.1.10 Alarm Mode Screen 7 – Left Tower, Lower Sensor

(Thermistor) Over-Range

ALARM

LEFT TOWER

LOWER SENSOR

OVER-RANGE

8.9.1.11 Alarm Mode Screen 8 - Right Tower Drying – Low

Pressure (Open Pressure Switch Circuit)

ALARM

RIGHT TOWER

DRYING

LOW PRESSURE

8.9.1.12 Alarm Mode Screen 9 – Right Tower Regenerating

– High Pressure (Closed Pressure Switch Circuit)

ALARM

RIGHT TOWER

REGENERATING

HIGH PRESSURE

8.9.1.13 Alarm Mode Screen 10 – Right Tower Regenerating-

Low Pressure (Open Pressure Switch Circuit)

ALARM

RIGHT TOWER

REGENERATING

LOW PRESSURE

8.9.1.14 Alarm Mode Screen 11 – Right Tower, Upper Sensor

(Thermistor) Under-Range

ALARM

RIGHT TOWER

UPPER SENSOR

UNDER-RANGE

8.9.1.15 Alarm Mode Screen 12 – Right Tower, Upper Sensor

(Thermistor) Over-Range

ALARM

RIGHT TOWER

UPPER SENSOR

OVER-RANGE

8.9.1.16 Alarm Mode Screen 13 – Right Tower, Lower Sensor

(Thermistor) Under-Range

ALARM

RIGHT TOWER

LOWER SENSOR

UNDER-RANGE

8.9.1.17 Alarm Mode Screen 14 – Right Tower, Lower Sensor

(Thermistor) Over-Range

ALARM

RIGHT TOWER

LOWER SENSOR

OVER-RANGE

— 36 —

8.9.1.18 Alarm Mode Screen 15 – Alarm Drain 1

ALARM

DRAIN 1

8.9.1.19 Alarm Mode Screen 16 – Alarm Drain 2

ALARM

DRAIN 2

8.9.2 Service messages

There are two service levels (normal and severe) as described in Program Mode. Each service level has preset time intervals for servicing the filters, desiccant, and valves. Time continues to accumulate as long as power is supplied to the controller, whether the controller is switched on or off.

When a service time interval expires, the controller operates as follows.

The service LED blinks and the appropriate service message is shown on the text display. (See 8.9.1)

When the service interval for filters has expired the three filter

LEDs also blink. NOTE: If the dryer has 1 or 2 filter monitors, the timer for filter service is disabled. When the filter monitor(s) sends an alarm signal (change filter) to the Level 2 Controller, the controller displays the same LEDs and messages it would if the timer for filter service had expired.

The dryer continues to cycle normally. NOTE: The LEDs for

the valves, pressure switches, and desiccant towers are not used for service indication (as in the Level 1 Controller).

To extinguish the service LED and clear the service message from the text display, go to Program Mode and reset the appropriate service timer. If a filter monitor is installed, reset the monitor to clear the

Service LED.

The following text display is shown for each service message.

Replacement or repair of the affected item may or may not be necessary. The service reminders are used to schedule routine evaluation of the operational status of key components.

8.9.2.1 Service Mode Screen 1 – Service filters

SERVICE DRYER

FILTERS

Check filter Delta-P gauges and ensure that drains are functioning properly. Inspect pilot air filter element. Check filter monitors, if equipped.

8.9.2.2 Service Mode Screen 2 – Service desiccant

SERVICE DRYER

DESICCANT

Check moisture indicator or outlet dew point and inspect mufflers for excessive dusting.

8.9.2.3 Service Mode Screen 3 – Service valves

SERVICE DRYER

VALVES

Ensure that valves are cycling properly. Check for switching failure alarms and adjust purge pressure. Check for leaks.

8.10 Display Mode

Display Mode is active when the user exits Program Mode or

Setup Mode (unless MANUAL cycle was selected in Setup Mode) and no alarms are active.

The LEDs for the valves, pressure switches, and desiccant towers operate in the same manner as in the Level 1 Controller, except in the case of an alarm or service reminder (see 5.b and 7.b in

Alarm & Service Mode).

Display Mode is comprised of several screens (described below). The controller automatically scrolls through the screens, displaying each one for 4 seconds. The user can override the 4 second time period and force the next screen to be displayed by pressing .

The screens are displayed in the following sequence: 1, 2, 3A,

4, 5, 6, 1, 2, 3B, 4, 5, 6, 1, 2, 3C, 4, 5, 6, 1, 2, 3D, 4, 5, 6, … with the exceptions noted below.

8.10.1 Display Mode Screen 1 – Dew point class and cycle type.

2: -40°C/-40°F

DEMAND CYCLE

8.10.2 Display Mode Screen 2 – Energy savings.

This screen is not displayed if FIXED cycle is selected.

ENERGY SAVINGS

XX%

8.10.3 Display Mode Screen 3A – Service reminder (filters).

This screen is not displayed if 1 or 2 filter monitors are detected.

HOURS TO SERVICE

FILTERS: XXXX

8.10.4 Display Mode Screen 3B – Service reminder (desiccant).

HOURS TO SERVICE

DESICCANT: XXXX

8.10.5 Display Mode Screen 3C – Service reminder (valves).

HOURS TO SERVICE

VALVES: XXXX

8.10.6 Display Mode Screen 3D – Valve cycle counter.

CYCLE COUNTER

XXXXXXX

8.10.7 Display Mode Screen 4 – Dryer outlet dew point, (AUX2, analog input).

This screen is not displayed if jumper 3 is not installed.

OUTLET DEW POINT

±XX°C ±XXX°F

8.10.8 Display Mode Screen 5 – Dryer inlet pressure, (AUX3, analog input).

This screen is not displayed if jumper 4 is not installed.

INLET PRESSURE

XXBARG XXXPSIG

— 37 —

8.10.9 Display Mode Screen 6 – Dryer inlet temperature, (AUX3, analog input).

This screen is not displayed if jumper 5 is not installed.

INLET TEMP.

±XX°C ±XXX°F

8.11 Test Mode

• Test Mode is active when the user exits Setup Mode after selecting operation in MANUAL CYCLE.

• Test Mode is comprised of eight screens (descriptions follow the table below). Each screen corresponds to one of eight program steps (described in the table below).

Press to advance from one screen (program step) to the next. Be sure to read and understand all cautions listed with the

screen (program step) descriptions.

If the temperature is below 40°F or the thermistor circuit is open, the second line of the display will read “UNDER-RANGE” instead of the temperature reading. (Refer to screens 2, 3, 4, 6, 7, and

8.)

If the temperature is above 150°F or the thermistor circuit is shorted, the second line of the display will read “OVER-RANGE” instead of the temperature reading. (Refer to screens 2, 3, 4, 6,

7, and 8.)

Upon entering Test Mode, the program can be at any one of the eight steps.

To exit Test Mode:

1. Use to manually advance the program to step 1 or 5.

a) The program must be set at step 1 or 5 to exit Test

Mode.

b) Screen 9 is displayed for 3 seconds if the user attempts to exit the program from step 2, 3, or 4.

c) Screen 10 is displayed for 3 seconds if the user attempts to exit the program from step 6, 7, or 8.

2. Press and hold for 3 seconds to exit Test Mode. The display switches to Screen 2 of Setup Mode.

3. Use to select DEMAND CYCLE or FIXED CYCLE.

4. Press to accept the selection and activate Display

Mode.

8.11.1 Test Mode Screen 1 – Step 1

TEST MODE STEP 1

OK TO EXIT NOW

• No temperature display on this screen.

Press to advance to screen 2.

8.11.2 Test Mode Screen 2 – Step 2

TEST MODE STEP 2

XX°C XXX°F

The left tower drying light is blinking to indicate the thermistor location (upper left) that corresponds to the temperature display.

• Press to advance to screen 3.

8.11.3 Test Mode Screen 3 – Step 3

TEST MODE STEP 3

XX°C XXX°F

• The right tower regenerating light is blinking to indicate the thermistor location (lower right) that corresponds to the temperature display.

Press to advance to screen 4.

8.11.4 Test Mode Screen 4 – Step 4

TEST MODE STEP 4

XX°C XXX°F

The left tower drying light is blinking to indicate the thermistor location (upper left) that corresponds to the temperature display.

Caution: Do not advance to step 5 until the right tower

has fully pressurized.

Press to advance to screen 5.

8.11.5 Test Mode Screen 5 – Step 5

TEST MODE STEP 5

OK TO EXIT NOW

• No temperature display on this screen.

Press to advance to screen 6.

8.11.6 Test Mode Screen 6 – Step 6

TEST MODE STEP 6

XX°C XXX°F

The right tower drying light is blinking to indicate the thermistor location (upper right) that corresponds to the temperature display.

• Press to advance to screen 7.

8.11.7 Test Mode Screen 7 – Step 7

TEST MODE STEP 7

XX°C XXX°F

The left tower regenerating light is blinking to indicate the thermistor location (lower left) that corresponds to the temperature display.

Press to advance to screen 8.

8.11.8 Test Mode Screen 8 – Step 8

TEST MODE STEP 8

XX°C XXX°F

The right tower drying light is blinking to indicate the thermistor location (upper right) that corresponds to the temperature display.

Caution: Do not advance to step 1 until the left tower has

fully pressurized.

Press to advance to screen 1.

