SERIES TZETZE400 / 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 INSTALLATION, START-UP & MAINTENANCE MANUAL MODEL NO.: TZE400 / TZE3500 REV 2 – April 25,.2001 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 INSTALLATION, START-UP & MAINTENANCE MANUAL MODEL NO.: TZE400 / TZE3500 REV 2 – April 25,.2001 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 operation and servicing. In the interest of further development. 1.. Ingersoll-Rand® accepts no liability for corrosion damage and malfunctions caused by aggressive media.2 SAFETY INSTRUCTIONS This technical manual contains basic tips. which. START-UP & MAINTENANCE MANUAL MODEL NO. it is improperly used. This adsorption dryer is designed for neutral media free of aggressive water. oil and solid elements. Ingersoll-Rand® reserves the right to make changes at any time. it is improperly maintained or serviced. in keeping with the essential characteristics of the adsorption dryer described here. This can result in the loss of all damage claims. 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. which must be followed during set-up. and it must always be within reach at the place where the adsorption dryer is being used. 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.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.: TZE400 / TZE3500 REV 2 – April 25. Page 5 .2001 SECTION 1 INTRODUCTION 1. may be necessary for increasing efficiency or for reasons relating to safety or to normal business practice.INSTALLATION. Applications other than those mentioned in this manual must be agreed to by Ingersoll-Rand® and confirmed in writing. • • This dot refers to working or operational steps. 1.2. The sign of a hyphen marks enumerations. inspection and assembly work The operator is to make sure that all maintenance.. ☛ Advices This sign refers to a procedure or sequence of particular interest or importance.: TZE400 / TZE3500 REV 2 – April 25. inspection and assembly work is carried out by special personnel who are authorized and qualified. special attention should be paid to the following attention and danger sign: Page 6 .2. 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. START-UP & MAINTENANCE MANUAL MODEL NO. The steps are to be carried out in the order of their appearance from top to bottom.INSTALLATION. All tips must be followed to ensure proper use of this adsorption dryer. whose disregard could endanger people and machines.1 Identification of signs and symbols in this technical manual The safety tips contained in this technical manual.2001 SECTION 1 1. For this reason.2 Safety tips for maintenance. and who are adequately informed through careful study of the technical manual. START-UP & MAINTENANCE MANUAL MODEL NO. 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.2001 SECTION 1 1. Areas of responsibility and supervision of the personnel must be precisely established by the operator.2 Safety tips for maintenance. there is no restriction on the use of fire extinguishing material.2.. then they must be trained and instructed.3 PERSONNEL QUALIFICATION The personnel involved in operation. Should the personnel not possess the necessary knowledge. rinse eyes immediately with a lot of clear water. − If the desiccant is spilled. the reaction with water and foam is defined as strong. − In case of fire. 1. maintenance. this training may be carried out by the manufacturer / supplier at the request of the operator of the adsorption dryer. Danger! Wear protective goggles when working with the desiccant! Advices for protection − If desiccant comes into contact with the eyes. inspection and assembly must have the corresponding qualifications to do this work. ☛ Advices Refer to the desiccant material safety data sheet (MSDS) when installing or disposing of desiccant. clean up without causing swirls of dust. − A mask must be worn. the operator is to make sure that the personnel completely understand the contents of the technical manual.INSTALLATION. If need be. Further. ☛ Page 7 . is depressurized and disconnected from the electric power supply.: TZE400 / TZE3500 REV 2 – April 25. dry and oil-free compressed air or gases.4 PRODUCT INFORMATION The adsorption dryer is used for the purpose of drying compressed air and other gases according to its respective design.4. − The min. and correspondingly its humidity increases. provides pure. and depending on certain conditions at the outlet. TZE400 – TZE3500 150 PSIG 500 °F -20 °F Page 8 . 1. if: − The flow capacity of the medium to be dried increases. “UM” ASME Symbol.: TZE400 / TZE3500 REV 2 – April 25.and after-filter. Range of application Type Operating overpressure Temperature Max.1 Pressure vessel regulations The pressure vessels are designed according to the standard technical requirements. Max. 1.2 Airtightness test All adsorption dryers are subjected to an airtightness test prior to shipment using compressed air. 1.. As a "standard model" the adsorption dryer is equipped with two desiccant vessels and a pre. Min.3 Overloading Attention! Protect the adsorption dryer from overloads! The adsorption dryer can become overloaded. − The temperature of the air at entry. They fulfill the test of the certifying procedure and carry the “U”.4. − The pre-filtration and separation of impurities are not sufficient.2001 SECTION 1 1.INSTALLATION.4. operating pressure is under cut. START-UP & MAINTENANCE MANUAL MODEL NO. 2001 SECTION 1 1. START-UP & MAINTENANCE MANUAL MODEL NO.. 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 6 8 10 12 8 Hour Nema Cycle – 4 Hours drying/ 4 Hours Regeneration .4 Technical data sheet MODEL Flow (SCFM) @ 100 PSIG 100°F IAT Vessel OD – Inches Desiccant type Lbs.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 .41 F PDP .INSTALLATION.4.: TZE400 / TZE3500 REV 2 – April 25.40 C/F PRESSURE DEWPOINT . 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 .40 C/F PRESSURE DEWPOINT .: TZE400 / TZE3500 REV 2 – April 25.2001 SECTION 1 1. 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 .41 F PDP .INSTALLATION. START-UP & MAINTENANCE MANUAL MODEL NO.4..4 Technical data sheet (Continued) MODEL Flow (SCFM) @ 100 PSIG 100°F IAT Vessel OD – Inches Desiccant type Lbs. 41 F PDP . START-UP & MAINTENANCE MANUAL MODEL NO.4.36 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 . 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 .2001 SECTION 1 1.4 Technical data sheet (Continued) MODEL Flow (SCFM) @ 100 PSIG 100°F IAT Vessel OD – Inches Desiccant type Lbs.: TZE400 / TZE3500 REV 2 – April 25.INSTALLATION.40 C/F PRESSURE DEWPOINT .. 