Manual Tze 400 To Tze3500 v2 PDF

SERIES TZE
TZE400 / TZE3500 EMS OPTION 3V OPTION LDP OPTION
TZE Externally Heated Desiccant Compressed Air Dryers
INSTALLATION, START-UP & MAINTENANCE MANUAL MODEL NO.: TZE400 / TZE3500 REV 2 April 25,.2001
TABLE OF CONTENTS
FOREWORD................................................................................................................................. 4 SECTION 1 INTRODUCTION .................................................................................................. 5 1.1 GENERAL INFORMATION ............................................................................................. 5 1.2 SAFETY INSTRUCTIONS................................................................................................ 5 1.2.1 Identification of signs and symbols in this technical manual ..................................... 6 1.2.2 Safety tips for maintenance, inspection and assembly work....................................... 6 1.3 PERSONNEL QUALIFICATION...................................................................................... 7 1.4 PRODUCT INFORMATION ............................................................................................. 8 1.4.1 Pressure vessel regulations.......................................................................................... 8 1.4.2 Airtightness test .......................................................................................................... 8 1.4.3 Overloading................................................................................................................. 8 1.4.4 Technical data sheet .................................................................................................... 9 1.4.5 DRYER FLOW CAPACITIES................................................................................. 12 1.4.6 Transport ................................................................................................................... 13 1.4.7 Storage ...................................................................................................................... 13 1.4.8 Use of a pre and after filter ....................................................................................... 13 SECTION 2 INSTALLATION .................................................................................................. 14 2.1 SET-UP AND INSTALLATION...................................................................................... 14 2.1.1 Mechanical installation ............................................................................................. 15 2.1.2 Filter installation ....................................................................................................... 16 2.1.3 Electrical installation ................................................................................................ 16 2.1.4 EMS Installation (If option purchased)..................................................................... 17 SECTION 3 START UP AND OPERATION ........................................................................ 18 3.1 START UP........................................................................................................................ 18 3.1.1 Pressurizing dryer ..................................................................................................... 18 3.1.2 Energizing dryer controls.......................................................................................... 19 3.1.3 EMS Start up............................................................................................................. 20 3.2 OPERATOR INTERFACE............................................................................................... 21 3.2.1 Dryer status ............................................................................................................... 22 3.2.2 Alarm information .................................................................................................... 23 3.2.3 Dryer operation modes.............................................................................................. 24 3.2.4 Heater sheath information......................................................................................... 24 3.2.5 Heater outlet information.......................................................................................... 25 3.2.6 Regeneration outlet information ............................................................................... 25 3.3 PROGRAM STEPS .......................................................................................................... 26 SECTION 4 MAINTENANCE ................................................................................................. 28 4.1 SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE...................................... 28 4.2 REPLACEMENT / DISPOSAL OF THE DESICCANT ................................................. 29 4.3 HYGROMETER MAINTENANCE (EMS Option only)................................................. 29
Page 2
4.4 FILTERS ........................................................................................................................... 29 4.4.1 General comments and use ....................................................................................... 29 4.4.2 Function .................................................................................................................... 30 4.4.3 Assembly and installation ......................................................................................... 30 4.4.4 Maintenance.............................................................................................................. 30 4.4.5 Changing of filter elements....................................................................................... 31 4.4.6 Accessories ............................................................................................................... 31 SECTION 5 CALIBRATION .................................................................................................... 32 5.1 PURGE ADJUSTMENT .................................................................................................. 32 5.2 PRESSURE SWITCH ADJUSTMENT ........................................................................... 33 SECTION 6 SPARE PARTS LIST ......................................................................................... 34 6.1 RECOMMENDED SPARES FOR TZE400, TZE500 & TZE650................................... 34 6.2 RECOMMENDED SPARES FOR TZE820, TZE1000, TZE1225 & TZE1500.............. 35 6.3 RECOMMENDED SPARES FOR TZE1800, TZE2100, TZE2500 & TZE3500............ 36 SECTION 7 TROUBLE SHOOTING & FAULTS ................................................................. 37 7.1 THE DEWPOINT HAS DETERIORATED..................................................................... 37 7.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE.................................................... 38 7.3 SWITCHING FAILURE ALARM ................................................................................... 38 7.3 SWITCHING FAILURE ALARM (Continued)............................................................... 39 7.4 PRESSURE DROP TOO HIGH....................................................................................... 40 7.5 SHORT-TERM SHUT-DOWN........................................................................................ 40 7.6 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE............................. 41 7.7 RE-STARTING ................................................................................................................ 41 SECTION 8 ANNEX ................................................................................................................... 1
Page 3
FOREWORD
This technical manual of Ingersoll-Rand is an aid in getting to know the adsorption dryer better and in utilising its possibilities for application in accordance with its intended use. Furthermore, this manual contains important information for safe, proper and economic operation. All instructions must be followed as written in order to avoid danger and damages which could cause downtime and premature wear and tear on the adsorption dryer. In addition to the technical manual and the accident prevention regulations which are valid and compulsory in the country and in the particular workplace where the adsorption dryer is being used, the recognized special rules for safe and proper working procedures are also to be heeded. The technical manual must always be within reach wherever the adsorption dryer is being used. Each person involved with the set-up, start-up, operation, maintenance and repair of the adsorption dryer in the User Company must have first read and understood the technical manual and especially the safety tips.
Page 4
SECTION 1
INTRODUCTION
1.1
GENERAL INFORMATION The adsorption dryer of the TZE400 TZE3500 series is built according to the latest technological developments and recognized safety rules. Its use however can endanger life and limb of the user or of third parties, and can lead to considerable damage to the adsorption dryer and other material assets if: it is operated by personnel not trained or instructed in its use, it is improperly used, it is improperly maintained or serviced.
This can result in the loss of all damage claims. This adsorption dryer is designed for neutral media free of aggressive water, oil and solid elements. Ingersoll-Rand accepts no liability for corrosion damage and malfunctions caused by aggressive media. Applications other than those mentioned in this manual must be agreed to by Ingersoll-Rand and confirmed in writing. In the interest of further development, Ingersoll-Rand reserves the right to make changes at any time, which, in keeping with the essential characteristics of the adsorption dryer described here, may be necessary for increasing efficiency or for reasons relating to safety or to normal business practice.
1.2
SAFETY INSTRUCTIONS This technical manual contains basic tips, which must be followed during set-up, operation and servicing. It is thus of utmost importance that it be read by the assembly technician before installation and start-up as well as by the specialist / operator in charge, and it must always be within reach at the place where the adsorption dryer is being used.
Page 5
SECTION 1 1.2.1 Identification of signs and symbols in this technical manual The safety tips contained in this technical manual, whose disregard could endanger people and machines, are indicated by a general danger sign and the additional markings Danger! or Attention!
Danger! / Attention!
Warning against electrical voltage!
Safety tips printed directly on the adsorption dryer must be heeded at all times and must be kept completely legible.
Advices
This sign refers to a procedure or sequence of particular interest or importance. All tips must be followed to ensure proper use of this adsorption dryer. This dot refers to working or operational steps. The steps are to be carried out in the order of their appearance from top to bottom. The sign of a hyphen marks enumerations.
1.2.2 Safety tips for maintenance, inspection and assembly work The operator is to make sure that all maintenance, inspection and assembly work is carried out by special personnel who are authorized and qualified, and who are adequately informed through careful study of the technical manual. For this reason, special attention should be paid to the following attention and danger sign:
Page 6
SECTION 1 1.2.2 Safety tips for maintenance, inspection and assembly work (Continued) Attention! Never make structural changes to the adsorption dryer! Only use original spare and accessory parts! Never weld on a pressure vessel or change it in any way! Carry out maintenance work only when the adsorption dryer is switched off, is depressurized and disconnected from the electric power supply.
Advices
Refer to the desiccant material safety data sheet (MSDS) when installing or disposing of desiccant. Danger! Wear protective goggles when working with the desiccant! Advices for protection If desiccant comes into contact with the eyes, rinse eyes immediately with a lot of clear water. If the desiccant is spilled, clean up without causing swirls of dust. In case of fire, there is no restriction on the use of fire extinguishing material; the reaction with water and foam is defined as strong. A mask must be worn. 1.3 PERSONNEL QUALIFICATION The personnel involved in operation, maintenance, inspection and assembly must have the corresponding qualifications to do this work. Areas of responsibility and supervision of the personnel must be precisely established by the operator. Should the personnel not possess the necessary knowledge, then they must be trained and instructed. If need be, this training may be carried out by the manufacturer / supplier at the request of the operator of the adsorption dryer. Further, the operator is to make sure that the personnel completely understand the contents of the technical manual.
Page 7
SECTION 1 1.4 PRODUCT INFORMATION The adsorption dryer is used for the purpose of drying compressed air and other gases according to its respective design. As a "standard model" the adsorption dryer is equipped with two desiccant vessels and a pre- and after-filter, and depending on certain conditions at the outlet, provides pure, dry and oil-free compressed air or gases. 1.4.1 Pressure vessel regulations The pressure vessels are designed according to the standard technical requirements. They fulfill the test of the certifying procedure and carry the U, UM ASME Symbol. Range of application Type Operating overpressure Temperature Max. Max. Min. 1.4.2 Airtightness test All adsorption dryers are subjected to an airtightness test prior to shipment using compressed air. 1.4.3 Overloading Attention! Protect the adsorption dryer from overloads! The adsorption dryer can become overloaded, if: The flow capacity of the medium to be dried increases, The temperature of the air at entry, and correspondingly its humidity increases, The min. operating pressure is under cut, The pre-filtration and separation of impurities are not sufficient.
TZE400 TZE3500 150 PSIG 500 F -20 F
Page 8
SECTION 1 1.4.4 Technical data sheet MODEL Flow (SCFM) @ 100 PSIG 100F IAT Vessel OD Inches Desiccant type Lbs. Desiccant / Vessel Inlet connection Outlet connection FILTER Prefilter Afterfilter Pilot air filter Voltage Heater KW Cycle time Outlet Dewpoint EMS Control High Humidity Alarm Pressure Switch Setpoints Purge Pressure Setting Low Purge Alarm Setpoint Heater Outlet Setpoint End HeatingTemperature End Cooling Temperature Heater Sheath Alarm Process flow 272 2 NPT 2 NPT HE563 DP563 AR-0003G/B TZE400 400 18 TZE500 500 18 350 2NPT 2 NPT TZE650 650 18 481 2 NPT 2 NPT TZE820 820 20 673 3 NPT 3 NPT
Activated Alumina
HE563 HE 706 HE 1100 DP563 DP 706 DP 1100 AR-0003G/B AR-0003G/B G03V 460/3/60 Standard Consult Factory for other voltages
8 10 12 8 Hour Nema Cycle 4 Hours drying/ 4 Hours Regeneration - 40 C/F PRESSURE DEWPOINT - 41 F PDP - 36 F PDP
PSL 10 PSIG / PSH 30 PSIG Below line Pressure 70 Psig 65 Psig 55 Psig 55 Psig 60 Psig 55 Psig 45 Psig 45 Psig 425 F 200 F 120 F 1000 F DOWNWARD DRYING / UPWARD REGENERATION
Page 9
SECTION 1 1.4.4 Technical data sheet (Continued)
MODEL Flow (SCFM) @ 100 PSIG 100F IAT Vessel OD Inches Desiccant type Lbs. Desiccant / Vessel Inlet connection Outlet connection FILTER Prefilter Afterfilter Pilot air filter Voltage Heater KW Cycle time Outlet Dewpoint EMS Control High Humidity Alarm Pressure Switch Setpoints Purge Pressure Setting Low Purge Alarm Setpoint Heater Outlet Setpoint End HeatingTemperature End Cooling Temperature Heater Sheath Alarm Process flow
TZE1000 1000 24 814 3 NPT 3 NPT HE1100 DP1100 G03V
TZE1225 1225 24 956 3 NPT 3 NPT
TZE1500 1500 28 1129 3 NPT 3 NPT
TZE1800 1800 28 1325 4 FLG 4 FLG
Activated Alumina
HE 1380 HE 2100 HE 2100 DP 1380 DP 2100 DP 2100 G03V G03V G03V 460/3/60 Standard Consult Factory for other voltages 21 25 28 8 Hour Nema Cycle 4 Hours drying/ 4 Hours Regeneration - 40 C/F PRESSURE DEWPOINT - 41 F PDP - 36 F PDP
17
PSL 10 PSIG / PSH 30 PSIG Below line Pressure 70 Psig 60 Psig 65 Psig 70 Psig 60 Psig 50 Psig 55 Psig 60 Psig 425 F 200 F 120 F 1000 F DOWNWARD DRYING / UPWARD REGENERATION
Page 10
SECTION 1 1.4.4 Technical data sheet (Continued)
MODEL Flow (SCFM) @ 100 PSIG 100F IAT Vessel OD Inches Desiccant type Lbs. Desiccant / Vessel Inlet connection Outlet connection FILTER Prefilter Afterfilter Pilot air filter Voltage Heater KW Cycle time Outlet Dewpoint EMS Control High Humidity Alarm Pressure Switch Setpoints Purge Pressure Setting Low Purge Alarm Setpoint Heater Outlet Setpoint End HeatingTemperature End Cooling Temperature Heater Sheath Alarm Process flow
TZE2100 2100 30 1510 4 FLG 4 FLG HE 2100 DP 2100 G03V
TZE2500 2500 36 Activated Alumina 1871 4 FLG 4 FLG
TZE3500 3500 40 2789 6 FLG 6 FLG
HE 2750 HE 4100 DP 2750 DP 4100 G03V G03V 460/3/60 Standard Consult Factory for other voltages
32
36 53 8 Hour Nema Cycle 4 Hours drying/ 4 Hours Regeneration - 40 C/F PRESSURE DEWPOINT - 41 F PDP - 36 F PDP
PSL 10 PSIG / PSH 30 PSIG Below line Pressure 60 Psig 70 Psig 60 Psig 50 Psig 60 Psig 425 F 200 F 120 F 1000 F DOWNWARD DRYING / UPWARD REGENERATION 50 Psig
Page 11
SECTION 1 1.4.5 DRYER FLOW CAPACITIES Model Selection Chart

