Manual TZ820-TZ1710 REV 6-MITCHELL - Ingersoll...

TZ820 - TZ1710 EMS OPTION LDP OPTION 3V OPTION

TZ Heatless DesiccantCompressed Air Dryers

More Than Air. Answers.Online answers: http://www.air.irco.coPhone : 1-800-526-3615

Form :APDD 789CCN: 38019691 July 2002

SERIES TZ

INSTALLATION, START-UP & MAINTENANCE MANUALMODEL NO.: TZ820 / TZ1710

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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 .......................................................................... 8Model ....................................................................................................................... 81.4.2 Airtightness test............................................................................................. 81.4.3 Overloading ................................................................................................... 81.4.4 Technical data sheet ..................................................................................... 91.4.5 Transport ..................................................................................................... 101.4.6 Storage........................................................................................................ 101.4.7 Use of a pre and after filter .......................................................................... 10

SECTION 2 INSTALLATION ...................................................................................... 112.1 SET-UP AND INSTALLATION ........................................................................... 11

SECTION 3 START UP AND OPERATION................................................................ 123.1 START UP/ SHUT DOWN.................................................................................. 123.2 DESCRIPTION OF THE OPERATION............................................................... 12

3.2.1 Description of the operation......................................................................... 133.2.2 Dryer operating sequence (No control or alarm option)............................... 143.2.3 Operating sequence (EMS Option) ............................................................. 153.2.4 Alarms ......................................................................................................... 173.2.5 Electrical control .......................................................................................... 18

3.3 SPECIAL EQUIPMENT ...................................................................................... 183.3.1 EMS Controls .............................................................................................. 183.3.2 EMS Controls – Start-up and operation....................................................... 19

SECTION 4 MAINTENANCE ...................................................................................... 214.1 REPLACEMENT OF THE DESICCANT............................................................. 224.2 DISPOSAL OF THE DESICCANT...................................................................... 224.3 CHANGING OF THE REGENERATION ORIFICE ............................................. 224.4 FILTERS............................................................................................................. 23

4.4.1 General comments and use ........................................................................ 234.4.2 Function....................................................................................................... 234.4.3 Assembly and installation ............................................................................ 234.4.4 Maintenance................................................................................................ 234.4.5 Changing of filter elements.......................................................................... 244.4.6 Accessories ................................................................................................. 24

SECTION 5 DRYER FLOW CAPACITY AND PURGE ADJUSTMENT...................... 255.1 DRYER FLOW CAPACITY................................................................................. 255.2 CORRECTION FACTOR FOR INLET TEMPERATURE .................................... 255.3 PURGE ADJUSTMENT...................................................................................... 26


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SECTION 6 SPARE PARTS LIST............................................................................... 276.1 SPARE PARTS LIST FOR TZ820 – TZ1710...................................................... 276.2 SERVICE BULLETIN.......................................................................................... 28

SECTION 7 TROUBLE SHOOTING & FAULTS......................................................... 447.1 THE DEW POINT IS TOO HIGH........................................................................ 447.2 THE ADSORPTION DRYER DOES NOT SWITCH OVER ................................ 457.3 BACK PRESSURE IS TOO HIGH DURING REGENERATION PHASE ............ 467.4 SHORT-TERM SHUT-DOWN ............................................................................ 467.5 SHUT-DOWN IN CASE OF A FAULT OR FOR MAINTENANCE ...................... 477.6 RE-STARTING ................................................................................................... 47

SECTION 8 APPENDIX A............................................................................................. 1


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FOREWORD

This technical manual of IInnggeerrssoollll--RRaanndd®® is an aid in getting to know the adsorptiondryer better and in utilizing 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 which arevalid 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.


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SECTION 1 INTRODUCTION

1.1 GENERAL INFORMATION

The adsorption dryer of the TZ820 – TZ1710 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 with or without notice, which, in keeping with the essentialcharacteristics of the adsorption dryer described here, may be necessary forincreasing efficiency or for reasons relating to safety or to normal business practice.

1.2 SAFETY INSTRUCTIONS

This technical manual contains basic tips, which must be followed during set-up,operation and servicing. It is thus of utmost importance that it be read by 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.


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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! Safety sign in accordance with DIN 4844 - W9

Warning against electrical voltage!Safety sign in accordance with DIN 4844 - W8

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

☛ Recommendations

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:


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SECTION 1

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.

☛ RecommendationsRefer to the desiccant material safety data sheet (MSDS) when installing ordisposing of desiccant (See Appendix A).

Danger! Wear protective goggles when working with thedesiccant!

☛ Recommendations 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.


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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 application

Model TZ820 – TZ1710Operating overpressure 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.− Introduction of oil into the air.


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SECTION 1

1.4.4 Technical data sheet

Model TZ820 TZ1050 TZ1200 TZ1450 TZ1710Medium Air, free of aggressive elementsConnection FLG – 150# 3” 3” 3” 3” 4”

Flow capacity (1) (STD)SCFM

820 1050 1200 1450 1710

Flow capacity (1) (LDP)SCFM

574 735 840 1015 1197

Desiccant

Standard Input temp.: from 100°F and dew point (2) –40°C (-40°F)Filled with: activated alumina

LDP Dryers Input temp.: from 100°F and dew point (2) –74°C (-100°F)Filled with: activated alumina

Quantity of desiccantPer vessel [Lbs.] 460 600 700 800 952

Filter size 1100 1100 1380 1380 2100

Control PLC ControllerOperating voltage

Standard 120 V / 60 Hz (AC)

Special voltage Consult factoryDrying time

Standard 5 minLDP Dryers 2 min

(1) Flow capacity in SCFM at 100 PSIG according to DIN ISO 7183(2) Pressure dew point

NOTE: Settings for EMS:

Standard dryers EMS Control -40°F (-40°C) High humidity -35°F (-35°C)LDP Dryers EMS Control -100°F (-74°C) High humidity -95°F (-69°C)


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SECTION 1

1.4.5 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.