69 115 0.. Consult factory 2. Multiply pressure corrected flow by the temperature correction factor to obtain the flow of the dryer corrected for pressure and temperature: 1140 X (0.0 105 0. Example: To size for an inlet flow of 950 SCFM @ 105 F and 110 Psig.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. Model TZE 1000 can flow 969 SCFM at the inlet conditions specified.85) = 969 SCFM 3. Confirm model selection. 1. CORRECTION FACTOR FOR INLET TEMPERATURE TEMPERATURE DEGREES F Correction Factor 80 1. Higher pressures available as an option. This case would be the TZE1000 which can dry 1140 SCFM. activated alumina and average inlet air flow.: TZE400 / TZE3500 REV 2 – April 25. 2.85 110 0. NOTE: Settings for EMS: Standard dryers EMS Control (-41°C) LDP Dryers EMS Control (-74°C) High humidity (-36°C) High humidity (-69°C) Page 12 .1 100 1.1 90 1. START-UP & MAINTENANCE MANUAL MODEL NO.2001 SECTION 1 1.4.565 120 0.455 To correct for an inlet temperature other than 100 F multiply dryer capacity by the temperature correction factor listed above. 8 hour NEMA cycle.INSTALLATION. Based on – 40 F PDP. The requirements of 950 SCFM is less so model TZE1000 is correct. Select model that produce at least 950 SCFM at 110 Psig. Since no condensate accumulates in the after-filter. 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.2001 SECTION 1 1. a pre-filter is installed in front of the adsorption dryer. oil and dirt from getting into the desiccant. There has to be a min.4. the Transport Company must be informed to register the damage. since an oil film on the desiccant reduces the drying capacity and the dewpoint. ☛ Information When making enquiries by phone or fax.8 Use of a pre and after filter In order to prevent droplets of condensate. it must be checked for damage that may have occurred during transport. an after-filter is mounted behind the adsorption dryer. 1. ambient temp. 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.: TZE400 / TZE3500 REV 2 – April 25. Page 13 . this filter is always equipped with a manual valve.. START-UP & MAINTENANCE MANUAL MODEL NO. If necessary.7 Storage If the adsorption dryer is to be stored for a longer period of time.4.6 Transport After the adsorption dryer has been delivered. of +1°C (33°F). In order to prevent breakdowns in downstream consumers caused by material that has been abraded from the desiccant bed.INSTALLATION.4. its place of storage must be dry and free of dust. the adsorption dryers of the series TZE400 – TZE3500. the adsorption dryer is to be placed onto vibration dampers.2001 SECTION 2 INSTALLATION 2. Should vibrations occur on the installation location. Since the adsorption dryer has already been completely wired at our factory. Warning! Use the appropriate. a by-pass pipe with an additional shut-off valve should be mounted onto the adsorption dryer. The equipment should be unloaded as close as possible to the installation site to minimize any chances of equipment damage.. load-rated lifting equipment and observe safe lifting procedures during all operations of installation. ☛ Advice Should you still have questions regarding installation. 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. in order to be able to guarantee an uninterrupted supply of compressed air in case the adsorption dryer breaks down. START-UP & MAINTENANCE MANUAL MODEL NO.INSTALLATION.1 SET-UP AND INSTALLATION Once at the installation location. Also. you can request installation blueprints separately from Ingersoll-Rand Davidson NC. 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 customer only has to connect the power supply cable to the terminal strip according to the supplied wiring diagrams. Page 14 .: TZE400 / TZE3500 REV 2 – April 25. START-UP & MAINTENANCE MANUAL MODEL NO. protective barriers may be required to prevent possible damage. the silencer can be removed and purge exhaust can be connected to a vent header. Because of vibration during shipping some tube fittings may have loosened. If the equipment is installed in a high traffic area. Full flow relief valves to protect the system from over-pressure must be provided by others in accordance with local regulations. 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.1 SET-UP AND INSTALLATION (Continued) 2.. 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 .: TZE400 / TZE3500 REV 2 – April 25. Do not hydrostatically test the pressure vessels. etc. If required. inspect all connections for tightness.2001 SECTION 2 2.1 Mechanical installation • • • • • • • • The equipment should be located in an area with adequate clearances for service. 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. anchor the Ingersoll-Rand type TZE Dryer to a solid. Follow recommendations for pipe sizing listed below. If not supplied as part of the equipment package by Ingersoll-Rand they should be supplied and installed by others. To ensure satisfactory regeneration of the desiccant chambers is achieved. Therefore. Utilizing the mounting holes provided on the skid. It must be verified that these exist so that future servicing of the Dryer System may take place. The purge exhaust connection on the TZE820 and larger dryers must be connected to a vent header.1. System isolation and by-pass valves should be installed. The purge exhaust on the TZE650 and smaller dryers is equipped with an exhaust muffler/silencer. the purge exhaust piping should be sized as follows to prevent "back pressure" build up. Remove all protective shipping crates.INSTALLATION. flange covers. level foundation designed to support the equipment. An overhead clearance of not less than two feet above each adsorber tower is required for loading of the desiccant. START-UP & MAINTENANCE MANUAL MODEL NO.2001 SECTION 2 2.1. • Connect drain port to a condensate collector. Only one electrical entrance is required. • Ground the frame of the dryer in accordance with the recognised electrical codes..2 Filter installation Models TZE400. The following installation applies to all models that are shipped with filters loose. • Locate the prefilter as close to the dryer inlet connection as possible.INSTALLATION. Refer to the dryer nameplate or the electrical drawing for the supply voltage and amp requirement to properly size the electrical service amp rating. be connected to the control room or operator station so that an immediate response to the dryer trouble alarm may be given when required. • It is recommended that the common alarm relay.1. • A disconnect switch is not provided with the dryer and must be supplied by end user. located in the dryer control panel.1 SET-UP AND INSTALLATION (Continued) 2. TZE 650 are shipped with filters mounted and piped to the dryer. All internal wiring is done at the factory. 