MODEL TZE 400 TZE 500 TZE 650 TZE820 TZE1000 TZE1225 TZE1500 TZE1800 TZE2100 TZE2500 TZE3500
Maximum Inlet Air Pressure (Psig) 150 150 150 150 150 150 150 150 150 150 150
Average Inlet Air Flow (SCFM) Based upon 100 F Inlet Air Temperature Inlet Air Pressure (Psig)
80 310 400 505 640 805 955 1150 1405 1600 1985 2700 90 355 460 580 735 920 1100 1275 1610 1835 2270 3095 100 400 500 650 820 1000 1225 1500 1800 2100 2500 3500 110 440 550 705 905 1140 1360 1600 1995 2275 2820 3845 120 480 590 790 990 1255 1490 1730 2190 2500 3100 4195 130 520 645 850 1070 1325 1610 1875 2375 2700 3355 4570 140 550 680 905 1150 1420 1735 2010 2535 2890 3585 4890 150 575 755 960 1225 1510 1850 2135 2705 3075 3820 5205
1. Higher pressures available as an option. Consult factory 2. Based on 40 F PDP, 8 hour NEMA cycle, activated alumina and average inlet air flow.
CORRECTION FACTOR FOR INLET TEMPERATURE

TEMPERATURE DEGREES F Correction Factor 80 1.1 90 1.1 100 1.0 105 0.85 110 0.69 115 0.565 120 0.455
To correct for an inlet temperature other than 100 F multiply dryer capacity by the temperature correction factor listed above. Example: To size for an inlet flow of 950 SCFM @ 105 F and 110 Psig. 1. Select model that produce at least 950 SCFM at 110 Psig. This case would be the TZE1000 which can dry 1140 SCFM. 2. Multiply pressure corrected flow by the temperature correction factor to obtain the flow of the dryer corrected for pressure and temperature: 1140 X (0.85) = 969 SCFM 3. Confirm model selection. Model TZE 1000 can flow 969 SCFM at the inlet conditions specified. The requirements of 950 SCFM is less so model TZE1000 is correct. NOTE: Settings for EMS: Standard dryers EMS Control (-41C) LDP Dryers EMS Control (-74C)
High humidity (-36C) High humidity (-69C)
Page 12
SECTION 1 1.4.6 Transport After the adsorption dryer has been delivered, it must be checked for damage that may have occurred during transport. If necessary, the Transport Company must be informed to register the damage.
Information When making enquiries by phone or fax, please provide the following information: 1) 2) 3) 4) 5) Equipment Serial Number Equipment Operating Pressure Equipment Operating Temperature Approximate time in service Nature of Problem
1.4.7 Storage If the adsorption dryer is to be stored for a longer period of time, its place of storage must be dry and free of dust. There has to be a min. ambient temp. of +1C (33F).
1.4.8 Use of a pre and after filter In order to prevent droplets of condensate, oil and dirt from getting into the desiccant, a pre-filter is installed in front of the adsorption dryer, since an oil film on the desiccant reduces the drying capacity and the dewpoint. In order to prevent breakdowns in downstream consumers caused by material that has been abraded from the desiccant bed, an after-filter is mounted behind the adsorption dryer. Since no condensate accumulates in the after-filter, this filter is always equipped with a manual valve. Both filters are equipped with a differential pressure gauge (standard) as this ensures an indirect display of the degree of contamination of the filter elements.
Page 13
SECTION 2
INSTALLATION
2.1
SET-UP AND INSTALLATION Once at the installation location, the adsorption dryers of the series TZE400 TZE3500, which are supplied with a base frame, must be positioned so that the side from which it is to be operated is easily accessible. The piping is to be connected to the adsorption dryer at a light slope. A shut-off valve is to be installed on the inlet and outlet sides of the adsorption dryer. Also, a by-pass pipe with an additional shut-off valve should be mounted onto the adsorption dryer, in order to be able to guarantee an uninterrupted supply of compressed air in case the adsorption dryer breaks down. Should vibrations occur on the installation location, the adsorption dryer is to be placed onto vibration dampers. Since the adsorption dryer has already been completely wired at our factory, the customer only has to connect the power supply cable to the terminal strip according to the supplied wiring diagrams.
Advice Should you still have questions regarding installation, you can request installation blueprints separately from Ingersoll-Rand Davidson NC.
Warning! Use the appropriate, load-rated lifting equipment and observe safe lifting procedures during all operations of installation. The equipment should be unloaded as close as possible to the installation site to minimize any chances of equipment damage.
Page 14
SECTION 2 2.1 SET-UP AND INSTALLATION (Continued)
2.1.1 Mechanical installation The equipment should be located in an area with adequate clearances for service. An overhead clearance of not less than two feet above each adsorber tower is required for loading of the desiccant. Remove all protective shipping crates, flange covers, etc. Utilizing the mounting holes provided on the skid, anchor the Ingersoll-Rand type TZE Dryer to a solid, level foundation designed to support the equipment. Do not hydrostatically test the pressure vessels. All TZE dryers pressure vessels and welded piping are hydrostatically tested at one and one-half times the design pressure after fabrication and before assembly. If the equipment is installed in a high traffic area, protective barriers may be required to prevent possible damage. Because of vibration during shipping some tube fittings may have loosened. Therefore, inspect all connections for tightness. Ensure that the inlet and outlet connections to and from the Ingersoll-Rand type TZE Dryer are made using the correct rated fittings and piping to meet the design conditions. System isolation and by-pass valves should be installed. If not supplied as part of the equipment package by Ingersoll-Rand they should be supplied and installed by others. It must be verified that these exist so that future servicing of the Dryer System may take place. Full flow relief valves to protect the system from over-pressure must be provided by others in accordance with local regulations. The purge exhaust on the TZE650 and smaller dryers is equipped with an exhaust muffler/silencer. If required, the silencer can be removed and purge exhaust can be connected to a vent header. Follow recommendations for pipe sizing listed below. The purge exhaust connection on the TZE820 and larger dryers must be connected to a vent header. To ensure satisfactory regeneration of the desiccant chambers is achieved, the purge exhaust piping should be sized as follows to prevent "back pressure" build up. INSTALLED LENGTH OF EXHAUST PIPE Up to 10 Ft Up to 25 Ft Up to 50 Ft Up to 100 Ft PIPE SIZE REQUIRED Same size as the dryer exhaust One size larger than dryer exhaust Two sizes larger than dryer exhaust Three sizes larger than dryer exhaust
Page 15
2.1.2 Filter installation Models TZE400, TZE500, TZE 650 are shipped with filters mounted and piped to the dryer. The following installation applies to all models that are shipped with filters loose. PREFILTER INSTALLATION Mount prefilter in such a way as to allow clearance for the element installation and removal. Locate the prefilter as close to the dryer inlet connection as possible. The filter must be piped so that the correct flow direction indicated on the filter is followed. Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection. Connect drain port to a condensate collector. Use an easily visible collector to aid in operational inspection. AFTERFILTER INSTALLATION Mount afterfilter in such a way as to allow clearance for the element installation and removal. The filter must be piped so that the correct flow direction indicated on the filter is followed. Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection. 2.1.3 Electrical installation Connect the dryer to a correctly sized power supply. Refer to the dryer nameplate or the electrical drawing for the supply voltage and amp requirement to properly size the electrical service amp rating. Only one electrical entrance is required. All internal wiring is done at the factory. A disconnect switch is not provided with the dryer and must be supplied by end user. Ground the frame of the dryer in accordance with the recognised electrical codes. It is recommended that the common alarm relay, located in the dryer control panel, be connected to the control room or operator station so that an immediate response to the dryer trouble alarm may be given when required.
Page 16
2.1.3 Electrical installation (Continued) Before energizing the electrical circuit, the electrical heater assembly should be inspected to determine that no moisture has accumulated in the heater enclosure or terminations, thus preventing damage to the heater assembly and associated components due to burn out. A 1000 volt meg-ohmmeter should be used to determine the phase to ground insulation resistance for each phase. A minimum value of 500 Kohms should exist.
2.1.4 EMS Installation (If option purchased) On 3, 4 and 6 (TZE820 and larger) probe sample line must be run from downstream of the afterfilter. 10-ft length of 1/8 stainless steel tubing and necessary compression fittings are provided. Tubing fittings are to be installed downstream of the afterfilter. The differential pressure indicator port on the outlet nozzle of the afterfilter should be used. Replace the DPI fitting with the TEE provided. Insert 1/8 tubing into compression fitting and tighten. Run 1/8 tubing back to the hygrometer housing. Cut to necessary length and connect to the upper connection fitting. While tubing is semi-flexible, care must be taken when bending tubing to ensure that tubing does not kink. If sample port is installed at a distance further than tubing supplied contact Ingersoll-Rand for assistance.
Page 17
SECTION 3 3.1 START UP
START UP AND OPERATION
Attention! All pipes and wire connections are to be tightened! Furthermore, before start-up: The pipes must be checked for the presence of scale, abraded material from the threading, or other similar impurities. All shut off valves on the pre-filter, adsorption dryer, after-filter and on the bypass line should be closed. The ambient temperature must not be less than 33F. Breakdowns resulting from faulty installation do not fall under Ingersoll-Rand's warranty obligation.
3.1.1 Pressurizing dryer Prior to pressurizing the Ingersoll-Rand Type TZE Dryer system, verify the following: Dryer On Off switch is in the off position. System outlet block valve is closed. Prefilter, afterfilter and pilot air filter vent valves are closed. Desiccant chamber vent valve is closed. Pilot air isolation valve is open. Hygrometer adjustment/isolation valves are closed. (EMS option only) Slightly open the inlet isolation valve slowly admitting compressed air to the system. When full system operating pressure has been reached all connections should be soap bubble tested for leaks. Any leaks should be repaired and retested prior to placing the equipment in service. If some gas other than the process air will be used for leak testing, consult Ingersoll-Rand for its compatibility with system components before proceeding. Fully open the inlet isolation valve. When the system is filled with process air and leak tight and start-up is completed, then slowly open the system outlet valve to pressurize the downstream piping. During the procedure, ensure that the dryer system pressure does not fall beyond 95% of its reading prior to opening the system outlet valve. This will protect the equipment internal components (i.e. filter elements, desiccant) from gas velocities above design conditions.
Page 18
SECTION 3 3.1.1 Pressurizing dryer (Continued) When pressurizing is complete then fully open the system outlet valve to place the equipment in service. Verify the system inlet pressure and temperature are at the design operating levels. Ensure that the pilot pressure regulator is set between 80 and 100 Psig.