☛ RecommendationsFor transport within the company, only the skid of the adsorption dryersTZ820 – TZ1710 may be used.

1.4.6 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).

1.4.7 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.


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SECTION 2 INSTALLATION

2.1 SET-UP AND INSTALLATION

Once at the installation location, the adsorption dryers of the series TZ820 –TZ1710, 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 connected tothe 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 additional shut-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.

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

NOTE: The dryer must be installed indoors in a heated environment(min. 33°F) to ensure proper operation and warranty protection.


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SECTION 3 START UP AND OPERATION

3.1 START UP/ SHUT DOWN

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.

☛ Recommendations The following sequence is to be heeded for the initial start-up:

• Slowly open the inlet valve and observe the pressure build-up on thechamber pressure gauges of the adsorption dryer. An abrupt pressurebuild-up is to be avoided

• Turn the switch to the "POWER ON" position..• The adsorption dryer must be powered approx. 3-4 hours with the shut-

off valve behind the after-filter closed; this regenerates the desiccant.• After the regeneration phase, open the shut-off valve behind the after-

filter slowly while observing the chamber pressure gauge; if the shut-offvalve is opened too abruptly, it could put a stress on the system.

• The adsorption dryer is now ready for operation and functionscontinuously and fully automatically.

3.2 DESCRIPTION OF THE OPERATION

The IInnggeerrssoollll--RRaanndd adsorption dryer of the series TZ820 – TZ1710 functionsaccording to the pressure change principle, using dry air regeneration. Twoadsorption vessels filled with desiccant are installed parallel to each other for thispurpose. While the medium is being dried in one vessel, regeneration takes placein the other vessel. The changeover from one vessel to the other is performed in afixed rhythm by means of a time-dependent control system. The adsorption dryeroperates continuously and fully automatically.


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SECTION 3

3.2.1 Description of the operation

TZ HEATLESS TYPE DRYER (TZ820 – TZ1710)

• The IInnggeerrssoollll--RRaanndd TZ dryer has a NEMA cycle time of 10 minutes (STD) or 4minutes (LDP) depending upon the air quality desired. In a 10 minute cycle, 5minutes is dedicated to drying for each chamber (5 minutes half cycle). In a 4minutes cycle, the half cycle is then 2 minutes.

• Through the inlet switching valve wet air enters either desiccant chamber at theinlet (bottom) and is dried as it flows upward through the desiccant bed. Dry airexits the dryer through the outlet check valve.

• At the outlet of each chamber, a portion of the dry air (purge air) is diverted tothe regenerating chamber. The dry air, at near atmospheric pressure, willremove previously adsorbed moisture as it flows downward through thedesiccant bed exiting through the purge exhaust muffler.

• The purge air is controlled by a purge adjusting valve and purge orifices locatedin the purge line. Purge pressure can be monitored on the purge pressuregauge. Refer to section on purge adjustment for instructions on setting thepurge rate.

• Near the end of each half cycle, the chamber being regenerated will be re-pressurized. For this to occur, the exhaust valve of the chamber beingregenerated closes while purge air continues to flow. Re-pressurizing theregenerated chamber to operating pressure before placing it into serviceminimizes fluidization of the desiccant and helps prevent desiccant abrasionwhich causes desiccant dust to prematurely block pilot and after-filter elements.

• Dryers operating at pressures greater than 120-125 PSIG or in an acceleratedNEMA cycle could be fitted with a re-pressurizing valve. This valve assists theregenerated chamber to reach dryer operating pressure before chamberswitchover.

• Chamber switchover takes place when both towers are fully pressurized tominimize desiccant movement.

When switchover is complete, the regenerated tower will be placed into service andthe exhausted tower will begin a depressurization/regeneration cycle.


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SECTION 3

3.2.2 Dryer operating sequence (No control or alarm option)

The IInnggeerrssoollll--RRaanndd TZ820 –TZ1710 heatless air dryers use a SIEMENS PLC as itsstandard controller. In the event of a power failure, the exhaust valves will close andthe dryer will pressurize both chambers. Since this control panel uses retentiveprogramming the dryer will return to the same step in the cycle the dryer was inbefore power was lost.

Energizing control panel : Power is turned ON – electrical circuit energized.

STEP 1 SELECT LEFT CHAMBER DRYING.- De-energize solenoid EV-1R.- Energize solenoid EV-1L.- Inlet valve positioned for left chamber drying.- When 3 seconds have passed, go to STEP 2

STEP 2 RIGHT CHAMBER DEPRESSURIZATION.- Keep energized EV-1L- Energize EV-2R opening right chamber dump/exhaust valve.- When regeneration time has passed, go to STEP 3

STEP 3 RIGHT CHAMBER REPRESSURIZATION.- Keep energized EV-1L.- De–energize EV-2R closing right chamber dump/exhaust valve.- The repressurization timer begins a countdown of 45 seconds.- Inlet valve remains in current position.- When repressurization time has passed, go to STEP 4

STEP 4 RIGHT CHAMBER DRYING.- De-energize solenoid EV-1L- Energize solenoid EV-1R.- Inlet valve positioned for right chamber drying.- When 3 seconds have passed, go to STEP 5

STEP 5 LEFT CHAMBER DEPRESSURIZATION.- Keep energized EV-1R- Energize EV-2L, opening right chamber dump/exhaust valve.- When regeneration time has passed, go to STEP 6


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SECTION 3

3.2.2 Dryer operating sequence (No control or alarm option) – (Continued)

STEP 6 RIGHT CHAMBER REPRESSURIZATION.- Keep energized EV-1R.- De–energize EV-2L closing right chamber dump/exhaust valve.- The repressurization timer begins a countdown of 45 seconds.- Inlet valve remains in current position.

The dryer has completed 1 full cycle and will repeat steps 1 through 6 until poweris removed from the control panel.

