ICP IDRY Guida utente

Instructions for installation and operation english

This manual contains important information and should be made available to all personnel who operate and/or maintain this product.

Carefully read this manual before attempting to operate or perform maintenance on this equipment

www.icompressorpartners.com

iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 1

Contents

1. SAFETY AND SYSTEM PRECAUTIONS ...................................................................................................................................................3

1.1 Definition of the Safety Symbols.............................................................................................................................................3

1.2 Operational Warnings ...........................................................................................................................................................3

2. INSPECTION AND INSTALLATION .........................................................................................................................................................4

2.1 Incoming Inspection and Transportation ..............................................................................................................................4

2.2 Design and Use of the Dryer .................................................................................................................................................4

2.3 Location and Installation .......................................................................................................................................................4

2.4Filters Mounted with Bypass .................................................................................................................................................6

3. TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION ......................................................................................................................7

3.1 Technical Data by Model Size ................................................................................................................................................7

3.2 Correction Factors .................................................................................................................................................................8

3.3 General Function ...................................................................................................................................................................8

3.4 Flow Diagram ........................................................................................................................................................................9

3.5 Cycle Operation ...................................................................................................................................................................10

4. PURGE VALVE ADJUSTMENT ..............................................................................................................................................................11

5. START-UP ............................................................................................................................................................................................12

5.1 Verification Prior to Start-up ...............................................................................................................................................12

5.2 Start-up Procedures ............................................................................................................................................................13

5.3 General Operation ..............................................................................................................................................................14

6. ISOLATION AND SHUT DOWN PROCEDURES .....................................................................................................................................14

7. CONTROLLER INFORMATION AND OPERATION ................................................................................................................................15

7.1 Display Overview .................................................................................................................................................................15

7.2 Startup ................................................................................................................................................................................15

7.3 Controller Inputs .................................................................................................................................................................15

7.4 Contoller Outputs ................................................................................................................................................................16

7.5 Controller Settings ..............................................................................................................................................................16

7.6 Service Rest Button .............................................................................................................................................................18

7.8 Power Requirements ...........................................................................................................................................................18

8. MAINTENANCE AND SERVICE .............................................................................................................................................................19

8.1 Routine Maintenance ...................................................................................................................................................................19

iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 2

8.2 Maintenance and Service Intervals ..............................................................................................................................................20

8.3 Fuses .............................................................................................................................................................................................20

8.4 Desiccant Replacement ................................................................................................................................................................21

8.5 Inlet and Exhaust Valve Repair .....................................................................................................................................................21

9. TROUBLESHOOTING GUIDE ................................................................................................................................................................22

10. MAINTENANCE AND SPARE PARTS ..................................................................................................................................................25

10.1 Required Maintenance Parts ......................................................................................................................................................25

10.2 Spare Parts .................................................................................................................................................................................27

11. DISMANTLING OF THE DRYER ..........................................................................................................................................................28

12. ELECTRICAL WIRING DIAGRAM ........................................................................................................................................................29

13. GENERAL DESCRIPTION OF PARTS ...................................................................................................................................................29

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iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 3

1. SAFETY AND SYSTEM PRECAUTIONS

1.1 Definition of the Safety Symbols

Before attempting any

service, please read

the manual

General Warning:

Risk of damage or injury

Electrical Hazard:

Possibility of

electrocution

Warning:

Under pressure

Warning:

High temperature

Warning:

Non-breathable air

Warning:

Water cannot be used

to extinguish fire

Warning:

Do not operate if parts

are missing or have been

tampered with

Warning:

Machine level noise

may exceed 85 dBA

Warning:

Personal

protection

required

Warning:

All work to be

performed by qualified

personnel only

Operations that can be

performed by qualified

operators1

Compressed air inlet connection

Compressed air outlet connection

Connection point for condensate drain

1Only experienced and trained personnel familiar with all of the relevant laws, rules and regulations, capable to perform the needed activities and to

identify and avoid possible dangerous situations while handling, installing, using and servicing the machine.

1.2 Operational Warnings

WARNING: VESSELS UNDER PRESSURE

In most countries, states, cities and/or local municipalities the installation, operation and maintenance of

devices where pressure vessels are in use are subject to local boiler and pressure vessel regulations.

The end user is responsible for following all of the relevant laws, rules and regulations and ensuring that only

experienced and trained personnel install and/or operate the dryer.