— 38 —

Program Step

Left tower status

Right tower status

Left tower pressure switch

1

drying regen.

closed

2

drying regen.

closed

3

drying regen.

closed

4

drying regen.

closed

5

regen.

drying closed

Right tower pressure switch

Left inlet solenoid

(see Note 1)

Left purge solenoid

Right inlet solenoid

(see Note 1)

Right purge solenoid

closed off off off off closed off off on off closed at start, open at end off off on on open at start, closed at end off off on off closed off off off off

Inlet shuttle valve

(see Note 2)

Left inlet valve

(see Note 1) open open open to left chamber open open open

Left purge valve

Right inlet valve

(see Note 1)

Right purge valve

closed open closed closed closed closed closed closed open closed closed closed closed open closed

Temperature display thermistor location

none upper left lower right upper left none

Note 1: Standard Pressure Models 4100 & 5400 ONLY. High Pressure Models 40 through 450 ONLY.

Note 2: Standard Pressure Models 40 through 3000 ONLY.

Table 8-2

Cycle Sequence Steps

closed closed open closed upper right

6

regen.

drying closed closed

7

regen.

drying closed at start, open at end closed on off off on on off off off open to right chamber closed open open closed lower left

8

regen.

drying open at start, closed at end closed on off off off closed closed open closed upper right

8.11.9 Test Mode Screen 9 – Attempting to exit test mode from step 2, 3, or 4

TO EXIT TEST

GO TO STEP 5

• This screen is displayed for 5 seconds if the user attempts to exit test mode from step 2, 3, or 4.

• At the end of the 5-second time period, the display returns to the previous screen (2, 3, or 4).

8.11.10 Test Mode Screen 10 – Attempting to exit test mode from step 6, 7, or 8.

TO EXIT TEST

GO TO STEP 1

This screen is displayed for 5 seconds if the user attempts to exit test mode from step 6, 7, or 8.

At the end of the 5-second time period, the display returns to the previous screen (6, 7, or 8).

— 39 —

Dryer MOP

ISO Class

Dew Point

Cycle Time (minutes)

Time t2 t3 t4 t5 t6 t0 t1 t7 t8

00:00

00:02

00:06

01:12

02:00

02:02

02:06

03:12

04:00

1

-73°C

-100°F

4

01:06

2

60-150 psig

3

-40°C

-40°F

-20°C

-4°F

10 16

Time from start of cycle

(minutes : seconds)

00:00 00:00

00:02

00:06

04:00

05:00

00:02

00:06

06:55

08:00

05:02

05:06

09:00

10:00

4

+3°C

+38°F

24

00:00

00:02

00:06

10:50

12:00

08:02

08:06

14:55

16:00

Reference Data

12:02

12:06

22:50

24:00

03:54 06:49 10:44

00:00

00:02

00:06

00:48

02:00

02:02

02:06

02:48

04:00

5

-73°C

-100°F

4

120-250 psig

6 7

-40°C

-40°F

-20°C

-4°F

10 16

Time from start of cycle

(minutes : seconds)

00:00 00:00

00:02

00:06

03:00

05:00

00:02

00:06

05:40

08:00

05:02

05:06

08:00

10:00

08:02

08:06

13:40

16:00

8

+3°C

+38°F

24

00:00

00:02

00:06

09:20

12:00

12:02

12:06

21:20

24:00

Purge time (min:sec)

[(t3-t2) or (t7-t6)]

Repress. time (min:sec)

[(t4-t3) or (t8-t7)]

00:48 01:00 01:05 01:10

00:42

01:12

02:54

02:00

05:34

02:20

09:14

02:40

NOTE: When operated in the Demand Mode, drying times t4-t0 and t8-t4 can extend to a maximum of 30 minutes each. Purge times in the

Demand Mode, regardless of the ISO Class selection, will always be equal to the purge times of the ISO Class 2 (10 min.) Fixed Cycle (3:54 for

150 psig MOP and 2:54 for 250 psig MOP).

Table 8-3

Fixed Cycle Timing – Level 2 Controller

— 40 —

Process valve name

(Process valve state w/ de-energized pilot solenoid valve)

t0 t1 t2

Left Tower Drying

Right Tower Regenerating

Half Cycle

t3

Time (refer to Table 8-3) t4 t5 t6

Right Tower Drying

Left Tower Regenerating

Half Cycle

Pilot Energized

(open)

t7

Left purge valve

(normally closed)

Left inlet valve (normally open)

(See NOTE 1)

Right inlet valve (normally open)

(See NOTE 1)

Right purge valve

(normally closed)

Pilot Energized (closed)

Pilot Energized

(open)

Pilot Energized (closed)

Normal status of pressure switches

Left tower pressure switch

Right tower pressure switch closed closed closed closed closed closed for < 5 sec. then open closed open at t3, closed before t4 closed closed closed closed closed for < 5 sec. then open closed open at t7, closed before t8 closed

Pressure switch status that causes an alarm

Left tower drying

Low tower pressure a

Left tower regenerating

Fail to de-pressurize b

Left tower regenerating

Fail to re-pressurize c

Right tower drying

Low tower pressure d open

1 open

1 closed

1 open

1 open

2 open

1

Right tower regenerating

Fail to de-pressurize e

Right tower regenerating

Fail to re-pressurize f closed

1 open

2

Note

Stop cycle on fault

Comments

1: Check for fault condition at 15, 25,

35,... seconds into the half-cycle no

If the fault condition is clear for 1 cycle: the alarm LED stays on (without blinking) and the alarm message continues to be displayed. Once the fault condition is clear, pressing the reset button will clear the alarm LED and message.

2: Check for fault condition just before the end of the half-cycle yes

If the fault condition clears: tower cycling resumes and the alarm LED stays on (without blinking). Once the fault condition is clear, pressing the reset button will clear the alarm LED and message.

a: Blink the Alarm LED and display the following text message: Alarm + Left Tower Drying + Low Pressure b: Blink the Alarm LED and display the following text message: Alarm + Left Tower Regenerating + High Pressure c: Blink the Alarm LED and display the following text message: Alarm + Left Tower Regenerating + Low Pressure d: Blink the Alarm LED and display the following text message: Alarm + Right Tower Drying + Low Pressure e: Blink the Alarm LED and display the following text message: Alarm + Right Tower Regenerating + High Pressure f: Blink the Alarm LED and display the following text message: Alarm + Right Tower Regenerating + Low Pressure

NOTE 1: Standard Pressure Models 4100 & 5400 ONLY. High Pressure Models 40 through 450 ONLY

t8

Table 8-4

Event Sequence and Component Status – Level 2 Controller

— 41 —

24

25

22

23

19

20

21

17

18

15

16

12

13

14

05

06

07

03

04

01

02

08

09

10

11

38

39

36

37

33

34

35

40

31

32

29

30

26

27

28

46

47

44

45

48

49

50

41

42

43

51

52

53

54

55

56

CUSTOMER

AC POWER

CONNECT�ONS

85-264 �A C

1 PHASE

47-63 H�

SEE NOTE 1

OPT�ONAL

CUSTOMER

DC POWER

CONNECT�ONS

11.5-28 �DC

SEE NOTE 2

COMMON

ALARM

CONNECT�ONS

SEE NOTE 5

HOT

BLK

NEUTRAL

WHT

PE

GRN/YEL

POS.(+)

NEG.(-)

TB5-43

TB5-42

TB4-41

TB4-40

TB4-39

TB4-38

ELECTR�C DRA�N 2

TB4-37

TB4-36

TB6-49

TB6-48

TB6-47

TB6-46

TB6-45

TB6-44

ELECTR�C DRA�N 1

TB4-35

TB3-33

LE�T PURGE �A L� E

TB3-34

TB3-31

LE�T �NLET �A L� E

(SEE NOTE 6)

TB3-32

TB3-29

RIGHT PURGE VALVE

TB3-30

TB3-27

RIGHT INLET VALVE

(SEE NOTE 6)

TB3-28

TB2-25

DRAIN ALARM 2

TB2-26

TB2-23

DRAIN ALARM 1

TB2-24

AC TO DC

POWER SUPPLY

BOARD

NEG. (-)

BLACK POS. (+)

RED

DT2_COM

DT2_NO

DT1_COM

DT1_NO

+5

+5

+5

+12

+12

+12

+12

TB2-21

1

4

PRESSURE SWITCH 2 (RIGHT TOWER)

TB2-22

86

87

88

89

90

91

92

93

94

99

100

95

96

97

98

79

80

77

78

81

82

83

84

85

63

64

65

66

67

68

69

70

71

72

73

74

75

76

57

58

59

60

61

62

101

102

103

104

105

106

4

1 t°

LEFT TOP

THERMISTOR

TB1-16 t°

LEFT BOTTOM

THERMISTOR

TB1-14 t°

RIGHT TOP

THERMISTOR

TB1-12 t°

RIGHT BOTTOM

THERMISTOR

TB1-10

AUX 1

AUX 2

AUX 3

AUX 4

TB2-19

TB2-17

REMOTE START/STOP

TB2-18

TB1-15

TB1-13

TB1-11

TB1-9

TB1-7

TB1-8

TB1-5

TB1-6

TB1-3

TB1-4

TB1-1

TB1-2

+5

PRESSURE SWITCH 1 (LEFT TOWER)

TB2-20

+5

+5

+5

+5

+5

+

+

+

+

C

C

C

C

C

C

C

C

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

139

140

141

142

143

144

145

110

111

112

113

114

115

116

107

108

109

�1-12

�1-31

�1-28

�1-27

�1-25

�1-26

�1-8

�1-29

�1-15

�1-11

�1-3

�1-6

�1-5

�1-10

�1-9

�1-7

�1-30

�1-32

�1-17

�1-19

�1-18

�1-21

�1-1

�1-34

�1-2

�1-4

�1-33

�1-13

�1-14

�1-20

�1-22

�1-24

+5

AD4

AD3

AD2

AD1

E

R/W

RS

+5

+5

+5

+5

G

G

G

G

G

G

A

A

A

A

A

R

G

G

A

G

+5�

SER��CE MA�N

SER��CE 1

SER��CE 2

SER��CE 3

LE�T �NLET (SEE NOTE 6)

R�GHT �NLET (SEE NOTE 6)

LE�T PURGE

R�GHT PURGE

PRESSURE SW�TCH 1

PRESSURE SW�TCH 2

LE�T TOWER DRY�NG

LE�T TOWER REGEN

R�GHT TOWER DRY�NG

R�GHT TOWER REGEN

COMMON ALARM

POWER ON

REMOTE PUSHBUTTON

CONNECTOR

VACUUM

FLUORESCENT

TEXT DISPLAY

SELECT

�2-1

ENTER

�2-3

POWER

ON/O��

�2-5

ALARM

RESET

�2-7

NOTES:

1. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS AC (ALTERNATING CURRENT). TERMINALS TB6-44, TB6-46 AND TB6-48 CAN BE USED TO PROVIDE ACCESSORY POWER AT THE SAME VOLTAGE AND

FREQUENCY. AC POWER IS DIRECTED TO POWER SUPPLY BOARD WHERE IT IS CONVERTED TO 12 VDC AND RETURNED TO THE CONTROL BOARD.

