THL Series Manual

INSTALLATION, OPERATION & MAINTENANCE MANUAL

FOR

HEATLESS REGENERATIVE

COMPRESSED AIR DRYER

models

THL-200 through THL- 5000

P.O Box 879

2150 W. 6th Ave. - unit P

Broomfield, CO 80038

Phone:303-465-3063

Order Entry Fax: 303-465-9294 www.airdryers.com

P/N THL200 - 5000

WARNING

READ ALL INFORMATION IN THIS MANUAL BEFORE BEGINNING INSTALLATION OR OPERATION OF THE

DRYER. BEFORE STARTING MAINTENANCE PROCEDURES, TURN OFF THE MAIN POWER TO THE DRYER

AND COMPLETELY DEPRESSURIZE THE UNIT TO PREVENT PERSONAL INJURY.

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS PRESSURIZED.

NEVER OPERATE THIS DRYER ABOVE THE RATED OPERATING CONDITIONS. OPERATION ABOVE SPECI-

FIED CONDITIONS WILL RESULT IN DECREASED PERFORMANCE, POSSIBLE DAMAGE TO THE UNIT AND/

OR PERSONAL INJURY.

SEE BACK OF THIS MANUAL FOR ADDITIONAL SAFETY INSTRUCTIONS.

PAGE 1

HANDLING THE DRYER

1.1 HANDLING INSTRUCTIONS

WARNING

DO NOT LIFT THE DRYER BY PIPING OR CONTROL BOX. THESE

COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF THE

DRYER. PERSONAL INJURY AND/OR EQUIPMENT DAMAGE MAY

RESULT.

Lift the dryer by the lifting lugs on both vessels.

SECTION 1

If the unit is to be stored outdoors, it MUST BE covered completely.

The cover must be adequate to prevent rain or snow from accumulating on the dryer. The location must be free of standing water and mud. The preferred location, if outdoors, is on a paved surface.

If the unit is to be lifted by an overhead device, attach the lifting chains or cables to the skid angle and the vessel lifting lugs. Make sure that the chains or cables are clear of all piping and dryer components.

1.2 STORAGE INSTRUCTIONS

The ideal place to store the unit is indoors. The location should be free from corrosive gasses and extreme humidity. These conditions will cause damage to the unit. The unit should be covered with a tarpaulin to keep the unit clean.

1.3 EQUIPMENT CHECK

Inspect the dryer for any damage that may have occurred during shipment. Inspect all fittings, piping connections, fasteners, etc. for loose connections. Also check gauges and lights for cracks or breakage.

IF DRYER HAS BEEN DAMAGED DURING SHIPMENT:

(1) NOTIFY CARRIER IMMEDIATELY AND FILE A CLAIM.

(2) CONSULT FACTORY BEFORE OPERATING THE DRYER.

SAFETY INSTRUCTIONS

2.1 HANDLING

DO NOT LIFT THE DRYER BY PIPING OR CONTROL BOX. THESE

COMPONENTS ARE NOT DESIGNED TO HOLD THE WEIGHT OF

THE DRYER. PERSONAL INJURY AND/OR EQUIPMENT DAMAGE

MAY RESULT.

WHEN LIFTING THE DRYER, ALWAYS USE THE LIFTING LUGS

PROVIDED ON BOTH TOWERS.

MAKE SURE THAT ALL LIFTING EQUIPMENT IS CAPABLE OF

SUPPORTING THE WEIGHT OF THE DRYER.

2.2 INSTALLATION

BEFORE STARTING INSTALLATION PROCEDURES, TURN OFF

POWER TO THE AREA WHERE THE DRYER WILL BE INSTALLED.

SERIOUS PERSONAL INJURY MAY RESULT IF THIS SAFETY RULE

IS NOT FOLLOWED.

THESE ASME CODE VESSELS MUST BE PROTECTED BY

PRESSURE RELIEF VALVES. Refer to OSHA 1910.169 Par. b, Sub.

Par (3) and ASME Boiler and Pressure Vessel Code, Section VIII,

Division 1, UG-125 through UG-136. Also comply with all state and local codes.

WHEN INSTALLING AND OPERATING THIS EQUIPMENT, COMPLY

WITH THE NATIONAL ELECTRICAL CODE AND ALL APPLICABLE

FEDERAL, STATE, AND LOCAL CODES.

WHEN INSTALLING THIS DRYER, MAKE SURE THAT THE NEMA

RATING OF THE CONTROL BOX IS APPLICABLE TO THE

INSTALLATION.

MAKE SURE THAT ALL CUSTOMER SUPPLIED WIRING AND

ELECTRICAL DEVICES ARE PROPERLY SIZED TO HANDLE THE

ELECTRICAL REQUIREMENTS OF THE DRYER.

ALWAYS WEAR EYE PROTECTION, GLOVES AND A RESPIRATORY

PROTECTIVE DEVICE WHEN HANDLING THE DESICCANT.

DESICCANT DUST MAY CAUSE EYE AND SKIN IRRITATION. AVOID

BREATHING THE DUST AND PROLONGED CONTACT WITH THE

SKIN.

SECTION 2

2.3 OPERATION

DO NOT OPERATE DRYER IF EITHER VESSEL IS LEAKING.

IMMEDIATELY TAKE THE DRYER OUT OF SERVICE.

ANY DAMAGE TO THE VESSELS CAN MAKE THEM UNSAFE

TO USE. INSPECT OUTSIDE AND INSIDE OF VESSELS

REGULARLY FOR CORROSION AND ANY DAMAGE (I.E.,

DENTS, GOUGES OR BULGES). IF DAMAGED, TAKE OUT OF

SERVICE IMMEDIATELY.

DO NOT OPERATE THIS DRYER ABOVE THE MAXIMUM RATED

WORKING PRESSURE.

OPERATING CONDITIONS FOR PROPER PERFORMANCE OF

THIS DRYER ARE DIFFERENT THAN MAXIMUM OPERATING

CONDITIONS FOR THE VESSELS. BE SURE TO CHECK THE

DRYER OPERATING CONDITIONS. SEE SECTION 3.1.

USE THIS DRYER FOR COMPRESSED AIR ONLY.

AIR FROM THIS DRYER IS NOT SUITABLE FOR BREATHABLE

AIR SYSTEMS WITHOUT FURTHER TREATMENT.

DO NOT OPERATE THIS DRYER IF EITHER VESSEL HAS BEEN

DAMAGED BY FIRE. TAKE OUT OF SERVICE IMMEDIATELY

AND NOTIFY YOUR CERTIFYING AUTHORITY.

2.4 MAINTENANCE

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THE

DRYER WHILE IT IS PRESSURIZED. TURN OFF MAIN POWER

TO THE DRYER AND DEPRESSURIZE THE DRYER COM-

PLETELY BEFORE STARTING MAINTENANCE PROCEDURES.

DO NOT WELD OR GRIND EITHER VESSEL. IT WILL NOT BE

SAFE TO OPERATE. (Note: Any uncertified alteration to the vessels VOIDS the ASME Code Certification and the

Warranty.)

FIRST AID IN CASE OF EYE CONTACT WITH DESICCANT DUST;

IMMEDIATELY FLUSH THE EYES WITH PLENTY OF WATER FOR AT

LEAST 15 MINUTES. CONSULT A PHYSICIAN.

PAGE 2

DIMENSIONS AND SPECIFICATIONS

3.1 DRYER SPECIFICATIONS

WEIGHT (with desiccant installed)

HL-200 HL-250

N4 STANDARD 660 lbs 715 lbs

ALL OTHERS 700 lbs 755 lbs

SECTION 3

HL-375 HL-500 HL-650 HL-800 HL-1000 HL-1250 HL-1500 HL-1750 HL-2000

1035 lbs 1160 lbs 1680 lbs 1830 lbs 2635 lbs 2885 lbs 3870 lbs 4095 lbs 4370 lbs

1075 lbs 1200 lbs 1720 lbs 1870 lbs 2675 lbs 2925 lbs 3910 lbs 4135 lbs 4410 lbs

DIMENSIONS

.............. See SECTIONS 3.2 through 3.4

IN/OUT CONNECTION

All models have 150# ANSI RF flanged inlet and outlet connections. Bolt holes straddle centerlines.

HL-200 HL-250 HL-375

1-1/2" 1-1/2" 1-1/2"

HL-500

1-1/2"

HL-650 HL-800

2-1/2" 2-1/2"

HL-1000 HL-1250 HL-1500 HL-1750 HL-2000

2-1/2' 2-1/2" 3" 3" 3"

VESSELS (desiccant towers)

Construction .................. Manufactured to the ASME CODE, Section VIII, Division 1.

Models HL-200 through HL-250 vessels stamped "UM" symbol. Models HL-375 and larger vessels stamped "U" symbol.

Design Pressure ............ 150 PSIG

Design Temperature ...... -20

O

F TO 300

O

F

PIPING

Threaded fittings: .......... ANSI B16.3

Threaded unions: .......... ANSI B16.39

Flanges: ......................... ANSI B16.5

Pipe: ............................... Carbon steel, Schedule 40

VALVES

Inlet ............................... Proprietary 3-Way piloted shuttle valve

Outlet ............................. Two (2) Check valves, butterfly type

Purge ............................. Normally closed, diaphragm type

CONTROL AIR FILTER

Construction .................. Zinc housing

ELECTRICAL

Standard 115 Volt .......... 115-120V/1PH/50-60Hz

Optional 230 Volt: .......... Main power: 220-240V/1PH/50-60Hz

Control power: Transformed to 115-120V/1PH/50-60Hz, on Emcon II units only

DESICCANT

Material .......................... Activated Alumina, 1/8" (2-5 MM) Bead type

Quantity Per Tower (LBS)

HL-200

106

HL-250

130

HL-375

203

HL-500 HL-650

266 366

OPERATING CONDITIONS

Inlet Air Pressure ............................MIN 60 PSIG ......... MAX 150 PSIG

Inlet Air Temperature .....................MIN 40

O

Ambient Air Temperature ...............MIN 40

O

F ............... MAX 120

O

F

F ............... MAX 120

O

F

HL-800 HL-1000 HL-1250 HL-1500 HL-1750 HL-2000

440 560 678 872 986 1119

RATED INLET CONDITIONS

Inlet Air Pressure ............................100 PSIG

Inlet Air Temperature .....................100

O

F

Relative Humidity (saturation) ........100% RH

FLOW CAPACITIES (SCFM) at various pressures (100

0

F)

HL-200

HL-250

HL-375

HL-500

HL-650

HL-800

HL-1000

HL-1250

60 PSIG

130

163

244

326

423

521

651

814

HL-1500

977

HL-1750

1140

HL-2000

1303

80 PSIG 100 PSIG 110 PSIG 125 PSIG 140 PSIG 150 PSIG

165 200 209 221 232 240

206

310

413

537

661

826

1032

1238

1445

1651

250

375

500

650

800

1000

1250

1500

1750

2000

261

391

521

678

834

1043

1303

1564

1825

2085

276

414

552

717

883

1104

1380

1655

1931

2207

290

436

581

755

929

1161

1452

1742

2032

2323

300

449

599

779

959

1198

1498

1797

2097

2397

PAGE 3


3.2 DIMENSIONS Models HL-200 through HL-800

SECTION 3

A B C D E F G H I J K L M N

HL-200 37.50

24.00

12.00 18.75

9.00

84.38

4.38

3.38

3.75

3.25 1-1/2 35.00

20.00

2.00

HL-250 37.50

24.00

12.00 18.75

9.00

84.38

4.38

3.38

3.75

3.25 1-1/2 35.00

20.00

2.00

HL-375 43.13

24.00

12.00 21.57

9.00

81.13

4.38

3.38

7.25

8.00 1-1/2 40.63

20.00

2.00

HL-500 43.13

24.00

12.00 21.57

9.00

81.13

4.38

3.38

7.25

8.00 1-1/2 40.63

20.00

2.00

HL-650 53.75

36.00

18.00 26.88

16.75

95.25

5.50

4.00

8.00 13.25 2-1/2 50.50

32.00

2.00

HL-800 53.75

36.00

18.00 26.88

16.75

95.25

5.50

4.00

8.00 13.25 2-1/2 50.50

32.00

2.00

PAGE 4

O P Q

1.25 8.50

.50

1.25 8.50

.50

1.25 8.50 1.00

1.25 8.50 1.00

1.63 8.50 1.50

1.63 8.50 1.50


3.3 DIMENSIONS Models THL-1000 through THL-1250

SECTION 3

PAGE 5


3.4 DIMENSIONS Models THL-1500 through THL-2000

SECTION 3

PAGE 6

INSTALLING THE DRYER

4.1 LOCATION

WARNING

DO NOT INSTALL THIS DRYER IN AN ENVIRONMENT OF

CORROSIVE CHEMICALS, EXPLOSIVE GASSES, POISONOUS

GASSES, OR SATURATED STEAM HEAT.