In most countries, states, cities and/or local municipalities the installation may only be carried out by a

licensed installation company. Inspections must be carried out by a qualified and licensed third-party firm in

accordance with all applicable laws, rules and regulations for the region where the dryer is installed.

The pressure vessels used in this device are built according to the American Society of Mechanical Engineers

(ASME) standard Section 8, Division 1.

Compressed Air Warning:

Compressed air is a highly dangerous energy source.

Never work on the dryer while components are under pressure.

Never point the compressed air stream or the condensate drain outlet towards anybody.

The end user is responsible for the installation of the dryer as laid out in this manual. If proper commissioning steps are

not followed, the warranty will be void and dangerous situations involving injury or death and/or damages to the

machine could occur.

Only qualified personnel can use and service electrically powered devices. Before attempting any maintenance:

Ensure that no part of the machine is powered and is locked out of the electrical mains by following proper

“Lock-out, Tag-out” procedures and requirements.

Ensure that no part of the dryer is under pressure by isolating the dryer from the compressed air system.

Any change to the machine or to the standard operating parameters (see page 5), if not previously verified and

authorized by the manufacturer, in addition to creating a potentially dangerous situation, will void the warranty.

Don’t use water to extinguish fire on the dryer or in the surrounding area.

ARIA

AIR

LUFT

AIR

iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 4

2. INSPECTION AND INSTALLATION

2.1 Incoming Inspection and Transportation

All dryers are tested and inspected at the factory prior to shipping. Thoroughly inspect and verify the integrity of the

packaging upon receipt and note any damage on the freight bill. Place the unit as close as possible to the installation

point before unpacking the contents and inspect for concealed damage. Freight claims are to be filed with the carrier

immediately and the manufacturer’s technical service department notified thereafter.

To move the packaged unit, we suggest the use of a suitable crane or forklift. We do not recommend moving the

unit by any hand operated or manual mechanism.

Handle with care. Heavy blows could cause irreparable damage.

Even when packaged, keep the machine protected from severe weather.

The packaging materials are recyclable. Each material must be properly disposed in a manner complying

with the rules and regulations of the local municipality government.

2.2 Design and Use of the Dryer

This dryer has been designed, manufactured and tested to be used only to separate the humidity normally contained in

compressed air, any other use is considered to be improper. The manufacturer is not responsible for any problems

arising from the improper use of this machine.

The end user, in any and all cases, is responsible for any resulting damages.

Moreover, the correct use of this machine requires the verification of certain installation conditions, in particular:

Voltage and frequency of the electrical power supplied

Pressure, temperature, flow rate and chemical composition of the incoming compressed air

Ambient temperatures

The dryer is supplied as tested and fully assembled. The only operation left for the end user is the connection to the plant

and adjustment of the purge rate in compliance with the instructions given in this manual. Factory settings are at

nominal conditions at 100 psig and the stated model flow rate (see page 5).

The purpose of the machine is the separation of water vapor that is present in compressed air. It is not

intended to separate oil or other contaminants that are present in compressed air.

The dried compressed air output from this dryer cannot be used for respiration purposes of any kind.

2.3 Location and Installation

Serious consideration should be given when selecting the installation site for the dryer, as an improper

location could directly affect the proper operation of the dryer.

This unit is not suitable to be used in explosive atmospheres, where risk of fire could exist, in the presence

of gaseous or solid pollutants or in outdoor applications or areas exposed to the elements.

Do not use water to extinguish fire on the dryer or in the surrounding area.

Machine level noise could be higher than 85 dBA. Install the unit in a dedicated area where people are not

normally present. The installer and/or end user is responsible for the correct installation of the dryer in

order to prevent excessive noise exposure in the work environment. The installer and/or end user is

responsible to install proper safety signs at the installation site.

iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 5

Technicians that service the machine must wear hearing and eye protection while servicing the dryer. Each

employee must select a proper personal protection device (PPD) hearing protector such as earmuffs, ear

canal caps or earplugs in order to prevent permanent hearing damage or loss.

Minimum Installation Requirements:

Select a clean, dry room that is free of dust and protected from atmospheric disturbances.

The location must be smooth, horizontally level, able to bear the weight of the dryer and vibration free

Minimum ambient temperature of +40 °F

Maximum ambient temperature of +120 °F

Allow a clearance of at least 3’ on all sides of the dryer in order easily facilitate all maintenance needs

The dryer is not required to be anchored to the supporting surface

Coalescing pre-filter with drain must be installed

The location of an air receiver tank will vary depending on compressor type and application conditions

Incorrect installation may void warranty.

