manual tze 400 to tze3500 v2.pdf

TZE400 / TZE3500EMS OPTION3V OPTIONLDP OPTION

TZEExternally Heated Desiccant

Compressed Air Dryers

SERIES TZE

INSTALLATION, START-UP & MAINTENANCE MANUALMODEL NO.: TZE400 / TZE3500

REV 2 – April 25,.2001

TABLE OF CONTENTS

FOREWORD................................................................................................................................. 4SECTION 1 INTRODUCTION.................................................................................................. 5

1.1 GENERAL INFORMATION ............................................................................................. 51.2 SAFETY INSTRUCTIONS................................................................................................ 5

1.2.1 Identification of signs and symbols in this technical manual ..................................... 61.2.2 Safety tips for maintenance, inspection and assembly work....................................... 6

1.3 PERSONNEL QUALIFICATION...................................................................................... 71.4 PRODUCT INFORMATION ............................................................................................. 8

1.4.1 Pressure vessel regulations.......................................................................................... 81.4.2 Airtightness test .......................................................................................................... 81.4.3 Overloading................................................................................................................. 81.4.4 Technical data sheet .................................................................................................... 91.4.5 DRYER FLOW CAPACITIES................................................................................. 121.4.6 Transport ................................................................................................................... 131.4.7 Storage ...................................................................................................................... 131.4.8 Use of a pre and after filter ....................................................................................... 13

SECTION 2 INSTALLATION .................................................................................................. 142.1 SET-UP AND INSTALLATION...................................................................................... 14

2.1.1 Mechanical installation ............................................................................................. 152.1.2 Filter installation ....................................................................................................... 162.1.3 Electrical installation ................................................................................................ 162.1.4 EMS Installation (If option purchased)..................................................................... 17

SECTION 3 START UP AND OPERATION ........................................................................ 183.1 START UP........................................................................................................................ 18

3.1.1 Pressurizing dryer ..................................................................................................... 183.1.2 Energizing dryer controls.......................................................................................... 193.1.3 EMS Start up............................................................................................................. 20

3.2 OPERATOR INTERFACE............................................................................................... 213.2.1 Dryer status ............................................................................................................... 223.2.2 Alarm information .................................................................................................... 233.2.3 Dryer operation modes.............................................................................................. 243.2.4 Heater sheath information......................................................................................... 243.2.5 Heater outlet information.......................................................................................... 253.2.6 Regeneration outlet information ............................................................................... 25

3.3 PROGRAM STEPS .......................................................................................................... 26SECTION 4 MAINTENANCE ................................................................................................. 28

4.1 SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE...................................... 284.2 REPLACEMENT / DISPOSAL OF THE DESICCANT ................................................. 294.3 HYGROMETER MAINTENANCE (EMS Option only)................................................. 29


REV 2 – April 25,.2001

4.4 FILTERS........................................................................................................................... 294.4.1 General comments and use ....................................................................................... 294.4.2 Function .................................................................................................................... 304.4.3 Assembly and installation ......................................................................................... 304.4.4 Maintenance.............................................................................................................. 304.4.5 Changing of filter elements....................................................................................... 314.4.6 Accessories ............................................................................................................... 31

SECTION 5 CALIBRATION.................................................................................................... 325.1 PURGE ADJUSTMENT .................................................................................................. 325.2 PRESSURE SWITCH ADJUSTMENT ........................................................................... 33

SECTION 6 SPARE PARTS LIST......................................................................................... 346.1 RECOMMENDED SPARES FOR TZE400, TZE500 & TZE650................................... 346.2 RECOMMENDED SPARES FOR TZE820, TZE1000, TZE1225 & TZE1500.............. 356.3 RECOMMENDED SPARES FOR TZE1800, TZE2100, TZE2500 & TZE3500............ 36

SECTION 7 TROUBLE SHOOTING & FAULTS................................................................. 377.1 THE DEWPOINT HAS DETERIORATED..................................................................... 377.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE.................................................... 387.3 SWITCHING FAILURE ALARM ................................................................................... 387.3 SWITCHING FAILURE ALARM (Continued)............................................................... 397.4 PRESSURE DROP TOO HIGH....................................................................................... 407.5 SHORT-TERM SHUT-DOWN........................................................................................ 407.6 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE............................. 417.7 RE-STARTING ................................................................................................................ 41

SECTION 8 ANNEX................................................................................................................... 1


REV 2 – April 25,.2001

FOREWORD

This technical manual of IInnggeerrssoollll--RRaanndd®® is an aid in getting to know the adsorptiondryer better and in utilising its possibilities for application in accordance with itsintended 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 damageswhich could cause downtime and premature wear and tear on the adsorption dryer.

In addition to the technical manual and the accident prevention regulations whichare valid and compulsory in the country and in the particular workplace where theadsorption dryer is being used, the recognized special rules for safe and properworking procedures are also to be heeded. The technical manual must always bewithin reach wherever the adsorption dryer is being used.

Each person involved with the set-up, start-up, operation, maintenance and repairof the adsorption dryer in the User Company must have first read and understoodthe technical manual and especially the safety tips.


REV 2 – April 25,.2001

SECTION 1 INTRODUCTION

1.1 GENERAL INFORMATION

The adsorption dryer of the TZE400 – TZE3500 series is built according to the latesttechnological developments and recognized safety rules. Its use however canendanger life and limb of the user or of third parties, and can lead to considerabledamage 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 andsolid elements. IInnggeerrssoollll--RRaanndd®® accepts no liability for corrosion damage andmalfunctions caused by aggressive media.

Applications other than those mentioned in this manual must be agreed to byIInnggeerrssoollll--RRaanndd®® and confirmed in writing.

In the interest of further development, IInnggeerrssoollll--RRaanndd®® reserves the right to makechanges at any time, which, in keeping with the essential characteristics of theadsorption dryer described here, may be necessary for increasing efficiency or forreasons 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 theassembly 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 theadsorption dryer is being used.


REV 2 – April 25,.2001

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 endangerpeople and machines, are indicated by a general danger sign and the additionalmarkings Danger! or Attention!

Danger! / Attention!

Warning against electrical voltage!

Safety tips printed directly on the adsorption dryer must be heeded at all times andmust be kept completely legible.

☛ Advices

This sign refers to a procedure or sequence of particular interest orimportance. All tips must be followed to ensure proper use of this adsorptiondryer.• 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 workis carried out by special personnel who are authorized and qualified, and who areadequately informed through careful study of the technical manual. For this reason,special attention should be paid to the following attention and danger sign:


REV 2 – April 25,.2001

SECTION 1 1.2.2 Safety tips for maintenance, inspection and assembly work (Continued)

Attention!

− Never make structural changes to the adsorptiondryer!

− 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 adsorptiondryer is switched off, is depressurized anddisconnected from the electric power supply.

☛ AdvicesRefer to the desiccant material safety data sheet (MSDS) when installing ordisposing of desiccant.

Danger! Wear protective goggles when working with thedesiccant!