3.1.2 Energizing dryer controls Turn ON-OFF switch to the ON position. A SIEMENS programmable controller with individual input/output modules controls the dryer cycle. A copy of the program complete with a full listing of inputs, outputs, internal coils, timers counters is included later in this manual. This should be used as a reference guide to ensure dryer is cycling. A manual mode is included in the dryer program to allow for fast cycling to verify to operation of the dryer. It is recommended that the operational program of the dryer and the wiring schematic be studied before operating the dryer. NOTE : If EMS option selected: The hygrometer will signal an open circuit, and humidity alarm light will illuminate until probe cable is connected to hygrometer probe.
While dryer is in the purging mode for either chamber the purge pressure setting should be checked. Refer to the specification sheet in this manual for the correct purge pressure setting. Use the manual purge adjustment valve to adjust the purge setting. Warning! Failure to correctly set the purge pressure can lead to improper regeneration of the desiccant bed, resulting in a dewpoint failure when that chamber is returned to service.
Page 19
SECTION 3 3.1.3 EMS Start up The startup procedure for the EMS system will be as follows. Refer to the assembly drawing in the following section. The EMS hygrometer probe has been shipped inside of its own desiccant chamber to ensure that the probe does not become saturated with ambient air during storage and transport. Do not remove probe from the housing until dryer system has been started and probe is to be inserted into the sample cell. 1. 2. 3. 4. Verify that the humidity probe is installed into the sample cell Connect the coaxial cable to the humidity probe Fully open the inlet valve to the sample cell Partially open the discharge valve of the sample cell to bleed off a small amount of sample air. Do not fully open discharge valve 5. Perform a soap test to verify for leaks on all parts of the sample line connections and the humidity sample cell. 6. The digital display will now read the dewpoint of the dryer system. It will take a short period of time for a humidity probe to be purged of humidity and give the correct dewpoint. Humidity cell assembly
Page 20
SECTION 3 3.2 OPERATOR INTERFACE
F1 => DRYER STATUS F2 => MANUAL STEP AHEAD (MANUAL MODE ONLY) F3 => DRYER ALARM STATUS F4 => ALARM RESET SHIFT=> In order to choose one of the next four options, the SHIFT button must be pressed first. An s in the lower right corner indicates the upper row is now active. F5 => DRYER OPERATING MODE MENU F6 => HEATER SHEATH TEMPERATURE AND SETPOINT F7 => HEATER OUTLET TEMPERATURE AND SETPOINTS F8 => REGEN. OUTLET TEMPERATURE AND SETPOINTS ARROWS ALLOW USER TO SCROLL UP OR DOWN INSIDE OF DISPLAY. A FLASHING ARROW ON THE RIGHT SIDE OF THE SCREEN INDICATE THAT MORE INFORMATION IS AVAILABLE IN THE DIRECTION OF THE ARROW AND CAN BE ACCESSED BY USING THE SCROLL ARROWS. ESC => MUST PUSH ESC AGAIN TO ACCESS WHEN IN MENU MODE. ENTER=> NO FUNCTIONALITY FOR THIS BUTTON. Page 21
SECTION 3 3.2 OPERATOR INTERFACE (Continued)
3.2.1 Dryer status The F1 key is pressed to display the present status of the dryer. This allows you to see where, in the sequence, the dryer is. A message can appear below the dryer status at any time when in manual mode. A blinking arrow on the right side of the display will indicate this. To access the messages, press the green arrow on the right side of the interface. Message identification
Select Left Chamber Drying Left Chamber Drying R/C in depress mode Left Chamber Drying R/C in heating mode Left Chamber Drying R/C in cooling mode Left Chamber Drying R/C in repress mode Left Chamber Drying R/C in standby mode Left Chamber in EMS mode R/C in standby mode Select Right Chamber drying Right Chamber drying L/C in depress mode Right Chamber drying L/C in heating mode Right Chamber drying L/C in cooling mode Right Chamber drying L/C in repress mode Right Chamber drying L/C in standby mode Right Chamber in EMS mode L/C in standby mode
Message description
Opening the left chamber inlet valve. Closing the right chamber inlet valve. Depressurizing the right chamber. Heating the right chamber for regeneration. Cooling the right chamber. Pressurizing the right chamber. Right chamber in standby until the end of the half cycle. The dryer is in EMS mode on the left chamber. This will extend the half cycle for a maximum of twelve (12) hours or until the outlet dewpoint goes higher than 40F. Opening the right chamber inlet valve. Closing the left chamber inlet valve. Depressurizing the left chamber. Heating the left chamber for regeneration. Cooling the left chamber. Pressurizing the right chamber. Right chamber in standby until the end of the half cycle. The dryer is in EMS mode on the left chamber. This will extend the half cycle for a maximum of twelve (12) hours or until the outlet dewpoint goes higher than 40F.
Page 22
3.2.2 Alarm information The F3 button is pressed to display a status of the dryer alarms. If there is no alarm, a NO ALARM message will appear. If more than one (1) alarm is active, a flashing arrow will appear on the right side of the display. To access the messages, press the green arrow on the right side of the interface. In order to reset the alarms, press the F4 key than all the non-active alarms will be reset. If all the alarm conditions have been cleared, the NO ALARM message will appear. MESSAGE IDENTIFICATION
Heater Outlet over temperature Thermocouple module in error Thermocouple out of range Low purge alarm Check press. at PS-3 Heater failure alarm Fail reach Setpoint Oversheath alarm Sheath Temperature too high Depress failure on left chamber Depress failure on right chamber Repress failure on left chamber Repress failure on right chamber High Humidity alarm NO ALARM
MESSAGE DESCRIPTION
Heater outlet temperature is above the setpoint. Indicates the thermocouple module has lost its 24Vdc supply. Indicates a thermocouple connected to the module is defective or open. The purge pressure is below the set point or the pressure switch is defective. The heater has failed to reach the set point temperature within 15 minutes. The heater sheath is above the setting. The left chamber did not reach the low setting of the pressure switch with time limit. The right chamber did not reach the low setting of the pressure switch with time limit. The left chamber did not reach the high setting of the pressure switch with time limit. The right chamber did not reach the high setting of the pressure switch with time limit. Indicates the outlet dewpoint is above alarm setpoint. Indicates no alarm is active.
Page 23
3.2.3 Dryer operation modes The F5 button is pressed to display status of the dryer modes of operation. The actual mode will be displayed whether dryer is in automatic or manual mode. To change to actual mode of the dryer, press F2 when in the dryer mode screen. The actual mode will change from one to the other each time the F2 button is pressed. If the dryer mode screen is left unattended for thirty seconds, it will automatically switch to the dryer status screen. In manual mode, the READY TO STEP AHEAD PRESS F2 TO CONTINUE message will be shown when the dryer is ready to perform the next step. In order to be go to the next step in manual mode you must not be in the dryer operation mode screen. Failure to do so will simply change the operating mode of the dryer.
MESSAGE IDENTIFICATION DRYER IN AUTO MODE DRYER IN MANUAL MODE READY TO STEP AHEAD PRESS F2 TO CONTINUE MESSAGE DESCRIPTION The dryer is in automatic mode. It means the dryer will perform its cycle without any external intervention except in case of alarm. The dryer is in manual mode. It means the dryer will need external intervention in order to do to the following step. If no external intervention is provided the dryer will stay in the actual step. The dryer is ready to go to the next step when in manual mode. The user must wait for this signal in order to press F2 and make the dryer stepping ahead in its cycle.
3.2.4 Heater sheath information The F6 button is to access the heater sheath information. On this screen the actual sheath temperature in degrees Fahrenheit is displayed so as the alarm set point for the over-sheath temperature alarm. The set point can not be changed from the interface.
MESSAGE IDENTIFICATION HEATER SHEATH XXXX F ALARM SETPOINT YYYY F MESSAGE DESCRIPTION Displays temperature of the heater sheath (XXXX) and also at which temperature the dryer will fall in alarm (YYYY). Both temperatures are in Fahrenheit
Page 24
3.2.5 Heater outlet information The F7 button is to access the heater outlet information. On this screen the actual temperature in degrees Fahrenheit is displayed so as the alarm set point for the heater outlet over-temperature and heating failure alarm. The set point can not be changed from the interface.
MESSAGE IDENTIFICATION MESSAGE DESCRIPTION
HEATER OUTLET XXXX F HEAT CONTROL YYYY F
HEATER OUTLET XXXX F HEAT FAIL AT ZZZZ F
HEATER OUTLET XXXX F HEAT OVERTEMP VVVV F
Displays the heater outlet temperature (XXXX) and the regulation temperature setting (YYYY) of the heater. Both temperatures are in Fahrenheit Displays the actual heater outlet temperature (XXXX) and the heating failure alarm temperature setting (ZZZZ). Both temperatures are in Fahrenheit. Displays the actual heater outlet temperature (XXXX) and the high outlet temperature alarm setting (VVVV). Both temperatures are in Fahrenheit.
3.2.6 Regeneration outlet information The F8 button is to access the regeneration outlet information. On this screen the actual temperature in degrees Fahrenheit is displayed so as the control set points for end of heating and end of cooling. The set points can not be changed from the interface.
MESSAGE IDENTIFICATION MESSAGE DESCRIPTION
REGEN OUTLET XXXX F HEAT SETPOINT YYYY F
REGEN OUTLET XXXX F COOL SETPOINT ZZZZ F
Displays the actual regeneration outlet temperature (XXXX) and the end of heating mode temperature setting (YYYY). Both temperatures are in Fahrenheit. Displays the actual regeneration outlet temperature (XXXX) and the end of cooling mode temperature setting (YYYY). Both temperatures are in Fahrenheit.
Page 25
SECTION 3 3.3 PROGRAM STEPS
R E T E N T IV E SEQ UENC E
STEP 1
O P E N LE FT CHAMBER V A LV E
E V -1 L & E V -1 R (V A L V E T O M O V E ) 1 0 S E C O N D S T IM E R F O R V A L V E T O O P E N
10 SECO N D S H AVE PA SSED AND LEFT C H AM BER A B O V E 6 0 P S IG
STEP 2
CLOSE IN L E T
E V -1 L & E V -1 1 R W A IT 5 S E C O N D S F O R V A L V E T O C L O S E
5 SECO NDS HA VE PASS ED
STEP 3
DEPRESS CHAMBER
E V -2 R E V -3 R (IF R /C < = 1 0 P S IG ) E N E R G IZ E E V -1 L A N D E V -1 1 R
1 0 S E C O N D S H A V E P A S S E D A F T E R R IG H T C H A M B E R B E L O W 3 0 P S IG
STEP 4
R IG H T H E A T IN G
S T A R T R IG H T C H A M B E R H E A T IN G M O D E F O R 1 4 0 M IN U T E S M A X IM U M E N E R G IZ E E V -1 L A N D E V -1 1 R
H E A T IN G T IM E R D O N E O R P U R G E O U T L E T T E M P E R A T U R E A B O V E 2 0 0 F
STEP 5
R IG H T C O O L IN G
S T A R T R IG H T C H A M B E R C O O L IN G M O D E F O R 1 0 0 M IN U T E S M A X IM U M A N D 6 0 M IN U T E S M IN IM U M . E N E R G IZ E E V -1 L A N D E V -1 1 R
IF C O O L IN G T IM E R D O N E (1 0 0 M IN U T E S ) O R P U R G E O U T L E T T E M P E R A T U R E B E L O W 1 2 0 F A N D 6 0 M IN U T E S H A V E P A S S E D .
STEP 6
REPRESS R IG H T
E N E R G IZ E E V -1 L A N D E V -1 1 R
120 SEC O ND S H AV E PASSED AN D BOT H C H AM B ER A R E A B O V E 6 0 P S IG
STEP 7
R IG H T STANDB
E N E R G IZ E E V -1 L A N D E V -1 1 R
D R Y E R H A L F C Y C L E IS C O M P L E T E (2 4 0 M IN U T E S ) O R B A D D E W P O IN T O R D D S O F F A N D B O T H C H A M B E R A R E A B O V E 6 0 P S IG
Page 26
SECTION 3 3.3 PROGRAM STEPS (Continued)
STEP 8
OPEN RIGHT CHAMBER INLET VALVE
EV-1L & EV-1R (VALVE TO MOVE) 10 SECONDS TIMER FOR VALVE TO OPEN
10 SECONDS HAVE PASSED AND RIGHT CHAMBER ABOVE 60 PSIG
STEP 9
CLOSE LEFT CHAMBER INLET VALVE