NOTE: All piping and electrical connections should be inspected prior to installation to ensure they have maintained

their integrity during shipping and locating the dryer.

First, make the initial connections as follows:

1. Inlet piping including an isolation valve

2. Outlet piping including an isolation valve

3. Coalescing pre-filter and particulate post-filter

We recommend the dryer be installed with a 0.01 micron iPUR coalescing pre-filter at the inlet and a 1.0 micron

iPUR particulate post-filter at the outlet. It is recommended to install both 5.0 micron and

1.0 micron filters upstream of the dryer in order to maintain the operational lifespan of the inlet filter to the

dryer. In addition, we recommend the use of a iMAT zero air loss drain on the pre-filter and at all other

condensate collection points, especially those upstream of the dryer.

Locate the coalescing pre-filter as close to the dryer as possible while still maintaining sufficient space for routine

maintenance and service. Inlet air entering the dryer must pass through a coalescing pre-filter in order remove entrained

condensate and oil to prevent fouling of the desiccant and maintain standard operation. Any liquid condensate entering

the desiccant bed will lead to overloading of the dryer, poor dew point performance and rapid deterioration of the

desiccant material. Any oil entering the desiccant bed may permanently reduce the capacity of the desiccant material.

Desiccant dust traveling downstream of the dryer may cause contamination and/or accelerated wear to other

components and equipment. Therefore, a particulate post-filter should be provided to prevent desiccant dust from

traveling downstream. Activated alumina is considered a nuisance dust and proper precautions should be taken when

handling desiccant (refer to applicable MSDS sheet).

4. IMPORTANT! Bypass piping is necessary. Only bubble tight valves should be used.

5. Make the required electrical connections; please refer the type plate of your dryer. The end user is

responsible for providing short circuit protection for the dryer.

6. Points of access should be provided upstream and downstream of the dryer for periodic monitoring of

dew point, pressure and temperature prior to finalizing the installation. Taking periodic dew point

measurements just downstream of the dryer gives the best indication of whether the dryer is

performing optimally. We recommend using METPOINT® instrumentation to ensure accurate

measurements.

7. All piping must be adequately supported and at least of equal size to the dryer connections.

iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 6

Before any attempt is made to operate the dryer, the operator must thoroughly read and understand this

installation and operation manual.

Optimal Installation Diagram

Air Compressor

After Cooler

iPUR Inline Water Separator

iPUR 5.0 Micron (Grade G) Filtration

Receiver Tank

iPUR 1.0 Micron (Grade F) Filtration

iDRY iDHLBe Desiccant Dryer with iPUR Pre and Post-filtration

Dry Air Outlet

Condensate Drainage Points for iMAT

Optimal installation is with moderately sized receivers at the inlet and outlet side of the dryer. This allows for the

additional free cooling and moisture collection and more consistent dryer inlet flow provided by an upstream receiver,

while providing the most reliable shop air supply due to the downstream receiver.

Under no circumstances should the peak demand air flow exceed the maximum rated air flow of the dryer.

We recommend the dryer be installed with a 0.01 micron iPUR coalescing pre-filter at the inlet and a 1

micron iPUR particulate post-filter at the outlet. It is recommended to install both 5 micron and 1 micron

filters upstream of the dryer in order to maintain the operational lifespan of the inlet filter.

2.4 Mounted Filters with Bypass

Mounted Filters with Bypass is an optional setup for the heatless regenerative

dryer. The three valve system bypass allows for the flow of air to be uniterupted

while servicing or completing preventative maintinance such as:

Exchange pre- and post- filters

Services exhaust sIlencers

Change desiccant

iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 7

3. TECHNICAL SPECIFICATIONS AND GENERAL FUNCTION

3.1 Technical Data by Model Size

iDRY iDHLBe

Model Size

080

100

120

160

200

250

300

400

500

650

800

Flow Rate

scfm

100

120

160

200

250

300

400

500

650

800

Inlet / Outlet Connection

in. (NPT-F)

1 ¼

1 ½

2 ½

Height (A)

in.

Width (B)

in.

Depth (C)

in.

Adsorbent Material

Activated Alumina

⅛”

Total per Dryer

Lbs.