☛ 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 musthave the corresponding qualifications to do this work. Areas of responsibility andsupervision of the personnel must be precisely established by the operator. Shouldthe personnel not possess the necessary knowledge, then they must be trained andinstructed. If need be, this training may be carried out by the manufacturer / supplierat the request of the operator of the adsorption dryer. Further, the operator is tomake sure that the personnel completely understand the contents of the technicalmanual.


REV 2 – April 25,.2001

SECTION 1

1.4 PRODUCT INFORMATION

The adsorption dryer is used for the purpose of drying compressed air and othergases according to its respective design. As a "standard model" the adsorption dryeris equipped with two desiccant vessels and a pre- and after-filter, and depending oncertain conditions at the outlet, provides pure, dry and oil-free compressed air orgases.

1.4.1 Pressure vessel regulations

The pressure vessels are designed according to the standard technicalrequirements. They fulfill the test of the certifying procedure and carry the “U”,“UM” ASME Symbol.

Range of applicationType TZE400 – TZE3500

Operatingoverpressure

Max. 150 PSIG

TemperatureMax.

Min.

500 °F

-20 °F 1.4.2 Airtightness test

All adsorption dryers are subjected to an airtightness test prior to shipment usingcompressed 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.


REV 2 – April 25,.2001

SECTION 1

1.4.4 Technical data sheet

MODEL TZE400 TZE500 TZE650 TZE820Flow (SCFM) @ 100 PSIG100°F IAT

400 500 650 820

Vessel OD – Inches 18 18 18 20Desiccant type Activated AluminaLbs. Desiccant / Vessel 272 350 481 673Inlet connection 2 NPT 2NPT 2 NPT 3 NPTOutlet connection 2 NPT 2 NPT 2 NPT 3 NPTFILTER• Prefilter• Afterfilter• Pilot air filter

HE563 DP563AR-0003G/B

HE563 DP563AR-0003G/B

HE 706DP 706AR-0003G/B

HE 1100DP 1100G03V

Voltage 460/3/60 Standard - Consult Factory for other voltages

Heater KW 6 8 10 12Cycle time 8 Hour Nema Cycle –

4 Hours drying/ 4 Hours RegenerationOutlet Dewpoint - 40 C/F PRESSURE DEWPOINTEMS Control - 41 F PDPHigh Humidity Alarm - 36 F PDPPressure Switch Setpoints PSL – 10 PSIG / PSH – 30 PSIG Below line PressurePurge Pressure Setting 70 Psig 65 Psig 55 Psig 55 PsigLow Purge Alarm Setpoint 60 Psig 55 Psig 45 Psig 45 PsigHeater Outlet Setpoint 425 FEnd HeatingTemperature 200 FEnd Cooling Temperature 120 FHeater Sheath Alarm 1000 FProcess flow DOWNWARD DRYING / UPWARD REGENERATION


REV 2 – April 25,.2001

SECTION 1

1.4.4 Technical data sheet (Continued)

MODEL TZE1000 TZE1225 TZE1500 TZE1800Flow (SCFM) @ 100 PSIG100°F IAT

1000 1225 1500 1800

Vessel OD – Inches 24 24 28 28Desiccant type Activated AluminaLbs. Desiccant / Vessel 814 956 1129 1325Inlet connection 3 NPT 3 NPT 3 NPT 4 FLGOutlet connection 3 NPT 3 NPT 3 NPT 4 FLGFILTER• Prefilter• Afterfilter• Pilot air filter

HE1100 DP1100G03V

HE 1380 DP 1380G03V

HE 2100DP 2100G03V

HE 2100DP 2100G03V


Heater KW 17 21 25 28Cycle time 8 Hour Nema Cycle –

4 Hours drying/ 4 Hours RegenerationOutlet Dewpoint - 40 C/F PRESSURE DEWPOINTEMS Control - 41 F PDPHigh Humidity Alarm - 36 F PDPPressure Switch Setpoints PSL – 10 PSIG / PSH – 30 PSIG Below line PressurePurge Pressure Setting 70 Psig 60 Psig 65 Psig 70 PsigLow Purge Alarm Setpoint 60 Psig 50 Psig 55 Psig 60 PsigHeater Outlet Setpoint 425 FEnd HeatingTemperature 200 FEnd Cooling Temperature 120 FHeater Sheath Alarm 1000 FProcess flow DOWNWARD DRYING / UPWARD REGENERATION


REV 2 – April 25,.2001

SECTION 1

1.4.4 Technical data sheet (Continued)

MODEL TZE2100 TZE2500 TZE3500Flow (SCFM) @ 100 PSIG100°F IAT

2100 2500 3500

Vessel OD – Inches 30 36 40Desiccant type Activated AluminaLbs. Desiccant / Vessel 1510 1871 2789Inlet connection 4” FLG 4” FLG 6” FLGOutlet connection 4” FLG 4” FLG 6” FLGFILTER• Prefilter• Afterfilter• Pilot air filter

HE 2100 DP 2100G03V

HE 2750 DP 2750G03V

HE 4100DP 4100G03V


Heater KW 32 36 53Cycle time 8 Hour Nema Cycle –

4 Hours drying/ 4 Hours RegenerationOutlet Dewpoint - 40 C/F PRESSURE DEWPOINTEMS Control - 41 F PDPHigh Humidity Alarm - 36 F PDPPressure Switch Setpoints PSL – 10 PSIG / PSH – 30 PSIG Below line PressurePurge Pressure Setting 60 Psig 70 Psig 60 PsigLow Purge Alarm Setpoint 50 Psig 60 Psig 50 PsigHeater Outlet Setpoint 425 FEnd HeatingTemperature 200 FEnd Cooling Temperature 120 FHeater Sheath Alarm 1000 FProcess flow DOWNWARD DRYING / UPWARD REGENERATION


REV 2 – April 25,.2001

SECTION 1

1.4.5 DRYER FLOW CAPACITIES

Model Selection Chart

Average Inlet Air Flow (SCFM) Based upon 100 F Inlet Air TemperatureInlet Air Pressure (Psig)MODEL

MaximumInlet AirPressure(Psig) 80 90 100 110 120 130 140 150

TZE 400 150 310 355 400 440 480 520 550 575TZE 500 150 400 460 500 550 590 645 680 755TZE 650 150 505 580 650 705 790 850 905 960TZE820 150 640 735 820 905 990 1070 1150 1225TZE1000 150 805 920 1000 1140 1255 1325 1420 1510TZE1225 150 955 1100 1225 1360 1490 1610 1735 1850TZE1500 150 1150 1275 1500 1600 1730 1875 2010 2135TZE1800 150 1405 1610 1800 1995 2190 2375 2535 2705TZE2100 150 1600 1835 2100 2275 2500 2700 2890 3075TZE2500 150 1985 2270 2500 2820 3100 3355 3585 3820TZE3500 150 2700 3095 3500 3845 4195 4570 4890 5205

1. Higher pressures available as an option. Consult factory2. Based on – 40 F PDP, 8 hour NEMA cycle, activated alumina and average inlet air flow.