2. CUSTOMER POWER CONNECTIONS WHEN SUPPLY VOLTAGE IS DC (DIRECT CURRENT). RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER SHOULD

MAKE THEIR POWER CONNECTIONS AT TERMINALS TB5-42 AND TB5-43.

3. VOLTAGE RATING OF VALVES IS 12 VDC.

4. VOLTAGE RATING OF SWITCHES IS 5 VDC.

5. WITH UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB4-39 AND TB4-41. CONTACTS ARE RATED AT 5 AMPS.

6. STANDARD PRESSURE MODELS 4100 & 5400 ONLY. HIGH PRESSURE MODELS 40 THROUGH 450 ONLY.

�2-2

�2-4

�2-6

�2-8

Figure 8-2

Electrical Schematic – Level 2 Controller

— 42 —

J2 (RPB)

1 2 3 4 5 6 7 8

SELECT

ENTER

ENCLOSURE DOOR INTERIOR

1 2 3 4

5 6

7 8

REMOTE PUSHBUTTON

SWITCH CONNECTIONS

POWER ON / OFF

ALARM_RESET

Figure 8-3

(continued on next page)

Point-to-Point Diagram – Level 2 Controller

— 43 —

JUMPER

ENCLOSURE

INTERIOR

J3

J1

J4

POWER SUPPLY

JP1

J5

J8

RED

BLK

BLACK

WHITE

GRN/YEL

RED

BLACK

JP8

1 2 3

4

5 6 7 8 9

10

11 12

13

14 15

16 17

18

19

20 21 22 23 24 25 26 27 28 29

30 31

32 33 34

35

36

37 38

39 40 41

TB1 TB2 TB3 TB4

CUSTOMER

AC POWER

CONNECTIONS

85-264 VAC

47-63 HZ

CUSTOMER

DC POWER

CONNECTIONS

11.5-28 VDC

JUMPER PINS

JUMPER BASE

RIGHT_BTM_THERM

RIGHT_TOP_THERM

ALARM CONTACTS

TEST DRAIN 2

TEST DRAIN 1

JUMPER

ON

LEFT_BTM_THERM

JUMPER

OFF

LEFT_TOP_THERM

JUMPERS

JUMPER NO. &

FUNCTION

JP1 - MAXIMUM OPERATING PRESSURE

JP2 - DRAIN TEST FUNCTIONAL

JP3 - (NOT USED)

JP4 - (NOT USED)

JP5 - (NOT USED)

JP6 - (NOT USED)

JP7 - (NOT USED)

JP8 - (NOT USED)

JUMPER

OFF

150 PSIG

NO

--

--

--

--

--

--

JUMPER

ON

250 PSIG

YES

--

--

--

--

--

--

REMOTE START / STOP

4 1

+5

LEFT TOWER PRESSURE SWITCH

4 1

+5

RIGHT TOWER PRESSURE SWITCH

DRAIN ALARM 1

LEFT PURGE VALVE

+12

LEFT INLET VALVE

(SEE NOTE 5)

+12

RIGHT PURGE VALVE

+12

RIGHT INLET VALVE

(SEE NOTE 5)

+12

DRAIN ALARM 2

NOTES:

1. SEE FIGURE 8-5 FOR RECOMMENDED AWG CONDUCTOR SIZES.

2. CUSTOMER SUPPLIED AC (ALTERNATING CURRENT) INPUT POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB6-44, TB6-46 AND TB6-48. FOR CUSTOMER SUPPLIED DC (DIRECT CURRENT) POWER,

THE RED AND BLACK WIRES FROM THE POWER SUPPLY BOARD SHOULD BE REMOVED AND THE CUSTOMER POWER CONNECTIONS SHOULD BE MADE AT TERMINALS TB5-42 AND TB5-43.

3. IN THE ‘JUMPER OFF’ POSITION, THE JUMPER CAN BE COMPLETELY REMOVED OR STORED ON A SINGLE PIN. IN THE ‘JUMPER ON’ POSITION, THE JUMPER IS INSTALLED ACROSS BOTH PINS TO PROVIDE

CONTINUITY.

4. WITH UNIT ON AND NO ALARMS, THERE SHOULD BE CONTINUITY BETWEEN TERMINALS TB4-39 AND TB4-41. CONTACTS ARE RATED AT 5 AMPS.

5. STANDARD PRESSURE MODELS 4100 & 5400 ONLY. HIGH PRESSURE MODELS 40 THROUGH 450 ONLY.

Figure 8-3 (continued from previous page)

Point-to-Point Diagram – Level 2 Controller

— 44 —

7L 8L

6L

5L

4L

3L

16L

12L

11L

10L

1L

1PB

VACUUM FLOURESCENT

TEXT DISPLAY

4PB

3PB

2PB

LEGEND

1L SERVICE REMINDER 3 - PRE FILTERS (AMBER)

3L LEFT TOWER REGENERATING (AMBER)

4L LEFT PURGE VALVE OPEN (GREEN)

5L LEFT TOWER DRYING (GREEN)

6L PRESSURE SWITCH 1 (LEFT TOWER) CLOSED (GREEN)

7L SERVICE REMINDER 1 - PILOT AIR FILTER (AMBER)

8L SERVICE REMINDER 2 - AFTER FILTERS (AMBER)

10L RIGHT TOWER REGENERATING (AMBER)

11L RIGHT PURGE VALVE OPEN (GREEN)

12L RIGHT TOWER DRYING (GREEN)

13L POWER ON INDICATOR (GREEN)

14L MAIN SERVICE REMINDER (AMBER)

13L 14L

ENCLOSURE DOOR EXTERIOR

15L

15L COMMON ALARM (RED)

16L PRESSURE SWITCH 2 (RIGHT TOWER) CLOSED (GREEN)

1PB SELECT SWITCH

2PB POWER ON/OFF SWITCH

3PB ALARM RESET SWITCH

4PB ENTER SWITCH

CNTRLPCB CONTROL BOARD

CR ALARM CONTROL RELAY

DISPPCB DISPLAY BOARD

JMP CONFIGURATION JUMPERS

J1 FILTER MONITOR 2 CONNECTOR

J2 FILTER MONITOR 1 CONNECTOR

J3 RS232 SERIAL I/O CONNECTOR

J4 PICPROG. CONNECTOR

J6 XILINX PROGRAM CONNECTOR

J7 POWER SUPPLY INPUT CONNECTOR

PS AC TO DC POWER SUPPLY

RPB REMOTE SWITCH TERMINALS

TB1 ANALOG INPUT TERMINALS

TB2 SWITCH INPUT TERMINALS

TB3 VALVE OUTPUT TERMINALS

TB4 CONTACT OUTPUT TERMINALS

TB5 DC POWER INPUT TERMINALS

TB6 AC POWER INPUT TERMINALS

Figure 8-4

(continued on next page)

Panel Layout – Level 2 Controller

(Note: Figure is representative of Standard Pressure Models 40 through 3000.)

(Note: Overlay for Standard Pressure Models 4100 & 5400 depicts a different inlet valve and outlet/purge circuit. Overlay for High Pressure Models 40 through 450 depicts a different inlet valve circuit.)

— 45 —

RPB

1 2 3 4 5 6 7 8

DISPPCB

J1

J2

JMP

CNTRLPCB

J3 J4

ENCLOSURE DOOR INTERIOR

J6

PS

J7

U5

C5

J1

J3

R52

C10

L2

C21

J7

J2

L3

L4

L5

R1

R2

R3

R4

R5

R6

R7

R8

R9 R10

JP1

JP2

JP3

JP4

JP5

JP6

JP7

JP8

C13

C1

C14

U4

C15

R16

C11

F1

U3

R15

U2

C22

J4

C23

R21

J5

J8

L6

C36

C32

R30

C42

R34

Q1

D7

C46

C47

K1

R37

FL9 D11

C55

VR1

F2 R49

46

45

44

43

42

49

48

47

R50

C52

U12

U9

L7

C20 C18

R14

FL1 FL2

FL3

FL4

FL5

FL6

FL7 FL8

U6

C29

U7

C33

U8

C39

C38

U10

C43

D2 D3

D5

D6

U11

C48

D8

R42

C53

R40 R41

R44

R43

Q2

R48

R45

R47

D13

Q3

D14

D10 D12

K2 K3 K4

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41

L

L

N

N

PE

PE

DC

DC

R51

TB6

TB5

CR

TB1 TB4

CONTACTS

TB2

ENCLOSURE INTERIOR

TB3

Figure 8-4 (continued from previous page)

Panel Layout – Level 2 Controller

— 46 —

LOCATION FUNCTION

# OF

CONDUCTORS

AWG

SIZE

CABLE DIAMETER RANGE

MIN. DIA. MAX. DIA.