2.: TZE400 / TZE3500 REV 2 – April 25. PREFILTER INSTALLATION • Mount prefilter 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. • The filter must be piped so that the correct flow direction indicated on the filter is followed. AFTERFILTER INSTALLATION • Mount afterfilter in such a way as to allow clearance for the element installation and removal. TZE500.3 Electrical installation • Connect the dryer to a correctly sized power supply. • Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection. • Ensure that all piping and valves are equivalent or larger in size to the dryer inlet connection. Use an easily visible collector to aid in operational inspection. Page 16 . INSTALLATION. 4” and 6” (TZE820 and larger) probe sample line must be run from downstream of the afterfilter. Cut to necessary length and connect to the upper connection fitting. Replace the DPI fitting with the ‘TEE’ provided. thus preventing damage to the heater assembly and associated components due to burn out. If sample port is installed at a distance further than tubing supplied contact Ingersoll-Rand for assistance. START-UP & MAINTENANCE MANUAL MODEL NO. A 1000 volt meg-ohmmeter should be used to determine the phase to ground insulation resistance for each phase.3 Electrical installation (Continued) • Before energizing the electrical circuit. 2. The differential pressure indicator port on the outlet nozzle of the afterfilter should be used.. the electrical heater assembly should be inspected to determine that no moisture has accumulated in the heater enclosure or terminations. 10-ft length of 1/8” stainless steel tubing and necessary compression fittings are provided. Run 1/8” tubing back to the hygrometer housing. While tubing is semi-flexible. Page 17 .: TZE400 / TZE3500 REV 2 – April 25.2001 SECTION 2 2. A minimum value of 500 Kohms should exist. Tubing fittings are to be installed downstream of the afterfilter.1 SET-UP AND INSTALLATION (Continued) 2. care must be taken when bending tubing to ensure that tubing does not kink.1.1.4 EMS Installation (If option purchased) • • • • • • • On 3”. Insert 1/8” tubing into compression fitting and tighten. This will protect the equipment internal components (i. − The ambient temperature must not be less than 33°F. ensure that the dryer system pressure does not fall beyond 95% of its reading prior to opening the system outlet valve. Fully open the inlet isolation valve. START-UP & MAINTENANCE MANUAL MODEL NO.1 START UP START UP AND OPERATION Attention! All pipes and wire connections are to be tightened! Furthermore.1. Hygrometer adjustment/isolation valves are closed. verify the following: Dryer On – Off switch is in the off position. System outlet block valve is closed. afterfilter and pilot air filter vent valves are closed.e.. Desiccant chamber vent valve is closed.INSTALLATION. If some gas other than the process air will be used for leak testing. Breakdowns resulting from faulty installation do not fall under Ingersoll-Rand's warranty obligation. (EMS option only) Slightly open the inlet isolation valve slowly admitting compressed air to the system. consult Ingersoll-Rand for its compatibility with system components before proceeding. 3. Pilot air isolation valve is open. • • Page 18 . before start-up: − The pipes must be checked for the presence of scale. desiccant) from gas velocities above design conditions. then slowly open the system outlet valve to pressurize the downstream piping. When full system operating pressure has been reached all connections should be soap bubble tested for leaks. When the system is filled with process air and leak tight and start-up is completed. adsorption dryer. During the procedure. Any leaks should be repaired and retested prior to placing the equipment in service. or other similar impurities.1 Pressurizing dryer • Prior to pressurizing the Ingersoll-Rand Type TZE Dryer system. Prefilter. after-filter and on the bypass line should be closed. abraded material from the threading.2001 SECTION 3 3. − All shut off valves on the pre-filter.: TZE400 / TZE3500 REV 2 – April 25. filter elements. timers counters is included later in this manual. A copy of the program complete with a full listing of inputs. 3. Page 19 . Warning! Failure to correctly set the purge pressure can lead to improper regeneration of the desiccant bed. NOTE : If EMS option selected: The hygrometer will signal an open circuit.1. Ensure that the pilot pressure regulator is set between 80 and 100 Psig. This should be used as a reference guide to ensure dryer is cycling. Use the manual purge adjustment valve to adjust the purge setting. Verify the system inlet pressure and temperature are at the design operating levels. outputs. START-UP & MAINTENANCE MANUAL MODEL NO. A SIEMENS programmable controller with individual input/output modules controls the dryer cycle.: TZE400 / TZE3500 REV 2 – April 25.. A manual mode is included in the dryer program to allow for fast cycling to verify to operation of the dryer.2001 SECTION 3 3. It is recommended that the operational program of the dryer and the wiring schematic be studied before operating the dryer. resulting in a dewpoint failure when that chamber is returned to service. • 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.1 Pressurizing dryer (Continued) • • • When pressurizing is complete then fully open the system outlet valve to place the equipment in service.INSTALLATION. and humidity alarm light will illuminate until probe cable is connected to hygrometer probe. internal coils.1.2 Energizing dryer controls • • Turn ON-OFF switch to the ON position. 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. 4. It will take a short period of time for a humidity probe to be purged of humidity and give the correct dewpoint. START-UP & MAINTENANCE MANUAL MODEL NO. Do not fully open discharge valve 5. 6.2001 SECTION 3 3.INSTALLATION.. 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 remove probe from the housing until dryer system has been started and probe is to be inserted into the sample cell. Perform a soap test to verify for leaks on all parts of the sample line connections and the humidity sample cell.1. 2. 