CORRECTION FACTOR FOR INLET TEMPERATURE

TEMPERATUREDEGREES F

80 90 100 105 110 115 120

Correction Factor 1.1 1.1 1.0 0.85 0.69 0.565 0.455

To correct for an inlet temperature other than 100 F multiply dryer capacity by thetemperature 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 conditionsspecified. The requirements of 950 SCFM is less so model TZE1000 is correct.

NOTE: Settings for EMS:Standard dryers EMS Control (-41°C) High humidity (-36°C)LDP Dryers EMS Control (-74°C) High humidity (-69°C)


REV 2 – April 25,.2001

SECTION 1

1.4.6 Transport

After the adsorption dryer has been delivered, it must be checked for damage thatmay have occurred during transport. If necessary, the Transport Company must beinformed to register the damage.

☛ Information

When making enquiries by phone or fax, please provide the followinginformation:

1) Equipment Serial Number2) Equipment Operating Pressure3) Equipment Operating Temperature4) Approximate time in service5) Nature of Problem

1.4.7 Storage

If the adsorption dryer is to be stored for a longer period of time, its place of storagemust be dry and free of dust. There has to be a min. ambient temp. of +1°C (33°F).

1.4.8 Use of a pre and after filter

In order to prevent droplets of condensate, oil and dirt from getting into thedesiccant, a pre-filter is installed in front of the adsorption dryer, since an oil film onthe desiccant reduces the drying capacity and the dewpoint. In order to preventbreakdowns in downstream consumers caused by material that has been abradedfrom the desiccant bed, an after-filter is mounted behind the adsorption dryer. Sinceno condensate accumulates in the after-filter, this filter is always equipped with amanual valve.Both filters are equipped with a differential pressure gauge (standard) as thisensures an indirect display of the degree of contamination of the filter elements.


REV 2 – April 25,.2001

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 sidefrom which it is to be operated is easily accessible. The piping is to be connectedto the adsorption dryer at a light slope. A shut-off valve is to be installed on the inletand outlet sides of the adsorption dryer. Also, a by-pass pipe with an additionalshut-off valve should be mounted onto the adsorption dryer, in order to be able toguarantee an uninterrupted supply of compressed air in case the adsorption dryerbreaks down. Should vibrations occur on the installation location, the adsorptiondryer is to be placed onto vibration dampers.Since the adsorption dryer has already been completely wired at our factory, thecustomer only has to connect the power supply cable to the terminal strip accordingto the supplied wiring diagrams.

☛ AdviceShould you still have questions regarding installation, you can requestinstallation blueprints separately from IInnggeerrssoollll--RRaanndd Davidson NC.

Warning!Use the appropriate, load-rated lifting equipmentand observe safe lifting procedures during alloperations of installation.The equipment should be unloaded as close aspossible to the installation site to minimize anychances of equipment damage.


REV 2 – April 25,.2001

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 forservice. An overhead clearance of not less than two feet above eachadsorber 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 IInnggeerrssoollll--RRaanndd

type TZE Dryer to a solid, level foundation designed to support theequipment.

• Do not hydrostatically test the pressure vessels. All TZE dryers pressurevessels and welded piping are hydrostatically tested at one and one-halftimes the design pressure after fabrication and before assembly.

• If the equipment is installed in a high traffic area, protective barriers may berequired 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 IInnggeerrssoollll--RRaannddtype TZE Dryer are made using the correct rated fittings and piping to meetthe design conditions.

• System isolation and by-pass valves should be installed. If not supplied aspart of the equipment package by Ingersoll-Rand they should be suppliedand installed by others. It must be verified that these exist so that futureservicing of the Dryer System may take place.

• Full flow relief valves to protect the system from over-pressure must beprovided by others in accordance with local regulations.

• The purge exhaust on the TZE650 and smaller dryers is equipped with anexhaust muffler/silencer. If required, the silencer can be removed and purgeexhaust can be connected to a vent header. Follow recommendations forpipe sizing listed below.

• The purge exhaust connection on the TZE820 and larger dryers must beconnected to a vent header. To ensure satisfactory regeneration of thedesiccant chambers is achieved, the purge exhaust piping should be sizedas follows to prevent "back pressure" build up.

INSTALLED LENGTH OF EXHAUST PIPE PIPE SIZE REQUIREDUp to 10 Ft Same size as the dryer exhaustUp to 25 Ft One size larger than dryer exhaustUp to 50 Ft Two sizes larger than dryer exhaustUp to 100 Ft Three sizes larger than dryer exhaust


REV 2 – April 25,.2001

SECTION 2


2.1.2 Filter installation

Models TZE400, TZE500, TZE 650 are shipped with filters mounted and piped tothe dryer. The following installation applies to all models that are shipped with filtersloose.

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 amprequirement to properly size the electrical service amp rating. Only oneelectrical entrance is required. All internal wiring is done at the factory.

• A disconnect switch is not provided with the dryer and must be supplied byend user.

• Ground the frame of the dryer in accordance with the recognised electricalcodes.

• It is recommended that the common alarm relay, located in the dryer controlpanel, be connected to the control room or operator station so that animmediate response to the dryer trouble alarm may be given when required.


REV 2 – April 25,.2001

SECTION 2


2.1.3 Electrical installation (Continued)

• Before energizing the electrical circuit, the electrical heater assembly shouldbe inspected to determine that no moisture has accumulated in the heaterenclosure or terminations, thus preventing damage to the heater assemblyand associated components due to burn out. A 1000 volt meg-ohmmetershould be used to determine the phase to ground insulation resistance foreach 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 fromdownstream of the afterfilter.

• 10-ft length of 1/8” stainless steel tubing and necessary compression fittingsare provided.

• Tubing fittings are to be installed downstream of the afterfilter. The differentialpressure 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, caremust be taken when bending tubing to ensure that tubing does not kink.

• If sample port is installed at a distance further than tubing supplied contactIInnggeerrssoollll--RRaanndd for assistance.


REV 2 – April 25,.2001

SECTION 3 START UP AND OPERATION

3.1 START UP

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 similarimpurities.

− 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 33°F.

Breakdowns resulting from faulty installation do not fall under IInnggeerrssoollll--RRaanndd'swarranty obligation.

3.1.1 Pressurizing dryer

• Prior to pressurizing the IInnggeerrssoollll--RRaanndd Type TZE Dryer system, verify thefollowing:- 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 thesystem. When full system operating pressure has been reached allconnections should be soap bubble tested for leaks. Any leaks should berepaired and retested prior to placing the equipment in service. If some gasother than the process air will be used for leak testing, consult Ingersoll-Randfor its compatibility with system components before proceeding. Fully openthe inlet isolation valve.

• When the system is filled with process air and leak tight and start-up iscompleted, then slowly open the system outlet valve to pressurize thedownstream piping. During the procedure, ensure that the dryer systempressure does not fall beyond 95% of its reading prior to opening the systemoutlet valve. This will protect the equipment internal components (i.e. filterelements, desiccant) from gas velocities above design conditions.