in.

mm in.

mm

1

2

10

11

8

9

12

13

5

6

7

3

4

FACTORY

CONNECTIONS

OPTIONAL

DEVICES

FACTORY

CONNECTIONS

STANDARD

DEVICES

HUMIDITY-DEW POINT SENSOR

DRAIN 1 (POWER & TEST)

DRAIN 1 (ALARM)

DRAIN 2 (POWER & TEST)

DRAIN 2 (ALARM)

FILTER MONITOR 1

FILTER MONITOR 2

ANALOG INPUT 1

ANALOG INPUT 2

ANALOG INPUT 3

THERMISTOR 1 LEFT TOWER - UPPER

THERMISTOR 2 RIGHT TOWER - UPPER

THERMISTOR 3 LEFT TOWER - LOWER

THERMISTOR 4 RIGHT TOWER - LOWER

PRESSURE SWITCH - RIGHT TOWER

PRESSURE SWITCH - LEFT TOWER

SOLENOID - LEFT PURGE VALVE

SOLENOID - LEFT INLET VALVE*

SOLENOID - RIGHT PURGE VALVE

SOLENOID - RIGHT INLET VALVE*

ALARM CONTACTS

2

4

2

4

2

TBD

TBD

2

2

2

2

2

2

2

2

2

2

2

2

2

2

22

22

18

18

18

18

18

16

22

22

22

22

18

0.230

0.230

0.181

0.181

0.181

0.181

0.181

0.181

0.114

0.114

0.114

0.114

0.181

14

15

16

USER

CONNECTIONS

REMOTE STOP / START

RS232

INPUT POWER

2

3

3

16

22

14

* STANDARD PRESSURE MODELS 4100 & 5400 ONLY. HIGH PRESSURE MODELS 40 THROUGH 450 ONLY.

0.181

0.114

0.230

5.8

5.8

2.9

2.9

2.9

2.9

4.6

4.6

4.6

4.6

4.6

4.6

4.6

4.6

2.9

5.8

0.395

0.395

0.250

0.250

0.250

0.250

0.312

0.312

0.312

0.312

0.312

0.312

0.312

0.312

0.250

10.0

10.0

7.9

7.9

7.9

7.9

7.9

7.9

6.4

6.4

6.4

6.4

7.9

7.9

6.4

0.395

10.0

CONNECTOR

SIZE

ENCLOSURE

HOLE DIA.

in.

mm

PG-11

PG-11

PG-7

PG-7

PG-7

PG-7

PG-9

PG-9

PG-9

PG-9

PG-9

PG-9

PG-9

PG-9

PG-7

PG-11

0.733

0.733

18.6

18.6

0.492

12.5

0.492

12.5

0.492

12.5

0.492

12.5

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.599

15.2

0.492

12.5

0.733

18.6

0.87" [22 mm]

1.97" [50 mm]

1

3 5

7 9 11 13

15

2

4 6

8 10 12 14

2.20" [56 mm]

3.15" [80 mm]

1.10" [28 mm]

4.17" [106 mm]

5.35" [136 mm]

6.54" [166 mm]

7.72" [196 mm]

8.90" [226 mm]

10.00" [254 mm]

BOTTOM VIEW - HINGE LEFT

16

Figure 8-5

Enclosure Penetrations – Level 2 Controller

2.74" [70 mm]

3.45" [88 mm]

— 47 —

9. Operation

9.1 Start-up

9.1.1 Controller Settings (Level 1 or Level 2 Controller)

• Set or verify settings on the Level 1 or Level 2 Controller. General information regarding both controllers can be found in section 5.

Detailed operational points are presented in sections 7 and 8.

WARNING - Enclosure may have live electric parts. De-energize dryer before opening enclosure.

If a Cycle or Energy (purge) Savings % change is made while the dryer is operating, the change will occur at the end of the current half-cycle. If it is necessary to begin a new selection immediately, shut the unit off and then back on. Note: A tower that

is actively purging when the power on/off button is actuated will be subjected to a rapid repressurization that can lead to fluidization and subsequent abrasion of the desiccant bed.

Ideally, dryers should only be powered off during those portions of the drying cycle when both desiccant towers are

at full operating pressure.

If switching to a cycle mode producing a lower dew point (e.g. 0°F to -40°F [-17.8°C to -40°C]) while the dryer is operating, one or two days of operation may be needed before the new dew point is achieved.

9.1.2 Initial Pressurization

SLOWLY pressurize dryer to full line pressure. (If the dryer was installed with inlet and outlet isolation valves, the inlet isolation valve should be slowly opened while the outlet isolation valve remains closed.)

During initial start-up, check the entire system for leaks. If necessary, de-pressurize the dryer and correct any leaks.

9.1.3 Energizing the Dryer

(Timer Based Controller) Energize the dryer using the disconnect fuse located next to the customer connections in the bottom of the control box.

(Level 1 or Level 2 Controller) Energize the dryer using the power switch located on the control panel.

NOTE: The switching failure alarm may be activated if the unit is energized before it is pressurized. To deactivate alarm, allow dryer to cycle to next step and press the reset button.

9.1.4 Adjusting the Purge Rate

Determine the following:

Maximum operating pressure (MOP) of dryer from the dryer serial number tag.

Air pressure at inlet to dryer.

ISO Class cycle setting (Class 1, 2, 3, or 4). Note: For units

with the Level 2 Controller and the Automatic Purge Saving

System in the demand cycle mode use the ISO Class 2 (10 min.) purge pressure settings only.

Energy (purge) Savings % setting. This setting is applicable to the Level 1 Controller only.

9.1.4.1 Purge Rate Pressure – Models 40 to 3000

Refer to Table 9-4 for the proper purge rate pressure setting corresponding to the conditions listed in Section 9.1.4. Note: For

units with the Level 2 Controller and the Automatic Purge

Saving System in the demand cycle mode use the ISO Class

2 (10 min.) purge pressure settings only.

Adjust purge rate valve until purge pressure gauge indicates the required pressure. The purge pressure adjustment valve on Models 40 through 3000 is a quarter-turn ball valve located in the smaller bypass line of the upper piping in the rear of the dryer. Refer to Figure 4-2. Models 40 through 3000 use a double orifice purge circuit. Equally sized orifices are located at either end of the bypass line. The purge pressure adjustment valve, and a pressure tap for the purge pressure gauge are piped between the two orifices. Looking at the front of the dryer, when the left tower is drying and the right tower is purging, purge air flows from left to right through the first orifice, then the purge pressure adjustment valve, past the pressure tap for the purge pressure gauge, through the second and final orifice and into the offline tower. The pressure in the purge circuit just before the final orifice controls the purge flow rate. Because the purge pressure tap lies between the purge pressure adjustment valve and the orifice closest to the right hand tower, the purge pressure can only be correctly read and adjusted when the purge flow is from left to right. This only occurs when the right hand tower is actively purging. IMPORTANT: Purge pressure adjustment must be

made while the RIGHT HAND TOWER AS SEEN FROM THE

FRONT OF THE UNIT is regenerating and the right hand tower is actively purging (the purge valve associated with the right

tower is open and air is exhausting from its muffler). Due to the symmetry of the design, identical orifices at opposite ends and the bi-directional flow characteristics of the purge pressure adjustment ball valve, purge flow will be similar when towers switch and the purge flow is from the drying tower on the right towards the regenerating tower on the left. Purge pressure as indicated by the purge pressure gauge should be disregarded during this half of the operating cycle.

The purge pressure adjustment valve should never be fully closed.

Proper purge flow is required to regenerate and re-pressurize the offline tower. Should the tower fail to re-pressurize, a switching failure alarm will be initiated, and the cycle will be stopped before tower switch over.

After the purge pressure has been correctly set, the handle of the purge pressure adjustment valve may be removed and stored to prevent tampering with the setting.

9.1.4.2 Purge Rate Pressure – Models 4100 to 5400

Refer to Table 9-4 for the proper purge rate pressure setting corresponding to the conditions listed in Section 9.1.4. Note: For

units with the Level 2 Controller and the Automatic Purge

Saving System in the demand cycle mode use the ISO Class

2 (10 min.) purge pressure settings only.

Adjust purge rate valve until purge pressure gauge indicates the required pressure. The purge pressure adjustment valve on

Models 4100 through 5400 is a globe valve located in the smaller by-pass line of the upper piping in the front of the dryer. Refer to

Figure 4-3. IMPORTANT: Adjustment must be made while

either tower is purging (air exhausting from muffler).

— 48 —

• The purge pressure adjustment valve should never be fully closed.

Proper purge flow is required to regenerate and re-pressurize the offline tower. Should the tower fail to re-pressurize, a switching failure alarm will be initiated, and the cycle will be stopped before tower switch over.

• After the purge pressure has been correctly set, the handle of the purge pressure adjustment valve may be removed and stored to prevent tampering with the setting.

Insufficient purge air will eventually result in saturation of the desiccant beds and wet air downstream. Verify that maximum operating pressure mode, cycle time, energy (purge) savings percent selection, and purge pressure are correctly set.

9.1.5 Bringing the Dryer Online

Establish a normal flow through the dryer. Slowly open the outlet isolation valve if present. Close any dryer by-pass valves.

NOTE: When dew points below -40°F (-40°C) are required, the dryer must be run with an inlet flow rate of less than 50% of maximum until the desired dew point is attained. Depending on the initial dryness of the desiccant, this can take as long as 2 to 3 days. This stabilization period is required on initial startup, after the dryer has been shutdown for extended periods of time, or after dryer maintenance (desiccant change, etc.) has been performed.

9.1.6 Readjusting the Purge Rate

With the inlet pressure to the dryer at its minimum level, readjust the purge pressure per the instructions in Section 9.1.4.