Locate dryer in a protected, well vented area where ambient temperatures are between 40 o

F and 120 over and around the dryer for access to desiccant fill and drain ports and controls.

Refer to SECTIONS 3.2 through 3.4 for dryer dimensions.

o

F. Allow sufficient clearance

SECTION 4

Basic bypass piping should include an inlet isolation valve, a bypass valve, and an outlet isolation valve. The isolation and bypass valves must be bubble-tight.

4.2-2 FILTERS

CAUTION

A PROPERLY RATED COALESCING PREFILTER MUST BE

INSTALLED BEFORE THE DRYER TO REMOVE LUBRICATING

OILS, DUST AND PIPE SCALE CONTAMINATION. FAILURE TO

USE A PREFILTER WILL RESULT IN DAMAGE TO THE DRYER

AND VOIDS THE WARRANTY.

If this dryer must be installed where ambient temperatures are below

40 o

F, insulation and heat tracing must be properly installed on the inlet piping, purge exhaust line and the desiccant towers to prevent freezing of the equipment.

Make sure that the elements are installed in all filter housings prior to start up.

Position the dryer in the upright position on a solid, level, vibration free surface capable of supporting the dryer’s weight.

Refer to SECTION

3.1 for dryer specifications.

The dryer should not be located in extremely dirty areas where airborne contaminants can accumulate on the dryer. If this cannot be prevented, the dryer should be cleaned periodically. An accumulation of dirt on the dryer may cause the inlet transfer valve to fail.

THE DRYER AND PREFILTER ARE NOT DESIGNED TO HANDLE

LIQUID WATER. IF LIQUID WATER IS PRESENT IN THE AIR

SYSTEM, A SEPARATOR WITH AN AUTOMATIC DRAIN MUST BE

INSTALLED UPSTREAM TO THE PREFILTER AND DRYER TO

PREVENT FLOODING.

4.2 PIPING AND ANCILLARY EQUIPMENT

A coalescing prefilter must be installed before the dryer to remove lubricating oils, dust and pipe scale contamination. It is recommended that a high efficiency coalescing filter with an automatic drain or electric drain valve be installed. The filter should be equipped with a pressure differential indicator to monitor the condition of the element.

CAUTION

Make sure that the inlet air piping is connected at the bottom and the outlet air piping is connected at the top of the dryer.

Make sure that the inlet and outlet piping to and from the dryer is properly supported. Excessive stress may cause damage and/or dryer malfunction.

Remove protective caps or covers from all valves before installing this dryer.

A particulate afterfilter should be installed downstream of the dryer to remove any desiccant dust. The filter should be equipped with a pressure differential indicator to monitor the condition of the element.

Make sure that the filters are properly installed according to the instructions provided with them.

4.3 INSTALLING THE PRESSURE RELIEF VALVES

If this dryer is to be installed into an existing piping system, clean the existing inlet piping to remove all accumulated dirt, pipe scale, etc., before connecting the dryer. Make sure that the inlet and outlet shutoff valves are tightly closed before connecting to the existing piping system.

CAUTION

THESE ASME CODE VESSELS MUST BE PROTECTED BY

PRESSURE RELIEF VALVES. Refer to OSHA 1910.169 Par. b,

Sub. Par (3) and ASME Boiler and Pressure Vessel Code, Section

VIII, Division 1, UG-125 through UG-136. Also comply with all state and local codes.

If excessive vibrations are present in the piping, install a flexible hose between the compressor and the dryer inlet.

When installing the piping and any additional components, make sure that adequate pipe supports are used. Excessive stress on the dryer and components may cause damage or premature failure. Use either overhead or stiff-leg type supports.

Connections are provided in the outlet piping for the installation of pressure relief valves. Reference SECTIONS 3.2 through 3.4 for location and connection size.

Install the pressure relief valves into the provided connections. If pressure relief valves were not purchased with the dryer, the following valve sets are available from your local TTE representative.

Make sure that the piping is correctly connected to the dryer. The inlet is the bottom connection and the outlet is the top connection.

Reference SECTIONS 3.2 through 3.4 for dryer dimensions and connection locations.

Once the location has been determined, place the dryer into position.

Lift the dryer by the lifting lugs only.

Reference SECTION 1 for handling instructions.

When the dryer is in place, it can be fastened to the mounting surface.

Reference SECTIONS 3.2 through 3.4 for dryer dimensions.

4.2-1 BYPASS PIPING (optional)

The installation of bypass piping is not required, but will allow the dryer and filter(s) to be taken off stream without interrupting the air system.

In Figure 4A, several recommended bypass piping layouts and additional components are shown.

DRYER

MODEL

HL-200

HL-250

HL-375

HL-500

HL-650

HL-800

HL-1000

HL-1250

HL-1500

HL-1750

HL-2000

VALVE

PART NO.

14-1448 (2)

14-1448 (2)

14-1833 (2)

14-1833 (2)

14-1834 (2)

14-1834 (2)

14-1835 (2)

14-1835 (2)

14-1836 (2)

14-1836 (2)

14-1836 (2)

PAGE 7


FIGURE 4A RECOMMENDED PIPING CONFIGURATIONS AND COMPONENTS

3 VALVE BYPASS

9 VALVE BYPASS

11 VALVE BYPASS

SECTION 4

DRYER

MODEL

HL-200

HL-250

HL-375

HL-500

HL-650

HL-800

HL-1000

HL-1250

HL-1500

HL-1750

HL-2000

IN/OUT

1-1/2"

RF FLG

1-1/2"

RF FLG

1-1/2"

RF FLG

1-1/2"

RF FLG

2-1/2"

RF FLG

2-1/2"

RF FLG

2-1/2"

RF FLG

2-1/2"

RF FLG

3"

RF FLG

3"

RF FLG

3"

RF FLG

PREFILTER

MODEL

F200-265-1

1

/

4

-C

F200-265-1

F200-350-1

1

1

F200-500-2-C

F200-600-3-C

F200-800-3-C

F200-1000-3-C

F101-1500-C

F101-1500-C

F101-2000-C

F101-2000-C

/

4

-C

/

2

-C

IN/OUT

1-1/4"

NPT(F)

1-1/4"

NPT(F)

1-1/2"

NPT(F)

2"

NPT(F)

3"

NPT(F)

3"

NPT(F)

3"

NPT(F)

3"

NPT(F)

3"

NPT(F)

4"

RF FLG

4"

RF FLG

DRAIN

VALVE

MODEL

EDV-2006

EDV-2006

EDV-2006

EDV-2006

EDV-2006

EDV-2006

EDV-2006

EDV-2006

EDV-2006

EDV-2006

EDV-2006

DEL-P

IND.

MODEL

PD-5

PD-5

PD-5

PD-5

PD-5

PD-5

PD-5

PD-2

PD-2

PD-2

PD-2

AFTERFILTER

MODEL

F200-265-1

1

/

4

-RB

F200-265-1

F200-350-1

1

1

/

4

-RB

/

2

-RB

F200-500-2-RB

F200-600-3-RB

F200-800-3-RB

F200-1000-3-RB

F101-1500-RB

F101-1500-RB

F101-2000-RB

F101-2000-RB

IN/OUT

1-1/4"

NPT(F)

1-1/4"

NPT(F)

1-1/2"

NPT(F)

2"

NPT(F)

3"

NPT(F)

3"

NPT(F)

3"

NPT(F)

3"

NPT(F)

3"

NPT(F)

4" RF FLG

4"

RF FLG

DEL-P

IND.

MODEL

PD-5

PD-5

PD-5

PD-5

PD-5

PD-5

PD-5

PD-2

PD-2

PD-2

PD-2

PAGE 8


4.4 REMOTE PURGE EXHAUST PIPING

To reduce noise during purging and tower depressurization, this dryer was supplied with mufflers for installation on the purge exhaust valves.

If the sound or humidity discharged from the dryer is unacceptable, the purge of this dryer can be remotely piped away.

IMPORTANT

Make sure that the piping is as short as possible and does not create back pressure on the dryer. To prevent liquid accumulation in the piping and purge valves, the piping must be at the same level or lower than the purge valves.

The purge line must be vented to atmospheric pressure. If the ambient temperature at the venting end of the piping is subject to temperatures below 40 o

F, freeze protection must be installed.

The purge valves have threaded pipe connections. Reference

Sections 3.2 through 3.4 for location. Use adequate pipe supports to prevent stress on valves.

The distance will determine the size of piping that is recommended.

For distances of 10 feet or less, use piping of the same size as the purge valves. For distances up to 20 feet, use piping one size larger than the purge valves.

SECTION 4

4.6-1 STANDARD CONTROL BOX (115V & 230V)

The power supply to the dryer is to be connected to the dryer control box. A 7/8" dia hole was provided in the bottom of the box for the connection of conduit or a cord grip connector.

Check the electrical rating of the dryer as listed on the dryer data tag.

Make sure that the power source is correct for the dryer rating.

Remove the box cover to access the power and alarm terminals.

Wire the power supply as shown in Figure 4C (Standard Control

Box). Connect the wiring to the dryer box. Comply with all codes applicable for this installation.

FIGURE 4C ELECTRICAL CONNECTIONS

(STANDARD CONTROL BOX)

4.5 INSTALLING THE PURGE MUFFLERS

To reduce the sound level during purge and tower depressurization, this dryer was supplied with mufflers for installation on the purge exhaust valves.

Mufflers were shipped separately. They should NOT be installed until the dryer has been operated for several hours. From desiccant installation, some dust may be present in the desiccant towers.

Operating the dryer with the mufflers installed immediately after the towers have been filled with the desiccant or during initial start up may cause the mufflers to clog.

IMPORTANT

The dryer must be operated for several hours without the mufflers after the towers have been filled with desiccant. This will prevent the mufflers from becoming clogged.

FIGURE 4B PURGE MUFFLER INSTALLATION

Control Power: 115V /1PH/50-60Hz; 230V/1PH/50-60Hz

Max amp draw: 0.3 AMPS; 0.15 AMPS

General Alarm Contacts: 115V-230V/1PH/60Hz, 0.25 amps

4.6-2 CYCLE SAVER / FAILURE TO SWITCH (115V & 230V)

Same instructions as Standard Control Box except wire the power supply as shown in Figure 4D (Cycle Saver / Failure To Switch).

FIGURE 4D ELECTRICAL CONNECTIONS

(CYCLE SAVER / FAILURE TO SWITCH)

NOTE

Dryer Models HL-1500 thru HL-2000

Have flanged muffler connections.

4.6 ELECTRICAL CONNECTIONS

WARNING

SERIOUS PERSONAL INJURY AND DAMAGE TO THE DRYER

WILL OCCUR IF THE DRYER IS CONNECTED TO A POWER

SOURCE OTHER THAN THE VOLTAGE LISTED ON THE DATA

TAG.

WHEN INSTALLING THE ELECTRICAL CONNECTIONS FOR

THIS DRYER, COMPLY WITH NATIONAL ELECTRICAL CODE

AND ALL APPLICABLE FEDERAL, STATE AND LOCAL

CODES

Control Power: 115V /1PH/50-60Hz; 230V/1PH/50-60Hz

Max amp draw: 1 AMPS; 0.5 AMPS

General Alarm Contacts: 115V-230V/1Ph/60Hz, 3 amps

PAGE 9


4.6-3 EMCON II (115 VOLT)

The electrical controls for the Emcon II dryers are housed in a NEMA 4 rated fiberglass enclosure.

Reference Figure 4E to locate the power input terminals. Access into the enclosure for wiring and conduit can be made by carefully drilling a hole in the bottom of the enclosure.

IMPORTANT

Do NOT wire the power supply directly to the

PLC. Wire the power supply to the input terminals as shown in Figure 4E.

Connect the proper conduit and wiring as required for this installation by all applicable codes.

Make the necessary connections to the power input terminals.

SECTION 4

FIGURE 4E ELECTRICAL CONNECTIONS EMCON II (115 VOLT)

4.6-4 EMCON II (230 VOLT)

The main electrical controls for the Emcon II dryers are housed in a NEMA 4 rated fiberglass enclosure.