REV 2 – April 25,.2001

SECTION 3

3.1.1 Pressurizing dryer (Continued)

• When pressurizing is complete then fully open the system outlet valve toplace the equipment in service.

• Verify the system inlet pressure and temperature are at the design operatinglevels.

• 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 modulescontrols the dryer cycle. A copy of the program complete with a full listing ofinputs, outputs, internal coils, timers counters is included later in this manual.This should be used as a reference guide to ensure dryer is cycling. Amanual mode is included in the dryer program to allow for fast cycling toverify to operation of the dryer.

It is recommended that the operational program of the dryer and thewiring schematic be studied before operating the dryer.

NOTE : If EMS option selected:The hygrometer will signal an open circuit, and humidity alarmlight will illuminate until probe cable is connected to hygrometerprobe.

• While dryer is in the purging mode for either chamber the purge pressuresetting should be checked. Refer to the specification sheet in this manual forthe correct purge pressure setting. Use the manual purge adjustment valveto adjust the purge setting.

Warning!Failure to correctly set the purge pressure can lead toimproper regeneration of the desiccant bed, resultingin a dewpoint failure when that chamber is returnedto service.


REV 2 – April 25,.2001

SECTION 3

3.1.3 EMS Start up

The startup procedure for the EMS system will be as follows. Refer to the assemblydrawing in the following section.

The EMS hygrometer probe has been shipped inside of its own desiccant chamberto ensure that the probe does not become saturated with ambient air during storageand transport. Do not remove probe from the housing until dryer system has beenstarted and probe is to be inserted into the sample cell.

1. Verify that the humidity probe is installed into the sample cell2. Connect the coaxial cable to the humidity probe3. Fully open the inlet valve to the sample cell4. Partially open the discharge valve of the sample cell to bleed off a small amount

of sample air. Do not fully open discharge valve5. 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 thecorrect dewpoint.

Humidity cell assembly


REV 2 – April 25,.2001

SECTION 3

3.2 OPERATOR INTERFACE

F1 => DRYER STATUSF2 => MANUAL STEP AHEAD (MANUAL MODE ONLY)F3 => DRYER ALARM STATUSF4 => ALARM RESET

SHIFT=> In order to choose one of the next four options, the SHIFT buttonmust be pressed first. An “s” in the lower right corner indicates theupper row is now active.

F5 => DRYER OPERATING MODE MENUF6 => HEATER SHEATH TEMPERATURE AND SETPOINTF7 => HEATER OUTLET TEMPERATURE AND SETPOINTSF8 => REGEN. OUTLET TEMPERATURE AND SETPOINTS

ARROWS ALLOW USER TO SCROLL UP OR DOWN INSIDE OFDISPLAY. A FLASHING ARROW ON THE RIGHT SIDE OF THE SCREENINDICATE THAT MORE INFORMATION IS AVAILABLE IN THEDIRECTION OF THE ARROW AND CAN BE ACCESSED BY USING THESCROLL ARROWS.

ESC => MUST PUSH ESC AGAIN TO ACCESS WHEN IN MENU MODE.

ENTER=> NO FUNCTIONALITY FOR THIS BUTTON.


REV 2 – April 25,.2001

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 youto see where, in the sequence, the dryer is. A message can appear below the dryerstatus at any time when in manual mode. A blinking arrow on the right side of thedisplay will indicate this. To access the messages, press the green arrow on theright side of the interface.

Message identification Message description

Select Left Chamber Drying • Opening the left chamber inlet valve.• Closing the right chamber inlet valve.

Left Chamber DryingR/C in depress mode

• Depressurizing the right chamber.

Left Chamber DryingR/C in heating mode

• Heating the right chamber for regeneration.

Left Chamber DryingR/C in cooling mode

• Cooling the right chamber.

Left Chamber DryingR/C in repress mode

• Pressurizing the right chamber.

Left Chamber DryingR/C in standby mode

• Right chamber in standby until the end of the half cycle.

Left Chamber in EMS modeR/C in standby mode

• The dryer is in EMS mode on the left chamber. This willextend the half cycle for a maximum of twelve (12)hours or until the outlet dewpoint goes higher than –40F.

Select Right Chamber drying • Opening the right chamber inlet valve.• Closing the left chamber inlet valve.

Right Chamber dryingL/C in depress mode

• Depressurizing the left chamber.

Right Chamber dryingL/C in heating mode

• Heating the left chamber for regeneration.

Right Chamber dryingL/C in cooling mode

• Cooling the left chamber.

Right Chamber dryingL/C in repress mode

• Pressurizing the right chamber.

Right Chamber dryingL/C in standby mode

• Right chamber in standby until the end of the half cycle.

Right Chamber in EMS modeL/C in standby mode

• The dryer is in EMS mode on the left chamber. This willextend the half cycle for a maximum of twelve (12)hours or until the outlet dewpoint goes higher than –40F.


REV 2 – April 25,.2001

SECTION 3


3.2.2 Alarm information

The “F3” button is pressed to display a status of the dryer alarms. If there is noalarm, 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 themessages, press the green arrow on the right side of the interface. In order to resetthe alarms, press the “F4” key than all the non-active alarms will be reset. If all thealarm conditions have been cleared, the “NO ALARM” message will appear.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTIONHeater Outlet over temperature • Heater outlet temperature is above the setpoint.

Thermocouple module in error • Indicates the thermocouple module has lostit’s 24Vdc supply.

Thermocouple out of range • Indicates a thermocouple connected to themodule is defective or open.

Low purge alarmCheck press. at PS-3

• The purge pressure is below the set point orthe pressure switch is defective.

Heater failure alarmFail reach Setpoint

• The heater has failed to reach the set pointtemperature within 15 minutes.

Oversheath alarmSheath Temperature too high

• The heater sheath is above the setting.

Depress failure on left chamber • The left chamber did not reach the low settingof the pressure switch with time limit.

Depress failure on right chamber • The right chamber did not reach the lowsetting of the pressure switch with time limit.

Repress failure on left chamber • The left chamber did not reach the highsetting of the pressure switch with time limit.

Repress failure on right chamber • The right chamber did not reach the highsetting of the pressure switch with time limit.

High Humidity alarm • Indicates the outlet dewpoint is above alarmsetpoint.

NO ALARM • Indicates no alarm is active.


REV 2 – April 25,.2001

SECTION 3


3.2.3 Dryer operation modes

The “F5” button is pressed to display status of the dryer modes of operation. Theactual mode will be displayed whether dryer is in automatic or manual mode. Tochange to actual mode of the dryer, press “F2” when in the dryer mode screen. Theactual 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 automaticallyswitch to the dryer status screen. In manual mode, the “READY TO STEP AHEADPRESS F2 TO CONTINUE” message will be shown when the dryer is ready toperform the next step. In order to be go to the next step in manual mode you mustnot be in the dryer operation mode screen. Failure to do so will simply change theoperating mode of the dryer.