NOTE: Adjustment must be made while the appropriate tower is purging (air exhausting from muffler).

9.2 Operational Check Points

9.2.1 Power to unit

Check periodically that there is power to the unit (indicating lights illuminated).

9.2.2 Moisture Indicator

Every four hours check moisture indicator. Indicator should be green.

The color change moisture indicator indicates the outlet relative humidity of the desiccant dryer.

Green indicates a R.H. below 3% and yellow indicates a R.H. above 3%. Table 9-5 cross references outlet pressure dew points to moisture indicator changes from green to yellow at various inlet temperatures.

NOTE: During start-up the indicator may be yellow, however, it should begin to change to green within four hours.

9.2.3 Purge Pressure Setting

Every four hours check the purge pressure gauge for the proper setting and adjust as required. Adjustment should be made when the inlet pressure to the dryer is at its minimum level. NOTE: Adjustment must be made while the appropriate tower is purging (air exhausting from muffler).

9.2.4 Alarms

Periodically check for flashing red alarm LED.

9.2.4.1 Alarms –Level 1 Controller

Alarm light will flash if either tower fails to pressurize or de-pressurize to the required levels at the proper time. Refer to Section 7.4.3 and

Table 7.6.

NOTE: Alarm will activate if dryer is energized without being pressurized. If this occurs, allow dryer to cycle to next step and press reset button. Alarm light will continue to illuminate even if fault clears.

To clear alarm, press reset button.

If the tower being regenerated fails to re-pressurize, the dryer will not switch towers. The switching failure alarm will be activated and the dryer will remain in this mode until the tower re-pressurizes.

9.2.5 Tower Status LEDs

Illuminated LEDs indicate which tower is on-line drying or off-line regenerating.

9.2.6 Tower Pressure Gauges

Periodically check tower pressure gauges to verify that the pressure gauge of the online tower reads line pressure and the pressure gauge of the offline tower reads below 2 psig (0.14 kgf/ cm

2

).

NOTE: Read the offline tower pressure gauge when the tower is purging (air exhausting from muffler).

9.2.7 Check Mufflers For Back Pressure

Excessive back pressure may result due to the accumulation of desiccant fines (dust) in the muffler cartridges. This sometimes occurs after start-up due to dusting of the desiccant during tower filling and dryer transport. If the tower pressure gauge of the off-stream tower rises above 5 psig (3.5 kgf/ cm

2

), the muffler elements should be replaced.

9.2.8 Process Valves

Determine if air control valves are operating and sequencing correctly.

Refer to Section 3.3 for a general description of operating sequence.

Refer to Tables 7-3 and 7-4 for time sequences for Level 1 Controllers.

Refer to Tables 8-4 and 8-5 for time sequences for Level 2 Controllers.

9.2.8.1 Valves – Models 40 through 3000

Inlet/Outlet switching valves are non-lubricated shuttle valves.

Pressure differences between the online and offline desiccant towers cause the shuttle valve to shift.

High Pressure Models 40 through 450 ONLY. Inlet switching valves are normally open, pneumatically piston-actuated, Y-angle poppet valves. A yellow indicator can be seen through a clear window at the top of the actuator when the valve is in the open position.

Purge/repressurization valves are normally closed, pneumatically piston-actuated, Y-angle poppet valves. A yellow indicator can be seen through a clear window at the top of the actuator housing when the valve is in the open position.

12 volt DC, normally-closed, 3-way pilot solenoid valves are wired to the controller and are used to direct pilot air to the actuators of the purge/repressurization valves.

Purge pressure and subsequent flow is adjusted by means of a quarter-turn ball valve located in the bypass line of the upper piping

Models 40 through 3000 are equipped with a single safety relief valve that has been sized at a minimum to provide overpressure protection due to a fire for both desiccant towers.

— 49 —

9.2.8.2 Valves – Models 4100 through 5400

Inlet switching valves are resilient seated butterfly valves with double acting pneumatic rack and pinion actuators. A yellow arrow indicator located on the top of the actuator output shaft points to valve position indicator icons. Pilot air is directed to actuator ports to open both inlet valves upon loss of power.

Purge/repressurization valves are resilient seated butterfly valves with spring return, fail closed, pneumatic rack and pinion actuators.

A yellow arrow indicator located on the top of the actuator output shaft points to valve position indicator icons. Pilot air is directed to actuator ports to close both purge/repressurization valves upon loss of power.

12 volt DC, single solenoid, 4-way pilot valves are wired to the controller and are used to direct pilot air to the actuators of the inlet switching and purge/repressurization valves.

Two mainline outlet and two smaller purge line check valves are installed in the upper piping to control the flow of outlet and purge air. Check valve sticking will result in excessive air discharge through a muffler. Excessive air discharge through the muffler can be associated with a leaking outlet check valve on the same side or a purge check valve of the opposite side tower.

Purge pressure and subsequent flow is adjusted by means of a throttling globe valve located in the bypass line of the upper piping

Models 4100 through 5400 are equipped with multiple safety relief valves that have been sized to provide overpressure protection for capacities equal to or greater than the adjusted capacity of the dryer at its maximum operating pressure.

The tower pressure gauge of the online tower should read line pressure. Air should not be leaking from the purge-repressurization valve of the on-line tower.

The tower pressure gauge of the offline tower should read below

2 psig (0.14 kgf/ cm

2

) while that tower is purging. If excessive air is exhausting during the purge cycle, the inlet-switching valve on the same side may have failed to close or a check valve may be sticking.

9.3 Operating Sequence

9.3.1 Operating sequence – Timer Based Controllers

The operating sequence for dryers equipped with Timer Based

Controllers appears in Tables 6.1 and 6.2.

9.3.2 Operating sequence – Level 1 Controllers

The operating sequence for dryers equipped with Level 1 Controllers appears in Tables 7.3 and 7.4.

9.3.3 Operating sequence – Level 2 Controllers

The operating sequence for dryers equipped with Level 2 Controllers appears in Tables 8-2, 8-4, and 8-5.

9.4 Dryer Shut Down

• If the dryer installation is equipped with dryer bypass and inlet and outlet isolation valves, the bypass valve should be opened and the inlet and outlet isolation valves closed.

• De-pressurize the dryer by allowing the controller to run through tower change cycles until pressure gauges on both towers read zero. Manual test mode may be used to speed up this process.

NOTE: Below 60 psig (4.22 kgf/ cm

2

) purge/repressurization valves may not open. Opening the manual drain on the pilot air filter or any mounted pre or afterfilters may bleed off remaining pressure.

Turn dryer off using on-off switch (indicating LEDs extinguished).

9.5 Loss of Power

Control valves are designed so that upon loss of power the air dryer is capable of drying air until the desiccant exposed to the airflow is saturated.

9.6 Operating Parameters

Verify that dryer is operating within the following design parameters:

9.6.1 Maximum Operating Pressure (MOP):

• 150 psig (10.5 kgf/cm

2

) is standard.

• 250 psig (17.6 kgf/cm

2

) is optional.

Refer to Dryer Serial Number Tag.

WARNING - Do not operate the dryer at pressures above the maximum operating pressure shown on the serial number tag.

NOTE: Consult factory for applications requiring higher maximum operating pressures.

9.6.2 Minimum Operating Pressures:

9.6.2.1 For 150 psig (10.5 kgf/cm

2

) MOP models -

60 psig (4.2 kgf/cm

2

) is the minimum operating pressure for dryers operated on a 4,10,16, or 24-minute cycle.

9.6.2.2 For 250 psig (17.6 kgf/cm

2

) MOP models -

120 psig (8.44 kgf/cm

2

) is the minimum operating pressure for dryers operated on a 4,10,16, or 24-minute cycle.

Refer to Dryer Serial Number Tag.

WARNING - Do not operate the dryer at pressures below the minimum operating pressure shown on the serial number tag.

NOTE: Consult factory for applications requiring lower minimum operating pressures.

9.6.3 Maximum Compressed Air Temperature at Dryer Inlet:

• 140°F (60°C) for all models.

9.6.4 Ambient Temperatures:

9.6.4.1 Minimum Ambient Temperature:

• Standard units: 35°F (2°C)

• Units with optional low ambient package: -20°F ( -29°C)

9.6.4.2 Maximum Ambient Temperature:

• 120°F (49°C)

NOTE: If dryer is installed in ambients below 35°F (2°C), low ambient protection requiring heat tracing and insulation of the prefilter bowls, auto drains and/or sumps, and lower piping with inlet switching and purge/repressurization valves is necessary to prevent condensate from freezing. If installing heat tracing, observe electrical class code requirements for type of duty specified. Purge mufflers and their relief mechanisms must be kept clear from snow and ice buildup that could prevent proper discharge of compressed air.

— 50 —

9.7 Maximum Inlet Flow Capacity

Refer to Table 9-1 for maximum inlet flow at rated conditions of

100 psig (7.0 kgf/cm 2) and 100°F (38°C).

At other conditions, multiply inlet flow from Table 9-1 by the multipliers from Tables 9-2 and 9-3 that correspond to the pressure and temperature at the inlet to the dryer.

9.8 Purge and Outlet Flows

9.8.1 Maximum Purge Flow

Maximum Purge Flow is the amount of purge air flowing through the off-stream tower when the purge/repressurization valve is open. After the purge/repressurization valve closes, the purge flow will gradually decrease as the off-stream tower re-pressurizes to line pressure.

For maximum purge flow multiply the Inlet Flow At Rated

Conditions from Table 9-1 by Maximum Purge Flow Factor from

Table 9-6 that corresponds to the dryer MOP, Cycle Time Setting, and air pressure at inlet to dryer. Note: For Level 2 Controller

equipped dryers supplied with the Automatic Purge Saving

System operating in the Demand Cycle Mode, use ISO Class

2 (10 minutes) as the cycle time.