1. Refer to the assembly drawing in the following section.3 EMS Start up The startup procedure for the EMS system will be as follows. Humidity cell assembly Page 20 .: TZE400 / TZE3500 REV 2 – April 25. The digital display will now read the dewpoint of the dryer system. 3. : TZE400 / TZE3500 REV 2 – April 25. ESC => MUST PUSH ESC AGAIN TO ACCESS WHEN IN MENU MODE.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.INSTALLATION. F5 => DRYER OPERATING MODE MENU F6 => HEATER SHEATH TEMPERATURE AND SETPOINT F7 => HEATER OUTLET TEMPERATURE AND SETPOINTS F8 => REGEN. the SHIFT button must be pressed first. OUTLET TEMPERATURE AND SETPOINTS ARROWS ALLOW USER TO SCROLL UP OR DOWN INSIDE OF DISPLAY. ENTER=> NO FUNCTIONALITY FOR THIS BUTTON. An “s” in the lower right corner indicates the upper row is now active.. 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. Page 21 .2001 SECTION 3 3. START-UP & MAINTENANCE MANUAL MODEL NO. This will extend the half cycle for a maximum of twelve (12) hours or until the outlet dewpoint goes higher than – 40F. Right chamber in standby until the end of the half cycle. Right chamber in standby until the end of the half cycle. 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. A message can appear below the dryer status at any time when in manual mode. in the sequence. Heating the left chamber for regeneration.2. Cooling the right chamber. START-UP & MAINTENANCE MANUAL MODEL NO. The dryer is in EMS mode on the left chamber. Opening the right chamber inlet valve. To access the messages.1 Dryer status The “F1” key is pressed to display the present status of the dryer.INSTALLATION. This allows you to see where. Closing the right chamber inlet valve. The dryer is in EMS mode on the left chamber. Page 22 . Pressurizing the right chamber. Pressurizing the right chamber. Cooling the left chamber. Heating the right chamber for regeneration.: TZE400 / TZE3500 REV 2 – April 25. Closing the left chamber inlet valve. Depressurizing the right chamber. the dryer is. press the green arrow on the right side of the interface. This will extend the half cycle for a maximum of twelve (12) hours or until the outlet dewpoint goes higher than – 40F.2 OPERATOR INTERFACE (Continued) 3.2001 SECTION 3 3. A blinking arrow on the right side of the display will indicate this.. Depressurizing the left chamber. The left chamber did not reach the low setting of the pressure switch with time limit. The right chamber did not reach the high setting of the pressure switch with time limit. START-UP & MAINTENANCE MANUAL MODEL NO.INSTALLATION. In order to reset the alarms. MESSAGE IDENTIFICATION Heater Outlet over temperature Thermocouple module in error Thermocouple out of range Low purge alarm Check press.2 Alarm information The “F3” button is pressed to display a status of the dryer alarms. 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. To access the messages. The right chamber did not reach the low setting of the pressure switch with time limit. The heater has failed to reach the set point temperature within 15 minutes. If more than one (1) alarm is active. The purge pressure is below the set point or the pressure switch is defective. the “NO ALARM” message will appear. Indicates a thermocouple connected to the module is defective or open.2. The left chamber did not reach the high setting of the pressure switch with time limit. press the green arrow on the right side of the interface. If there is no alarm. press the “F4” key than all the non-active alarms will be reset. Page 23 .2 OPERATOR INTERFACE (Continued) 3. a “NO ALARM” message will appear.2001 SECTION 3 3. Indicates the thermocouple module has lost it’s 24Vdc supply.. If all the alarm conditions have been cleared. Indicates the outlet dewpoint is above alarm setpoint. Indicates no alarm is active.: TZE400 / TZE3500 REV 2 – April 25. a flashing arrow will appear on the right side of the display. The heater sheath is above the setting. 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 dryer is ready to go to the next step when in manual mode. To change to actual mode of the dryer. Both temperatures are in Fahrenheit Page 24 . 3.3 Dryer operation modes The “F5” button is pressed to display status of the dryer modes of operation. The dryer is in manual mode. 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.: TZE400 / TZE3500 REV 2 – April 25. press “F2” when in the dryer mode screen.INSTALLATION. The user must wait for this signal in order to press “F2” and make the dryer stepping ahead in its cycle. it will automatically switch to the dryer status screen. If the dryer mode screen is left unattended for thirty seconds. 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).2 OPERATOR INTERFACE (Continued) 3..2. START-UP & MAINTENANCE MANUAL MODEL NO. In order to be go to the next step in manual mode you must not be in the dryer operation mode screen. The set point can not be changed from the interface. the “READY TO STEP AHEAD PRESS F2 TO CONTINUE” message will be shown when the dryer is ready to perform the next step. Failure to do so will simply change the operating mode of the dryer. The actual mode will be displayed whether dryer is in automatic or manual mode. In manual mode. It means the dryer will need external intervention in order to do to the following step. It means the dryer will perform its cycle without any external intervention except in case of alarm.2001 SECTION 3 3. If no external intervention is provided the dryer will stay in the actual step. The actual mode will change from one to the other each time the “F2” button is pressed.2. INSTALLATION.2001 SECTION 3 3. Both temperatures are in Fahrenheit Displays the actual heater outlet temperature (XXXX) and the heating failure alarm temperature setting (ZZZZ). 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. Displays the actual regeneration outlet temperature (XXXX) and the end of cooling mode temperature setting (YYYY). 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.2 OPERATOR INTERFACE (Continued) 3. Displays the actual heater outlet temperature (XXXX) and the high outlet temperature alarm setting (VVVV). The set point can not be changed from the interface. 3. Both temperatures are in Fahrenheit.2. The set points can not be changed from the interface. Both temperatures are in Fahrenheit.. 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.6 Regeneration outlet information The “F8” button is to access the regeneration outlet information. START-UP & MAINTENANCE MANUAL MODEL NO. Both temperatures are in Fahrenheit.: TZE400 / TZE3500 REV 2 – April 25. Page 25 .5 Heater outlet information The “F7” button is to access the heater outlet information.2. Both temperatures are in Fahrenheit. 