5 SECONDS HAVES PASSED
EV-11L & EV-1R WAIT 5 SECONDS FOR VALVE TO CLOSE
STEP 10
LEFT CHAMBER DEPRESS
EV-2L EV-3L (IF L/C <=10 PSIG) ENERGIZE EV-1R AND EV-11L
10 SECONDS HAVE PASSED AFTER LEFT CHAMBER BELOW 30 PSIG
STEP 11
LEFT CHAMBER HEATING PERIOD
START LEFT CHAMBER HEATING MODE FOR 140 MINUTES MAXIMUM ENERGIZE EV-1R AND EV-11L
HEATING TIMER DONE OR PURGE OUTLET TEMPERATURE ABOVE 200 F
STEP 12
LEFT CHAMBER COOLING PERIOD
START LEFT CHAMBER COOLING MODE FOR 100 MINUTES MAXIMUM AND 60 MINUTES MINIMUM. ENERGIZE EV-1R AND EV-11L
IF COOLING TIMER DONE (100 MINUTES) OR PURGE OUTLET TEMPERATURE BELOW 120 F AND 60 MINUTES HAVE PASSED.
STEP 13
LEFT CHAMBER REPRESS.
ENERGIZE EV-1R AND EV-11L
120 SECONDS HAVE PASSED AND BOTH CHAMBER ARE ABOVE 60 PSIG
STEP 14
LEFT CHAMBER STANDBY
ENERGIZE EV-1R AND EV-11L
DRYER HALF CYCLE IS COMPLETE (240 MINUTES) OF BAD DEWPOINT OR DDS OFF AND BOTH CHAMBER ARE ABOVE 60 PSIG)
Page 27
SECTION 4
MAINTENANCE Advice In order to ensure continuous and trouble-free operation, a maintenance contract with Ingersoll-Rand is recommended.
4.1
SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE Daily Check prefilter automatic drain valve to ensure drain is working properly. Blow down daily to remove accumulated fluids. Check filter differential pressures. A filter differential pressure of 5-8 PSID indicates a dirty filter element and should be replaced. Filter elements should last between 6 12 months under normal use. Check correct purge pressure. Ensure dryer is cycling without alarms.
Weekly Check all mufflers for backpressure. Replace if clogged or dirty. Verify heater operation.
Every 3 Months Check operating conditions, purge rate, line pressure, inlet flow. Check dryer operating cycle for proper operation of valve operators, solenoid valves, dump valves, heaters, pressure switches and temperature controller. Check the outlet dewpoint. Blow down relief valves Check heater outlet temperature is between 400 and 425F. Verify pressure switch operation. Inspect pilot air filter element. If element seems clogged, dirty or damaged, replace element.
Annually Disassemble, clean and inspect the inlet switching, purge exhaust and depress. Replace all worn or damaged parts. Disassemble, clean and inspect the outlet and purge check valves. Replace all worn or damage parts. Inspect the desiccant through the chamber fill port. Replace desiccant if broken or coated with oil. Replace prefilter, afterfilter and pilot air filter elements at least once a year.
Page 28
SECTION 4 4.2 REPLACEMENT / DISPOSAL OF THE DESICCANT In order to ensure trouble-free operation, we recommend replacing the desiccant every 8000 Hours, or every 2 years on latest. NOTE : Refer to the desiccant MSDS document in the annex of this manual for instructions and precautions on handling and disposing of desiccant.
The dryer is filled from the top and emptied from the bottom. Refer to the General Arrangement drawing for location of fill and drain ports. To drain the desiccant, remove the drain plug/cover and catch the old desiccant in a suitable container. Replace the desiccant drain plug/cover. Remove the fill cap and refill the chamber with the specified desiccant. Refer to the spare parts section for desiccant quantity. Do not tamp the desiccant. Replace the fill cap. Soap test both fill and drain ports for leaks before returning the dryer to service. Desiccant chambers should never be completely filled. Fill to a level approximately 3 below the upper circumference weld on the desiccant vessel.
NOTE:
4.3
HYGROMETER MAINTENANCE (EMS Option only) NOTE: Refer to the separate document on hygrometer maintenance and operation located in the annex of this manual.
4.4
FILTERS
4.4.1 General comments and use Filters of the series HE are suitable for filtering solids, oil and condensate out of compressed air and other neutral, compressed gases. This new filtration concept is characterized by high flows at low differential pressure.
Page 29
SECTION 4 4.4 FILTERS (Continued)
4.4.2 Function The soiled medium flows through the filter element "Series HE" from the inside to the outside. Solids are filtered out by impact or by the effect of inertia, whereas oil particles and drops of humidity are filtered out by the effect of coalescence. By the force of gravity, the filtered-out droplets collect in the lower filter vessel and are drained automatically or manually. 4.4.3 Assembly and installation
Advices
Within the piping system, the filters should always be used where the air or gas temperature is lowest. The piping system must be cleaned before filters assembling. The filters must always be installed vertically. An arrow on the upper part of the housing marks the direction of the flow. Sufficient free space should be left at the bottom for the changing of filter elements.
4.4.4 Maintenance
Advices
The filter element should be replaced when a differential pressure of > 10 PSID has been reached, or on latest after 1 year of operation. The functioning of the automatic condensate drain is to be tested weekly by manual operation. Should there be no condensate drain, then, depending on the amount, the condensate on the pre-filter is to be removed several times a day by opening the hand drain.
Page 30
SECTION 4 4.4 FILTERS (Continued)
4.4.5 Changing of filter elements Danger! The soiled filter elements are changed only when the housings are DEPRESSURIZED! Filter elements are to be changed according to the following steps: Separate the lower part of the housing from the upper part. Loosen and remove the element by hand. Install the new element and the O-ring and making sure that the element seats perfectly. Re-install filter bowl assembly. Elements of the HE or DP series can NOT be cleaned with compressed air.
4.4.6 Accessories
Advices Pressure differential gauge: Indicates the degree to which the elements are soiled. Automatic condensate drain: Continuously draws off the condensate that has collected. Hand drain: Used when there is little or no condensate.
Page 31
SECTION 5 5.1
CALIBRATION
PURGE ADJUSTMENT The dryers purge system includes an adjustment valve, purge orifice and a pressure indicating gauge (Panel mounted). This system has been factory set to the correct pressure for the dryer inlet conditions of 100F and 100 Psig. This valve must be kept in the specified position when the dryer is operating or the dryer will not step ahead / regenerate. SETTING PURGE FLOW Refer to the specification sheet for the correct purge pressure setting (PI-3). Ensure dryer is at operating pressure. Wait until dryer is in a regeneration mode (Heating or cooling). Open or close purge adjustment valve until correct pressure is shown on the purge pressure gauge. (PI-3 on flow schematic, located on gauge panel).
TESTING PURGE PRESSURE SWITCH AND ALARM SHUTDOWN. Periodically verify this pressure and the low purge alarm (PS-3). Close the purge service valve. Check that the heater contactor de-energize. Check that the Dryer In Alarm light illuminates. When test is complete, re-open the service valve and set pressure to correct pressure following steps listed in Setting Purge Pressure section. Reset the alarm.
Page 32
SECTION 5 5.2 PRESSURE SWITCH ADJUSTMENT Pressure switch adjustment for externally heated dryers
Adjustment knob
On a TZE dryer there are five (5) pressure switches (PSH-1, PSL-1, PSH-2, PSL-2 and PS-3). The PSH pressure switches are set at 30 PSIG below the operating pressure of the dryer, while the PS-3 (purge pressure) is set at 10 PSIG below the purge adjustment setting and all use the normally open contact. When the adjustment is done, the contact between "C" and "NO" should close when increasing to the desired pressure. The PSL switches are set at 10 PSIG regardless the operating pressure and use the normally closed contact. When the adjustment is done, the contact between "C" and "NC" should close when decreasing to the desired pressure. To increase the pressure, screw the knob toward the pressure switch diaphragm. To decrease the pressure, do the opposite.
Page 33
SECTION 6 6.1
SPARE PARTS LIST
RECOMMENDED SPARES FOR TZE400, TZE500 & TZE650