9.8.2 Average Purge Flow

For dryers with Level 1 or 2 Controllers operating in the fixed cycle mode, the Average Purge Flow is the actual amount of flow used during the entire purge/repressurization cycle. It includes the maximum purge flow for a portion of the purge/repressurization time and the volume of air used for repressurization, averaged over the cycle time.

For average purge flow multiply the Inlet Flow At Rated Conditions from Table 9-1 by Average Purge/Repressurization Flow Factor from Table 9-7 that corresponds to the dryer MOP, Cycle Time

Setting, Energy (purge) Savings % setting, and air pressure at inlet to dryer.

9.8.3 Minimum Outlet Air Flow

Determine minimum outlet flow available from dryer by subtracting

Maximum Purge Flow found above from inlet flow to the dryer.

9.8.4 Average Outlet Air Flow

For dryers with Level 1 or 2 Controllers operating in the fixed cycle mode, the average outlet flow available from dryer can be determined by subtracting the Average Maximum Purge Flow found above from the inlet flow to the dryer.

9.9 EXAMPLE

Find the maximum inlet flow, maximum purge flow, and minimum outlet flow for a 60 SCFM unit with a MOP of 150 psig operated with 120 psig and 100°F inlet conditions on a 10 minute cycle.

Dryer will operate with an inlet airflow of 46 SCFM.

Step 1: Find Maximum Inlet Flow at 120 psig by multiplying

Maximum Inlet Flow at Rated Conditions from Table 9-1 by Inlet

Pressure Correction Factor for 120 psig from Table 9-2 and Inlet

Temperature from Table 9-3:

60 x 1.08 x 1.00 =64.8 SCFM.

Step 2: Find Maximum Purge Flow by multiplying Maximum Inlet

Flow at Rated Conditions from Table 9-1 by Maximum Purge Flow

Factor from Table 9-5:

60 x 0.162 =9.7 SCFM.

Step 3: Find Minimum Outlet Flow available by subtracting

Maximum Purge Flow (Step 2) from actual inlet flow:

46 -9.7 =36.3 SCFM.

— 51 —

MODEL

SCFM (1) m

3

/hr (2)

40 60

40 60

90

90

115

115

165

165

260

260

370

370

450

450

590

590

750

750

930 1130 1350 1550 2100 3000 4100 5400

930 1130 1350 1550 2100 3000 4100 5400

68 102 153 195 280 442 629 765 1002 1274 1580 1920 2294 2633 3568 5097 6966 9175

Table 9-1 Maximum Inlet Flow at Rated Conditions

INLET

PRESSURE psig kgf/cm

2

MULTIPLIER

60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 240 250

4.2

4.9

5.6

6.3

7.0

7.7

8.4

9.1

9.8 10.5 11.2 12.0 12.7 13.4 14.1 14.8 15.5 16.2 16.9 17.6

0.65 0.74 0.83 0.91 1.00 1.04 1.08 1.12 1.16 1.20 1.23 1.27 1.30 1.34 1.37 1.40 1.43 1.46 1.49 1.52

Table 9-2 Inlet Pressure Correction Factors

INLET

TEMPERATURE

MULTIPLIER

°F

°C

100 and below 105 110 115 120 125 130 135 140

38 and below 41 43 46 49 52 54 57 60

1.00

0.98 0.96 0.93 0.89 0.85 0.81 0.76 0.70

Table 9-3 Inlet Temperature Correction Factor

CYCLE

DRYER MOP

INLET

PRESSURE

ISO CL.1 4 min.

ISO CL.2 10 min.

ISO CL.3 16 min.

ISO CL.4 24 min.

150 psig (10.5 kgf/cm

2

) 250 psig (17.6 kgf/cm

2

) psig 60-100 110 120 130 140 150 120 130 140 150 160 170 180 190 200 210 220 230 240 250

kgf/cm

2

4.2-7.0 7.7 8.4 9.1 9.8 10.5 8.4 9.1 9.8 10.5 11.2 12.0 12.7 13.4 14.1 14.8 15.5 16.2 16.9 17.6

psig

kgf/cm

psig

kgf/cm

psig

2

2

35 33 31 29 28 27 83 80 76 74 71 69 66 64 63 61 59 58 56 55

2.5

2.3 2.2 2.0 2.0 1.9 5.8 5.6 5.3 5.2 5.0 4.9 4.6 4.5 4.4 4.3 4.1 4.1 3.9 3.9

20 19 18 17 16 15 44 42 40 39 37 36 35 33 32 31 31 30 29 28

1.4

1.3 1.3 1.2 1.1 1.1 3.1 3.0 2.8 2.7 2.6 2.5 2.5 2.3 2.2 2.2 2.2 2.1 2.0 2.0

18 17 16 15 14 13 35 33 32 30 29 28 27 26 25 25 24 23 23 22

kgf/cm

2

1.3

1.2 1.1 1.1 1.0 0.9 2.5 2.3 2.2 2.1 2.0 2.0 1.9 1.8 1.8 1.8 1.7 1.6 1.6 1.5

psig 16 15 15 14 13 13 30 29 28 26 25 24 24 23 22 21 21 20 20 19

kgf/cm

2

1.1

1.1 1.1 1.0 0.9 0.9 2.1 2.0 2.0 1.8 1.8 1.7 1.7 1.6 1.5 1.5 1.5 1.4 1.4 1.3

Table 9-4 Purge Pressure (Note: For units with the Level 2 Controller operating in the Demand Cycle Mode, use the ISO Class 2 (10 min.) purge pressure settings only, regardless of ISO Class operating mode.)

INLET

TEMPERATURE

OUTLET P.D.P.

°F

°C

°F

°C

35 40 50 60 70 80 90 100 110 120

2 4 10 16 21 27 32 38 43 49

-34 -28 -22 -16 -10 -4 3 9 15 21

-37 -33 -30 -27 -23 -20 -16 -13 -9 -6

Table 9-5 Outlet Pressure Dew points at Moisture Indicator Color Change

DRYER MOP 150 psig (10.5 kgf/cm

2

) 250 psig (17.6 kgf/cm

2

)

INLET

PRESSURE psig 60-100 110 120 130 140 150 120 130 140 150 160 170 180 190 200 210 220 230 240 250 kgf/cm

2

4.2-7.0 7.7

8.4

9.1

9.8 10.5 8.4

9.1

9.8 10.5 11.2 12.0 12.7 13.4 14.1 14.8 15.5 16.2 16.9 17.6

ISO CL.1 4 min. 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249 0.249

CYCLE

ISO CL.2 10 min. 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175 0.175

ISO CL.3 16 min. 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161 0.161

ISO CL.4 24 min. 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153 0.153

Table 9-6 Maximum Purge Flow Factor

— 52 —

DRYER MOP

INLET PRESSURE (psig)

INLET PRESSURE (kg/cm

2

)

ISO CLASS 1

4 MIN. CYCLE

-100°F / -73°C

PRESSURE

DEWPOINT

ENERGY

(PURGE)

SAVINGS

SETTING

0%

10%

20%

30%

40%

50%

60%

70%

ISO CLASS 2

4 MIN. CYCLE

-40 °F / -40 °C

PRESSURE

DEWPOINT

ISO CLASS 3

16 MIN. CYCLE

-4 °F / -20 °C

PRESSURE

DEWPOINT

ISO CLASS 4

24 MIN. CYCLE

-+38 °F / +3 °C

PRESSURE

DEWPOINT

ENERGY

(PURGE)

SAVINGS

SETTING

ENERGY

(PURGE)

SAVINGS

SETTING

ENERGY

(PURGE)

SAVINGS

SETTING

0%

10%

20%

30%

40%

50%

60%

70%

0%

10%

20%

30%

40%

50%

60%

70%

0%

10%

20%

30%

40%

50%

60%

70%

60

0.140

0.126

0.112

0.098

0.085

0.071

0.057

0.044

0.141

0.127

0.114

0.100

0.086

0.073

0.059

0.045

0.139

0.125

0.111

0.098

0.084

0.070

0.057

0.043

4.2

0.147

0.134

0.120

0.106

0.093

0.079

0.065

0.052

70

0.140

0.126

0.113

0.099

0.085

0.072

0.058

0.044

0.142

0.128

0.114

0.101

0.087

0.073

0.060

0.046

0.139

0.125

0.112

0.098

0.084

0.071

0.057

0.043

4.9

0.149

0.136

0.122

0.108

0.095

0.081

0.067

0.053

80

0.140

0.127

0.113

0.099

0.086

0.072

0.058

0.045

0.143

0.129

0.115

0.101

0.088

0.074

0.060

0.047

0.139

0.126

0.112

0.098

0.084

0.071

0.057

0.043

5.6

0.151

0.137

0.124

0.110

0.096

0.083

0.069

0.055

150 psig (10.5 kgf/cm

2

)

100 110

0.141

0.128

0.114

0.100

0.087

0.073

0.059

0.045

0.144

0.130

0.117

0.103

0.089

0.076

0.062

0.048

0.140

0.126

0.112

0.099

0.085

0.071

0.058

0.044

7.0

0.155

0.141

0.127

0.114

0.100

0.086

0.072

0.059

0.136

0.123

0.110

0.097

0.084

0.071

0.057

0.044

0.139

0.126

0.113

0.100

0.087

0.073

0.060

0.047

0.135

0.121

0.108

0.095

0.082

0.069

0.056

0.043

7.7

0.151

0.138

0.124

0.111

0.098

0.085

0.072

0.059

90

0.141

0.127

0.113

0.100

0.086

0.072

0.059

0.045

0.143

0.130

0.116

0.102

0.088

0.075

0.061

0.047

0.140

0.126

0.112

0.098

0.085

0.071

0.057

0.044

6.3

0.153

0.139

0.125

0.112

0.098

0.084

0.071

0.057

120

0.132

0.119

0.106

0.094

0.081

0.068

0.056

0.043

0.135

0.122

0.110

0.097

0.084

0.072

0.059

0.046

0.130

0.117

0.105

0.092

0.079

0.067

0.054

0.041

8.4

0.148

0.135

0.122

0.110

0.097

0.084

0.072

0.059

DRYER MOP

INLET PRESSURE (psig)