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). START-UP & MAINTENANCE MANUAL MODEL NO.2001 SECTION 3 3. 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 .: TZE400 / TZE3500 REV 2 – April 25.3 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 ºF 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 ..INSTALLATION. 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 ºF A N D 6 0 M IN U T E S H A V E P A S S E D . : TZE400 / TZE3500 REV 2 – April 25. ENERGIZE EV-1R AND EV-11L IF COOLING TIMER DONE (100 MINUTES) OR PURGE OUTLET TEMPERATURE BELOW 120º F AND 60 MINUTES HAVE PASSED. 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 .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 200º F STEP 12 LEFT CHAMBER COOLING PERIOD START LEFT CHAMBER COOLING MODE FOR 100 MINUTES MAXIMUM AND 60 MINUTES MINIMUM.2001 SECTION 3 3. STEP 13 LEFT CHAMBER REPRESS. START-UP & MAINTENANCE MANUAL MODEL NO..INSTALLATION. Page 28 . Replace all worn or damaged parts.. heaters. inlet flow. Verify pressure switch operation. pressure switches and temperature controller. Check filter differential pressures. Every 3 Months Check operating conditions. solenoid valves. START-UP & MAINTENANCE MANUAL MODEL NO. Filter elements should last between 6 –12 months under normal use. afterfilter and pilot air filter elements at least once a year. ☛ 4. Blow down daily to remove accumulated fluids. purge rate. a maintenance contract with Ingersoll-Rand is recommended. Inspect the desiccant through the chamber fill port.: TZE400 / TZE3500 REV 2 – April 25. clean and inspect the inlet switching. Disassemble. dump valves.1 SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE Daily • • • • • • • • • • • • • Check prefilter automatic drain valve to ensure drain is working properly. Weekly Check all mufflers for backpressure. purge exhaust and depress. Replace all worn or damage parts. Ensure dryer is cycling without alarms. Annually • • • • Disassemble.INSTALLATION. Blow down relief valves Check heater outlet temperature is between 400 and 425°F. Check correct purge pressure. If element seems clogged. line pressure. Replace if clogged or dirty. Verify heater operation. Check dryer operating cycle for proper operation of valve operators. replace element. clean and inspect the outlet and purge check valves.2001 SECTION 4 MAINTENANCE Advice In order to ensure continuous and trouble-free operation. Inspect pilot air filter element. Replace desiccant if broken or coated with oil. Check the outlet dewpoint. Replace prefilter. A filter differential pressure of 5-8 PSID indicates a dirty filter element and should be replaced. dirty or damaged. or every 2 years on latest. Replace the desiccant drain plug/cover. Fill to a level approximately 3” below the upper circumference weld on the desiccant vessel. This new filtration concept is characterized by high flows at low differential pressure. Refer to the General Arrangement drawing for location of fill and drain ports.2 REPLACEMENT / DISPOSAL OF THE DESICCANT In order to ensure trouble-free operation.4. Replace the fill cap.1 General comments and use Filters of the series HE are suitable for filtering solids.4 FILTERS 4. we recommend replacing the desiccant every 8000 Hours. The dryer is filled from the top and emptied from the bottom. Refer to the spare parts section for desiccant quantity.2001 SECTION 4 4. Remove the fill cap and refill the chamber with the specified desiccant. Desiccant chambers should never be completely filled.. • • • To drain the desiccant. oil and condensate out of compressed air and other neutral. Do not tamp the desiccant. remove the drain plug/cover and catch the old desiccant in a suitable container. Page 29 . NOTE: 4. 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. Soap test both fill and drain ports for leaks before returning the dryer to service. NOTE : Refer to the desiccant MSDS document in the annex of this manual for instructions and precautions on handling and disposing of desiccant.: TZE400 / TZE3500 REV 2 – April 25. START-UP & MAINTENANCE MANUAL MODEL NO. compressed gases.INSTALLATION. 3 Assembly and installation ☛ − − − − − Advices Within the piping system.2 Function The soiled medium flows through the filter element "Series HE" from the inside to the outside.INSTALLATION. An arrow on the upper part of the housing marks the direction of the flow.2001 SECTION 4 4. depending on the amount. or on latest after 1 year of operation.: TZE400 / TZE3500 REV 2 – April 25. The functioning of the automatic condensate drain is to be tested weekly by manual operation.. The filters must always be installed vertically. the condensate on the pre-filter is to be removed several times a day by opening the hand drain.4. 4.4.4 Maintenance ☛ − − − Advices The filter element should be replaced when a differential pressure of > 10 PSID has been reached. Solids are filtered out by impact or by the effect of inertia. The piping system must be cleaned before filters assembling.4. the filters should always be used where the air or gas temperature is lowest. By the force of gravity. Sufficient free space should be left at the bottom for the changing of filter elements. Should there be no condensate drain. then. START-UP & MAINTENANCE MANUAL MODEL NO. 4.4 FILTERS (Continued) 4. Page 30 . whereas oil particles and drops of humidity are filtered out by the effect of coalescence. the filtered-out droplets collect in the lower filter vessel and are drained automatically or manually. 