Dryers rated for 230V/1PH/60Hz are equipped with a power transformer located in a separate enclosure on the dryer. All main power supply (230V) connections will be made in the transformer enclosure.

Reference Figure 4F for connection details. Connect to the enclosure using the proper conduit and wiring as required for this installation by all applicable codes.

Control Power:

Max amp draw:

115V/1PH/60Hz

2 AMPS

General Alarm Contacts: 115V-230V/1PH/60Hz, 2 amps

FIGURE 4F ELECTRICAL CONNECTIONS EMCON II (230 VOLT)

General Alarm Contacts: 115V-230V/1PH/60Hz, 2 amps

PAGE 10

START UP

5.1 START UP

WARNING

BEFORE STARTING THIS DRYER, FOLLOW THE INSTALLATION

INSTRUCTIONS AND PROCEDURES COMPLETELY. SERIOUS

PERSONAL INJURY CAN RESULT IF INSTRUCTIONS ARE NOT

CAREFULLY AND COMPLETELY FOLLOWED.

DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS

DRYER WHILE IT IS PRESSURIZED.

For the Standard Control Box, make sure the Stop button is pressed.

For the Cycle Saver and Emcon II Control Boxes, make sure that the

Power switch is in the OFF position.

SECTION 5

conditions, the purge metering valve must be adjusted to maintain the required purge flow rate listed in Figure 5B.

Determine the dryer minimum operating pressure. Using the chart in Figure

5A, find the valve setting for that pressure. The valve is equipped with a set screw which must be loosened before the valve is adjusted. Adjust the needle valve to the desired setting. Tighten the set screw to prevent tampering.

FIGURE 5A PURGE METERING VALVE SETTINGS

If the dryer is being started up for the first time or after the desiccant has been changed, the purge mufflers must be removed.

The dryer should be operated until no desiccant dust is visible at the purge valves. Then the mufflers can be reinstalled. See

Section 2.2 for safety precautions concerning the desiccant dust.

WARNING

WHEN OPERATING THIS DRYER WITHOUT THE MUFFLERS

INSTALLED, USE HEARING PROTECTION.

If bypass piping was installed on this dryer as outlined in SECTION 4.2, close the inlet and outlet isolation valves. Open the bypass valve.

Pressurize the air system. Once the air system is pressurized, slowly open the inlet isolation valve. DO NOT open the outlet isolation valve.

To start the dryer with a Standard Control Box, press the Run button which will light the Run LED. For Cycle Saver and Emcon II Control

Boxes, place the Power switch in the ON position. One tower will already be pressurized. The other tower will depressurize. The purge valve on the tower that is not pressurized will be open, air should be exhausting from the muffler.

If the dryer is being operated at a pressure other than inlet rated

1/2" & 3/4" VALVES used on models HL-200 THROUGH HL-500

MODEL

HL-200

HL-250

HL-375

HL-500

HL-650

HL-800

HL-1000

HL-1250

HL-1500

HL-1750

HL-2000

60 PSIG

3.5 turns

3.6 turns

4.5 turns

5.6 turns

2.7 turns

2.8 turns

3.0 turns

3.4 turns

3.8 turns

4.0 turns

4.2 turns

80 PSIG

3.3 turns

3.4 turns

4.0 turns

4.6 turns

2.6 turns

2.7 turns

2.8 turns

3.0 turns

3.3 turns

3.5 turns

3.9 turns

1" VALVE used on models HL-650 through HL-2000

FACTORY

SETTING

100 PSIG

3.2 turns

3.3 turns

3.8 turns

4.2 turns

2.5 turns

2.6 turns

2.7 turns

2.9 turns

3.0 turns

3.2 turns

3.4 turns

120 PSIG

3.1 turns

3.2 turns

3.7 turns

4.0 turns

2.3 turns

2.5 turns

2.6 turns

2.7 turns

2.9 turns

3.0 turns

3.2 turns

150 PSIG

3.0 turns

3.1 turns

3.5 turns

3.8 turns

2.2 turns

2.3 turns

2.5 turns

2.6 turns

2.7 turns

2.8 turns

3.0 turns

Dryers equipped with CYCLE SAVER or EMCON II controls will begin a

20 minute start up cycle. While in the start up cycle the dryer will operate for 5 minutes on each tower to allow the humistat(s) to reach equilibrium. Any time the dryer is restarted after a loss of power or pressure in both towers, it will restart in the start up cycle.

The dryer is equipped with a purge metering valve. The setting should be checked before placing the dryer on stream.

5.2 ADJUSTING THE PURGE FLOW

IMPORTANT

NEVER OPERATE THE DRYER WITH THE PURGE METERING

VALVE CLOSED. IF THE VALVE IS CLOSED, THE TOWERS WILL

NOT REPRESSURIZE AND SWITCHING FAILURE WILL OCCUR.

DO NOT ADJUST THE PURGE METERING VALVE ABOVE OR

BELOW THE RECOMMENDED SETTING FOR THE OPERATING

CONDITIONS OF THIS INSTALLATION. IMPROPER SETTING MAY

CAUSE POOR DRYER PERFORMANCE AND/OR EXCESSIVE USE

OF PROCESS AIR.

The purge flow can be adjusted for the operating conditions. Standard dryers are equipped with a micrometer type needle valve. The valve can be adjusted to the desired setting.

5.3 CONDITIONING THE DESICCANT BED

To condition the desiccant bed, the dryer is operated without any outlet flow, while the towers regenerate with purge air.

To start the dryer with a Standard Control Box, press the Run button which will light the Run LED. For Cycle Saver and Emcon II Control Boxes, place the Power switch in the ON position.

Dryers equipped with the Standard Contol Box should be set on the 10 minute time cycle. Dryers equipped with Emcon II and Cycle Saver should be set in the Fixed Mode. Observe the dryer for several cycles. Make sure that it is operating properly.

This dryer was shipped with the purge flow set for the rated inlet flow at

100 PSIG. Reference Section 3.1 for rated flow. This setting should be correct for most installations. Before placing the dryer on stream, check the purge metering valve setting.

At initial start up or after extended shutdowns (over one month), the dryer may take 24 to 48 hours of continuous operation for the bed to be conditioned.

Moisture that has accumulated on the desiccant bed should be removed before the dryer is placed on stream.

Figure 5B shows the purge flow required for each model. This flow is required to properly regenerate the desiccant beds.

FIGURE 5B REQUIRED PURGE FLOW

DRYER

MODEL

HL-200

HL-250

HL-375

HL-500

HL-650

PURGE

FLOW

36.0 SCFM

45.0 SCFM

67.5 SCFM

90.0 SCFM

117.0 SCFM

HL-800

144.0 SCFM

DRYER

MODEL

HL-1000

HL-1250

HL-1500

HL-1750

HL-2000

PURGE

FLOW

180.0 SCFM

225.0 SCFM

270.0 SCFM

315.0 SCFM

360.0 SCFM

Once the moisture indicator on the dryer turns blue, the desiccant bed is ready. Place the dryer on stream by opening the outlet isolation valve. Make sure that the by-pass valve is closed.

PAGE 11

PRINCIPLE OF OPERATION

6.1 PRINCIPLE OF OPERATION

HL Series Heatless Regenerative Air Dryers utilize the pressure swing principle of operation. The desiccant bed in one tower dries the air stream while the desiccant bed in the other tower is regenerated.

SECTION 6

To achieve maximum performance from this dryer, it should be operated continuously. Operating this dryer for single shift periods may result in varied outlet dew point performance.

A purge of dry air is used for tower regeneration. It is taken from the outlet of the dryer.

The dryer operation consists of four stages; REPRESSURIZATION,

CHANGEOVER/DEPRESSURIZATION, DRYING and

REGENERATION.

The dryer is equipped with a purge metering valve to allow the correct amount of dry air to flow into the regenerating tower. The heat created during adsorption of moisture in the drying tower is retained in the desiccant bed and increases the moisture removal capacity of the purge air.

6.1-1 REPRESSURIZATION STAGE

Repessurization occurs in the regenerating tower. Repessurization must occur before tower changover. This reduces shock to the desiccant and the possibility of downstream pressure spikes.

The timing cycle of the dryer is controlled by two 3-way pilot valves.

A patented shuttle valve system is used to repressurize, changeover, and depressurize the towers. The inlet transfer valve is controlled by the pilot valves. The movement of the shuttle in the inlet transfer valve mechanically actuates the external pneumatic limit switches, which open the purge valves and depressurize the tower. The shuttle cannot shift until the tower pressures are nearly equal. The dryer cannot depressurize until the shuttle has fully seated and the one of the limit switches is engaged.

The purge valve is closed and the purge air, which was vented to atomosphere earlier in the cycle, is now used to repressurize the regenerated tower.

The pilot valves SV1 & SV2 de-energize causing the purge valve on the regenerating tower to close. The purge air, which was vented to atmosphere earlier in the cycle, is now used to repressurize the regenerated tower.

FIGURE 6A PNEUMATIC SCHEMATIC for DRYERS WITH STANDARD CONTROL

PAGE 12

PRINCIPLE OF OPERATION SECTION 6

6.1-2 CHANGEOVER/DEPRESSURIZATION STAGE

Tower changeover occurs after the previous regenerating tower is pressurized. The controller signals the inlet transfer valve to switch.

The tower that was on line and drying the process air will begin to depressurize.

Pressure in the regenerating tower will approach full line pressure. The pilot valves SV1 or SV2 will energize. Pilot air will be supplied to one side of the inlet transfer valve. The inlet transfer valve shuttle will move to the side that has pilot pressure.

When the inlet transfer valve changes position, the position indicator will move and actuate the other pneumatic limit switch. This will open the purge valve on the tower that was drying the process air, causing the tower to depressurize.

6.1-3 DRYING AND REGENERATION STAGE

During the drying stage, one tower is pressurized with process air.

This tower is in the drying stage. The process air passes through the desiccant bed, which adsorbs moisture from the air. The regeneration stage of one tower occurs at the same time as the drying stage in the opposite tower. During the regeneration stage, a percentage of dry air is directed through the desiccant bed of the offstream tower. The purge air is vented through the purge valve to the atmosphere.

The pilot valves SV1 or SV2 are either energized or de-energized depending on which tower is on stream (drying). If SV2 is energized, the

LEFT tower is drying and if SV1 is energized, the RIGHT tower is drying.

CYCLE SAVER and EMCON II models:

If the dryer is being operated in the AUTO MODE, tower changeover is delayed until the dew point controller(s) signal the circuit board or

PLC. The dryer will automatically change towers after 4 hours of

ENERGY SAVINGS.

6.2 MOISTURE INDICATOR

The moisture indicator is in the center of the panel. The moisture indicator is a clear plastic tube filled with moisture sensing crystals. A sample of outlet air is directed through the indicator.

The crystals will change colors from PINK (indicating wet air) to

BLUE (indicating dry air) as the dew point of the air changes from

+20

O

F to -40

O

F.

FIGURE 6B PNEUMATIC SCHEMATIC for DRYERS WITH CYCLE SAVER OR EMCON II

Pneumatic schematic shown above for units equipped with CYCLE

SAVER.

Pneumatic schematic shown above for units equipped with PLC controls featuring EMCON II.

PAGE 13

USING THE STANDARD CONTROL

7.1 STANDARD CONTROL

The STANDARD CONTROL is a compact NEMA 4X control box. It has the following features:

• Dryer Status LEDs

- POWER ON

- RUN

- HOLD

- SWITCHING FAILURE

- L/R TOWER DRYING

- L/R TOWER REGENERATING

- DRYER PURGING

The Dryer Status LEDs are located on the front panel of the control box.

Figure 7A shows the location of each.

Note: There is a Red LED located on the inside of the control box. This LED flashes on and off indicating

the timer is active.

Start the dryer per SECTION 5.1. When the Left tower is pressurized and on line drying the process air, the corresponding LEFT TOWER DRYING LED is illuminated. When the right tower is pressurized and on line drying the process air, the corresponding RIGHT TOWER DRYING LED is illuminated.

The DRYER PURGING LED is illuminated when the corresponding purge exhaust valve is open. During repressurization this LED will not be illuminated. Repressurization occurs for approximately 20 seconds just before tower changeover. The operation timing sequence of the dryer is shown in

Figure 7C TIMING CHART FOR STANDARD CONTROL.