INLET PRESSURE (kg/cm

2

)

ISO CLASS 1

4 MIN. CYCLE

-100 °F / -73 °C

PRESSURE

DEWPOINT

ENERGY

(PURGE)

SAVINGS

SETTING

0%

10%

20%

30%

40%

ISO CLASS 2

10 MIN. CYCLE

-40 °F / -40 °C

PRESSURE

DEWPOINT

ENERGY

(PURGE)

SAVINGS

SETTING

50%

60%

70%

0%

10%

20%

30%

40%

ISO CLASS 3

16 MIN. CYCLE

-4 °F / -20 °C

PRESSURE

DEWPOINT

ENERGY

(PURGE)

SAVINGS

SETTING

50%

60%

70%

0%

10%

20%

30%

40%

ISO CLASS 4

24 MIN. CYCLE

+38 °F / +3 °C

PRESSURE

DEWPOINT

ENERGY

(PURGE)

SAVINGS

SETTING

50%

60%

70%

0%

10%

20%

30%

40%

50%

60%

70%

160

0.063

0.051

0.040

0.116

0.105

0.093

0.082

0.071

0.067

0.056

0.045

0.118

0.107

0.096

0.085

0.074

0.060

0.049

0.038

0.084

0.073

0.062

0.122

0.111

0.100

0.089

0.078

11.2

0.139

0.128

0.117

0.106

0.095

150

0.064

0.052

0.041

0.119

0.107

0.096

0.084

0.073

0.068

0.056

0.045

0.121

0.109

0.098

0.087

0.075

0.062

0.050

0.039

0.084

0.072

0.061

0.125

0.113

0.102

0.091

0.079

10.5

0.141

0.129

0.118

0.106

0.095

140

0.065

0.053

0.042

0.122

0.110

0.098

0.087

0.075

0.069

0.057

0.045

0.124

0.112

0.100

0.089

0.077

0.063

0.051

0.039

0.084

0.072

0.060

0.128

0.116

0.104

0.092

0.081

9.8

0.143

0.131

0.119

0.107

0.095

130

0.067

0.054

0.042

0.126

0.114

0.101

0.089

0.077

0.070

0.058

0.046

0.128

0.115

0.103

0.091

0.079

0.065

0.053

0.040

0.084

0.072

0.060

0.131

0.119

0.107

0.095

0.082

9.1

0.145

0.133

0.120

0.108

0.096

120

0.068

0.056

0.043

0.130

0.117

0.105

0.092

0.079

0.072

0.059

0.046

0.132

0.119

0.106

0.094

0.081

0.067

0.054

0.041

0.084

0.072

0.059

0.135

0.122

0.110

0.097

0.084

8.4

0.148

0.135

0.122

0.110

0.097

Table 9-7 Average Purge / Repressurization Flow Factors ( 150 and 250 psig MOPs)

250 psig (17.6 kgf/cm

2

)

180 190

0.060

0.050

0.039

0.110

0.100

0.089

0.079

0.068

0.065

0.055

0.044

0.113

0.103

0.092

0.081

0.071

0.058

0.047

0.037

0.084

0.074

0.063

0.118

0.107

0.097

0.086

0.076

12.7

0.137

0.126

0.116

0.105

0.095

0.060

0.049

0.039

0.108

0.098

0.088

0.077

0.067

0.065

0.054

0.044

0.111

0.101

0.090

0.080

0.070

0.057

0.047

0.036

0.085

0.075

0.064

0.116

0.106

0.095

0.085

0.075

13.4

0.136

0.126

0.116

0.105

0.095

170

0.061

0.051

0.040

0.113

0.102

0.091

0.081

0.070

0.066

0.055

0.044

0.115

0.105

0.094

0.083

0.072

0.059

0.048

0.037

0.084

0.073

0.062

0.120

0.109

0.098

0.088

0.077

12.0

0.138

0.127

0.116

0.106

0.095

200

0.059

0.049

0.039

0.106

0.096

0.086

0.076

0.066

0.064

0.054

0.044

0.109

0.099

0.089

0.079

0.069

0.056

0.046

0.036

0.085

0.075

0.065

0.114

0.104

0.094

0.084

0.074

14.1

0.135

0.125

0.115

0.105

0.095

130

0.128

0.115

0.103

0.091

0.079

0.067

0.054

0.042

0.131

0.119

0.107

0.095

0.082

0.070

0.058

0.046

0.126

0.114

0.101

0.089

0.077

0.065

0.053

0.040

9.1

0.145

0.133

0.120

0.108

0.096

0.084

0.072

0.060

140

0.124

0.112

0.100

0.089

0.077

0.065

0.053

0.042

0.128

0.116

0.104

0.092

0.081

0.069

0.057

0.045

0.122

0.110

0.098

0.087

0.075

0.063

0.051

0.039

9.8

0.143

0.131

0.119

0.107

0.095

0.084

0.072

0.060

150

0.121

0.109

0.098

0.087

0.075

0.064

0.052

0.041

0.125

0.113

0.102

0.091

0.079

0.068

0.056

0.045

0.119

0.107

0.096

0.084

0.073

0.062

0.050

0.039

10.5

0.141

0.129

0.118

0.106

0.095

0.084

0.072

0.061

220

0.058

0.048

0.038

0.102

0.093

0.083

0.073

0.064

0.063

0.054

0.044

0.105

0.096

0.086

0.077

0.067

0.054

0.045

0.035

0.087

0.077

0.068

0.111

0.102

0.092

0.083

0.073

15.5

0.135

0.125

0.115

0.106

0.096

210

0.058

0.048

0.039

0.104

0.094

0.084

0.075

0.065

0.064

0.054

0.044

0.107

0.097

0.088

0.078

0.068

0.055

0.045

0.036

0.086

0.076

0.066

0.113

0.103

0.093

0.083

0.074

14.8

0.135

0.125

0.115

0.106

0.096

240

0.057

0.047

0.038

0.099

0.090

0.081

0.071

0.062

0.063

0.054

0.045

0.102

0.093

0.084

0.075

0.066

0.053

0.044

0.035

0.088

0.079

0.070

0.109

0.100

0.090

0.081

0.072

16.9

0.134

0.125

0.116

0.107

0.098

230

0.057

0.048

0.038

0.100

0.091

0.082

0.072

0.063

0.063

0.054

0.044

0.104

0.095

0.085

0.076

0.066

0.054

0.044

0.035

0.088

0.078

0.069

0.110

0.101

0.091

0.082

0.072

16.2

0.134

0.125

0.116

0.106

0.097

250

0.056

0.047

0.038

0.097

0.088

0.079

0.070

0.061

0.063

0.054

0.045

0.101

0.092

0.083

0.074

0.065

0.052

0.043

0.034

0.089

0.080

0.071

0.108

0.099

0.090

0.081

0.072

17.6

0.134

0.125

0.116

0.107

0.098

— 53 —

10. Maintenance

WARNING - The heatless desiccant dryer is a pressure-containing device. De-pressurize before servicing. (See Section 3.3)

Note: Level 1 and 2 Controllers are equipped with Service Reminder functions for filters, desiccant and valves.

10.1 Desiccant Replacement

NOTE: The use of the correct replacement desiccant is necessary for proper dryer operation. Never use hygroscopic salts of the type commonly used in “deliquescent ” type dryers.

10.1.1 Frequency Of Desiccant Replacement

Desiccant should be replaced whenever the required dew point cannot be maintained while the dryer is being operated within its design conditions and there are no mechanical malfunctions. Refer to section

10.0 for troubleshooting hints.

NOTE: Desiccant life is determined by the quality of the inlet air. Proper filtering of the inlet air will extend the life of the desiccant. Typically desiccant life is 3 to 5 years.

10.1.2 Procedure for Desiccant Charge Replacement

De-pressurize and de-energize the dryer.

Remove the fill and drain plugs from desiccant tower and drain the spent desiccant. Place a container at the base of the vessel to collect the desiccant. If necessary tap the sides of the vessels with a rubber mallet to loosen desiccant.

NOTE: Use extreme care when inserting rods or other tools through the desiccant fill or drain ports to loosen packed desiccant. Internal flow diffusers at the ends of the desiccant beds can be damaged or punctured by sharp instruments. These diffusers are necessary to distribute the airflow and keep the desiccant beads within the tower. Desiccant beads in exhaust mufflers, afterfilters, or the piping connected to the desiccant towers may indicate a perforation of a diffuser.

Replace the drain plug using Teflon tape or another pipe thread sealant suitable for compressed air service.

Fill the desiccant tower as full as possible with dry desiccant. Do not tamp or otherwise pack the desiccant.

Replace the fill plug using Teflon tape or another pipe thread sealant suitable for compressed air service.

Repeat this procedure for the other tower.

10.1.3 Insuring Desiccant Dryness

Replacement desiccant is shipped in airtight containers. Keep the covers on these containers tightly closed until use to avoid moisture contamination. If desiccant is exposed to air it can be heated in an oven at 400°F (204°C) for four hours before use. Alternatively, if the dryer is not refilled with dry desiccant, it may be necessary to operate the unit with an inlet flow rate of less than 50% of maximum rated inlet capacity until the desiccant has regenerated fully.

10.2 Purge Mufflers

Purge mufflers should be checked regularly, changed annually.