4.4. START-UP & MAINTENANCE MANUAL MODEL NO.6 Accessories ☛ Advices Pressure differential gauge: Indicates the degree to which the elements are soiled.4 FILTERS (Continued) 4.2001 SECTION 4 4.4.: TZE400 / TZE3500 REV 2 – April 25.5 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.INSTALLATION.. • Elements of the “HE” or “DP” series can NOT be cleaned with compressed air. Page 31 . • Re-install filter bowl assembly. Automatic condensate drain: Continuously draws off the condensate that has collected. Hand drain: Used when there is little or no condensate. • Install the new element and the O-ring and making sure that the element seats perfectly. • Loosen and remove the element by hand. TESTING PURGE PRESSURE SWITCH AND ALARM SHUTDOWN.INSTALLATION. purge orifice and a pressure indicating gauge (Panel mounted).: TZE400 / TZE3500 REV 2 – April 25. Check that the Dryer In Alarm light illuminates. When test is complete. Open or close purge adjustment valve until correct pressure is shown on the purge pressure gauge. This valve must be kept in the specified position when the dryer is operating or the dryer will not step ahead / regenerate. Wait until dryer is in a regeneration mode (Heating or cooling). re-open the service valve and set pressure to correct pressure following steps listed in Setting Purge Pressure section.. located on gauge panel). Reset the alarm. Check that the heater contactor de-energize.1 CALIBRATION PURGE ADJUSTMENT The dryers purge system includes an adjustment valve. Ensure dryer is at operating pressure. Page 32 . Periodically verify this pressure and the low purge alarm (PS-3). (PI-3 on flow schematic. START-UP & MAINTENANCE MANUAL MODEL NO.2001 SECTION 5 5. SETTING PURGE FLOW • • • • Refer to the specification sheet for the correct purge pressure setting (PI-3). This system has been factory set to the correct pressure for the dryer inlet conditions of 100F and 100 Psig. • • • • • Close the purge service valve. INSTALLATION. To increase the pressure. PSH-2.2001 SECTION 5 5. screw the knob toward the pressure switch diaphragm.. while the PS-3 (purge pressure) is set at 10 PSIG below the purge adjustment setting and all use the normally open contact. the contact between "C" and "NO" should close when increasing to the desired pressure. When the adjustment is done. To decrease the pressure. START-UP & MAINTENANCE MANUAL MODEL NO. When the adjustment is done. the contact between "C" and "NC" should close when decreasing to the desired pressure.: TZE400 / TZE3500 REV 2 – April 25. do the opposite. PSL-1. The PSL switches are set at 10 PSIG regardless the operating pressure and use the normally closed contact. The PSH pressure switches are set at 30 PSIG below the operating pressure of the dryer. Page 33 . PSL-2 and PS-3).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. 2001 SECTION 6 6.INSTALLATION.) 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.) 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. 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 . START-UP & MAINTENANCE MANUAL MODEL NO..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.: TZE400 / TZE3500 REV 2 – April 25.) 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. ) 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.2001 SECTION 6 6. 38015913 38006672 38015038 38015574 38006995 Included w/Exhaust valve kit TZE1225 Part no.) 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.) 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. 38015913 38016672 38015038 38015574 38006995 Included w/Exhaust valve kit TZE1000 Part no.. START-UP & MAINTENANCE MANUAL MODEL NO.INSTALLATION. TZE1000. 38015913 38006672 38015038 38015574 38006995 Included w/Exhaust valve kit TZE1500 Part no.2 RECOMMENDED SPARES FOR TZE820. 38015913 38006672 38015038 38015574 38006995 Included w/Exhaust valve kit 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.) 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 .) 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.: TZE400 / TZE3500 REV 2 – April 25. 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. 2001 SECTION 6 6. TZE2100. 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. 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.) 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.: TZE400 / TZE3500 REV 2 – April 25. START-UP & MAINTENANCE MANUAL MODEL NO.3 RECOMMENDED SPARES FOR TZE1800.) TZE2500 Part no.) 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 . 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. 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..) TZE3500 Part no.INSTALLATION. 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.) TZE2100 Part no. Replace heater Replace heater contactor Check purge pressure setting Check set-points of heater and purge exhaust.INSTALLATION. Heater contactor failure 3. Þ Check operation of drain trap. Incoming air flow too high Þ Problem external to dryer. Inspect prefilter if desiccant is coated with oil. Þ Check prefilter elements and seals for damage. 4. Þ Replace desiccant. 2.. Leaks at piping/tubing downstream of the dryer connections Þ Soap test dryer and repair all leaks. 3. Replace if necessary. Verify inlet flow rate and reduce as necessary to dryer specification. Ensure proper drainage.2001 SECTION 7 7. Repair or replace drain if necessary. Heater failure 2. Page 37 . Incorrect purge flow 4. Temperature setting to incorrect 1. Correct if necessary. Inlet pressure below design pressure Liquid water entering dryer Desiccant broken up or coated with oil Insufficient regeneration: 1.1 TROUBLE SHOOTING & FAULTS THE DEWPOINT HAS DETERIORATED Possible cause Remedy Incoming air temperature above design Þ Check compressor after cooler and condition cooling system.: TZE400 / TZE3500 REV 2 – April 25. Þ Adjust as necessary to reduce the inlet temperature to dryer specification. START-UP & MAINTENANCE MANUAL MODEL NO. Þ Check compressed air system. replace. Page 38 Pilot air insufficient Inlet air pressure below setpoint of pressure switches Solenoid valve not energizing . Þ Check operation of solenoid. Þ Check wiring from panel to the solenoid for an open or short circuit.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE Possible cause Hygrometer probe out of calibration Remedy Þ Refer to hygrometer manual in Annex. If clogged or dirty. Þ Inspect and repair. Þ Return probe to factory for certified recalibration. Replace if not functioning. Þ Check that pilot air isolation valve is fully open. Open circuit on probe electrical connection Incorrect flow across sensor Excessive moisture on sensor 7. Þ Refer to EMS startup section in this manual Þ Check sensor tubing and probe filter for buildup of moisture.2001 SECTION 7 7. Repair if necessary. section for instruction on field calibration. Repair if necessary. Þ Inspect pilot air tubing for kinks or breaks. START-UP & MAINTENANCE MANUAL MODEL NO.. depressurize pilot air filter and inspect element.: TZE400 / TZE3500 REV 2 – April 25. Allow tubing to dry and replace filter element. Þ Check that pilot air regulator is set at 100 PSIG. Þ Correct the low pressure problem to the dryer.3 SWITCHING FAILURE ALARM Possible cause Remedy Þ Close pilot air isolation valve.INSTALLATION. Switching failure repressurization on Þ Exhaust or depress valves not closing or leaking. Inspect as described above.3 SWITCHING FAILURE ALARM (Continued) Possible cause Remedy Inlet or purge