3.2.3 Operating sequence (EMS Option)

The IInnggeerrssoollll--RRaanndd TZ820-EMS – TZ1710-EMS and all “LDP” heatless air dryer usesa Siemens PLC as its standard controller. In the event of a power failure, theexhaust valves will close and dryer will pressurize both chambers. Since this controlpanel uses retentive programming, the dryer will return to the same step in the cycledryer was in before power was lost. (See NOTE 2)

Energizing control panel: Power is turned ON – electrical circuit energized.STEP 1 SELECT LEFT CHAMBER DRYING.

- De-energize solenoid EV-1R.- Energize solenoid EV-1L.- Inlet valve positioned for left chamber drying.- When 3 seconds have passed, go to STEP 2

STEP 2 RIGHT CHAMBER DEPRESSURIZATION.- Keep energized EV-1L

If not in EMS mode:- Energize EV-2R opening right chamber dump/exhaust valve.If in EMS mode and dewpoint is better than hygrometer setpoint:- EV-2R does not energize.When regeneration time has passed, go to STEP 3

STEP 3 RIGHT CHAMBER REPRESSURIZATION.- Keep energized EV-1L.- De–energize EV-2R closing right chamber dump/exhaust valve.- The repress timer begins a countdown of 45 seconds (See Note 1)- Inlet valve remains in current position.- When repressurization time has passed, go to STEP 4


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SECTION 3

3.2.3 Operating sequence (EMS option) – (Continued)

STEP 4 RIGHT CHAMBER DRYING.- De-energize solenoid EV-1L- Energize solenoid EV-1R.- Inlet valve positioned for right chamber drying.- When 3 seconds have passed, go to STEP 5

STEP 5 LEFT CHAMBER DEPRESSURIZATION.- Keep energized EV-1RIf not in EMS mode:- Energize EV-2L opening right chamber dump/exhaust valve.If in EMS mode and dewpoint is better than hygrometer setpoint:- EV-2R does not energize.When regeneration time has passed, go to STEP 6

STEP 6 LEFT CHAMBER REPRESSURIZATION.- Keep energized EV-1R.- De–energize EV-2L closing left chamber dump/exhaust valve.- The repress timer begins a countdown of 45 seconds (See note 1)- Inlet valve remains in current position.

NOTE 1: EV-3 and repress valves could be used if dryer operating at pressureabove 125 PSI (G) and / or dryer operating on a timing cycle otherthan 10 minute cycle. Refer to the specification sheet in this manualor to the flow schematic supplied with the dryer.

NOTE 2: If power failure occurs to the dryer or unit is turned off, both exhaustvalves will close. The inlet valve will remain in its position.

NOTE 3: The actual timer setting may differ from the previously notedsequence. Example: A dryer requiring 30 seconds to re-pressurize theregenerating chamber will have a regeneration time of 4 minutes and30 seconds. The half cycle time will remain at 5 minutes and full cycleat 10 minutes.

NOTE 4: The regeneration and repressurization times should be adjusted byIInnggeerrssoollll--RRaanndd trained personnel only. Changing the factory settings willresult in loss of dew point and/or failure to repressurize beforechangeover.


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SECTION 3

3.2.4 Alarms

** If any alarms options are supplied with dryer then a PLC will control the timing ofthe dryer.

COMMON ALARM RELAY

Common alarm relay comes with any optional alarm. If any one of the alarms areactivated, the common alarm relay will also be activated.

SWITCHING FAILURE ALARM (OPTIONAL, INCLUDED WITH EMS OPTION)

Two pressure switches, sensing desiccant chamber pressure, are provided. Analarm will be activated if both chambers remain at full pressure when regenerationis required. Furthermore, if pressure in both chambers remain below set pressure,after depressurization an alarm will be activated.

NOTE: Dryers equipped with EMS and operating in the EMS mode do notdepressurize during the purge cycle (and do not purge) when anacceptable dew point is maintained. During this condition theswitching failure alarm is cancelled.

The alarm has a 1-minute delay.

HIGH HUMIDITY ALARM (OPTIONAL, INCLUDED WITH EMS OPTION)

The hygrometer provided has been programmed to initiate an alarm if the dryeroutlet dew point falls below the setting. An alarm light is provided.

NOTE: The alarm has a 20-minute delay when the dryer is first powered up,then the alarm is instant if the condition exists.

IF THE HYGROMETER PROBE CONNECTION FAILS, then a fault will beobserved by the hygrometer. The high humidity alarm light will come on. The dryerwill go into a fixed cycle mode. The digital display will indicate ≤ - 202.


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SECTION 3

3.2.5 Electrical control

Danger!Work on electrical installations may only be done by aspecialist or by other persons instructed in this type ofwork as long as they are under the instruction andsupervision of a specialist; the general rules for workingwith electricity must be followed!

You will find the corresponding operating and control voltage on the data sheet.

The IInnggeerrssoollll--RRaanndd adsorption dryer of the TZ series is normally operated with a PLCcontroller. The set times are adjusted at the factory during the test run.Do not change these adjustments!

3.3 SPECIAL EQUIPMENT

3.3.1 EMS Controls

The EMS control option is an Energy Management System that monitors the dryerdewpoint performance and manages the requirement for regeneration of the dryer.The EMS controls major components are a digital dewpoint display hygrometer anda humidity sensor.The IInnggeerrssoollll--RRaanndd type TZ Air dryer is designed to provide a specific pressuredewpoint performance (generally –40 F (-40 C)) at the most severe operatingconditions specified. (Maximum flow at lowest pressure and highest inlettemperature). The regeneration purge flow rate required for the dryer is calculatedand adjusted to achieve this dewpoint and is based on these conditions.

For example, for dryers operating at 100 PSIG (690 kPa) and 100 F (38 C) thepurge flow rate is approximately 15% of the specified maximum inlet flow. Dryersoperating under less severe inlet conditions will introduce a reduced humidity load.The EMS controls have been factory programmed to monitor the dryer outletdewpoint performance and prevent initiation of a regeneration cycle under theseconditions.