MESSAGE IDENTIFICATION MESSAGE DESCRIPTION

DRYER IN AUTO MODE• The dryer is in automatic mode. It means the

dryer will perform its cycle without any externalintervention except in case of alarm.

DRYER IN MANUAL MODE

• The dryer is in manual mode. It means thedryer will need external intervention in order todo to the following step. If no externalintervention is provided the dryer will stay in theactual step.

READY TO STEP AHEADPRESS F2 TO CONTINUE

• The dryer is ready to go to the next step whenin manual mode. The user must wait for thissignal in order to press “F2” and make the dryerstepping ahead in its cycle.

3.2.4 Heater sheath information

The “F6” button is to access the heater sheath information. On this screen theactual sheath temperature in degrees Fahrenheit is displayed so as the alarm setpoint for the over-sheath temperature alarm. The set point can not be changedfrom the interface.


HEATER SHEATH XXXX FALARM SETPOINT YYYY F

• Displays temperature of the heater sheath(XXXX) and also at which temperature the dryerwill fall in alarm (YYYY). Both temperatures arein Fahrenheit


REV 2 – April 25,.2001

SECTION 3


3.2.5 Heater outlet information

The “F7” button is to access the heater outlet information. On this screen the actualtemperature in degrees Fahrenheit is displayed so as the alarm set point for theheater outlet over-temperature and heating failure alarm. The set point can not bechanged from the interface.


HEATER OUTLET XXXX FHEAT CONTROL YYYY F

• Displays the heater outlet temperature (XXXX)and the regulation temperature setting (YYYY)of the heater. Both temperatures are in Fahrenheit

HEATER OUTLET XXXX FHEAT FAIL AT ZZZZ F

• Displays the actual heater outlet temperature(XXXX) and the heating failure alarmtemperature setting (ZZZZ).Both temperatures are in Fahrenheit.

HEATER OUTLET XXXX FHEAT OVERTEMP VVVV F

• Displays the actual heater outlet temperature(XXXX) and the high outlet temperature alarmsetting (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 theactual temperature in degrees Fahrenheit is displayed so as the control set pointsfor end of heating and end of cooling. The set points can not be changed from theinterface.


REGEN OUTLET XXXX FHEAT SETPOINT YYYY F

• Displays the actual regeneration outlettemperature (XXXX) and the end of heatingmode temperature setting (YYYY). Both temperatures are in Fahrenheit.

REGEN OUTLET XXXX FCOOL SETPOINT ZZZZ F

• Displays the actual regeneration outlettemperature (XXXX) and the end of coolingmode temperature setting (YYYY). Both temperatures are in Fahrenheit.


REV 2 – April 25,.2001

SECTION 3

3.3 PROGRAM STEPS

S T E P 2 C L O S EIN LE T

E V-1L & EV -1R(V ALV E T O M O V E)1 0 SE C O N D S T IM ER F O R V AL VE T O O P EN

S T E P 3 E V-2RE V-3R (IF R /C <= 10 P S IG )E N ER G IZ E EV -1L A N D E V -11R

S T E P 4

S T E P 5

S T E P 7 R IG H TS T A N D B

1 20 S EC O N D S H AV E P A S S ED A N D B O T H C H AM B ERA R E AB O VE 60 PS IG

S T E P 6

R IG H TC O O L IN G

EN ER G IZ E E V-1L A N D E V-11 R

IF C O O LIN G T IM E R D O N E (10 0 M IN U T E S) O RPU R G E O U T LET T E M PE R A T U R E BE LO W 12 0ºF A N D 60M IN U T E S H AV E P A S S E D .

S T E P 1 O P E N LE F TC H A M B E R

V A LV E

H E AT IN G T IM ER D O N E O RPU R G E O U T LET T E M PE R A T U R E AB O VE 200 ºF

D E P R E S SC H A M B E R

R IG H TH E A T IN G

ST AR T R IG H T C H A M BE R H EA T IN G M O D EF O R 14 0 M IN U T E S M AX IM U MEN ER G IZ E E V-1L A N D E V-11 R

R E P R E S SR IG H T

E N ER G IZ E EV -1L A N D E V -11R

D R Y ER H A LF C YC LE IS C O M P LET E (24 0 M IN U T E S) O RBA D D EW PO IN T O R D D S O F F AN DBO T H C H A M BE R A R E AB O V E 6 0 PS IG

1 0 SE C O N D S H A V E PA S S E D A N D LE F T C H AM B ERA B O V E 60 P S IG

5 S EC O N D S H A VE P A SS ED

E V-1L & EV -11RW A IT 5 SE C O N D S F O R VA LV E T O C L O SE

1 0 SE C O N D S H A V E PA S S E D A F T ER R IG H T C H AM B ERB E LO W 30 PS IG

S T A R T R IG H T C H A M BE R C O O L IN G M O D EF O R 10 0 M IN U T ES M AX IM U M AN D 6 0M IN U T ES M IN IM U M .E N ER G IZ E EV -1L A N D E V -11R

R ET EN T IV ES EQ U EN C E


REV 2 – April 25,.2001

SECTION 3

3.3 PROGRAM STEPS (Continued)

STEP 9 CLOSE LEFT CHAMBER INLET

VALVE

EV-1L & EV-1R(VALVE TO MOVE)10 SECONDS TIMER FOR VALVE TO OPEN

STEP 10 EV-2LEV-3L (IF L/C <=10 PSIG)ENERGIZE EV-1R AND EV-11L

STEP 11

STEP 12

STEP 14 LEFT CHAMBER STANDBY

120 SECONDS HAVE PASSED AND BOTH CHAMBER ARE ABOVE 60 PSIG

STEP 13

LEFT CHAMBERCOOLING PERIOD

ENERGIZE EV-1R AND EV-11L

IF COOLING TIMER DONE (100 MINUTES) ORPURGE OUTLET TEMPERATURE BELOW 120ºF AND 60 MINUTES HAVE PASSED.

STEP 8 OPEN RIGHT CHAMBER INLET

VALVE

HEATING TIMER DONE ORPURGE OUTLET TEMPERATURE ABOVE 200ºF

LEFT CHAMBER DEPRESS

LEFT CHAMBERHEATING PERIOD

START LEFT CHAMBER HEATING MODE FOR 140 MINUTES MAXIMUMENERGIZE EV-1R AND EV-11L

LEFT CHAMBER REPRESS.

ENERGIZE EV-1R AND EV-11L

DRYER HALF CYCLE IS COMPLETE (240 MINUTES) OF BAD DEWPOINT OR DDS OFF ANDBOTH CHAMBER ARE ABOVE 60 PSIG)

10 SECONDS HAVE PASSED AND RIGHT CHAMBER ABOVE 60 PSIG

5 SECONDS HAVES PASSED

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

10 SECONDS HAVE PASSED AFTER LEFT CHAMBER BELOW 30 PSIG

START LEFT CHAMBER COOLING MODEFOR 100 MINUTES MAXIMUM AND 60 MINUTES MINIMUM.ENERGIZE EV-1R AND EV-11L


REV 2 – April 25,.2001

SECTION 4 MAINTENANCE

☛ Advice In order to ensure continuous and trouble-free operation, amaintenance contract with IInnggeerrssoollll--RRaanndd is recommended.