exhaust valves Þ Shutdown and depressurize dryer.INSTALLATION. Þ Regenerating chamber depress/exhaust valve failed to open. Check purge pressure settings. START-UP & MAINTENANCE MANUAL MODEL NO.. Check solenoid operation as listed above. Check valve internals are worn or damaged Switching failure depressurization Þ Shutdown and depressurize dryer. Replace if needed.: TZE400 / TZE3500 REV 2 – April 25. check the actuator stops to ensure that valve is fully closing (butterfly valves only). Þ Check the operation of the pressure switches. Inspect leaking valve seats and seals for damage or wear. Check associated solenoid valve operation as described above. Þ Online chamber outlet check valve leaking. Repair or replace if necessary. Þ Insufficient purge flow. Þ While valve is disassembled. Repair or replace valves. Check the purge pressure setting.2001 SECTION 7 7. Inspect and repair as described above. Page 39 . Þ Excessive purge flow. Þ Inspect purge and depress mufflers and replace if necessary. Check valve failure as listed above. Check automatic purge shut off valve for correct operation. Pressure switch malfunction valves leaking Þ Check the setpoint of the pressure switches. on Þ Off line desiccant chamber inlet valve or outlet check valve leaking. Readjust if necessary. inspect 7.2001 SECTION 7 7. Replace if clogged. Attention! Dryer will remain pressurized. Page 40 ..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 Þ Inspect desiccant and replace if required Þ Reduce inlet flow as necessary Þ Depressurize filters and elements.INSTALLATION.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.: TZE400 / TZE3500 REV 2 – April 25.and downstream of dryer. Then immediately switch off the adsorption dryer. START-UP & MAINTENANCE MANUAL MODEL NO. • 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.2001 SECTION 7 7. Apply the general safety regulations! ☛ Advices The following sequence is to be heeded when switching off the adsorption dryer: • • • • First switch off the dryer.INSTALLATION.1. • Switch on the unit once again.: TZE400 / TZE3500 REV 2 – April 25. proceed as in 3. TZE500 and TZE650 depressurize the dryer by using the hand valve mounted at the bottom of the after-filter. START-UP & MAINTENANCE MANUAL MODEL NO. Then close all the shut off valves up. For TZE820 and larger depressurize the dryer by using the hand valve mounted at the bottom of the desiccant chamber 7. For TZE400.and downstream of the adsorption dryer.6 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE Danger! Before any kind of maintenance or repair work is done.7 RE-STARTING • Close the hand valve mounted at the bottom of the after-filter and at the bottom of each desiccant chamber.. Page 41 . the adsorption dryer must be depressurized and disconnected from the power source. • If the adsorption dryer is re-started after a long standstill. Make certain dryer is not in heating or cooling mode. Annex A 1 . ANNEX CHEMICAL PRODUCT AND COMPANY DESCRIPTION Ingersoll-Rand Inc 800. 28036 .A Beaty Street. POTENTIAL HEALTH EFFECTS: Acute Eye: Causes foreign body irritation only. Davidson. CATALYST SUPPORT. GAS PURIFICATION Chemical Name or Synonym: ACTIVATED ALUMINA (GRADES A. EXPOSURE OR ACCIDENT CONTACT: (1) (514) 848-1454 For Product Information: Tel: (704) 896-4000 / Fax: (704) 896-4648 Product Use: DRYING AGENT. Number 1344-28-1 7732-18-5 WHMIS Hazard Y N Percentage > 93 Balance 3. EYE AND RESPIRATORY TRACT IRRITATION. EMERGENCY OVERVIEW: Physical Appearance and Odour: White powder solid.ACTIVATED ALUMINA (GRADES A. North Carolina. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 SECTION 8 1. B. FIRE. Component ALUMINA WATER COMPOSITION / INFORMATION ON INGREDIENTS CAS Reg. D & P) Molecular Formula: Al2O3 2.USA Emergency Phone numbers: FOR EMERGENCIES INVOLVING A SPILL. HAZARDS IDENTIFICATION A. odourless Warning Statements: DUSTS IN HIGH CONCENTRATIONS MAY CAUSE SKIN. LEAK. Consideration should be given to the possibility that overexposure to materials other than this product may have occurred. No specific antidote available. Skin absorption not likely Acute Inhalation: Low acute inhalation toxicity. wash with plenty of soap and water. MEDICAL CONDITIONS POSSIBLY AGGRAVATED BY EXPOSURE: Inhalation of product may aggravate existing chronic respiratory problems such as asthma. Chronic Effects: This product does not contain any ingredient designated by IARC. Ingestion: No harmful affects expected. May cause lung irritation. NTP. Acute Ingestion: Low acute oral toxicity. Do not leave victim unattended. chest pain. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 3. Inhalation: If respiratory irritation or distress occurs remove victim to fresh air. Skin contact may aggravate existing skin disease. call a physician or poison control centre. gentle stream of water for at least 15 minutes. HAZARDS IDENTIFICATION (Continued) POTENTIAL HEALTH EFFECTS: (Continued) Acute Skin: Non-irritating. shortness of breath. B. Seek medical attention if respiratory irritation or distress continues. emphysema or bronchitis.ACTIVATED ALUMINA (GRADES A. Seek medical attention if irritation develops or persists or if visual changes occur. FIRST AID MEASURES FIRST AID MEASURES FOR ACCIDENTAL: Eye Exposure: Hold eyelids open and flush with a steady. Skin Exposure: In case of contact. Seek medical attention if irritation develops or persists. Treat symptomatically. NOTES TO PHYSICIAN: All treatments should be based on observed signs and symptoms of distress in the patient. May cause constipation. Annex A 2 . 4. ACGIH or OSHA as probable or suspected human carcinogens. If appreciable quantities are swallowed. Provide adequate precautions.ACTIVATED ALUMINA (GRADES A. Annex A 3 . Avoid breathing dusts. Store in original container. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 5 FIRE FIGHTING MEASURES FIRE HAZARD DATA: Flash Point: Not Applicable Extinguishing Media: Not combustible. Use extinguishing method suitable for surrounding fire. 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. Special Fire Fighting Procedures: Fire-fighters should wear NIOSH/MSHA approved self-contained breathing apparatus and full protective clothing. HANDLING AND STORAGE Minimum/Maximum Storage Temperatures: Not available Handling: Avoid direct or prolonged contact with skin and eyes. 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. such as electrical grounding. Dry powders can build static electricity charges when subjected to the friction of conveying. 