The EMS controls system has the following standard features, refer to the enclosedtechnical bulletin for a complete overview of the digital hygrometer display.► Programmable alarm relays (EMS and High Humidity Alarm).► Digital display can be toggled to degrees F.► Detection for cable fault between hygrometer and moisture probe.► Stainless steel humidity probe sampling cell with service valves.


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SECTION 3

3.3.2 EMS Controls – Start-up and operation

The EMS controls system when supplied should be disabled for the initial 8 hoursof dryer operation. A dryer fitted with the EMS control will have a 3-position selectorswitch on the electrical control panel. The 3 positions of this switch will perform thefollowing actions:

Position 1: DRYER OFF Position 2: DRYER ONPosition 3: EMS ON

The DRYER ON position will allow the hygrometer to be energized yet force thedryer to operate on a FIXED CYCLE mode. The dryer SHOULD BE OPERATED INTHIS POSITION AT TIME OF INITIAL STARTUP AND AT ALL TIMES WHEN THEHYGROMETER OR HUMIDITY PROBE ARE REMOVED FOR SERVICE ORCALIBRATION.

The EMS ON position will control the dryer regeneration steps when the dewpointof the dryer is better than the factory adjusted setpoint programmed into the digitalhygrometer.

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

1. Verify that the sample line is connected from the dryer outlet (see flow schematicenclosed) to the inlet valve on the humidity probe sample cell.

2. Verify that the humidity probe is installed into the sample cell3. Connect the cable to the humidity probe4. Fully open the inlet valve to the sample cell5. Partially open the discharge valve of the sample cell to vent off a small amount

of sample air. Do not fully open discharge valve6. Perform a soap test to verify for leaks on all parts of the sample line connections

and the humidity sample cell.7. 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.


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SECTION 3

3.3.2 EMS Controls – Start up and operation (Continued)

Humidity cell assembly


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SECTION 4 MAINTENANCE

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

Also, the following points should be checked regularly:Daily

• Carry out a general visual check and watch out for possible disturbancesduring operation.

• Check function by manually operating the automatic condensate drain onthe pre-filter.

• Do an optical color test on the blue gel indicator for non-EMS dryers:

Indicator Color Approx. dew point [ °F]

Blue gel Blue Pink

Transparent

- 15 0 + 60

Weekly• Check the differential pressure on the pre-filter, which should not exceed

10 PSID. Values greater than this indicate that the filter cartridge must bechanged.

• Check the differential pressure on the after-filter, which should not exceed10 PSID. Values greater than this indicate that the filter cartridge must bechanged.

• Check the backpressure at the silencer placed behind the exhaust valve,it should not exceed 5 PSIG. Use the gauge of the vessel that is to beregenerated.

Annually or after every 2500 hours of operation• Check the desiccant for impurities and change it if necessary. A brownish

/ yellowish tone indicates that it has been soiled with oil. The desiccant hasa normal lifetime of about 8000 operating hours.

• Check the seat o’rings on the outlet check valves.• Check the function of the 3-port inlet valve operation by sending electrical

control signals.


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SECTION 4

4.1 REPLACEMENT OF THE DESICCANT

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

• Close dryer inlet/outlet isolation valves.• Depressurize and switch off the adsorption dryer.• Remove the drain plug and empty the old desiccant into a container.• Screw the plug back in and fill new desiccant from above into the vessels.• Pressurize the adsorption dryer and restore power to the dryer.

NOTE : The dessicant life is determined by the quality of the inlet air. Properfiltering of the inlet air will extent the life of the dessicant.

4.2 DISPOSAL OF THE DESICCANT

Danger! The desiccant can be disposed of at a suitabledisposal site in accordance with local or officialregulations. Don't forget: the desiccant may contain pollutants!

4.3 CHANGING OF THE REGENERATION ORIFICE

• Depressurize and remove power from the dryer.• The regeneration orifice (Quantity = 2) are integrated into orifice unions that

are threaded directly into the top purge manifold.• The orifice union valves can be disassembled using standard hex. Pipe

wrenches. The orifice disks are wedged between the two union parts.• Remove regeneration orifice and re-install new orifice as required.• Verify all previously disassembled piping joints are properly secured.

NOTE: Consult IInnggeerrssoollll--RRaanndd for recommendations and or replacement of thepurge regeneration orifice. Modification of the regeneration orifice canlead to performance deterioration of the dryer.

☛ Advice

Should the need for spare parts arise during work on the IInnggeerrssoollll--RRaannddadsorption dryer of the TZ820 – TZ1710 series, then the dryer type and theconstruction of the adsorption dryer must always be indicated. Thisinformation is given on the nameplate mounted on the electric cabinet.


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SECTION 4

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 concept ischaracterized by high flows at low differential pressure.

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

☛ Recommendations

− 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

☛ Recommendations

− 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 opening thehand drain.


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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

☛ Recommendations

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.


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SECTION 5 DRYER FLOW CAPACITY AND PURGE ADJUSTMENT

5.1 DRYER FLOW CAPACITY

Model Selection Chart

Average Inlet Air Flow (SCFM)Based upon 100 F Inlet Air Temperature Inlet Air Pressure

MODEL Max. InletAir Pressure(Psig) 80 90 100 110 120 130 140

TZ 820 150 640 735 820 890 960 1035 1105TZ 1050 150 830 960 1050 1215 1325 1410 1590TZ 1200 150 980 1095 1200 1305 1415 1520 1615TZ 1450 150 1110 1280 1450 1510 1700 1825 1950TZ 1710 150 1325 1515 1710 1810 1945 2080 2230

1. Higher pressures available as an option. Consult factory2. Based on – 40°F PDP, 10 Minute NEMA cycle, activated alumina and average inlet

air flow.

5.2 CORRECTION FACTOR FOR INLET TEMPERATURE

TEMPERATUREDEGREES F

80 90 100 105 110 115 120

Correction Factor 1.1 1.1 1.0 0.83 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.