ITEM DESCRIPTION TZE400 38006987 38015566 TZE500 38006987 38015566 TZE650 38006987 38015566 QUANTITY 2 2 2 2 2 2
Inlet valve c/w actuator Inlet valve kit Inlet valve Actuator kit Exhaust valve c/w actuator Exhaust valve kit Exhaust valve Actuator kit
Included w/inlet Included w/inlet Included w/inlet valve kit valve kit valve kit 38007001 38015582 Included w/ exhaust valve kit 38015855 38007050 38007076 N/A N/A 38007084 38006714 38006698 38006565 38015145 38015863 38006789 38015244 38006870 38006896 38006797 38006888 38006722 38006953 38006573 C/F C/F 38328167 N/A 38004834 (550 Lbs.) 38007001 38015582 Included w/ exhaust valve kit 38015855 38007050 38007076 N/A N/A 38007084 38006714 38006698 38006565 38015145 38015863 38006789 38015244 38006870 38006896 38006797 38006888 38006722 38006920 38006573 C/F C/F 38328167 N/A 38004834 (700 Lbs.) 38007001 38015582 Included w/ exhaust valve kit 38015855 38007050 38007076 N/A N/A 38007084 38006714 38006698 38006565 38015145 38015863 38006789 38015244 38006870 38006896 38006797 38006888 38006722 38006953 38006573 C/F C/F 38328167 N/A 38004834 (900 Lbs.)
Outlet check valve Outlet check valve kit Purge check valve Depress valve Depress valve kit Chamber relief valve Pressure gauge Temperature indicator Pressure switch Pressure regulator Solenoid block Light bulb Transformer primary fuse Transformer second. fuse Heater fuses Control fuse Alarm relay Heater contactor Heater element Pilot air filter element Prefilter element Afterfilter element Exhaust muffler Depress muffler Desiccant (Lbs.)
2 2 2 0 0 2 3 2 5 1 1 2 2 1 3 1 1 1 1 1 1 1 1 0
Page 34
SECTION 6 6.2 RECOMMENDED SPARES FOR TZE820, TZE1000, TZE1225 & TZE1500
ITEM DESCRIPTION Inlet valve c/w actuator Inlet valve kit Inlet valve actuator kit Exhaust valve c/w actuator Exhaust valve kit Exhaust valve actuator kit
TZE820 Part no. 38015913 38016672 38015038 38015574 38006995