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. store in tightly closed containers. mixing or sliding. Annex A 4 . WHMIS or ANSI standard(s): Air-purifying (half-mask/full-face) respirator with cartridges/canister approved for use against dusts. use and maintenance of worker protection equipment is generally available from equipment manufacturers. S= skin and C= ceiling limit: ALUMINA Notes ACGIH TWA 10 mg/cu. Assistance with selection. local exhaust ventilation at the point of generation. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 8. Respiratory Protection: When respirators are required. The following limits apply to this material. Because specific work environments and material handling practices vary. m STEL Engineering Controls: Where engineering controls are indicated by use conditions or a potential for excessive exposure exists. do not overlook the need to clean equipment and piping systems for maintenance and repairs. meeting the regulatory requirements. if indicated. where. While developing safe handling procedures. Waste resulting from these procedures should be handled in accordance with Section 13: Disposal Considerations. It is generally regarded as good practice to wear a minimum of safety glasses with side shields when working in industrial environments. Appropriate ANSI Z87 approved equipment should be selected for the particular use intended for this material. mists and fumes. safety procedures should be developed for each intended application.ACTIVATED ALUMINA (GRADES A. the following devices should provide protection from this material up to the conditions specified by the appropriate OSHA. Eye/Face Protection Eye and face protection requirements will vary dependent upon work environment conditions and material handling practices. select NIOSH/MSHA approved equipment based on actual or potential airborne concentrations and in accordance with the appropriate regulatory standards and/or industrial recommendations. EXPOSURE CONTROLS / PERSONAL PROTECTION Introductory Remarks: These recommendations provide general guidance for handling this product. in the absence of other airborne contaminants. the following traditional exposure control techniques may be used to effectively minimize employee exposures: general area dilution/exhaust ventilation. Under normal conditions. Exposure Guidelines: Exposure limits represent regulated or recommended worker breathing zone concentrations measured by validated sampling and analytical methods. or cosmetics in areas where this material is stored. drinking. shirts and pants).3 g/ml at 25°C (77°F). 9. using tobacco. beverages. PHYSICAL AND CHEMICAL PROPERTIES Physical and chemical properties here represent typical properties of this product. applying cosmetics or using the toilet. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 8. use. 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. Water Solubility: Insoluble Melting Point Range: 2050°C (3722°F) Boiling Point Range: Not Available Vapor Pressure: 1 mmHg at 2158°C (3916°F) Vapor Density: Not Available Molecular Weight: 101. Physical Appearance: White powder solid Odour: Odourless pH: Not Applicable Specific Gravity: Not Available Density: 3. (2) Wash hands and face carefully before eating.e. tobacco products. and/or consume foods. Consideration must be given both to durability as well as permeation resistance. EXPOSURE CONTROLS / PERSONAL PROTECTION (Continued) Skin Protection Skin contact should be minimized through use of gloves and suitable long-sleeved clothing (i. Contact the business area using the Product Information phone number in Section 1 for its exact specifications.96 Annex A 5 .ACTIVATED ALUMINA (GRADES A. (3) Wash exposed skin promptly to remove accidental splashes of contact with this material. No additional test data found for product. Acute Dermal Toxicity: No test data found for product. Acute Inhalation Toxicity: No test data found for product. Chronic Toxicity: This product does not contain any substances that are considered by OSHA. TOXICOLOGICAL INFORMATION Acute Eye Irritation: No test data found for product. Chemical Fate Information: No data found for product. NTP. Acute Respiratory Irritation: No test data found for product. Avoid the Following to Inhibit Hazardous Polymerization: not applicable 11. or ACGIH to be "probable" or "suspected" human carcinogens. Annex A 6 . Acute Oral Toxicity: No test data found for product.None known Hazardous Polymerization Will Not Occur. Acute Skin Irritation: No test data found for product. STABILITY AND REACTIVITY Chemical Stability: This material is stable under normal handling and storage conditions described in Section 7. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 10.ACTIVATED ALUMINA (GRADES A. ECOLOGICAL INFORMATION Ecotoxicological Information: No data found for product. 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 . 12. IARC. provincial and federal regulations. Possible disposal methods include the following: Stabilize and solidify this material with compatible binders. Some provinces have active "Waste Exchange" networks for re-use and recycling of wastes. Contact your local waste management companies to explore available options. Container Handling and Disposal: Rinse containers before disposal. All waste management activities must obey local. 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. Then place in a secure landfill. TRANSPORTATION INFORMATION Transportation Status: The listed Transportation Classification does not address regulatory variations due to changes in package size.ACTIVATED ALUMINA (GRADES A. TDG Status: Shipping Name: NON DANGEROUS IMO Status: Shipping Name: NOT REGULATED IATA Status: Shipping Name: NOT REGULATED 15. mode of shipment or other regulatory descriptors. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 13. 14. DISPOSAL CONSIDERATIONS Waste Disposal Method: Waste Management options should first consider possible re-use or recycling opportunities. Annex A 7 . is made.Minimal 0 Flammability Rating -. End of page 8 End of MSDS Document Annex A 8 . expressed or implied. D & P) Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95 16.HMIS (R): 0 Health Hazard Rating -.Minimal 0 Flammability Rating -.Minimal 0 Reactivity Rating -.NFPA (R): 0 Health Hazard Rating -.Minimal National Paint & Coating Hazardous Materials Identification System .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. OTHER INFORMATION National Fire Protection Association Hazard Ratings .ACTIVATED ALUMINA (GRADES A.