4.1 SUGGESTED PREVENTIVE MAINTENANCE SCHEDULE

Daily

• Check prefilter automatic drain valve to ensure drain is working properly. Blowdown daily to remove accumulated fluids.

• Check filter differential pressures. A filter differential pressure of 5-8 PSIDindicates a dirty filter element and should be replaced. Filter elements shouldlast 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 425°F.• 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 anddepress. Replace all worn or damaged parts.

• Disassemble, clean and inspect the outlet and purge check valves. Replaceall worn or damage parts.

• Inspect the desiccant through the chamber fill port. Replace desiccant ifbroken or coated with oil.

• Replace prefilter, afterfilter and pilot air filter elements at least once a year.


REV 2 – April 25,.2001

SECTION 4

4.2 REPLACEMENT / DISPOSAL OF THE DESICCANT

In order to ensure trouble-free operation, we recommend replacing the desiccantevery 8000 Hours, or every 2 years on latest.

NOTE : Refer to the desiccant MSDS document in the annex of thismanual for instructions and precautions on handling anddisposing of desiccant.

The dryer is filled from the top and emptied from the bottom. Refer to the GeneralArrangement drawing for location of fill and drain ports.

• To drain the desiccant, remove the drain plug/cover and catch the olddesiccant in a suitable container. Replace the desiccant drain plug/cover.

• Remove the fill cap and refill the chamber with the specified desiccant. Referto 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 toservice.

NOTE: Desiccant chambers should never be completely filled. Fill to alevel approximately 3” below the upper circumference weld onthe desiccant vessel.

4.3 HYGROMETER MAINTENANCE (EMS Option only)

NOTE: Refer to the separate document on hygrometer maintenance andoperation 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 ofcompressed air and other neutral, compressed gases. This new filtration conceptis characterized by high flows at low differential pressure.


REV 2 – April 25,.2001

SECTION 4

4.4 FILTERS (Continued)

4.4.2 Function

The soiled medium flows through the filter element "Series HE" from the inside tothe outside. Solids are filtered out by impact or by the effect of inertia, whereas oilparticles and drops of humidity are filtered out by the effect of coalescence. By theforce of gravity, the filtered-out droplets collect in the lower filter vessel and aredrained automatically or manually.

4.4.3 Assembly and installation

☛ Advices

− Within the piping system, the filters should always be used where the air or gastemperature 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 bymanual operation.

− Should there be no condensate drain, then, depending on the amount, thecondensate on the pre-filter is to be removed several times a day by openingthe hand drain.


REV 2 – April 25,.2001

SECTION 4

4.4 FILTERS (Continued)

4.4.5 Changing of filter elements

Danger! The soiled filter elements are changed only when thehousings 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.


REV 2 – April 25,.2001

SECTION 5 CALIBRATION

5.1 PURGE ADJUSTMENT

The dryers purge system includes an adjustment valve, purge orifice and a pressureindicating gauge (Panel mounted). This system has been factory set to the correctpressure 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 thedryer 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.


REV 2 – April 25,.2001

SECTION 5

5.2 PRESSURE SWITCH ADJUSTMENT

Pressure switch adjustment for externally heated dryers

On a TZE dryer there are five (5) pressure switches (PSH-1, PSL-1, PSH-2, PSL-2and PS-3).

The PSH pressure switches are set at 30 PSIG below the operating pressure of thedryer, while the PS-3 (purge pressure) is set at 10 PSIG below the purge adjustmentsetting and all use the normally open contact. When the adjustment is done, thecontact between "C" and "NO" should close when increasing to the desiredpressure.

The PSL switches are set at 10 PSIG regardless the operating pressure and use thenormally 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.

Adjustmentknob


REV 2 – April 25,.2001

SECTION 6 SPARE PARTS LIST

6.1 RECOMMENDED SPARES FOR TZE400, TZE500 & TZE650

ITEM DESCRIPTION TZE400 TZE500 TZE650 QUANTITYInlet valve c/w actuator 38006987 38006987 38006987 2Inlet valve kit 38015566 38015566 38015566 2Inlet valve Actuator kit Included w/inlet

valve kitIncluded w/inlet

valve kitIncluded w/inlet

valve kit2

Exhaust valve c/w actuator 38007001 38007001 38007001 2Exhaust valve kit 38015582 38015582 38015582 2Exhaust valve Actuator kit Included w/

exhaust valvekit

Included w/exhaust valve

kit

Included w/exhaust valve

kit

2

Outlet check valve 38015855 38015855 38015855 2Outlet check valve kit 38007050 38007050 38007050 2Purge check valve 38007076 38007076 38007076 2Depress valve N/A N/A N/A 0Depress valve kit N/A N/A N/A 0Chamber relief valve 38007084 38007084 38007084 2Pressure gauge 38006714 38006714 38006714 3Temperature indicator 38006698 38006698 38006698 2Pressure switch 38006565 38006565 38006565 5Pressure regulator 38015145 38015145 38015145 1Solenoid block 38015863 38015863 38015863 1Light bulb 38006789 38006789 38006789 2Transformer primary fuse 38015244 38015244 38015244 2Transformer second. fuse 38006870 38006870 38006870 1Heater fuses 38006896 38006896 38006896 3Control fuse 38006797 38006797 38006797 1Alarm relay 38006888 38006888 38006888 1Heater contactor 38006722 38006722 38006722 1Heater element 38006953 38006920 38006953 1Pilot air filter element 38006573 38006573 38006573 1Prefilter element C/F C/F C/F 1Afterfilter element C/F C/F C/F 1Exhaust muffler 38328167 38328167 38328167 1Depress muffler N/A N/A N/A 0Desiccant (Lbs.) 38004834

(550 Lbs.)38004834(700 Lbs.)

38004834(900 Lbs.)


REV 2 – April 25,.2001

SECTION 6

6.2 RECOMMENDED SPARES FOR TZE820, TZE1000, TZE1225 & TZE1500

ITEM DESCRIPTION TZE820Part no.

TZE1000Part no.

TZE1225Part no.

TZE1500Part no.