Included w/Exhaust valve kit
TZE1000 Part no. 38015913 38006672 38015038 38015574 38006995

TZE1225 Part no. 38015913 38006672 38015038 38015574 38006995

TZE1500 Part no. 38015913 38006672 38015038 38015574 38006995

Quantity 2 2 2 2 2 2
Outlet check valve Outlet check valve kit Purge check valve Depress valve Depress valve kit Chamber relief valve Temperature indicator Pressure switch Pressure regulator Solenoid block Light bulb Transformer primary fuse Transformer secondary fuse Heater fuses Control fuse Alarm relay Heater contactor Heater element Pilot air filter element Prefilter element Afterfilter element Exhaust muffler Depress muffler Desiccant (Lbs.)
38015715 38007027 38007068 38015541 38006961 38006532 38006706 38006565 38015145 38015889 38006789 38015244 38006870 38006821 38006797 38006888 38006722 38006953 38006680 C/F C/F N/A 38328175 38004834 (1120 Lbs.)
38015715 38007027 38007068 38015541 38006961 38006532 38006706 38006565 38015145 38015889 38006789 38015244 38006870 38015293 38006797 38006888 38006730 38006938 38006680 C/F C/F N/A 38328175 38004834 (1600 Lbs.)
38015715 38007027 38007068 38015541 38006961 38006532 38006706 38006565 38015145 38015889 38006789 38015244 38006870 38015335 38006797 38006888 38006730 38015475 38006680 C/F C/F N/A 38328175 38004834 (1912 Lbs.)
38015715 38007027 38007019 38015541 38006961 38006532 38006706 38006565 38015145 38015871 38006789 38015244 38006870 38015285 38006797 38006888 38006748 38006912 38006680 C/F C/F N/A 38328175 38004834 (2100 Lbs.)
2 2 2 2 2 2 2 5 1 1 2 2 1 3 1 1 1 1 1 1 1 0 2
Page 35
SECTION 6 6.3 RECOMMENDED SPARES FOR TZE1800, TZE2100, TZE2500 & TZE3500
ITEM DESCRIPTION Inlet valve c/w actuator Inlet valve kit Inlet valve actuator kit Exhaust valve c/w actuator Exhaust valve kit Exhaust valve actuator kit Outlet check valve Outlet check valve kit Purge check valve Depress valve Depress valve kit Chamber relief valve Pressure gauge Temperature indicator Pressure switch Pressure regulator Solenoid block Light bulb Transformer primary fuse Transformer second. Fuse Heater fuses Control fuse Alarm relay Heater contactor Heater element Pilot air filter element Prefilter element Afterfilter element Exhaust muffler Depress muffler Desiccant (Lbs.)
TZE1800 Part no. 38015921 38006664 38016093 38015913 38006672 38015038 38015764 38007043 38007019 38015558 38006979 38006532 38006714 38006706 38006565 38015145 38015871 38006789 38015244 38006870 38006854 38006797 38006888 38006771 38006912 38006680 C/F C/F N/A 38328175 38004834 (2650 Lbs.)
TZE2100 Part no. 38015921 38006664 38016093 38015913 38006672 38015038 38015764 38007043 38007019 38015558 38006979 38006532 38006714 38006706 38006565 38015145 38015871 38006789 38015244 38006870 38006839 38006797 38006888 38006771 C/F 38006680 C/F C/F N/A 38328175 38004834 (3020 Lbs.)
TZE2500 Part no. 38015921 38006664 38016093 38015913 38006672 38015038 38015764 38007043 38007019 38015558 38006979 38006532 38006714 38006706 38006565 38015145 38015871 38006789 38015244 38006870 38006862 38006797 38006888 38006755 38015467 38006680 C/F C/F N/A 38328175 38004834 (3750 Lbs.)
TZE3500 Part no. 38015921 38006664 38016093 38015913 38006672 38015038 38015822 38015830 38007035 38015558 38006979 38006532 38006714 38006706 38006565 38015145 C/F 38006789 38015244 38006870 38006847 38006797 38006888 38006763 C/F 38006680 C/F C/F N/A 38328175 38004834 (5400 Lbs.)
Quantity 2 2 2 2 2 2 2 2 2 2 2 2 3 2 5 1 1 2 2 1 3 1 1 1 1 1 1 1 0 2
Page 36
SECTION 7 7.1
TROUBLE SHOOTING & FAULTS
THE DEWPOINT HAS DETERIORATED
Possible cause Remedy Incoming air temperature above design Check compressor after cooler and condition cooling system. Adjust as necessary to reduce the inlet temperature to dryer specification. Incoming air flow too high Problem external to dryer. Verify inlet flow rate and reduce as necessary to dryer specification. Check compressed air system. Correct if necessary. Check prefilter elements and seals for damage. Replace if necessary. Check operation of drain trap. Ensure proper drainage. Repair or replace drain if necessary. Replace desiccant. Inspect prefilter if desiccant is coated with oil.
Inlet pressure below design pressure
Liquid water entering dryer
Desiccant broken up or coated with oil
Insufficient regeneration: 1. Heater failure 2. Heater contactor failure 3. Incorrect purge flow 4. Temperature setting to incorrect
1. 2. 3. 4.
Replace heater Replace heater contactor Check purge pressure setting Check set-points of heater and purge exhaust.
Leaks at piping/tubing downstream of the dryer
connections Soap test dryer and repair all leaks.
Page 37
SECTION 7 7.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE
Possible cause Hygrometer probe out of calibration
Remedy Refer to hygrometer manual in Annex, section for instruction on field calibration. Return probe to factory for certified recalibration. Inspect and repair. Refer to EMS startup section in this manual Check sensor tubing and probe filter for buildup of moisture. Allow tubing to dry and replace filter element.
Open circuit on probe electrical connection Incorrect flow across sensor
Excessive moisture on sensor
7.3
SWITCHING FAILURE ALARM Possible cause Remedy Close pilot air isolation valve, depressurize pilot air filter and inspect element. If clogged or dirty, replace. Check that pilot air isolation valve is fully open. Check that pilot air regulator is set at 100 PSIG. Inspect pilot air tubing for kinks or breaks. Repair if necessary. Correct the low pressure problem to the dryer. Check operation of solenoid. Replace if not functioning. Check wiring from panel to the solenoid for an open or short circuit. Repair if necessary. Page 38
Pilot air insufficient
Inlet air pressure below setpoint of pressure switches
Solenoid valve not energizing
SECTION 7 7.3 SWITCHING FAILURE ALARM (Continued) Possible cause Remedy
Inlet or purge exhaust valves Shutdown and depressurize dryer. Inspect leaking valve seats and seals for damage or wear. Repair or replace if necessary. While valve is disassembled, check the actuator stops to ensure that valve is fully closing (butterfly valves only). Check valve internals are worn or damaged Switching failure depressurization Shutdown and depressurize dryer. Repair or replace valves.
Inspect purge and depress mufflers and replace if necessary. on Off line desiccant chamber inlet valve or outlet check valve leaking. Inspect as described above. Regenerating chamber depress/exhaust valve failed to open. Check associated solenoid valve operation as described above. Excessive purge flow. Check the purge pressure setting. Online chamber outlet check valve leaking. Inspect and repair as described above.
Switching failure repressurization
on
Exhaust or depress valves not closing or leaking. Check solenoid operation as listed above. Check valve failure as listed above. Insufficient purge flow. Check purge pressure settings. Check automatic purge shut off valve for correct operation.
Pressure switch malfunction valves leaking
Check the setpoint of the pressure switches. Readjust if necessary. Check the operation of the pressure switches. Replace if needed.
Page 39
SECTION 7 7.4 PRESSURE DROP TOO HIGH
Possible cause Broken or fouled desiccant Inlet flow exceeding design flow rate Pre or after filter element dirty or clogged
Solution Inspect desiccant and replace if required Reduce inlet flow as necessary Depressurize filters and elements. Replace if clogged. inspect
7.5
SHORT-TERM SHUT-DOWN
Advices The following sequence is to be heeded when switching off the adsorption dryer: First close all the shut off valves up- and downstream of dryer, Then immediately switch off the adsorption dryer.
Attention! Dryer will remain pressurized.
Page 40
SECTION 7 7.6 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE Danger! Before any kind of maintenance or repair work is done, the adsorption dryer must be depressurized and disconnected from the power source. Apply the general safety regulations!
Advices The following sequence is to be heeded when switching off the adsorption dryer: First switch off the dryer. Make certain dryer is not in heating or cooling mode. Then close all the shut off valves up- and downstream of the adsorption dryer. For TZE400, TZE500 and TZE650 depressurize the dryer by using the hand valve mounted at the bottom of the after-filter. For TZE820 and larger depressurize the dryer by using the hand valve mounted at the bottom of the desiccant chamber
7.7
RE-STARTING Close the hand valve mounted at the bottom of the after-filter and at the bottom of each desiccant chamber. Slowly open the inlet isolation valve and pressurize the adsorption dryer up to the regular operating pressure by keeping the shut off valve mounted behind the after-filter closed. Switch on the unit once again. If the adsorption dryer is re-started after a long standstill, proceed as in 3.1.
Page 41
ACTIVATED ALUMINA (GRADES A, D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95
SECTION 8 1. ANNEX CHEMICAL PRODUCT AND COMPANY DESCRIPTION
Ingersoll-Rand Inc
800- A Beaty Street, Davidson, North Carolina, 28036 - USA Emergency Phone numbers: FOR EMERGENCIES INVOLVING A SPILL, LEAK, FIRE, EXPOSURE OR ACCIDENT CONTACT: (1) (514) 848-1454 For Product Information: Tel: (704) 896-4000 / Fax: (704) 896-4648 Product Use: DRYING AGENT, CATALYST SUPPORT, GAS PURIFICATION Chemical Name or Synonym: ACTIVATED ALUMINA (GRADES A, D & P) Molecular Formula: Al2O3 2. Component ALUMINA WATER COMPOSITION / INFORMATION ON INGREDIENTS CAS Reg. Number 1344-28-1 7732-18-5 WHMIS Hazard Y N Percentage > 93 Balance
3.
HAZARDS IDENTIFICATION
A. EMERGENCY OVERVIEW: Physical Appearance and Odour: White powder solid, odourless Warning Statements: DUSTS IN HIGH CONCENTRATIONS MAY CAUSE SKIN, EYE AND RESPIRATORY TRACT IRRITATION. B. POTENTIAL HEALTH EFFECTS:
Acute Eye: Causes foreign body irritation only.
Annex A 1