FIGURE 7A CONTROL BOX FRONT PANEL

SECTION 7

POWER ON

HOLD

LEFT

STOP RUN

SWITCHING FAILURE

TOWER DRYING

TOWER REGENERATING

RUN

RIGHT

SWITCHING FAILURE:

When there is a switching failure, the LED will be lit. This will energize the contacts shown in Figure 4C. The contacts can be wired for remote annunciation. To reset the Switching Failure Alarm press the Run button on the control box front panel.

DRYER PURGING

FIGURE 7B CYCLE TIME DETAIL

HOLD FEATURE:

For Low load or Static pressure conditions, the hold contacts shown on

Figure 4C can be wired to an auxiliary set of normally closed contacts on the compressor starter. This will stop the cycling of the dryer and repressurize both towers of the dryer, until there is demand on the compressor. The Hold LED will light, if the dryer is wired as described and the compressor is not running.

7.2 SETTING THE CYCLE TIME

Reference Figure 7B:

The setting for the time cycle is a 5 min/half cycle. For the half cycle time setting, the switches indicated for DS1 (2, 5, 7, & 8) as shown in the CYCLE TIME DETAIL have been factory set by pushing the switches up. The values for these switches are (256, 32, 8, & 4) sec., so when added together equal 300 sec or 5 min. WE DO NOT

RECOMMEND a time cycle setting below 2 min/half cycle. For this half cycle time setting, the switches that need to be pushed up are

DS1

(4, 5, 6, & 7) their values are (64, 32, 16, & 8) sec. so when added together equal

120 sec or 2 min.

5 6

FTS

ALARM

The setting for the alarm time is 96 sec. For the alarm time setting, the switches indicated for DS2 (5 & 6) as shown in the CYCLE TIME

DETAIL have been factory set by pushing the switches up. The values for these switches are (64 & 32) sec., so when added together equal

96 sec. WE DO NOT RECOMMEND CHANGING THIS SETTING.

NOTE: THE ALARM TIME SETTING NEEDS TO BE LESS THAN

THE HALF CYCLE TIME SETTING OR THIS WILL NEGATE

THE ALARM FUNCTION.

The setting for the pressurization time is 20 sec. For the pressurization time setting, the switches indicated for DS2 (2 & 4) as shown in the CYCLE TIME DETAIL have been factory set by pushing the switches up. The values for these switches are (16 & 4) sec., so when added together equal

20sec. WE DO NOT RECOMMEND CHANG-

ING THIS SETTING.

IMPORTANT

Operating this dryer on the 4 minute cycle will more than double the wear on the dryer components. To reduce wear on the dryer, operate the dryer on the 10 minute cycle if the -40 dew point is acceptable.

O

F

FIGURE 7C TIMING CHART FOR STANDARD CONTROL

PAGE 14

USING THE CYCLE SAVER CONTROL

8.1 CYCLE SAVER CONTROL

The CYCLE SAVER control uses a printed circuit board. It is housed in a NEMA 4X fiberglass enclosure. It has the following features:

- POWER SWITCH

- POWER ON LED

- CYCLE MODE PUSHBUTTON

- FIXED MODE LED

- AUTO MODE LED

- ENERGY SAVINGS LED

- SWITCHING FAILURE LED

- RESET PUSHBUTTON

- L/R TOWER DRYING LEDS

- L/R TOWER REGENERATING LEDS

The Dryer Status LEDs are located on the front panel of the control box. Figure 8A shows the location of each.

Note: There are six other LEDs located on the inside of the control box. Reference

SECTION 8.5.

Start the dryer per SECTION 5.1. When the left tower is pressurized and on line drying the process air, the corresponding LEFT TOWER

DRYING LED will be lit. When the right tower is pressurized and on line drying process air, the corresponding RIGHT TOWER LED is illuminated. The operation timing sequence of the dryer is shown in

Figure 8B TIMING CHART FOR CYCLE SAVER.

8.2 SETTING THE CYCLE MODE

Pressing the Cycle Mode Pushbutton will alternate between the FIXED and AUTO modes. This will light either the Fixed or Auto Mode LED.

8.2-1 OPERATING THE DRYER IN THE FIXED MODE

When operating the dryer in the FIXED MODE, press the Cycle

Mode Pushbutton until the Fixed Mode LED is lit. The dryer will not utilize the ENERGY SAVINGS feature.

The fixed cycle is a normal 10 minute cycle. The dryer changes towers every five minutes. The dryer goes through a normal tower changeover sequence (repressurization, tower changeover, depressurization).

SECTION 8

The SWITCHING FAILURE ALARM is operational in both the

FIXED and AUTO modes.

8.2-2 OPERATING THE DRYER IN AUTO MODE

When operating the dryer in the AUTO MODE, press the Cycle

Mode Pushbutton until the Cycle Mode LED is lit.

The dryer will operate in the start up cycle for the first 20 minutes of operation at every start up. After the start up cycle has been completed, the dryer will operate in the mode that the Cycle Mode is set (FIXED or AUTO).

In the Auto Mode, the length of time that a tower is in the drying stage is controlled by the humistat set point adjustment on the printed circuit board.

8.2-2A ENERGY SAVINGS

At the end of a normal regeneration stage, if the tower humistat indicates a good dew point, ENERGY SAVINGS has been activated. If the dew point is not low enough to activate ENERGY

SAVINGS, the dryer will switch towers.

When ENERGY SAVINGS is activated, the ENERGY SAVINGS

LED is illuminated. The purge exhaust valve on the regenerating tower is closed and that tower comes up to full line pressure. No purge air will be exhausted at this time.

The tower that was in the drying stage will remain on line and drying the process air until the dew point rises to the set point of the humistat.

The maximum time a tower can stay in energy savings is four hours. This is to prevent channeling of the desiccant under very low flow conditions.

FIGURE 8A CYCLE SAVER CONTROL BOX

PAGE 15

USING THE CYCLE SAVER CONTROL

8.3 FAILURE TO SWITCH ALARM

The FAILURE TO SWITCH ALARM is operational in the FIXED and AUTO modes.

The dryer is continuously being monitored for switching failure. Two pressure switches monitor the pressure in the desiccant towers. If pressure is present in the tower that should be in the regenerating stage, the alarm is activated. The printed circuit board gives the dryer 90 seconds to depressurize after tower changeover before the alarm is activated.

If one or both of the pressure switches fail, the alarm is NOT activated, but the dryer is switched into a 10 minute fixed cycle.

When the alarm is activated, the FAILURE TO

SWITCH LED is illuminated. The alarm does not stop the dryer from cycling. The FAILURE TO

SWITCH ALARM is a latching alarm. Once the problem causing the switching failure is corrected, the FAILURE TO SWITCH RESET PUSHBUTTON must be pressed to reset the alarm. If the alarm is reset and the problem is not corrected, the alarm will be re-activated after 90 seconds.

The switching failure alarm will activate when:

• The inlet transfer valve does not change positions and does not direct the process flow through the proper tower.

• The purge exhaust valve does not open on the regenerating tower or if tower pressure in the regenerating tower does not drop below 40 psig.

• The purge exhaust valve does not close on the regenerating tower to allow repressurization.

The GENERAL ALARM contact is closed when this alarm is activated.

FIGURE 8B TIMING CHART FOR CYCLE SAVER

LEFT TOWER PRESSURE (PS1)

RIGHT TOWER PRESSURE (PS2)

8.4 GENERAL ALARM

The general alarm contact was provided for the customer to wire the dryer’s alarm into a main control room, or to a warning light or horn.

The contact is a normally open dry contact. The contact is closed if the SWITCHING FAILURE ALARM has been activated. The contact will only reset if the alarm condition is corrected.

SECTION 8

FIGURE 8C CYCLE SAVER PRINTED CIRCUIT BOARD

8.5 PRINTED CIRCUIT BOARD (LEDs)

The Humidity Indication LED (RED) is on when the humidity is above the set point.

The SV1 Indication LED (GREEN) is on when the valve is energized.

The SV2 Indication LED (GREEN) is on when the valve is energized.

The SV3 Indication LED (GREEN) is on when the valve is energized

The PS1 Indication LED (GREEN) is on when the switch is closed.

The PS2 Indication LED (GREEN) is on when the switch is closed.

Note: These LEDs are located on the inside of the control box on the printed circuit board. Figure 8C illustrates the LEDs locations.

PAGE 16

USING THE EMCON II CONTROL

9.1 EMCON II CONTROL

The EMCON II control is programmable logic controller (PLC) based. It is housed in a NEMA 4X fiberglass enclosure.

The EMCON II control has the following features:

• Power Push-button/Light

• Cycle Selector Switch Fixed/Auto

• Energy Saving Activated Light

• Tower Status Lights

Left and Right Tower Drying

Left and Right Tower Regenerating

• Failure To Switch Alarm Light/Reset Push-button

• High Humidity Alarm Light/Reset Push-button

The Tower Status Lights are used to indicate which tower is on line drying the process air and which tower is regenerating.

The FAILURE TO SWITCH ALARM LIGHT is illuminated when the Failure To Switch Alarm is activated. The light is also a push-button which resets the alarm.

The HIGH HUMIDITY ALARM LIGHT is illuminated when the High Humidity Alarm is activated. The light is also a push-button which resets the alarm.

FIGURE 9A EMCON II CONTROL BOX

9.2 SETTING THE CYCLE SELECTOR

SWITCH

The Cycle Selector Switch is used to switch the dryer cycle. When the switch is set to the FIXED

MODE, the dryer will operate on a 10 minute cycle. When the switch is set to the AUTO

MODE, the dryer cycle is controlled by the PLC, the tower dew point controller and the outlet dew point controller.

When the dryer is operated in the AUTO MODE and the dew point controllers allow the dryer to operate in an extended cycle, the

ENERGY SAVINGS ACTIVATED LIGHT is activated.

9.2-1 OPERATING THE DRYER IN FIXED MODE

To operate the dryer in the FIXED MODE, set the CYCLE SELEC-

TOR SWITCH to the FIXED position. The dryer will not utilize the

ENERGY SAVINGS feature.

The fixed cycle is a normal 10 minute cycle. The dryer changes towers every five minutes. The dryer goes through a normal tower changeover sequence (repressurization, tower changeover, depressurization).

The SWITCHING FAILURE ALARM and the HIGH HUMIDITY

ALARM are operational in both the FIXED and AUTO modes.

9.2-2 OPERATING THE DRYER IN AUTO MODE

To operate the dryer in the AUTO MODE, set the CYCLE SELEC-

TOR SWITCH to the AUTO position.

The dryer will operate in the start up cycle for the first 20 minutes of operation at every start up. After the start up cycle is completed, the dryer will operate in the mode that the CYCLE SELECTOR

SWITCH is set (FIXED or AUTO).

In the auto mode, the length of time that a tower is in the drying stage is controlled by the microprocessor and both the tower and outlet humistats.

9.2-2A ENERGY SAVINGS

At the end of a normal regeneration stage, if both the outlet and tower humistats indicate good dew points, ENERGY SAVINGS is activated. If the dew points are not low enough to activate

SECTION 9

ENERGY SAVINGS, the dryer will switch towers.

When ENERGY SAVINGS is activated, the ENERGY SAVINGS

ACTIVATED light will be illuminated. The purge exhaust valve on the regenerating tower is closed and that tower comes up to full line pressure. No purge air will be exhausted at this time.

The tower that was in the drying stage will remain on line and drying the process air until the dew point rises to the set point of either humistat.

The maximum time a tower can stay in energy savings is four hours. This is to prevent channeling of the desiccant under very low flow conditions.

9.2-2B DEW POINT CALIBRATION CYCLE

When the dryer is in the calibration, cycle it will switch towers every 2.5 minutes. By reducing the drying cycle, the inlet moisture load on the towers will be decreased. This will try to push the drying mass transfer zone lower in the desiccant bed.

If the dew point of either tower stays high continuously for five consecutive drying cycles on that tower, the microprocessor will start short cycling the dryer. The dryer will remain in the calibration cycle until the tower dew point meter detects a good dew point in each tower for at least 10 seconds of each drying stage.

If the outlet dew point rises above the set point of the outlet humistat any time after the 20 minute start up cycle, the dryer will be switched into the calibration cycle for a minimum of 20 minutes, even if the outlet dew point returns to a good dew point

(below the humistat set point).

If the outlet dew point remains above the humistat set point

PAGE 17

USING THE EMCON II CONTROL

continuously for 15 minutes on either tower, the HIGH HUMIDITY ALARM is activated.