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SECTION 5

5.2 CORRECTION FACTOR FOR INLET TEMPERATURE (Continued)

Example: To size for an inlet flow of 950 SCFM @ 105 F and 110 Psig.

1. Select models that produce at least 950 SCFM at 110 Psig. This case wouldbe the TZ1050 which can dry 1215 SCFM.

2. Multiply pressure corrected flow by the temperature correction factor to obtainthe flow of the dryer corrected for pressure and temperature:1215 X (0.83) = 1008 SCFM

3. Confirm model selection. Model TZ 1050 can flow 1008 SCFM at the inletconditions specified. The requirements of 950 SCFM is less, so model TZ1050 is correct.

5.3 PURGE ADJUSTMENT

To adjust the purge pressure, the following steps are to be followed, refer to theflow schematics at the end of this manual:

1 The power is turned on, the dryer is operating.2 When either chamber is depressurized and being regenerated, adjust the

pressure on the pressure gauge using the purge adjusting valve supplied.3 Refer to the table below to adjust purge based on operating/inlet pressure.

TZ820 TZ1050 TZ1200 TZ1450 TZ1710P1 P2 P2 P2 P2 P280 76 CF 80 74 8090 80 90 82 78 82100 81 90 82 81 85110 81 97 82 77 82120 CF 98 CF CF CF

CF = CONSULT FACTORYP1 = Dryer inlet pressure (PSIG)P2 = Dryer purge pressure (PSIG) based on dryer inlet temperature (100°F)


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SECTION 6 SPARE PARTS LIST

6.1 SPARE PARTS LIST FOR TZ820 – TZ1710

DESCRIPTION TZ820Part no.

TZ1050Part no.

TZ1200Part no.

TZ1450Part no.

TZ1710Part no

Desiccant: ActivatedAlumina(LBS per dryer )

38004834(920)

38004834(1200)

38004834(1400)

38004834(1600)

38004834(1904)

Pressure Gauge 38006425 38006425 38006425 38006425 38006425Pressure regulator 38015145 38015145 38015145 38015145 38015145Muffler 38332292 38332292 38332292 38332292 383322923-port inlet valve c/wactuator

38015616 38015616 38015616 38015616 38015632

Repair kit for 3-port inlet 38015624 38015624 38015624 38015624 38015640Repair kit for 3-port inletvalve actuator

38015004 38015004 38015004 38015004 38015012

Exhaust valve 38331690 38331690 38331690 38331690 38331690Exhaust valve kit 38331708 38331708 38331708 38331708 38331708Exhaust valve actuator kit Included

w/exhaustvalve kit

Includedw/exhaustvalve kit




Check valve 38015673 38015673 38015673 38015673 38015673Check valve, Seat o-ring 38015681 38015681 38015681 38015681 38015681Check valve, Spring 38015699 38015699 38015699 38015699 38015699Check valve, Teflon 38015707 38015707 38015707 38015707 38015707Blue gel filling 38006490 38006490 38006490 38006490 38006490Solenoid block 38015863 38015863 38015863 38015863 38015863Pilot light bulb 38006524 38006524 38006524 38006524 38006524Relief Valve 38006532 38006532 38006532 38006532 38006532Fuse 38006540 38006540 38006540 38006540 38006540Alarm Relay * 38006888 38006888 38006888 38006888 38006888Pressure Switch * 38006565 38006565 38006565 38006565 38006565Pilot Air Filter Element I/R-DP19 I/R-DP19 I/R-DP19 I/R-DP19 I/R-DP19PLC * C/F C/F C/F C/F C/FEPROM * C/F C/F C/F C/F C/FHYGROMETER PROBE * C/F C/F C/F C/F C/F


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SECTION 6

6.2 SERVICE BULLETIN

Vane Type Actuator Installation, Operation & Service Instructions

Vane type actuators are compact 90° rotary pneumatic devices to operate quarter-turn valves. They are designed for pressures (supply and/or exhaust) up to 120PSIG maximum.

Explosion. DO NOT EXCEED PRESSURE RATINGS : excessive pressure mayrupture the actuator and cause personal injury and/or property damage.

INSTALLATION

1. Vane actuators are shipped from the factory with an indicator line stampedon the shaft ends which shows the position of the vane paddle. This indicatorshould be used in determining the mounting orientation of the actuator on thevalve.

2. Before mounting, the actuator and the valve must be placed in the sameposition (fully counter-clockwise or fully clockwise). Check the valve andactuator mounting surfaces, bracket, stem adapter and valve stem for properorientation and fit.

WARNING !VALVE & ACTUATOR DAMAGE.

Once installed, leave at least 1-16 inch axial clearance between the end of the actuatorshaft and the drive coupling to prevent valve and actuator damage.

Paddle postion indicatorShaft o-rings

Paddle o-ring

Bronze bushing

Nylon bearings

Stroke adjustment

Paddle


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SECTION 6

6.2 SERVICE BULLETIN (Continued)

3. Utilize all mounting holes provided on the actuator and assure a full boltdiameter of thread engagement into the actuator housing as a minimum.

4. Tighten all bolts and nuts uniformly, taking care to center the actuator on thevalve stem.

5. Actuators are shipped from the factory with the travel stops adjusted forapproximately 90 rotation.

It is usually necessary to make slight adjustments to the stop adjustingscrews alter the actuator ‘s installed on the valve,

Refer to the valve manufacturers recommendations for specific instructions.

If valve manufacturer’s instructions are not available, adjust the open positionactuator stop to allow for full opening of the valve.

6. Actuate the valve closed and adjust the closed position actuator stop toensure that the valve is completely seated in the closed position,

7. Cycle the valve back and forth to check for repeatability of seating,

8. Be sure that the actuator travel slops are what ends the rotation. This willprevent prolonged shaft loading and maximize the life of compensators.

WARNINGMASSIVE LEAKAGE. To reduce the possibility of inadvertent valve disassembly and line

entry, replace or rework all valves using old style cover mounted brackets. Temporarily tagthese valves until permanent corrective action is taken. See the Important Safety Bulletin

(PN 831 I~O) for details.