Quantity

Inlet valve c/w actuator 38015913 38015913 38015913 38015913 2Inlet valve kit 38016672 38006672 38006672 38006672 2Inlet valve actuator kit 38015038 38015038 38015038 38015038 2Exhaust valve c/w actuator 38015574 38015574 38015574 38015574 2Exhaust valve kit 38006995 38006995 38006995 38006995 2Exhaust valve actuator kit Included

w/Exhaust valvekit

Includedw/Exhaust valve

kit


kit


kit

2

Outlet check valve 38015715 38015715 38015715 38015715 2Outlet check valve kit 38007027 38007027 38007027 38007027 2Purge check valve 38007068 38007068 38007068 38007019 2Depress valve 38015541 38015541 38015541 38015541 2Depress valve kit 38006961 38006961 38006961 38006961 2Chamber relief valve 38006532 38006532 38006532 38006532 2Temperature indicator 38006706 38006706 38006706 38006706 2Pressure switch 38006565 38006565 38006565 38006565 5Pressure regulator 38015145 38015145 38015145 38015145 1Solenoid block 38015889 38015889 38015889 38015871 1Light bulb 38006789 38006789 38006789 38006789 2Transformer primary fuse 38015244 38015244 38015244 38015244 2Transformer secondary fuse 38006870 38006870 38006870 38006870 1Heater fuses 38006821 38015293 38015335 38015285 3Control fuse 38006797 38006797 38006797 38006797 1Alarm relay 38006888 38006888 38006888 38006888 1Heater contactor 38006722 38006730 38006730 38006748 1Heater element 38006953 38006938 38015475 38006912 1Pilot air filter element 38006680 38006680 38006680 38006680 1Prefilter element C/F C/F C/F C/F 1Afterfilter element C/F C/F C/F C/F 1Exhaust muffler N/A N/A N/A N/A 0Depress muffler 38328175 38328175 38328175 38328175 2Desiccant (Lbs.) 38004834

(1120 Lbs.)38004834

(1600 Lbs.)38004834

(1912 Lbs.)38004834

(2100 Lbs.)


REV 2 – April 25,.2001

SECTION 6

6.3 RECOMMENDED SPARES FOR TZE1800, TZE2100, TZE2500 & TZE3500

ITEM DESCRIPTION TZE1800Part no.

TZE2100Part no.

TZE2500Part no.

TZE3500Part no.

Quantity

Inlet valve c/w actuator 38015921 38015921 38015921 38015921 2Inlet valve kit 38006664 38006664 38006664 38006664 2Inlet valve actuator kit 38016093 38016093 38016093 38016093 2Exhaust valve c/w actuator 38015913 38015913 38015913 38015913 2Exhaust valve kit 38006672 38006672 38006672 38006672 2Exhaust valve actuator kit 38015038 38015038 38015038 38015038 2Outlet check valve 38015764 38015764 38015764 38015822 2Outlet check valve kit 38007043 38007043 38007043 38015830 2Purge check valve 38007019 38007019 38007019 38007035 2Depress valve 38015558 38015558 38015558 38015558 2Depress valve kit 38006979 38006979 38006979 38006979 2Chamber relief valve 38006532 38006532 38006532 38006532 2Pressure gauge 38006714 38006714 38006714 38006714 3Temperature indicator 38006706 38006706 38006706 38006706 2Pressure switch 38006565 38006565 38006565 38006565 5Pressure regulator 38015145 38015145 38015145 38015145 1Solenoid block 38015871 38015871 38015871 C/F 1Light bulb 38006789 38006789 38006789 38006789 2Transformer primary fuse 38015244 38015244 38015244 38015244 2Transformer second. Fuse 38006870 38006870 38006870 38006870 1Heater fuses 38006854 38006839 38006862 38006847 3Control fuse 38006797 38006797 38006797 38006797 1Alarm relay 38006888 38006888 38006888 38006888 1Heater contactor 38006771 38006771 38006755 38006763 1Heater element 38006912 C/F 38015467 C/F 1Pilot air filter element 38006680 38006680 38006680 38006680 1Prefilter element C/F C/F C/F C/F 1Afterfilter element C/F C/F C/F C/F 1Exhaust muffler N/A N/A N/A N/A 0Depress muffler 38328175 38328175 38328175 38328175 2Desiccant (Lbs.) 38004834

(2650 Lbs.)38004834

(3020 Lbs.)38004834

(3750 Lbs.)38004834 (5400

Lbs.)


REV 2 – April 25,.2001

SECTION 7 TROUBLE SHOOTING & FAULTS

7.1 THE DEWPOINT HAS DETERIORATED

Possible cause RemedyIncoming air temperature above designcondition

� Check compressor after cooler andcooling system.� Adjust as necessary to reduce the inlettemperature to dryer specification.

Incoming air flow too high � Problem external to dryer. Verify inletflow rate and reduce as necessary to dryerspecification.

Inlet pressure below design pressure � Check compressed air system. Correct ifnecessary.

Liquid water entering dryer � Check prefilter elements and seals fordamage. Replace if necessary.� Check operation of drain trap. Ensureproper drainage. Repair or replace drain ifnecessary.

Desiccant broken up or coated with oil � Replace desiccant. Inspect prefilter ifdesiccant is coated with oil.

Insufficient regeneration:1. Heater failure2. Heater contactor failure3. Incorrect purge flow4. Temperature setting to incorrect

1. Replace heater2. Replace heater contactor3. Check purge pressure setting4. Check set-points of heater and purge

exhaust.

Leaks at piping/tubing connectionsdownstream of the dryer

� Soap test dryer and repair all leaks.


REV 2 – April 25,.2001

SECTION 7

7.2 HIGH HUMIDITY ALARM OR SENSOR FAILURE

Possible cause RemedyHygrometer probe out of calibration � Refer to hygrometer manual in Annex,

section for instruction on field calibration.� Return probe to factory for certifiedrecalibration.

Open circuit on probe electricalconnection

� Inspect and repair.

Incorrect flow across sensor � Refer to EMS startup section in thismanual

Excessive moisture on sensor � Check sensor tubing and probe filter forbuildup of moisture. Allow tubing to dry andreplace filter element.

7.3 SWITCHING FAILURE ALARM

Possible cause Remedy

Pilot air insufficient� Close pilot air isolation valve,depressurize pilot air filter and inspectelement. If clogged or dirty, replace.� Check that pilot air isolation valve is fullyopen.� Check that pilot air regulator is set at 100PSIG.� Inspect pilot air tubing for kinks orbreaks. Repair if necessary.

Inlet air pressure below setpoint ofpressure switches

� Correct the low pressure problem to thedryer.

Solenoid valve not energizing� Check operation of solenoid. Replace ifnot functioning.� Check wiring from panel to the solenoidfor an open or short circuit. Repair ifnecessary.


REV 2 – April 25,.2001

SECTION 7

7.3 SWITCHING FAILURE ALARM (Continued)

Possible cause RemedyInlet or purge exhaust valvesleaking

� Shutdown and depressurize dryer. Inspectvalve seats and seals for damage or wear.Repair or replace if necessary.

� While valve is disassembled, check theactuator stops to ensure that valve is fullyclosing (butterfly valves only).

Check valve internals are worn ordamaged

� Shutdown and depressurize dryer. Repairor replace valves.

Switching failure ondepressurization

� Inspect purge and depress mufflers andreplace if necessary.

� Off line desiccant chamber inlet valve oroutlet check valve leaking. Inspect asdescribed above.

� Regenerating chamber depress/exhaustvalve failed to open. Check associatedsolenoid valve operation as describedabove.

� Excessive purge flow. Check the purgepressure setting.

� Online chamber outlet check valve leaking.Inspect and repair as described above.