The HIGH HUMIDITY ALARM is a latching alarm. Before the alarm can be reset, the dryer must operate for one complete cycle with the outlet dew point below the outlet humistat set point. Then the HIGH

HUMIDITY ALARM LIGHT/PUSH-BUTTON can be pressed to clear the alarm condition.

FIGURE 9B TIMING CHART FOR EMCON II

SECTION 9

9.3 FAILURE TO SWITCH ALARM

The FAILURE TO SWITCH ALARM is operational in the FIXED and AUTO modes.

Two pressure switches monitor the pressure in the desiccant towers. If pressure is present in the tower that should be in the regenerating stage, the alarm is activated. The microprocessor gives the dryer 90 seconds to depressurize after tower changeover before the alarm is activated.

If one or both of the pressure switches fail, the alarm is NOT activated, but the dryer is switched into a 10 minute fixed cycle.

When the alarm is activated, the FAILURE TO

SWITCH LIGHT/Push-button is illuminated.

The alarm does not stop the dryer from cycling.

The FAILURE TO SWITCH ALARM is a latching alarm. Once the problem causing the switching failure is corrected, the FAILURE TO

SWITCH LIGHT/PUSH-BUTTON must be pressed to reset the alarm. If the alarm is reset and the problem is not corrected, the alarm will be re-activated after 90 seconds.

The switching failure alarm will activate when:

• The inlet transfer valve does not change positions and does not direct the process flow through the proper tower.

• The purge exhaust valve does not open on the regenerating tower or if the tower pressure in the regenerating tower does not drop below 30 psig.

• The purge exhaust valve does not close on the regenerating tower to allow repressurization.

The GENERAL ALARM contact is closed when this alarm is activated.

LEFT TOWER PRESSURE (PS1)

RIGHT TOWER PRESSURE (PS2)

9.4 HIGH HUMIDITY ALARM

The HIGH HUMIDITY ALARM is operational in the FIXED and

AUTO modes. The alarm is disabled while the dryer is in the 20 minute start up cycle. When it is activated the dryer will continue to operate.

The HIGH HUMIDITY ALARM is a latching alarm condition. To turn off the light the reset button must be pushed. The GEN-

ERAL ALARM contacts are closed when this alarm is activated.

FIXED MODE

After the 20 minute start up cycle, if the outlet dew point remains above the humistat set point continuously for 15 minutes on either tower, the HIGH HUMIDITY ALARM is activated.

PAGE 18

AUTO MODE

If the outlet dew point rises above the set point of the outlet humistat anytime after the 20 minute start up cycle, the dryer will be forced into the calibration cycle for a minimum of 20 minutes. If the outlet dew point remains above the humistat set point continuously for 15 minutes on either tower, the HIGH HUMIDITY ALARM is activated.

9.5 GENERAL ALARM

The general alarm contact was provided for the customer to wire the dryer’s alarms into a main control room, or to a warning light or horn.

The contact is a normally open dry contact. The contact is closed if either the HIGH HUMIDITY ALARM or the SWITCHING FAILURE

ALARM is activated. The contact will only reset if the alarm condition has been corrected. There is an individual reset push-button for each alarm.

SHUTDOWN

10.1 SHUTDOWN PROCEDURES

Close the inlet and outlet isolation valves (if installed). Open the bypass valve (if installed). Let the dryer depressurize completely.

Turn the dryer off by either pressing the Stop button if the dryer has a

Standard Control Box or place the Power switch to the OFF

MAINTENANCE & TROUBLESHOOTING

11.1 DAILY INSPECTION

The following procedures should be performed daily:

• Check the dryer operating conditions, inlet temperature, ambient temperature, inlet pressure and inlet flow.

• Monitor the dryer for one complete cycle. Make sure it is operating properly.

• Check the purge mufflers. Purge air should be exhausting from one of the valves. If oil is present, the dryer and air system may be contaminated with lubricants.

• Inspect all upstream equipment, aftercoolers, separators, drains and filters.

• Check the pressure differential indicator on all prefilters and afterfilters. If the differential pressure is unacceptable, replace the elements.

• Check the prefilter(s) for proper draining. If the prefilter is not equipped with an automatic drain, it must be drained manually.

• Make sure that all bypass valves are tightly closed.

• Visually check the dryer and piping for damage.

•

Visually check the dryer moisture indicator (blue dry or pink wet)

SECTION 10

position for the Cycle Saver or Emcon II Control Boxes.

If maintenance is to be preformed on the dryer, make sure the dryer is completely depressurized. Tower pressure gauges must read 0

PSIG before removing any item on the dryer.

SECTION 11

Remove any oil, dirt, or scale from the towers and inlet piping. Do

NOT weld, grind or sandblast the vessels as this voids the ASME

Certification. The vessels may be steam cleaned internally and externally to remove dirt and oil.

CAUTION

Make sure that the towers are clean to prevent contamination of new desiccant.

Replace plugs securely on desiccant drain ports. Apply pipe thread sealant as necessary.

Make sure that the drain ports or hatch covers are installed before attempting to fill the towers. Load desiccant through the desiccant filler ports or hatches.

REFER TO SECTION 3.1 FOR PROPER

DESICCANT AMOUNTS.

Reinstall the fill port plugs. Apply pipe thread sealant as necessary.

Follow START UP PROCEDURES IN SECTION 5.1 to start up and place dryer in operation.

11.4 CONTROL AIR FILTER REPLACEMENT

Close the dryer inlet and outlet isolation valves (and open bypass valve if provided). Turn off the power and completely depressurize the dryer.

11.2 SCHEDULED MAINTENANCE

12 MONTHS

• Replace purge muffler elements

• Replace the control air filter element

24-60 MONTHS

• The desiccant in the towers should be replaced every two to five years. The life of the desiccant will vary depending on the inlet air conditions. Systems with excessive contaminants and/or inadequate filtration will decrease the life span of the desiccant drastically. Once the desiccant is contaminated with lubricants, it must be replaced.

WARNING

DO NOT REMOVE THE FILTER BOWL FROM HEAD UNTIL

HOUSING IS COMPLETELY DEPRESSURIZED.

After all pressure is out of the dryer, grasp the filter bowl firmly, while pushing the bowl upward turn it clockwise to remove it from the filter head.

Remove the used element from the head. Discard used element properly.

Remove new element from the shipping package. Place the new element into the filter head.

11.3 DESICCANT REPLACEMENT

WARNING

DO NOT ATTEMPT TO REMOVE PLUGS OR HATCH COVERS

UNTIL ALL AIR PRESSURE IS OUT OF THE VESSEL. CHECK

ALL TOWER PRESSURE GAUGES, MAKING SURE THAT THEY

ARE AT 0 PSIG AND INCOMING PRESSURE HAS BEEN TURNED

OFF.

ALWAYS WEAR EYE PROTECTION AND GLOVES WHEN

HANDLING THE DESICCANT. DESICCANT DUST MAY CAUSE

EYE AND SKIN IRRITATION. AVOID BREATHING THE DUST

AND PROLONGED CONTACT WITH THE SKIN.

FIRST AID IN CASE OF EYE CONTACT, IMMEDIATELY FLUSH

EYES WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES.

CONSULT A PHYSICIAN.

Take dryer off stream following the

SHUTDOWN PROCEDURES IN

SECTION 10.

Remove the plugs from the desiccant drain and fill ports; drain old desiccant from each tower.

While pushing the bowl upward into the head turn the bowl counterclockwise to lock it in place.

Following the start up procedures in SECTION 5.1 for the dryer, place the dryer on stream.

PAGE 19

MAINTENANCE & TROUBLESHOOTING SECTION 11

11.5 TROUBLESHOOTING

The following check list should be used as a guideline for troubleshooting problems. Each of the topics will reference other se ctions in this manual for further information.

IS THE DEW POINT ACCEPTABLE?

IS THE POWER ON?

Check the main power source. For dryers equipped with the

Standard Control Box make sure the Run button is pressed and the Run LED is lit. For dryers equipped with Cycle Saver or

Emcon II Control Boxes make sure the Power switch is in the

ON position.

IS THE SYSTEM PRESSURIZED?

The dryer is designed to operate at 60 to 150 psig. Check the upstream equipment and any isolation or bypass valves.

IS THE DRYER CYCLING?

• IS THE FAILURE TO SWITCH ALARM ACTIVATED?

If the dryer is not cycling the FAILURE TO SWITCH ALARM should be activated. The dryer should be checked to determine the cause of switching failure.

• IS THERE CONTROL AIR PRESSURE, 60 PSIG MINIMUM.

Make sure that the dryer inlet pressure is above 60 PSIG. Check the control air filter element and replace it with a new element.

Reference Section 11.4 for element replacement instructions.

• IS THE PURGE METERING VALVE SET PROPERLY? Reference

Section 5.2 for purge metering valve settings and procedures.

If the purge metering valve requires adjustment, follow the procedures in Section 5.2.

• WAS THE DESICCANT INSTALLED?

Make sure that the desiccant was installed. Reference Section

11.3 for desiccant replacement procedures.

• IS THE DESICCANT CONTAMINATED WITH LUBRICANTS?

Check the condition of the desiccant bed. If the bed is contaminated with lubricants, replace the desiccant following the procedures in Section 11.3.

• IS THE DESICCANT CONTAMINATED WITH MOISTURE?

If the dryer was operated under excessive inlet conditions, the desiccant bed may be saturated with liquid moisture. Check upstream equipment such as aftercoolers. Check the actual inlet conditions, correct them and condition the bed following the procedures in Section 5.3.

• ARE THE PILOT VALVES FAULTY? (SV1 & SV2)

Reference Section 11.5-3 for procedures to check the operation of the 3-way valves.

Replace any faulty 3-way valves.

• IS THE INLET VALVE FAULTY? Reference Section 11.5-5 for procedures to check the operation of the inlet transfer valve.

Rebuild or replace the inlet valve as necessary. Reference

Sections 12.9 & 12.10 for valve breakdowns and repair kit details.

• ARE THE BYPASS VALVES OPEN OR LEAKING?

Check the valves (if installed). Repair or replace if faulty.

IS THE ENERGY SAVINGS BEING ACTIVATED?

(CYCLE SAVER AND EMCON II MODELS ONLY)

• IS THE CYCLE SELECTOR SWITCH SET IN THE "AUTO"

MODE?

The Cycle Selector must be set in the "AUTO" mode in order for the dryer to activate the energy savings feature.

• IS A PURGE EXHAUST VALVE FAULTY? Reference Section

11.5-7 for procedures to check the operation of the purge exhaust valves.

Rebuild or replace the faulty purge exhaust valve. Reference

Section 12.11 through 12.15 for valve breakdowns and repair kit details.

• IS AN OUTLET CHECK VALVE FAULTY? Reference Section

11.5-8 for procedures to check the operation of the outlet check valves.

If a valve is faulty, replace it.

• IS THE DRYER BEING OPERATED AT THE MAXIMUM

OPERATING CONDITIONS? Reference Section 3.1 for rated inlet conditions.

Little or no energy savings will occur if the dryer is being operated at the maximum operating conditions.

• IS THE SOLENOID VALVE SV3 FAULTY? Reference Section

11.5-4 for procedures to check the operation of SV3.

If the valve SV3 is faulty replace it.

• ARE THE TOWER HUMISTAT AND SENSOR WORKING

PROPERLY?

Reference Section 11.5-9 for procedures to check the operation of the sensor and humistat.

• IS THE PURGE METERING VALVE SET PROPERLY? Reference

Section 5.2 for purge metering valve settings and procedures.

If the purge metering valve requires adjustment, follow the procedures in Section 5.2.

ARE THE TOWERS DEPRESSURIZING?

•ARE THE PNEUMATIC LIMIT SWITCHES FAULTY?

Reference Section 11.5-6 for procedures to check the operation of the pneumatic limit switches.

If either of the pneumatic limit switches are faulty, replace them both.

IS THE VISIBLE MOISTURE INDICATOR BLUE?

Reference

Section 6.2 for an explanation of operation for the moisture indicator.

• IS THE BLEED ORIFICE FITTING OR SINTERED MUFFLER

ON THE MOISTURE INDICATOR CLOGGED?

Inspect the bleed orifice fitting and the sintered filter on the back of the moisture indicator. They can be cleaned or replaced.

IS THE DEW POINT ACCEPTABLE?

• ARE THE INLET CONDITIONS WITHIN THE SPECIFICATIONS?

Reference Section 3.1 for the inlet conditions of the dryer.

Correct the inlet conditions if necessary. Excessive inlet flow will greatly reduce the performance of the dryer.

Check the sample cell isolation valve and the bleed orifice fitting.