3. B. HAZARDS IDENTIFICATION (Continued) POTENTIAL HEALTH EFFECTS: (Continued)
Acute Skin: Non-irritating. Skin absorption not likely Acute Inhalation: Low acute inhalation toxicity. May cause lung irritation, shortness of breath, chest pain. Acute Ingestion: Low acute oral toxicity. May cause constipation. Chronic Effects: This product does not contain any ingredient designated by IARC, NTP, ACGIH or OSHA as probable or suspected human carcinogens.
4.
FIRST AID MEASURES
FIRST AID MEASURES FOR ACCIDENTAL: Eye Exposure: Hold eyelids open and flush with a steady, gentle stream of water for at least 15 minutes. Seek medical attention if irritation develops or persists or if visual changes occur. Skin Exposure: In case of contact, wash with plenty of soap and water. Seek medical attention if irritation develops or persists. Inhalation: If respiratory irritation or distress occurs remove victim to fresh air. Seek medical attention if respiratory irritation or distress continues. Ingestion: No harmful affects expected. If appreciable quantities are swallowed, call a physician or poison control centre. Do not leave victim unattended. MEDICAL CONDITIONS POSSIBLY AGGRAVATED BY EXPOSURE: Inhalation of product may aggravate existing chronic respiratory problems such as asthma, emphysema or bronchitis. Skin contact may aggravate existing skin disease. NOTES TO PHYSICIAN: All treatments should be based on observed signs and symptoms of distress in the patient. Consideration should be given to the possibility that overexposure to materials other than this product may have occurred. Treat symptomatically. No specific antidote available. Annex A 2
5 FIRE FIGHTING MEASURES
FIRE HAZARD DATA: Flash Point: Not Applicable Extinguishing Media: Not combustible. Use extinguishing method suitable for surrounding fire. Special Fire Fighting Procedures: Fire-fighters should wear NIOSH/MSHA approved self-contained breathing apparatus and full protective clothing. Unusual Fire and Explosion Hazards: Not combustible. Hazardous Decomposition Materials (Under Fire Conditions): None known 6 ACCIDENTAL RELEASE MEASURES
Evacuation Procedures and Safety: Containment of Spill: Follow procedure described below under Cleanup and Disposal of Spill. Cleanup and Disposal of Spill: Scrape up and place in appropriate closed container (see Section 7: Handling and Storage) Environmental and Regulatory Reporting: Do not flush to drain 7. HANDLING AND STORAGE
Minimum/Maximum Storage Temperatures: Not available Handling: Avoid direct or prolonged contact with skin and eyes. Avoid breathing dusts. Dry powders can build static electricity charges when subjected to the friction of conveying, mixing or sliding. Provide adequate precautions, such as electrical grounding, or inert atmospheres when material is used in the presence of flammable materials to prevent ignition. Storage: Store in an area that is clean, dry, store in tightly closed containers. Store in original container.
Annex A 3
8. EXPOSURE CONTROLS / PERSONAL PROTECTION
Introductory Remarks: These recommendations provide general guidance for handling this product. Because specific work environments and material handling practices vary, safety procedures should be developed for each intended application. While developing safe handling procedures, do not overlook the need to clean equipment and piping systems for maintenance and repairs. Waste resulting from these procedures should be handled in accordance with Section 13: Disposal Considerations. Assistance with selection, use and maintenance of worker protection equipment is generally available from equipment manufacturers. Exposure Guidelines: Exposure limits represent regulated or recommended worker breathing zone concentrations measured by validated sampling and analytical methods, meeting the regulatory requirements. The following limits apply to this material, where, if indicated, S= skin and C= ceiling limit: ALUMINA Notes ACGIH TWA 10 mg/cu. m STEL
Engineering Controls: Where engineering controls are indicated by use conditions or a potential for excessive exposure exists, the following traditional exposure control techniques may be used to effectively minimize employee exposures: general area dilution/exhaust ventilation, local exhaust ventilation at the point of generation. Respiratory Protection: When respirators are required, select NIOSH/MSHA approved equipment based on actual or potential airborne concentrations and in accordance with the appropriate regulatory standards and/or industrial recommendations. Under normal conditions, in the absence of other airborne contaminants, the following devices should provide protection from this material up to the conditions specified by the appropriate OSHA, WHMIS or ANSI standard(s): Air-purifying (half-mask/full-face) respirator with cartridges/canister approved for use against dusts, mists and fumes. Eye/Face Protection Eye and face protection requirements will vary dependent upon work environment conditions and material handling practices. Appropriate ANSI Z87 approved equipment should be selected for the particular use intended for this material. It is generally regarded as good practice to wear a minimum of safety glasses with side shields when working in industrial environments.
Annex A 4
8. EXPOSURE CONTROLS / PERSONAL PROTECTION (Continued)
Skin Protection Skin contact should be minimized through use of gloves and suitable long-sleeved clothing (i.e. shirts and pants). Consideration must be given both to durability as well as permeation resistance. Work Practice Controls: Personal hygiene is an important work practice exposure control measure and the following general measures should be taken when working with or handling this material: (1) Do not store, use, and/or consume foods, beverages, tobacco products, or cosmetics in areas where this material is stored. (2) Wash hands and face carefully before eating, drinking, using tobacco, applying cosmetics or using the toilet. (3) Wash exposed skin promptly to remove accidental splashes of contact with this material. 9. PHYSICAL AND CHEMICAL PROPERTIES
Physical and chemical properties here represent typical properties of this product. Contact the business area using the Product Information phone number in Section 1 for its exact specifications. Physical Appearance: White powder solid Odour: Odourless pH: Not Applicable Specific Gravity: Not Available Density: 3.3 g/ml at 25C (77F). Water Solubility: Insoluble Melting Point Range: 2050C (3722F) Boiling Point Range: Not Available Vapor Pressure: 1 mmHg at 2158C (3916F) Vapor Density: Not Available Molecular Weight: 101.96 Annex A 5
10. STABILITY AND REACTIVITY
Chemical Stability: This material is stable under normal handling and storage conditions described in Section 7. Conditions to be avoided: Dusting conditions Materials/Chemicals to be avoided: Strong bases Strong acids The Following Hazardous Decomposition Products Might Be Expected: Decomposition Type: thermal - None known Hazardous Polymerization Will Not Occur. Avoid the Following to Inhibit Hazardous Polymerization: not applicable 11. TOXICOLOGICAL INFORMATION
Acute Eye Irritation: No test data found for product. Acute Skin Irritation: No test data found for product. Acute Dermal Toxicity: No test data found for product. Acute Respiratory Irritation: No test data found for product. Acute Inhalation Toxicity: No test data found for product. Acute Oral Toxicity: No test data found for product. Chronic Toxicity: This product does not contain any substances that are considered by OSHA, NTP, IARC, or ACGIH to be "probable" or "suspected" human carcinogens. No additional test data found for product. 12. ECOLOGICAL INFORMATION
Ecotoxicological Information: No data found for product. Chemical Fate Information: No data found for product.
Annex A 6
13. DISPOSAL CONSIDERATIONS
Waste Disposal Method: Waste Management options should first consider possible re-use or recycling opportunities. Some provinces have active "Waste Exchange" networks for re-use and recycling of wastes. Contact your local waste management companies to explore available options. All waste management activities must obey local, provincial and federal regulations. Possible disposal methods include the following: Stabilize and solidify this material with compatible binders. Then place in a secure landfill. Container Handling and Disposal: Rinse containers before disposal. 14. TRANSPORTATION INFORMATION
Transportation Status: The listed Transportation Classification does not address regulatory variations due to changes in package size, mode of shipment or other regulatory descriptors. TDG Status: Shipping Name: NON DANGEROUS IMO Status: Shipping Name: NOT REGULATED IATA Status: Shipping Name: NOT REGULATED 15. REGULATORY INFORMATION Status Y
Inventory Status Inventory CANADA (DSL)
WHMIS Classification: NOT CONTROLLED This product has been classified in accordance with the hazard criteria of the CPR (Controlled Products Regulations) and the MSDS contains all the information required by the CPR.
Annex A 7
16. OTHER INFORMATION
National Fire Protection Association Hazard Ratings - NFPA (R): 0 Health Hazard Rating -- Minimal 0 Flammability Rating -- Minimal 0 Reactivity Rating -- Minimal National Paint & Coating Hazardous Materials Identification System - HMIS (R): 0 Health Hazard Rating -- Minimal 0 Flammability Rating -- Minimal 0 Reactivity Rating Minimal Key Legend Information: ACGIH American Conference of Governmental Industrial Hygienists OSHA Occupational Safety and Health Administration TLV Threshold Limit Value PEL Permissible Exposure Limit TWA Time Weighted Average STEL Short Term Exposure Limit NTP National Toxicology Program IARC International Agency for Research on Cancer Disclaimer: The information herein is given in good faith but no warranty, expressed or implied, is made.
End of page 8 End of MSDS Document Annex A 8