SPEED OF OPERATION

The speed of operation is determined by a number of factors such as the distancefrom he pressure source, supply line and control valve sites, the torque requirementof the valve, pipeline flow conditions, and the size of the actuator. Cue to theinteraction of those variables, it is difficult to specify a normal operating time.

WARNINGACTUATOR DAMAGE. The 90° stroke for the MX3000 must exceed two seconds to

prevent actuator damage.


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SECTION 6


The 90° stroke for other Matryx models must exceed one second to preventactuator damage.

Slower stroke times may be obtained by using smaller orifices. lower supplypressure. or flow control valves to meter the supply and exhaust.

Clean, dry air or gas is essential for long service life and satisfactory operation. Ifinstrument air of this type is not available, it’s recommended that an in-line filterbe installed to prevent foreign particles (above 40 microns) from entering theactuator

New air lines often contain scare, metal chips and other debris which will damagecontrol valves and actuator seats.

MAINTENANCE

Matryx Vane Actuators will give long, dependable service on dry instrument airbefore any maintenance is required.

When leakage is detected, new seals should be installed as soon as possible toavoid irreparable damage to the actuator. See the following servicing instructions.

SERVICE INSTRUCTIONS

1. Disconnect air and electrical supplies fromactuator, Allow air in actuator to vent.

2. Remove actuator from valve and disconnect anyaccessories from the vane housing.

3. Remove cover screws from flange joint.

4. Carefully separate body halves by wedging themapart with a thin tool or by using a jackscrew.(Xomox does not supply the jackscrew.}

SECTION 6

WARNING .HAZARDOUS PROJECTILES DO NOTuse compressed air to separate body

halves. Compressed air will causerapid separation and can result in

personal injury


REV 6 – July, 2002

31


5. Remove paddle and inspect bearing area for excessive wear.

6. Remove both stop adjusting screw assemblies (thread-seal, washer, locknutand stop adjusting screw). Discard thread-seals.

7. Clean paddle and inside surfaces of actuator with an environmentally safesolvent and inspect surfaces for wear.

8. Remove silicone sealant on paddle and joint surface of actuator with a finegrade abrasive and. if necessary, an environmentally safe solvent.

9. Lubricate internal surfaces with supplied or recommended grease

WARNING0-RING DAMAGE. In some situations oil mist lubricators may increase 0-ring wear. Oil

dilutes the grease film and can increase 0-ring wear.

10. Replace shaft 0-rings and paddle 0-ring. Lubricate with supplied orrecommended grease.

11. Place paddle in bottom half of actuatorhousing at mid-stroke position.

12. Coat housing joint surface with highquality silicone sealant and replace tophousing.

13. With paddle rotated to right side, snugdown screws on left side, shoulder boltfirst. Rotate paddle to left side of actuator and snug down screws on rightside, shoulder boll first.

14. Tighten all screws securely.

WARNINGSEAL DAMAGE. Sealant must set for at least four hours before the actuator is

pressurized to maintain seal integrity.

15. Using a wrench, rotate shaft from one side to the other several timesmanually to wipe sealant from joint.

SECTION 6


REV 6 – July, 2002

32


16. Lightly oil stop adjusting screws.

17. Turn new thread seal into place on stop adjusting screw. DO NOT SLIDE ITOVER THE THREADS. Reinstall stop adjusting screw in actuator.

18. Reinstall flat washers and jam nuts on stop adjusting screws.

19. Readjust stop adjusting screws to approximate the 90° position.

Replacement parts.

Replacement parts for Matryx Actuators may be obtained by ordering the appropriateseal kit as listed below.

Valve Part Number Actuator Kit Part Number4” 02250130-317 02250130-1956” 02250130-318 02250130-196

Note : the above kits contain only the O-rings.


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SECTION 6


MAINTENANCE INSTRUCTIONS- SLEEVED PLUG VALVES

Replacement parts.Replacement parts are designed for maximum interchangeability between valvesizes, types and models. However, some are not interchangeable; and, to ensurereceiving correct parts, the following information must be supplied when orderingreplacement parts.

1. Specify if repair is in-line or out-of-line on all 1/2 and 3/4 inch valves as wellas 1 inch ductile iron valves.

2. Specify valve identification number (six digit number found on hub washer orflow indicator).

If you cannot supply the l.D. number, provide the following information:

a. Size.

b. Body and plug material.

c. Class (150, 300, 600).

d. Is valve for use on a toxic service such as Chlorine or HF? If yes,

specify.

e. Does valve have hex head bolts or allen head adjustment screws? If

allen head, advise if a “T” is stamped on the cover.

f. Is valve manual or actuated? If actuated, specify type of actuator.

Tufline valves are designed and built to give long, trouble-free service. Properlyapplied, adjusted and operated, these valves should require minimum attention.

The following procedures and illustrations have been prepared to assist you in themaintenance and repair of your Tufline valves. Please read instructions carefully. Ifthere are any questions, consult your Tufline valve representative or the factory at513-745-6000.

SECTION 6


REV 6 – July, 2002

34


Adjustments.

Loss of seal.All Tufline valves are factory adjusted and normally further adjustment is notrequired. However, if seepage does occur at the plug stem or downstream, thefollowing adjustments can be made.

Tighten each of the three adjustments bolts (or screws) 1/4 turn. Operate valveand check for leakage. Repeat as necessary to stop the seepage.

The need for frequent adjustment of the bolts, and/or many adjustments turnsindicates the seals are worn to the point of needing replacement (see page 4).Excessive tightening of the adjustment bolts will cause an increase in the valvestem torque.

Valve torque.Valves should be operated under service conditions for at least twelve hoursbefore any torque adjustments are made, since the initial breakaway torquenormally reduces with usage and temperature.

Running torques.Normal running torques may be less than the values shown in the tables below.

Valve torque may be greater if the valve is used to control a highly viscous orabrasive medium.