If necessary, replace the bleed orifice fitting and/or the bleed muffler.

• IS THE SAMPLE LINE DAMAGED OR PLUGGED?

Check the sample line following the procedures in Section 11.5-

10. Repair or replace the components as necessary.

11.5-2 CHECKING THE PROGRAMMABLE CONTROLLER

EMCON II MODELS ONLY:

The control system consists of three different control systems:

1. The programmable controller (PLC)

2. Input devices (24 volts DC components) a. Pressure switches b. Humistat(s) c. Reset push-button(s) d. Low voltage side of the Power ON/OFF Pushbutton e. Cycle selector switch

3. Output components a. Pilot valve(s) b. Light(s) c. General alarm contact

The PLC controls the cycling of the dryer. The program logic is stored on an electrically erasable EEPROM. Loss of power to the

PLC will not cause loss of the logic program.

PAGE 20


WARNING

THE POWER ON/OFF PUSH-BUTTON ON THE CONTROL BOX

DOES NOT TURN THE POWER OFF TO THE PLC.

The PLC is wired so it is energized when power is supplied to the control box, even if the power push-button is in the off position.

This is to prevent loss of retentive counter memory. The counters are used to monitor run time and cycle life of components. The retentive memory will hold the data safely for at least 30 days. The information stored in memory is accessible with a HMI Kit (not supplied).

11.5-2A (Optional) HMI KIT


A Human Machine Interface is available for this dryer. The monitor can be fastened to the PLC. It will allow the operator to view the counters and registers in the program on the PLC.

With the purchase of this HMI kit, a list of the counters and registers will be included. With the list and monitor, the operator can find out the following information:

• How long the dryer has been in operation.

• How many times the valves have been activated.

• How many times the HIGH HUMIDITY ALARM has been activated.

• How many times the FAILURE TO SWITCH ALARM has been activated.

• How long the dryer has operated in ENERGY SAVINGS.

• How long the dryer has operated in the CALIBRATION

CYCLE.

The PLC has power, run and error LEDs. If there is power to the

PLC, the power LED will be illuminated. If the power LED is not illuminated, check the power supply to the PLC. If there is power present, the PLC is faulty.

If the error LED is lighted, an error has occurred in the program logic. Consult factory.

The run LED must be on for the PLC to operate. If the run LED is off, turn the main power to the dryer off and on again. The PLC should reset and the run LED should turn on. If the LED does not turn on, consult factory.

If the power and run LEDs are on and the error LED off, the PLC may still be faulty. To verify that the input and output of the PLC are operating properly, the input and output devices must be checked. Figure 11B lists the inputs and outputs on the PLC and the corresponding devices.

SECTION 11

Reference Sections 11.5-2B and 11.5-2C for procedures to verify that the input and output devices are operating properly. If the devices are operating properly, the PLC will need to be replaced.

11.5-2B TESTING THE INPUT DEVICE

EMCOM II MODELS ONLY:

The PLC supplies a 24 volt DC signal to the input devices and alarm contacts. If the input device is activated, it will cause that input LED to light. The input LEDs are labeled 0 to 7.

The input devices can be easily tested for proper operation. With power to the control box, set the Power Push-button (PB1) to the

OFF position, then the ON position. This should cause LED 0 to light. Pushing the failure to switch light (PB2) should cause LED 3 to light. Pushing the high humidity light (PB3) should cause LED 5 to light. The fixed/auto selector switch can be tested as follows. In the fixed mode, LED 6 should be off. In the auto mode, LED 6 should be lighted. If these input devices do not function as described, they should be replaced.

The pressure switches monitor the failure to switch option. The inputs from the pressure switches (PS1, PS2) can be observed while the dryer is in operation. Any time there is more than 30 psig pressure in the left tower, pressure switch (PS1) should cause LED 1 to light. Any time there is more than 30 psig pressure in the right tower, pressure switch (PS2) should cause LED 2 to light. If the pressure switches do not respond as previously explained, replace them.

To check input 4 or 7, follow the procedures in Section 11.5-9 for calibrating the outlet humistat.

If the input devices are activated and LED is not illuminated, take a voltage measurement across the input terminals. If the device is faulty, it must be replaced. If the device is working properly, check the wiring from the PLC. If the wiring and device are good, the PLC is faulty and should be replaced. Reference Figure 11I DRYER

WIRING DIAGRAM for wiring and terminal numbers.

FIGURE 11A PROGRAMMABLE CONTROLLER DETAIL

INPUT

LEDs

OUTPUT

LEDs

NOT

USED

FIGURE 11B INPUT AND OUTPUT LIST (EMCON II)

INPUT DEVICES

0

3

4

1

2

PB1

PS1

PS2

PB2

CDP1

5

6

7

10

PB3

SW1

CDP2

SPARE

OUTPUT DEVICES

0 SV1 & PL7

1 SV2 & PL8

2 SV3 & CR1

3 PL2 & CR2

4 PL3 & CR3

5 PL4

6 SPARE

NOTE:

The general alarm contact is a normally open dry contact which is wired to terminals #5 and

#6.

The lights are run off 120 volts AC which is reduced to 24 volts DC through resistors and diodes on the printed circuit board.

The control relays (CR1, CR2, CR3) are mounted on the board which is mounted to the back of the control box door. CR2 and CR3 are the control relays which give you the general alarm contact.

11.5-2C TESTING THE OUTPUT DEVICES


The microprocessor’s outputs are 120 volts AC. The output LEDs are labeled 0 to 5. If the output’s LED is illuminated, that output is supplying 120 volts AC to its component.

To check outputs 0 through 2, follow the procedures in Section

11.5-3.

PAGE 21


There is no easy way to check outputs 3 through 5. Output 3 can be checked by causing a switching failure. Output 4 can be checked by creating a false outlet dew point by setting the outlet dew point humistat lower than the factory setting and allowing the dryer to go into HIGH HUMIDITY ALARM. Output 5 can be checked when either output 3 or 4 are checked.

Before attempting this procedure, consult the factory.

11.5-3 CHECKIING THE 3-WAY PILOT VALVES

(SV1 & SV2)

TOWER CHANGEOVER

All 3-way pilot valves have manual override buttons on the top of the valve. To test SV1 and SV2 do the following:

For dryers with the Standard Control Box make sure the Stop button is pressed and the dryer is pressurized. For dryers with Cycle Saver or Emcon II Control Boxes make sure the Power switch is in the

OFF position and the dryer is pressurized. Both towers should be at full line pressure Pushing the manual override of SV1 should cause the left tower to depressurize. Allow the left tower to come back up to full line pressure. Pushing the manual override of SV2 should cause the right tower to depressurize. If this does not happen, replace that solenoid valve.


With the Power push-button (PB1) in the ON position, the fixed/ auto selector switch in the fixed mode, and the dryer pressurized, monitor the outputs on the microprocessor. If output 0 is lighted,

SV1 should be activated, the left tower should be depressurized and the right tower should be pressurized and drying the compressed air. If output 1 is lighted, SV2 should be activated, the right tower should be depressurized and the left tower should be pressurized and drying your compressed air. These two operations can be monitored in one 10 minute fixed cycle.

If the above responses are not observed, first check to see if power is being supplied to each solenoid valve when the corresponding output LED on the PLC is lighted. Check the wiring between the

PLC and solenoid valves. If the PLC is not supplying power to the valve when the LED is illuminated, replace the PLC. If the valve has power but does not operate, it must be replaced.

11.5-4 CHECKING THE SOLENOID VALVE

(SV3)

TOWER SAMPLE SELECT

CYCLE SAVER AND EMCON II MODELS ONLY:

Solenoid valve (SV3) is used to switch the sample line to the tower that is on line drying your compressed air. It then feeds a sample of air to the tower dew point humistat's sample cell.

SECTION 11

With the dryer pressurized, the Power push-button in the

ON

position, and the dryer in the fixed mode, remove the bleed orifice from the tower dew point humistat’s sample cell. Monitor the air flow from the sample cell for one complete 10 minute cycle. There should be full line pressure coming from that sample cell for the whole cycle. If air pressure to the sample cell is lost at any part of the cycle, check the sample line filters and the solenoid valve

(SV3). Repair or replace as necessary.

11.5-5 CHECKING THE INLET TRANSFER VALVE

The inlet transfer valve will not switch positions unless the pressure in both desiccant towers is nearly equal. At tower changeover, the regenerating tower should approach full line pressure before the inlet valve will switch. Make sure that there are no leaks in the piping or fittings. Make sure that the purge exhaust valves are closing and that the purge metering valve is properly set.

The exhaust ports on top of the pilot valves (SV1 & SV2) should not have air exhausting through them continuously. If air is exhausting continuously through either of the exhaust ports, the inlet transfer valve is faulty and should be rebuilt or replaced.

To test the inlet transfer valve for proper operation, turn off the power, isolate and depressurize the dryer.

Remove the two pilot lines to the inlet valve. The pilot lines are connected to the outside flanges of the valve. Using an air nozzle and clean air, pressurize one of the ports. Observe the position indicator. It should move in the direction of the port that is being pressurized. No air should be exhausting from the other port.

Pressurize the other port. The valve should move to the other side.

If the valve does not move or air is being exhausted out of the port that is not pressurized, the inlet transfer valve must be rebuilt or replaced. Reference Section 12.9 & 12.10 for valve breakdown and parts listing.

11.5-6 CHECKING THE PNEUMATIC LIMIT SWITCHES

Mounted on the inlet transfer valve is a set of 3-way pneumatic limit switches. These switches control the pilot air to open and close the purge exhaust valves.

When a pneumatic limit switch is activated by the inlet transfer valve position indicator, pilot air is supplied to the purge exhaust valve on that side of the dryer.

To check the pneumatic limit switches, allow the dryer to cycle.

Check the pilot line to the purge exhaust valve on the side of the activated limit switch. If no air is present, the limit switch must be replaced. The limit switches are sold in sets only.

FIGURE 13C INLET TRANSFER VALVE DETAIL

PAGE 22


11.5-7 CHECKING THE PURGE EXHAUST VALVES

The purge exhaust valves are normally closed. They can be checked by removing the pilot air lines to them. The valves should be closed.

Using an air nozzle and clean air, pressurize the purge exhaust valves. The valves should open when pressurized. If valve does not open and close, it should be rebuilt or replaced. See Section 12.11

through 12.15 for valve breakdown and parts listing.

11.5-8 CHECKING THE OUTLET CHECK VALVES

This dryer uses two check valves for outlet air control. If either of the outlet valves fails, one of the following will occur:

• A large amount of air will purge from one tower

• The outlet air flow will be blocked

If either happens, the faulty check valve must be replaced.

11.5-9 CALIBRATING THE HUMISTAT

CYCLE SAVER AND EMCON II MODELS ONLY:

The set point for the humistat is calibrated by a set plug.

Unplug the cable from the sample cell. Plug the set plug into the end of the humistat cable.

For dryers equipped with the Cycle Saver Control Box turn the humistat set point adjustment located on the printed circuit board until the Humidity Indication LED is lit. This will calibrate the dew point meter.

Reference Figure 11E.

For dryers equipped with the Emcon II Control Box turn the potentiometer on the humistat board until you see the LED input light turn on.

This will calibrate the dew point meter.

Reference Figure 11D.

If you get no response from the humistat set point adjustment or the potentiometer with the set plug in, first check the cable connection. If the cable and set plug are good, replace the printed circut board

(Cycle Saver) or the humistat board (Emcon II).

The sensor can be tested by removing it from the sample cell and plugging it into the cable. With the sensor in the ambient air, the humistat should turn on the corresponding LED. Place the sensor back into the sample cell and allow compressed air to pass over it.

The LED for the humistat should turn off in several minutes if the air is dry. If you get no response from the LED, replace the dew point sensor.

CAUTION

NEVER USE AN OHMMETER TO CHECK THE SENSOR. THE

USE OF AN OHMMETER OR ANY ELECTRICAL TESTING

DEVICE WILL CAUSE DAMAGE TO THE SENSOR.

11.5-10 SAMPLE LINE MAINTENANCE

WARNING

DO NOT ATTEMPT TO REMOVE ANY FITTINGS UNTIL ALL AIR

PRESSURE IS OUT OF THE VESSEL. CHECK ALL TOWER

PRESSURE GAUGES, MAKING SURE THAT THEY ARE AT

0 PSIG AND THE DRYER IS ISOLATED.

Take dryer off stream following the

SHUTDOWN PROCEDURES IN

SECTION 10.