Manual Tze 400 To Tze3500 v2 PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Tze 400 To Tze3500 v2 PDF

Uploaded by

Copyright:

Available Formats

SERIES TZE

TZE400 / TZE3500 EMS OPTION 3V OPTION LDP OPTION

TZE Externally Heated Desiccant Compressed Air Dryers

Warning against electrical voltage!

TZE400 TZE3500 150 PSIG 500 F -20 F

SECTION 1 1.4.4 Technical data sheet (Continued)

TZE1000 1000 24 814 3 NPT 3 NPT HE1100 DP1100 G03V

TZE1225 1225 24 956 3 NPT 3 NPT

TZE1500 1500 28 1129 3 NPT 3 NPT

TZE1800 1800 28 1325 4 FLG 4 FLG

SECTION 1 1.4.4 Technical data sheet (Continued)

TZE2100 2100 30 1510 4 FLG 4 FLG HE 2100 DP 2100 G03V

TZE2500 2500 36 Activated Alumina 1871 4 FLG 4 FLG

TZE3500 3500 40 2789 6 FLG 6 FLG

SECTION 1 1.4.5 DRYER FLOW CAPACITIES Model Selection Chart

CORRECTION FACTOR FOR INLET TEMPERATURE

High humidity (-36C) High humidity (-69C)

SECTION 2 2.1 SET-UP AND INSTALLATION (Continued)

SECTION 2 2.1 SET-UP AND INSTALLATION (Continued)

SECTION 2 2.1 SET-UP AND INSTALLATION (Continued)

SECTION 3 3.1 START UP

START UP AND OPERATION

SECTION 3 3.2 OPERATOR INTERFACE

SECTION 3 3.2 OPERATOR INTERFACE (Continued)

SECTION 3 3.2 OPERATOR INTERFACE (Continued)

SECTION 3 3.2 OPERATOR INTERFACE (Continued)

SECTION 3 3.2 OPERATOR INTERFACE (Continued)

HEATER OUTLET XXXX F HEAT CONTROL YYYY F

HEATER OUTLET XXXX F HEAT FAIL AT ZZZZ F

HEATER OUTLET XXXX F HEAT OVERTEMP VVVV F

REGEN OUTLET XXXX F HEAT SETPOINT YYYY F

REGEN OUTLET XXXX F COOL SETPOINT ZZZZ F

SECTION 3 3.3 PROGRAM STEPS

10 SECO N D S H AVE PA SSED AND LEFT C H AM BER A B O V E 6 0 P S IG

5 SECO NDS HA VE PASS ED

120 SEC O ND S H AV E PASSED AN D BOT H C H AM B ER A R E A B O V E 6 0 P S IG

SECTION 3 3.3 PROGRAM STEPS (Continued)

OPEN RIGHT CHAMBER INLET VALVE

10 SECONDS HAVE PASSED AND RIGHT CHAMBER ABOVE 60 PSIG

CLOSE LEFT CHAMBER INLET VALVE

EV-11L & EV-1R WAIT 5 SECONDS FOR VALVE TO CLOSE

LEFT CHAMBER DEPRESS

10 SECONDS HAVE PASSED AFTER LEFT CHAMBER BELOW 30 PSIG

LEFT CHAMBER HEATING PERIOD

HEATING TIMER DONE OR PURGE OUTLET TEMPERATURE ABOVE 200 F

LEFT CHAMBER COOLING PERIOD

LEFT CHAMBER REPRESS.

ENERGIZE EV-1R AND EV-11L

LEFT CHAMBER STANDBY

ENERGIZE EV-1R AND EV-11L

SECTION 4 4.4 FILTERS (Continued)

SECTION 4 4.4 FILTERS (Continued)

SPARE PARTS LIST

RECOMMENDED SPARES FOR TZE400, TZE500 & TZE650

TZE820 Part no. 38015913 38016672 38015038 38015574 38006995

TZE1000 Part no. 38015913 38006672 38015038 38015574 38006995

TZE1225 Part no. 38015913 38006672 38015038 38015574 38006995

TZE1500 Part no. 38015913 38006672 38015038 38015574 38006995

TROUBLE SHOOTING & FAULTS

THE DEWPOINT HAS DETERIORATED

Inlet pressure below design pressure

Liquid water entering dryer

Desiccant broken up or coated with oil