Size (inches) PTFE sleeveFoot-Pounds at stemUHNMWPE

Sleeve foot-pounds at stem1/2 7 14¾ 7 141 15 30

1-1/2 40 802 46 923 55 1104 100 200

Size (inches)PTFE sleeveFoot-Pounds at stem

EG Wormgear

UHNMWPESleeve foot-pounds at stem EG Wormgear

6 13 34 22 588 18 45 30 118

10 33 109 48 12412 48 90 33 58

* Values at the plug can be greater**Torque at the input shaft less hand wheel or crank.


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SECTION 6


TOP SEAL REPLACEMENT INSTRUCTIONS

• Loosen the cover bolts (or nuts) approximately 4 turns each, being careful not to allow the release of the valve cover.• Rotate the plug 1/4 turn to release any trapped pressure within the valve.• Remove the hub (or E.G. actuator and bracket).• Remove the valve cover• Using a wrench to turn the plug, remove the plug and top seal parts. Top seal parts must be discarded

INSPECTION

For best sealing results inspect the followingcomponents:

1. The seal surface on the plug stem.

2. The plug surface.

3. The seal surface on the cover.

4. The body seal surface that mates with the cover.

5. The sleeve.

WARNING !!MASSIVE LEAKAGE. DO NOT attempt

to repair a valve or its accessorieswhile pressurized! Death or serious

injury could result.

WARNING !!MEDIA EXPOSURE. Depressurize,

clean, and neutralize any media thatmay remain in the valve and pipeline. If

the valve is in the pipeline, you mustfollow your line entry procedures.


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SECTION 6


These surfaces should be free from defects, which are typically caused bycorrosion, erosion, improper handling, or improper storage of a disassembledvalve. If defects are found on any of these parts, the valve must not be repaired.

Reassembly.

18. Replace the plug in the valve body with the ports in the open position.19. Install wedge ring onto plug stem. The small diameter end must be upward.20. Place assembly cone tool with formed PTFE diaphragm over plug stem. (In

valves that have a threaded stud atop the plug stem it will be necessary tomake a 5/16-inch diameter hole through the crown of the assembly conetool to allow the cone to rest on the top of the plug stem.)

21. Push the formed PTFE diaphragm over taper on assembly cone tool andonto plug stem, being sure to evenly distribute the pushing force on thecrown of the diaphragm to prevent back rolling and damage to the sealinglip.When installing the formed PTFE diaphragm, the thrust collar may beused as a pushing tool to push the diaphragm over the taper and onto thelargest diameter of the assembly cone tool.The thrust collar can now be set aside.Continue pushing the diaphragm over assembly cone tool and onto plugstem.

22. Check to see that the wedge ring has seated properly inside the crown ofthe formed PTFE diaphragm.

23. Remove and discard assembly cone tool.24. Install metal diaphragm25. Install the trust collar with that side facing up.26. On 1/2 through 4 inch valves, install the static eliminator with thin lip facing

down. (Not required on actuated valves.)27. Back out adjustment screws to within one thread of bottom of cover bore.28. Install the cover. To facilitate tightening of the cover bolts, press the plug

into the body with an arbor press until the bottom of the plug port openingis 1/16 inch above the bottom of the valve body port opening. Do not applyforce to the cover as this may damage the formed PTFE diaphragm.


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SECTION 6


If satisfactory results have not been obtained, consult the nearest TuflineService Center.

WARNING !!!VALVE DAMAGE. DO NOT

exceed maximum torque values.Personal injury and property

damage may result

12. Check to see that the metal diaphragm is centered in thevalve body counterbore.

13. Tighten the cover bolts alternately (criss-cross pattern)and incrementally until the following torque values arereached:

Bolt Size (inches) Foot-Pounds3/8 20

7/16 351/2 455/8 95

14. Tighten the adjusting bolts uniformly in 1/4 turnincrements until contact is made, then tighten anadditional 1/4 turn.

15. Replace the hub and wrench (or bracket andE.G.actuator) and rotate the plug.

16. Compare the valve torque against the values listed underRunning Torque on page 38.


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SECTION 6


REPAIR INSTRUCTIONS FOR 1 THROUGH 8 INCH VALVES, OUT-OF-LINE

2. To remove the sleeve, cut through the sleeve with a sharpknife at top and bottom side of the ports. Care must betaken not to score the valve body during sleeve removal.

WARNING !!MEDIA EXPOSURE. Depressurize,

clean, and neutralize any media thatmay remain in the valve and pipe-line.If the valve is in the pipeline, you must

follow your line entry procedures.Always wear appropriate safety•attire.Failure to follow this warning- couldresult in death, personal-injury, or

property damage.

WARNING !!MASSIVE LEAKAGE. DO NOT attempt to repair

a valve or its accessories while pressurized1

Death or serious injury could result.

WARNING !!MEDIA LEAKAGE. Discard and replace valve

body if scored. With a scored body, in-lineleakage may occur.

1. Loosen the cover bolts (or nuts) four turns each.Rotate the plug approximately 1/4 turn to releaseany trapped pressure within the valve. Remove thehub (or EG actuator and bracket). Remove thecover bolts. Remove cover Remove plug and topseal parts by turning plug with a wrench. Removeand discard the old top.


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SECTION 6


3. After the sleeve has been cut, insert a screwdriver behind the sleeve and curlthe sleeve away from the valve body. Remove the sleeve by prying it out ofthe body. Discard old sleeve. Clean the body and plug. Check pads forerosion and replace if necessary. Check the finish of the sealing surfaces onthe plug. Replace the plug if not smooth.

5. Place the large end of the plunger on top of the sleeve.Press the sleeve into the valve body with an arbor press.

Reverse the plunger and use the small end of theplunger to press through the loading ring. Remove thering plunger and loading

6. When the sleeve is in the body,use a screwdriver (or prybar)through the pod of the valve to tuck the edge of thesleeve port behind the retaining lip of the valve body.Repeat on the other port opening. Manually rotate thesleeve until the pods of the sleeve are aligned with thepods of the body.