Disconnect the sample line at the tee fitting.

Unthread the sample line from the tower at the bushing. Carefully pull the sample line assembly from the tower. Some desiccant will drain from the tower. Plug the coupling to prevent more desiccant from draining.

Unthread the sample line filter from the tubing. Clean or replace the filter. The filter is made of sintered bronze material. To clean it, use pressurized, clean air.

SECTION 11

Re-install the filter. Carefully push the assembly back into the tower and tighten the bushing into the coupling. DO NOT FORCE THE

ASSEMBLY. An application of pipe sealant to the bushing threads may be necessary. Reconnect the line at the tee fitting.

FIGURE 11D HUMISTAT DETAIL FOR EMCON II

NOTE

DRYERS EQUIPPED WITH EMCON II HAVE TWO HUMISTATS AND SAMPLE CELLS.

FIGURE 11E HUMISTAT DETAIL FOR CYCLE SAVER

FIGURE 11F SAMPLE LINE DETAIL

PAGE 23


11.6 WIRING DIAGRAMS

FIGURE 11G WIRING DIAGRAM for STANDARD CONTROL

SECTION 11

FIGURE 11H WIRING DIAGRAM for CYCLE SAVER

PAGE 24


FIGURE 11IIIII WIRING DIAGRAM for EMCON II

SECTION 11

FIGURE 11J WIRING DIAGRAM for OPTIONAL 230 VOLT TRANSFORMER BOX

PAGE 25

REPLACEMENT PARTS

12.1 STANDARD CONTROL AND CYCLE SAVER GAUGE PANEL REPLACEMENT

PARTS

8

9

6

7

10

ITEM

1

2

3

4

5

1

1

2

1

QTY

1

2

2

1

1

1

DESCRIPTION

Panel

2" Pressure Gauge, 0-200 PSIG

1/8" NPT x 1/4" Female Straight Tube Fitting

1/4" NPT Anchor Tube Fitting

1/4" NPT x 10-32 Reducer Bushing

10-32 Short Coupling

10-32 Choke Fitting

10-32 Sintered Filter

Visible Moisture Indicator Assembly

1/4" NPT x 1/4" Male Straight Tube Fitting

STANDARD

CONTROL

PART NO.

26-6487

29-0278

26-0233

26-1497

26-0296

26-0657

26-0490

26-0623

46-2300

26-0231

CYCLE

SAVER

PART NO.

26-5654

29-0278

26-0233

26-1497

26-0296

26-0657

26-0490

26-0623

46-2300

26-0231

12.2 EMCON II GAUGE PANEL REPLACEMENT PARTS

6

7

4

5

ITEM

1

2

3

8

9

10

QTY

1

4

1

1

1

1

1

1

4

2

DESCRIPTION

Panel

2" Pressure Gauge, 0-200 PSIG

1/8" NPT x 1/4" Female Straight Tube Fitting

1/4" NPT Anchor Tube Fitting


Visible Moisture Indicator Assembly

10-32 Choke Fitting


1/4" NPT x 10-32 Reducer Bushing


PART NO.

26-5655

29-0278

26-0233

26-1497

26-0231

46-2300

26-0490

26-0657

26-0296

26-0623

12.3 STANDARD CONTROL SYSTEM REPLACEMENT PARTS

2

3

1

1/4 ft.

2

2

2

2

1

1

2

1

QTY

1

1

1

2

9

10

11

12

7

8

5

6

13

14

15

16

ITEM

1

2

3

4

DESCRIPTION

Enclosure

Panel Membrane and Ribbon Connector

Circut Board

Pressure Switch

Female Connector Fitting

Threaded Seal Fitting

1/2" NPT x 2" LG Close Nipple, Galvanized

Seal Fitting

1/8" Solenoid Valve

Male Elbow Tube Fitting

Male Tee Tube Fitting

Nylon Tubing 1/4" Outside Diameter

1/2"Connector Locknut

8-32 Washer Stat-O-Seal

8-32UNF x 1" LG Rd Mach Grounding Screw

8-32UNF Hex Nut

115V

PART NO.

27-1139

26-6356

26-6469

26-5284

26-6492

26-3042

12-0515

26-0883

14-2082

26-0234

26-0504

26-0223

26-6491

28-1371

28-1372

28-1373

230V

PART NO.

27-1139

26-6356

26-6469

26-5284

26-6492

26-3042

12-0515

26-0883

14-2083

26-0234

26-0504

26-0223

26-6491

28-1371

28-1372

28-1373

SECTION 12

PAGE 26


12.4 CYCLE SAVER CONTROL REPLACEMENT PARTS

12

13

14

15

10

11

8

9

16

17

18

19

20

6

7

4

5

ITEM

1

2

3

DESCRIPTION

Enclosure

Label (Cycle Saver)

1/8" NPT Solenoid Valve

Male Connector Fitting

Male Tee Tube Fitting

Male Elbow Tube Fitting

Nylon Tubing 1/4" Outside Diamater

PC Mother Board

PC Display Board

Sample Cell Manifold

Sensor

Cable

Pressure Switch

Bulkhead Fitting

Switch (On/Off)

Male Connector Fitting

Dew Point Isolation Valve

10-32 Choke Fitting


1/4" x 10-32 Reducer Fitting

CYCLE SAVER

PART NO.

27-1141

30-1391

14-1721

26-0639

26-0504

26-0234

26-0223

26-6501

26-6502

26-6503

26-0817

26-6505

26-6471

26-6472

26-6507

26-2142

14-2110

26-0490

26-0657

26-0296

2

1

1

2

1

1

1

1

1

1

1

1

1

QTY

1

1

3

1

1

5

1/2 ft.

ITEM

21

22

23

24

25

26

27

28

29

DESCRIPTION


1/2" x 2" LG, Conduit Nipple

Seal Nut

Sensor Pin Insert

Washer

Ground Lock Nut

Washer (Phoenix)

Fuse 1- 6/10 Amp

Fuse 1/8 Amp

SECTION 12

CYCLE SAVER

PART NO.

26-0623

12-1876

26-6512

26-6504

26-6508

26-6511

26-6525

26-6527

26-6528

3

1

1

1

QTY

1

3

3

1

1

PAGE 27


12.5 EMCON II CONTROL REPLACEMENT PARTS

EMCON II

15

16

17

18

11

12

13

14

19

20

21

22

23

6

7

4

5

ITEM

1

2

3

8

9

10

DESCRIPTION

Fiberglass Enclosure

Back Panel

Programmable controller (programmed)

Pressure Switch

Bulkhead Female Tube Fitting

Thread Seal

Lighted Push-button (white)

Lighted Push-button (red)

Terminal Block

Fuse Block

Fuse 2 amp

Box Label

Humistat

Sensor

Set Plug

Cable

Threaded Mount For Sensor

1" NPT Tee, Galvanized

10-32 Choke Fitting


1/4" x 10-32 Reducer Bushing

1" NPT x 1/4" NPT Hex Bushing

Needle Valve 1/4" Tube Fitting

2

1

1

2

1

1

2

1

2

1

2

2

QTY

1

1

1

4

2

2

2

2

2

2

2

PART NO.

27-1081

27-1082

46-3296

26-5284

26-3127

26-3042

26-5621

26-5622

26-5623

26-5624

26-5625

30-1320

26-0814

26-0817

26-0818

46-2185

26-0816

14-1807

26-0490

26-0657

26-0296

14-1808

14-1306

SECTION 12

38

39

40

41

34

35

36

37

42

43

44

45

46

27

28

29

30

ITEM

24

25

26

31

32

33

DESCRIPTION

1/4" Nut And Sleeve Tube Fitting


Light (green)

Light (yellow)

Switch

Door Component Circuit Board

1/2" Conduit Hub Connector

1/2" NPT Close Nipple

3-Way Solenoid Valve

1/8" NPT x 1/4" Male Elbow Tube Fitting


1/8" NPT x 1/4" Male Branch Tee Tube Fitting

Snap Track Mounting Strip

Terminal Strip Marker

1/2" NPT x 1/4"" NPT Bushing

1/4" NPT Thermocouple Fitting

1/4" Union Elbow Tube Fitting

HMI Module Kit

Replacement LED, white

Replacement LED, red

Replacement LED, yellow

Replacement LED, green

Mounting Clip for PLC

EMCON II

1

2

1

2

5

1

3

3

1

3

4

1

QTY

2

4

1

1

2

2

4

1

1

2

2

PART NO.

26-3043

26-0623

26-5628

26-5632

26-5629

26-5633

26-3662

12-1668

14-1721

26-0234

26-0369

26-0504

26-5664

26-5762

14-0441

26-0862

26-0416

46-3326

26-5783

26-5786

26-5784

26-5785

26-6884

PAGE 28


12.6 REPLACEMENT PARTS HL-200 through HL-800

8

9

6

7

4

5

b c

3

a c

2

ITEM

1

a b

12

13

14

a

10

a

11

15

16

DESCRIPTION

Inlet Transfer Valve

Seat & Seal Kit for Inlet Transfer Valve

Position Indicator Kit for Inlet Transfer Valve

Shuttle Assembly Kit for Inlet Transfer Valve

Check Valve

Purge Valve

Diaphragm & Seal Kit for Purge Valve

Internal Repair Kit for Purge Valve

Spring Kit for Purge Valve

Diffuser basket

Stud

Sintered Filter

Leg Base

Leg

Purge Exhaust Muffler

Element, purge exhaust muffler

Control Air Filter

Element, control air filter

Purge Metering Valve

Pneumatic Limit Switch (set)

Manifold Block w/Pneumatic Limit Switches

Desiccant

Activated Alumina, 1/8" dia, 25# pail

Activated Alumina, 1/8" dia., 50# bag

Activated Alumina, 1/8" dia., 375# drum

Touch-Up Paint, 9oz. spray can

OPTIONAL SAFETY RELIEF VALVE (set)

HL-200

PART NO.

14-2014

26-6272

26-6273

26-6274

14-1788

14-1841

26-5687

26-5686

26-5688

46-0224

28-0409

26-1014

46-2347

46-2345

26-3262

26-5774

26-6830

26-6831

14-0474

14-0797

14-1037

33-0237 n/a n/a

45-0201

81-1715

-

9

1

1

1

1

2

1

n/a n/a

1

1

2

2

1

2

4

4

2

2

2

2

1

2

QTY

1

1

1

HL-250

PART NO.

14-2014

26-6272

26-6273

26-6274

14-1788

14-1841

26-5687

26-5686

26-5688

46-0224

28-0409

26-1014

46-2347

46-2345

26-3262

26-5774

26-6830

26-6831

14-0474

14-0797

14-1037

33-0237 n/a n/a

45-0201

81-1715

1

-

1

1

1

1

2

2

11 n/a n/a

1

1

2

2

4

1

2

4

2

2

QTY

1

1

2

2

1

1

SECTION 12

46-0224

28-0409

26-1014

46-2347

46-2345

26-3284

26-5775

26-6830

26-6831

14-0475

14-0797

14-1037

HL-375

PART NO.

14-2014

26-6272

26-6273

26-6274

14-1788

14-1801

26-5690

26-5689

26-5691

33-0237

n/a

33-0320

45-0201

81-1716

-

2

n/a

1

1

1

1

1

1

1

2

1

2

2

1

2

4

4

1

2

2

2

QTY

1

1

1

2

2

HL-500

PART NO.

14-2014

26-6272

26-6273

26-6274

14-1788

14-1801

26-5690

26-5689

26-5691

46-0224

28-0409

26-1014

46-2347

46-2345

26-3284

26-5775

26-6830

26-6831

14-0475

14-0797

14-1037

33-0237

n/a

33-0320

45-0201

81-1717

1

1

1

-

7

1

1

n/a

1

1

1

2

2

2

1

2

4

4

2

2

2

2

1

2

QTY

1

1

1

HL-650

PART NO.

14-0838

26-0642

26-1053

26-1038

14-1805

14-2123

n/a n/a

n/a

26-5656

28-0412

26-1014

46-2348

46-2346

26-3149

26-5776

26-6830

26-6831

26-0359

14-0797

14-1037

n/a

n/a

33-0320

45-0201

81-1718

1

1

-

n/a

1

1

2

1

n/a

2

1

1

2

2

1

2

n/a n/a

4

4

QTY

1

1

1

1

2

2

n/a

HL-800

PART NO.