Muffler disseminator elements become clogged with desiccant dust over time, creating back pressure and restricted purge flow.

Refer to section 9.2.7.

— 54 —

10.3 Valves

Process and pilot valves should be checked frequently for leaks and proper operation.

Purge pressure adjustment valve should be checked frequently for proper adjustment.

Refer to section 9.2.8.

10.4 Pilot Air Filter Element Replacement

10.4.1 Frequency of replacement

The pilot air filter contains a filter element that should be changed yearly. Replacement may be required sooner if pressure drop across cartridge prevents valves from actuating properly. Pilot air pressure should be in the range of 60-120 psig (4.2-8.4 kgf/cm

2

) and is controlled by a pressure regulator that has been set and sealed at 120 psig (8.4 kgf/cm

2

).

Warning – The pilot air filter housing is a pressure-containing device, de-pressurize before servicing. Slowly open manual drain valve on bottom of filter bowl by turning clockwise to verify that the housing is de-pressurized before removing bowl.

10.4.2 Procedure for element replacement

10.4.2.1 Models 40 through 3000

Isolate dryer from air supply

De-pressurize dryer by running dryer and allowing system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/repressurization valves from opening.

Remaining pressure can be vented to atmosphere through the manual vent on the pilot air filter. The system must be fully depressurized before removing the bowl.

Remove the filter bowl by turning counterclockwise and then pulling straight down.

Clean the filter bowl.

Replace the element. Reassemble in reverse order.

10.4.2.2 Models 4100 through 5400

Isolate dryer from air supply

De-pressurize dryer by running dryer and allowing system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/repressurization valves from opening.

Remaining pressure can be vented to atmosphere through the manual drain on the pilot air filter. The system must be fully depressurized before removing the bowl.

Remove the filter bowl by pushing up, turning counterclockwise and then pulling straight down.

Clean the filter bowl.

Replace the element – Pull off the old element and discard. Make certain O-ring inside top of replacement element is lubricated and in place and then push element onto filter head.

Clean and lubricate O-ring at top of bowl and reassemble in reverse order.

NOTE: Wave spring ends should be pointed down to prevent the wave spring from interfering with reassembly.

11. Troubleshooting

SYMPTOM

11.1 Indicator lights not illuminated

11.2 Moisture indicator turns yellow

(elevated outlet dew point)

11.3 Premature saturation of desiccant

11.4 Tower fails to repressurize to line pressure

11.5 Excessive purge is discharged during purge cycle

11.6 Excessive desiccant dust downstream

11.7 Switching Failure

Alarm

(Level 1 & Level 2

Controllers only)

POSSIBLE CAUSE(S)

No power to unit.

Off/On switch turned off.

CORRECTIVE ACTION

Check voltage at terminal board.

Turn on.

Blown fuse.

Off/on switch or board malfunction.

Design conditions exceeded.

Spent desiccant (useful service life has ended).

Contaminated desiccant (e.g. with oil)

Replace fuse.

Replace board.

Refer to Sections 4 & 9 to determine if dryer is being outside of design limitations.

Replace desiccant.

Take corrective action. Refer to Section 4.1 to determine proper prefiltration before changing desiccant.

Saturated desiccant (saturated with water)

Insufficient purge flow - Purge pressure too low

Incomplete tower depressurization (tower pressure greater than 2 psig) - clogged mufflers

Refer to 11.3 for corrective action. Operation at reduced flow may reactivate desiccant beds until desired outlet dew point is achieved.

Refer to Section 9 to determine correct Purge Pressure Indicator setting.

Replace muffler inserts.

Incomplete tower depressurization -

Purge/repressurization valve fails to open

Verify voltage to pilot solenoid valve. Check pilot air pressure (60-120 psig required). Verify proper actuator operation.

Insufficient purge time - Incorrect controller settings Refer to Section 7 or 8 to determine correct controller cycle settings.

Insufficient purge time - Faulty controller Refer to Section 7 or 8 to verify proper time sequence. Replace controller board as required.

Purge/repressurization valve fails to close (air loss from mufflers during tower repressurization portion of cycle)

Insufficient purge flow - Purge pressure too low

Verify removal of voltage to pilot solenoid valve. Verify proper actuator operation. This is a spring-assisted, normally closed valve. Check valve for obstruction or seat damage.

Refer to Section 9 to determine correct Purge Pressure Indicator setting .

Purge Pressure Adjustment Valve should never be completely closed.

Excessive purge flow - Purge pressure too high

Inlet switching valve fails to close.

Refer to Section 9 to determine correct Purge Pressure Indicator setting .

Verify voltage to pilot solenoid valve. Check pilot air pressure (60-120 psig required.) Verify proper actuator operation. Check valve for obstruction or seat damage.

Repair or replace valve(s) as needed.

(Models 40 through 3000) Shuttle Valve; or (Models

4100 through 5400) same tower Outlet Check or opposite tower Purge Check Valves fail to close

Fluidization of desiccant bed - design conditions for maximum rated flow exceeded

Fluidization of desiccant bed -

Rapid repressurization of offstream tower due to:

Faulty timer

Insufficient purge flow - purge pressure too low

Faulty pressure switches or control board

Offstream tower did not de-pressurize in time and/or below 10 psig

Offstream tower did not re-pressurize in time and/or above 10 psig

Refer to Section 4 or 9 to determine if dryer is being operated outside of design limitations.

Refer to Section 7 or 8 to verify proper time sequence.

Refer to Section 9 to determine correct Purge Pressure Indicator setting .

Replace components

Check mufflers, check or shuttle valve(s), inlet switching and purge/repressurization valves, purge pressure adjustment, and controller settings.

Check air supply to dryer, purge/repressurization valve, purge pressure adjustment, and controller settings.

— 55 —

12. Notes

Information from the dryer serial number tag can be recorded in the following table. This information may be necessary when communicating with

Service representatives.

Serial Number Tag Fields

Allowable Values from

Serial Number Tag

Actual Values at

Installation

Model Number:

Serial Number:

Service Code:

Rated Capacity:

Maximum Operating Temperature:

Desiccant Type:

VAC (AC Voltage):

AC Phase:

AC Frequency:

AC Wattage:

AC Holding Current:

VDC (DC Voltage)

DC Wattage:

DC Holding Current:

ETO DCF- Code (If Listed, Btm RH Corner)

EC- Code (If Listed, Btm RH Corner)

Additional information that may be useful when dealing with Service:

Location of installation (address and phone number): ________________________________________________________________________

Distributor purchased from: ____________________________________________________________________________________________

Repair Parts List Number and Revision: __________________________________________________________________________________

Indoors or outdoors installation: ________________________________________________________________________________________

Ambient temperature range: ___________________________________________________________________________________________

Prefilters: __________________________________________________________________________________________________________

Drains: ____________________________________________________________________________________________________________

Delta-P devices: ____________________________________________________________________________________________________

Afterfilters: _________________________________________________________________________________________________________

Delta-P devices: ____________________________________________________________________________________________________

Blocking or Isolation Valves: ___________________________________________________________________________________________

ISO Class Operating Mode: ____________________________________________________________________________________________

Fixed or Demand Cycle Mode (Level 2 controller only): ______________________________________________________________________

Outlet pressure dew point reading: ______________________________________________________________________________________

Additional accessories or special features: ________________________________________________________________________________

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

— 56 —

— NOTES —

— 57 —

— NOTES —

— 58 —

— NOTES —

— 59 —

WARRANTY

The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor, or eighteen months from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention the aforesaid warranty period. The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within the warranty period, provided such defect occurred in normal service and not as the result of misuse, abuse, neglect, or accident.

The warranty covers parts and labor for the warranty period. Repair or replacement shall be made at the factory or the installation site, at the sole option of the manufacturer. The manufacturer must first authorize any service performed on the product by anyone other than the manufacturer. Normal maintenance items requiring routine replacement are not warranted. Unauthorized service voids the warranty and any resulting charge or subsequent claim will not be paid.

THE FOREGOING WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WRITTEN, ORAL, OR STATUTORY,

AND IS EXPRESSED IN LIEU OF THE IMPLIED WARRANTY OF MERCHANTABILITY AND THE IMPLIED WARRANTY OF FITNESS

FOR A PARTICULAR PURPOSE. THE MANUFACTURER SHALL NOT BE LIABLE FOR LOSS OR DAMAGE BY REASON OF STRICT

LIABILITY IN TORT OR ITS NEGLIGENCE IN WHATEVER MANNER INCLUDING DESIGN, MANUFACTURE, OR INSPECTION OF

THE EQUIPMENT OR ITS FAILURE TO DISCOVER, REPORT, REPAIR, OR MODIFY LATENT DEFECTS INHERENT THEREIN. THE

MANUFACTURER, HIS REPRESENTATIVE OR DISTRIBUTOR SHALL NOT BE LIABLE FOR LOSS OF USE OF THE PRODUCT OR

OTHER INCIDENTAL OR CONSEQUENTIAL COSTS, EXPENSES, OR DAMAGES INCURRED BY THE BUYER, WHETHER ARISING

FROM BREACH OF WARRANTY, NEGLIGENCE OR STRICT LIABILITY IN TORT.

The manufacturer does not warranty any product, part, material, component, or accessory manufactured by others and sold or supplied in connection with the sale of the manufacturer’s products.

AUTHORIZATION FROM THE SERVICE DEPARTMENT IS NECESSARY BEFORE

MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE.

SERVICE DEPARTMENT : (724) 746-1100

SPX Dehydration & Process Filtration

1000 Philadelphia Street

Canonsburg, PA 15317-1700 U.S.A.

Phone: 724-745-1555 • Fax: 724-745-6040

Email: [email protected]

www.hankisonintl.com

© 2007 SPX Dehydration & Process Filtration. All rights reserved.

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