Switching failure onrepressurization

� Exhaust or depress valves not closing orleaking. Check solenoid operation as listedabove. Check valve failure as listed above.

� Insufficient purge flow. Check purgepressure settings. Check automatic purgeshut off valve for correct operation.

Pressure switch malfunctionvalves leaking

� Check the setpoint of the pressureswitches. Readjust if necessary.

� Check the operation of the pressureswitches. Replace if needed.


REV 2 – April 25,.2001

SECTION 7

7.4 PRESSURE DROP TOO HIGH

Possible cause SolutionBroken or fouled desiccant � Inspect desiccant and replace if required

Inlet flow exceeding design flow rate � Reduce inlet flow as necessary

Pre or after filter element dirty orclogged

� Depressurize filters and inspectelements. Replace if clogged.

7.5 SHORT-TERM SHUT-DOWN

☛ Advices

The following sequence is to be heeded when switching off theadsorption 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.


REV 2 – April 25,.2001

SECTION 7

7.6 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE

Danger! Before any kind of maintenance or repair work isdone, the adsorption dryer must be depressurizedand disconnected from the power source. Apply the general safety regulations!

☛ Advices

The following sequence is to be heeded when switching off the adsorptiondryer:

• First switch off the dryer. Make certain dryer is not in heating or coolingmode.

• Then close all the shut off valves up- and downstream of the adsorptiondryer.

• For TZE400, TZE500 and TZE650 depressurize the dryer by using thehand valve mounted at the bottom of the after-filter.

• For TZE820 and larger depressurize the dryer by using the hand valvemounted 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 bottomof each desiccant chamber.

• Slowly open the inlet isolation valve and pressurize the adsorption dryer up to theregular operating pressure by keeping the shut off valve mounted behind theafter-filter closed.

• Switch on the unit once again.• If the adsorption dryer is re-started after a long standstill, proceed as in 3.1.

ACTIVATED ALUMINA (GRADES A, D & P)Material Safety Data Sheet Date Prepared: Oct/22/97 Supersedes Date: Feb/06/95

Annex A1

SECTION 8 ANNEX

1. CHEMICAL PRODUCT AND COMPANY DESCRIPTION

Ingersoll-Rand Inc800- A Beaty Street, Davidson, North Carolina, 28036 - USA

Emergency Phone numbers:FOR EMERGENCIES INVOLVING A SPILL, LEAK, FIRE, EXPOSURE OR ACCIDENTCONTACT: (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. COMPOSITION / INFORMATION ON INGREDIENTS

Component CAS Reg. Number WHMIS Hazard PercentageALUMINA 1344-28-1 Y > 93WATER 7732-18-5 N Balance

3. HAZARDS IDENTIFICATIONA. EMERGENCY OVERVIEW:Physical Appearance and Odour:White powder solid, odourless

Warning Statements:DUSTS IN HIGH CONCENTRATIONS MAY CAUSE SKIN, EYE AND RESPIRATORYTRACT IRRITATION.

B. POTENTIAL HEALTH EFFECTS:

Acute Eye:Causes foreign body irritation only.


Annex A2

3. HAZARDS IDENTIFICATION (Continued)

B. 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 asprobable 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. Seekmedical 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 developsor persists.

Inhalation:If respiratory irritation or distress occurs remove victim to fresh air. Seek medical attention ifrespiratory irritation or distress continues.

Ingestion:No harmful affects expected. If appreciable quantities are swallowed, call a physician or poisoncontrol 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 ofdistress in the patient. Consideration should be given to the possibility that overexposure tomaterials other than this product may have occurred.Treat symptomatically. No specific antidote available.


Annex A3

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 fullprotective 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, mixingor sliding. Provide adequate precautions, such as electrical grounding, or inert atmospheres whenmaterial 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 A4

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

Introductory Remarks:These recommendations provide general guidance for handling this product. Because specific workenvironments and material handling practices vary, safety procedures should be developed for eachintended application. While developing safe handling procedures, do not overlook the need to cleanequipment and piping systems for maintenance and repairs. Waste resulting from these proceduresshould be handled in accordance with Section 13: Disposal Considerations.Assistance with selection, use and maintenance of worker protection equipment is generally availablefrom equipment manufacturers.

Exposure Guidelines:Exposure limits represent regulated or recommended worker breathing zone concentrations measuredby validated sampling and analytical methods, meeting the regulatory requirements. The followinglimits apply to this material, where, if indicated, S= skin and C= ceiling limit:

ALUMINANotes TWA STEL

ACGIH 10 mg/cu. m

Engineering Controls:Where engineering controls are indicated by use conditions or a potential for excessive exposureexists, the following traditional exposure control techniques may be used to effectively minimizeemployee exposures: general area dilution/exhaust ventilation, local exhaust ventilation at the pointof generation.

Respiratory Protection:When respirators are required, select NIOSH/MSHA approved equipment based on actual orpotential airborne concentrations and in accordance with the appropriate regulatory standards and/orindustrial recommendations.

Under normal conditions, in the absence of other airborne contaminants, the following devicesshould 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/canisterapproved for use against dusts, mists and fumes.

Eye/Face ProtectionEye and face protection requirements will vary dependent upon work environment conditions andmaterial handling practices. Appropriate ANSI Z87 approved equipment should be selected for theparticular use intended for this material.

It is generally regarded as good practice to wear a minimum of safety glasses with side shields whenworking in industrial environments.


Annex A5

8. EXPOSURE CONTROLS / PERSONAL PROTECTION (Continued)

Skin ProtectionSkin 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 generalmeasures 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 thebusiness 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 25°C (77°F).

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: 101.96


Annex A6

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 basesStrong 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 ACGIHto 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 A7

13. DISPOSAL CONSIDERATIONS

Waste Disposal Method:

Waste Management options should first consider possible re-use or recycling opportunities. Someprovinces have active "Waste Exchange" networks for re-use and recycling of wastes. Contact yourlocal waste management companies to explore available options. All waste management activitiesmust obey local, provincial and federal regulations. Possible disposal methods include thefollowing:

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 inpackage 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

Inventory StatusInventory StatusCANADA (DSL) Y

WHMIS Classification: NOT CONTROLLED

This product has been classified in accordance with the hazard criteria of the CPR (ControlledProducts Regulations) and the MSDS contains all the information required by the CPR.


Annex A8

16. OTHER INFORMATION

National Fire Protection Association Hazard Ratings - NFPA (R):0 Health Hazard Rating -- Minimal0 Flammability Rating -- Minimal0 Reactivity Rating -- Minimal

National Paint & Coating Hazardous Materials Identification System - HMIS (R):0 Health Hazard Rating -- Minimal0 Flammability Rating -- Minimal0 Reactivity Rating – Minimal

Key Legend Information:ACGIH - American Conference of Governmental Industrial HygienistsOSHA - Occupational Safety and Health AdministrationTLV - Threshold Limit ValuePEL - Permissible Exposure LimitTWA - Time Weighted AverageSTEL - Short Term Exposure LimitNTP - National Toxicology ProgramIARC - 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 8End of MSDS Document

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