150

230

340

480

625

795

940

Outlet Pressure Dew Point

°F

-40

Minimum Ambient Temperature

°F

Maximum Ambient Temperature

°F

120

Standard Inlet Air Temperature

°F

100

Maximum Inlet Air Temperature

°F

120

Minimum Air Pressure

psig

Standard Air Pressure

psig

100

Maximum Air Pressure

psig

150

Dryer ratings adhere to the following inlet conditions per ISO 7183, Table 2, Option A2:

Inlet Compressed Air Temperature 100 °F (38 °C)

Inlet Compressed Air Pressure 100 psig (7 bar)

Maximum Ambient Air Temperature 100 °F (38 °C)

Inlet Compressed Air Relative Humidity 100% (Saturated)

SCFM is defined as the volume of free air in cubic feet per minute measured at 14.7 psia (1.013 bar) at 68 °F (20 °C)

temperature with 0% relative humidity (0 WVP).

iDRY Series Heatless Regenerated Dryers: IOM10003-C (Rev. A) 8

3.2 Correction Factors

Operating Pressure and Inlet Air Temperature

Correction Factors

≤ 90°F

95°F

100°F

105°F

110°F

115°F

120°F

60 PSIG

0.89

0.76

0.65

0.59

0.49

0.44

0.38

70 PSIG

1.00

0.85

0.73

0.66

0.55

0.49

0.42

80 PSIG

1.00

0.96

0.82

0.74

0.62

0.55

0.48

90 PSIG

1.06

1.05

0.90

0.81

0.68

0.60

0.52

100 PSIG

1.10

1.00

0.90

0.76

0.67

0.58

110 PSIG

1.15

1.04

0.87

0.77

0.67

120 PSIG

1.20

1.08

0.91

0.80

0.70

130 PSIG

1.24

1.12

0.94

0.83

0.72

140 PSIG

1.28

1.15

0.97

0.86

0.74

150 PSIG

1.33

1.20

1.01

0.89

0.77

How to size the dryer capacity for actual conditions: How to select the dryer for actual conditions:

ADJUSTED CAPACITY = ADJUSTED CAPACITY =

Standard Flow Rate x Correction Factor System Flow Rate ÷ Correction Factor

Example: Example:

Dryer Model: iDRY iDHLBe 250 System Flow Rate: 300 scfm

Standard Flow Rate: 250 scfm Operating Conditions: 130 psig / 100 °F

Operating Conditions: 110 psig / 110 °F ADJUSTED CAPACITY = 300 scfm ÷ 1.24 = 242 scfm

ADJUSTED CAPACITY = 250 scfm x 0.87 = 218 scfm Select Dryer Model: iDRY iDHLBe 250

3.3 General Function

The iDRY iDHLBe heatless desiccant dyer series are fitted with two pressure vessels, positioned parallel to one another

and filled with adsorption material (⅛” activated alumina as standard). While the compressed air is dried in one tower,

the saturated desiccant is regenerated in the second. A minimal portion of the treated air is used for the regeneration

process and expelled along with the condensate, through the silencers.

The saturated inlet air is cycled through each of the two desiccant beds in an alternating sequence where one bed is on-

line at full line pressure and flow, adsorbing the water vapor. This is the drying bed.

The other bed is then considered to be in an off-line state at atmospheric pressure and is being regenerated by a

depressurized portion of the dried, treated outlet air (purge air). This is the regenerating bed.

The purge air is routed from the dry outlet air through the purge flow control valve, desiccant bed, purge exhaust valve

and finally exhausted to atmosphere through silencers to finish the regeneration process. Purge air consumption is

generally the highest cost involved with operating a heatless adsorption dryer and is non-recoverable. Therefore, the air

system where the dryer is installed must account for this usage (approximately 15% of the inlet air flow).

Just before the freshly regenerated bed is brought to an on-line state to become the drying bed, it is slowly pressurized

from atmospheric pressure up to line pressure. This is the re-pressurization step that prevents desiccant bed fluidization

(bed lifting) and dusting. The desiccant beds will now switch functions where the fresh desiccant bed is now drying and

the saturated bed is now regenerating.

This cycle will continue automatically unless the dryer is shut down.

All desiccant dryers work using the principle of adsorption, which is the process by which water vapor is removed from

the compressed air being dried. All desiccant material types are adversely affected by oil, aerosols, dirt, rust, scale and

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