14-0838

26-0642

26-1053

26-1038

14-1805

14-2123

n/a n/a n/a

26-5656

28-0412

26-1014

46-2348

46-2346

26-3149

26-5776

26-6830

26-6831

26-0359

14-0797

14-1037

33-0237

n/a

33-0320

45-0201

81-1719

1

1

1

-

6

1

1

n/a

2

1

1

2

2

2

1

2

n/a n/a

4

4

QTY

1

1

1

1

2

2

n/a

PAGE 29



ITEM

a

10

a

11

8

9

6

7

12

13

14

4

5

2

3

b c

1

a

15

16

DESCRIPTION





Check Valve

Purge Valve

Gasket

Stud

Sintered Filter

Leg Base

Leg








Desiccant






HL-1000

PART NO.

14-0838

26-0642

26-1053

26-1038

14-1826

14-2120

18-0217

28-0412

26-1014

46-2348

46-2346

26-3149

26-5776

26-6830

26-6831

26-0359

14-0797

14-1037

n/a n/a

33-0320

45-0201

81-1720

1

1

2

2

2

2

4

1

2

8

1

2

QTY

1

1

1

n/a n/a

3

1

1

1

-

1

1

HL-1250

PART NO.

14-0838

26-0642

26-1053

26-1038

14-1826

14-2120

18-0217

28-0412

26-1014

46-2348

46-2346

26-3149

26-5776

26-6830

26-6831

26-0359

14-0797

14-1037

33-0237 n/a

33-0320

45-0201

81-1721

1

1

2

2

2

2

4

1

2

8

1

2

QTY

1

1

1

10 n/a

3

1

1

1

-

1

1

SECTION 12

PAGE 30



ITEM

8

a

7

a

5

6

c

4

9

10

11

12

a b

2

3

b c

1

a

13

14

DESCRIPTION





Check Valve

Purge Valve

Diaphragm & Seal Kit for Purge Valve

Internal Repair Kit for Purge Valve

Spring Kit for Purge Valve

Gasket

Stud

Sintered Filter








Desiccant






HL-1500

PART NO.

14-0839

26-0643

26-1054

26-1039

14-1827

14-1832

26-6024

26-6026

26-6031

18-0227

28-0413

26-1014

26-0366

26-5777

26-6830

26-6831

26-0359

14-0797

14-1037

33-0237

n/a

33-0320

45-0201

81-1722

1

-

10

n/a

1

1

1

1

4

1

1

2

4

4

1

2

2

2

12

QTY

1

1

2

2

1

1

HL-1750

18-0227

28-0413

26-1014

26-0366

26-5777

26-6830

26-6831

26-0359

14-0797

14-1037

PART NO.

14-0839

26-0643

26-1054

26-1039

14-1827

14-1832

26-6024

26-6026

26-6031

33-0237 n/a

33-0320

45-0201

81-1722

1

-

4

n/a

1

1

1

1

5

1

1

1

2

4

12

4

2

2

2

2

1

2

QTY

1

1

1

HL-2000

PART NO.

14-0839

26-0643

26-1054

26-1039

14-1827

14-1832

26-6024

26-6026

26-6031

18-0227

28-0413

26-1014

26-0366

26-5777

26-6830

26-6831

26-0359

14-0797

14-1037

33-0237 n/a

33-0320

45-0201

81-1723

4

1

1

1

2

2

2

12

4

2

2

1

2

QTY

1

1

1 n/a

n/a

6

1

1

1

-

1

1

SECTION 12

PAGE 31


12.9 1-1/2" INLET TRANSFER VALVE (HL-200 through HL-500)

REPAIR KITS

SEAT & SEAL KIT

POSITION INDICATOR KIT

SHUTTLE ASSEMBLY KIT

PNEUMATIC LIMIT SWITCH SET

MANIFOLD BLOCK WITH PNEUMATIC LIMIT SWITCHES

1-1/2"

26-6272

26-6273

26-6274

14-0797

14-1037

SECTION 12

12.10 2-1/2" & 3" INLET TRANSFER VALVES

(2-1/2" HL-650 through HL-1250)

(3" HL-1500 through HL-2000)

PAGE 32

REPAIR KITS

SEAT & SEAL KIT

Consists of Item Numbers: 1(2), 3(2), 5(2), 6(2), 8(2), 9(5),13, 18(6) & 23

POSITION INDICATOR KIT

Consists of Item Numbers: 12, 14, & 16

SHUTTLE ASSEMBLY KIT

Consists of Item Numbers: 4, 7, 10, 11, & 24

PNEUMATIC LIMIT SWITCH SET

Consists of Item Numbers: 19

MANIFOLD BLOCK WITH PNEUMATIC LIMIT SWITCHES

Consists of Item Numbers: 17, 19 , & 21

2-1/2"

26-0642

26-1053

26-1038

14-0797

14-1037

3"

26-0643

26-1054

26-1039

14-0797

14-1037

12

13

14

15

10

11

8

9

6

7

4

5

ITEM

1

2

3

20

21

22

23

16

17

18

19

24

25

26

1

1

2

6

6

1

1

1

1

2

1

1

1

1

1

1

1

2

5

2

1

1

2

QTY

2

2

2

DESCRIPTION

Flange O-Ring

Flange Support Ring

Shuttle Seat

Snap Ring

Wiper RIng

Sealing O-Ring

Removable End Plate

Sealing O-Ring

Sealing O-RIng

Shuttle Stem

Shuttle

Lever Arm

Washer

Bushing

Roll Pin

Position Indicator

Manifold Block

Sealing O-ring

Pneumatic Limit Switch (set)

Cap Screw

Machine Screw

Valve Body

Split Ring

Roll Pin

Spacer Nut

Guard


12.11 1" PURGE VALVE (HL-200 & HL-250)

6

7

4

5

ITEM

1

2

3

10

11

8

9

12

1

1

1

1

QTY

1

2

2

1

1

1

2

1

DESCRIPTION

Body 1" NPT

Seat (cast brass)

Hex Lock Nut (1/4-28)

Disc Plate

O-Ring (viton)

Disc Spacer (brass)

Disc (hycar)

Disc Holder (brass)

O-Ring (viton)

Shaft

Lower Diaphragm Plate

Diaphragm (Buna N/nylon)

16

17

18

19

ITEM

13

14

15

20

21

22

23

24

1

1

1

1

QTY

1

1

1

1

1

1

1

1

DESCRIPTION

Cap (cast iron)

Upper Diaphragm Plate

Lockwasher Set (1/4")

O-Ring (AFLAS)

O-Ring Retainer (brass)

O-Ring (viton)

Hex HD. Cap Screw (1/4-20 x 7/8)

Hex Nut (1/4-20)

Retainer Nut

SQ.HD. Pipe Plug (1/4" NPT)

O-Ring (viton)

Spring

REPAIR KITS

DIAPHRAGM & SEAL KIT

Consists of Item Numbers: 3(2), 5, 7, 9(2), 12, 15, 16 & 18

INTERNAL REPAIR KIT

Consists of Item Numbers: 4, 6, 8, 10, 11, 14 & 17 and "DIAPHRAGM AND SEAL KIT "

SPRING KIT

Consists of Item Number: 24

SEAT REMOVAL TOOL

O-RING RETAINER REMOVAL TOOL

PART NO.

26-5687

26-5686

26-5688

26-5873

26-5874

12.12 1-1/2" PURGE VALVE (HL-375 & HL-500)

6

7

4

5

ITEM

1

2

3

8

9

10

11

12

1

1

2

1

QTY

1

1

1

1

1

1

2

1

DESCRIPTION

Body 1-1/2" NPT

Seat (cast brass)

Disc Plate


O-Ring (viton)

Disc Spacer (brass)

Disc (hycar)

Disc Holder (brass)

O-Ring (viton)


Diaphragm (Buna N/nylon)


ITEM

13

14

15

16

17

18

19

20

21

22

23

24

2

1

1

1

QTY

1

1

1

1

1

1

1

1

DESCRIPTION

Lockwasher Set (1/4")

Cap (cast iron)

Shaft


O-Ring (viton)

O-Ring (AFLAS)

Hex HD. Cap Screw (1/4-20 x 1-1/8)

Hex Nut (1/4-20)

Retainer Nut

SQ.HD. Pipe Plug (1/8" NPT)

O-Ring (viton)

Spring

REPAIR KITS

DIAPHRAGM & SEAL KIT

Consists of Item Numbers: 4(2), 5, 7, 9(2), 11, 13, 17 & 18(2)

INTERNAL PARTS KIT


SPRING KIT


SEAT REMOVAL TOOL

O-RING RETAINER REMOVAL TOOL

PART NO.

26-5690

26-5689

26-5691

26-5875

26-5876

12.13 1-1/2" PURGE VALVE (HL-650 & HL-800)

REPAIR KITS

REBUILD KIT

PART NO.

26-6929

12.14 2" PURGE VALVE (HL-1000 & HL-1250)

REPAIR KITS

REBUILD KIT

PART NO.

26-6853

SECTION 12

PAGE 33


12.15 3" PURGE VALVE (HL-1500 through HL-2000)

6

7

4

5

ITEM

1

2

3

10

11

12

13

8

9

1

1

2

1

QTY

1

1

1

1

1

1

1

1

2

DESCRIPTION

Body 3" Flanged

Seat (cast brass)

Disc Plate


Disc Spacer (brass)

O-Ring (viton)

Disc (hycar)*

Disc Holder (brass)

O-Ring (viton)

Shaft

Diaphragm

Cap (cast iron)


17

18

19

20

ITEM

14

15

16

21

22

23

24

25

2

6

1

1

QTY

1

2

1

1

1

6

1

1

DESCRIPTION

Lockwasher Set

Hex HD. Cap Screw (3/8-16 x 7/8)



O-Ring (viton)

O-Ring (AFLAS)

Hex HD. Cap Screw (3/8-16 x 1-1/2)

Hex Nut (3/8-16)

Gasket (copper)

Retainer Nut

Square Head Plug 1/8" NPT

Spring

REPAIR KITS

DIAPHRAM & SEAL KIT

Consists of Item Numbers: 4(2), 6, 7, 9(2), 11, 14, 18 & 19(2)

INTERNAL REPAIR KIT


SPRING KIT


* Disc is directional and should be installed with 3/64 smooth nitrile coating towards seat (away from disc holder)

PART NO.

26-6024

26-6026

26-6031

SECTION 12

PAGE 34


12.16 OPTIONAL 230 VOLT TRANSFORMER

ITEM

1

2

DESCRIPTION

Terminal Strip

Transformer

PART NO.

26-0250

26-5751

QTY

1

1

SECTION 12

14.17 HOW TO ORDER PARTS

To order parts for your dryer contact your local TTE representative or the representative where you purchased the dryer from. If you cannot find a local representaitve or have problems ordering the parts, contact the factory.

When contacting your local TTE representative or the factory, the following information is necessary:

Dryer model

Dryer serial number

Dryer part number

This information can be found on the dryer data tag. The data tag is located inside the door of the control box.

The Service Department can be reached by calling 303-465-3063 or faxing 303-645-9294. Hours are 8:00 AM EST to 5:00 PM EST, Monday through

Friday.

PAGE 35

PAGE 36

SAFETY PRECAUTIONS

Safety is everybody's business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious.

DANGER

DANGER WARNING

WARNING

DISCHARGE AIR USED FOR

BREATHING WILL CAUSE SEVERE

INJURY OR DEATH. CONSULT

FILTRATION SPECIALIST FOR

ADDITIONAL FILTRATION AND

TREATMENT EQUIPMENT TO

MEET HEALTH AND SAFETY

REGULATIONS.

AIR AND OIL UNDER PRESSURE

WILL CAUSE SEVERE

PERSONAL INJURY OR DEATH.

SHUT DOWN COMPRESSOR AND

RELIEVE SYSTEM OF ALL

PRESSURE BEFORE REMOVING

VALVES, CAPS, PLUGS,

FITTINGS, BOLTS AND FILTERs.

ELECTRICAL SHOCK FROM

IMPROPER GROUNDING CAN

CAUSE INJURY OR DEATH.

GROUND UNIT AND RELATED

EQUIPMENT ACCORDING TO

NATIONAL ELECTRICAL CODE

AND LOCAL REGULATIONS.

READ THE OPERATOR'S

MANUAL BEFORE STARTING OR

SERVICING THIS UNIT. FAILURE

TO ADHERE TO INSTRUCTIONS

CAN RESULT IN SEVERE

PERSONAL INJURY OR DEATH.

REPLACEMENT MANUALS CAN

BE PURCHASHED BY

CONTACTING THE

MANUFACTURER.

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