7. Tuck the bottom and top edges of the sleeve podopening into position behind the retaining lip of thevalve body.

If properly installed, the edges of the sleeve podsshould now be in perfect alignment and locked behindthe retaining lips of the body.

Also the bottom of the sleeve should be resting on thelower ledge of the body and the top of the sleeve should be tucked under theupper ledge of the body.

4. The replacement sleeve has been sized and taped at thefactory. Do not remove the tape until ready for use.Place the loading ring in the counterbore of the valve body.Remove the tape from the sleeve. Insert the sleeve so that itspods are 90° from being aligned with the waterway of the valvebody.Press the sleeve through the loading ring until the bottom ofthe sleeve is past the top of the retaining lips of the valve body(1/16 inch wide protruding metal rib that surrounds the valveport).


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SECTION 6


When installing the formed PTFE diaphragm, the thrustcollar may be used as a pushing tool to push the diaphragmover the taper and onto the largest diameter of the assemblycone tool.

12. The thrust collar can now be set aside. Continue pushingthe diaphragm over assembly cone tool and onto plugstem. Check to see that the wedge ring has seatedproperly inside the crown of the formed PTFE diaphragm.Remove and discard assembly cone tool. Install metaldiaphragm.

14. Install the thrust collar with flat side facing up. On 1 inchthrough 4 inch valves, install the static eliminator with thinlip facing down. (Not required on actuated valves

8. Insert the spreading tool into the sleeve and press tothe bottom of the valve. This presses the sleeve to thevalve body around the pods to prevent tearing of thesleeve during sizing.

9. Place the sizing plug into the valve body and press thesizing plug to the bottom of the valve.

Remove the sizing plug, using a jackscrew if necessary.There may be a small excess of sleeve material aroundthe ports which should be trimmed with a sharp knife.Do not mar the sealing areas of the sleeve or leakagemay result.

10. Insert the standard plug with the ports in the openposition. The top of the plug should drop withinapproximately 1/4 inch of the body counterbore. If itdoes not, resize with the sizing plug.

11. Install the wedge ring onto plug stem. The smalldiameter end should be upward. Place assembly conetool with formed PTFE diaphragm over plug stem.

12. Push the formed PTFE diaphragmover taper on cone and onto plugstem, being sure to evenly distributethe pushing force on the crown of thediaphragm to prevent back rolling anddamage to the sealing lip


REV 6 – July, 2002

41

SECTION 6


18. Tighten the adjustment bolts uniformly in 1/4 turn increments until contact is made;then tighten an additional 1/4 turn.

Replace hub (or E.G. actuator and bracket). Rotate the plug and compare thevalve torque against the values listed under Running Torque on page 3.

If satisfactory results have not been obtained, consult your nearest Tufline ServiceCenter.

15. On the valve cover, back adjusting bolts out to within onethread of bottom of cover bore.

16. Install the cover. To facilitate tightening of the cover bolts,press the plug into the body with an arbor press until thebottom of the plug port opening is 1/16 inch above thebottom of the valve body port opening.

Do not apply force to the cover, as this may damage theformed PTFE diaphragm

17. Check to see that the metal diaphragm is centered in thevalve body counterbore.

Tighten the cover bolts alternately (criss-cross pattern)and incrementally until the following torque values arereached:

Bolt Size (inches) Foot-Pounds3/8 20

7/16 351/2 455/8 95

WARNINGVALVE DAMAGE. DO NOT exceedtorque values. Personal injury and

property damage may result.


REV 6 – July, 2002

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SECTION 6


CHECK VALVE

Seat o’ring

Bushing

Bushing

Guide

Spring


REV 6 – July, 2002

43

SECTION 6


DEPRESS / EXHAUST VALVE

Valve actuator

Valve body

Valve body gasket

Valve seat disk


REV 6 – July, 2002

44

SECTION 7 TROUBLE SHOOTING & FAULTS

7.1 THE DEW POINT IS TOO HIGH

Possible cause Solution

• Operating pressure too low, airflow capacity too high

⇒ Increase operating pressure, reduce airflow capacity

• Air inlet temperature too high ⇒ Reduce temperature, or connect an aircooler upstream

• Differential pressure at the pre-filter too high

⇒ Check filter element for impurities, changeif necessary

• Condensate drain is notfunctioning

⇒ Check operation of the condensate drainand replace if necessary

• Desiccant is soiled or hasdisintegrated

⇒ Check pre-filter for impurities and eitherchange the filter element and change thecomplete desiccant and dispose of the olddesiccant

• Volume of regeneration gas toolow

⇒ Check regeneration purge adjustment isset in accordance with table 5.3


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SECTION 7

7.2 THE ADSORPTION DRYER DOES NOT SWITCH OVER

Possible cause Solution• Chamber pressure switch contact

is defective (1)⇒ Verify switch contact and replace if

necessary• Chamber pressure below pressure

switch settings (1)• Exhaust valve not fully closed

• Solenoid valve leaks

• Purge isolation valves partiallyopen or closed

⇒ Set switch 30 PSIG below normal operatingpressure

⇒ Verify valve for obstruction. Verify pilot airto exhaust valve is removed during therepress stage

⇒ Verify for air leakage on non-activatedsolenoid

⇒ Purge isolation valves (2) are to be fullyopen at all times

• Inlet valve failed to operateposition

⇒ Verify pilot air to inlet valve actuator.⇒ Verify solenoid valve.

• Inlet/exhaust valve failed toactivate

⇒ Verify wiring to terminal strip⇒ Verify wiring connector on the solenoid

valve assembly⇒ Verify pilot air service valve is open⇒ Verify pilot air filter element is not soiled

• Outlet check valve failed to close ⇒ Verify bushings on check valve are worn⇒ Verify spring on check valve⇒ Verify check valve seat o’ring

(1) Dryers with EMS option.


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SECTION 7

7.3 BACK PRESSURE IS TOO HIGH DURING REGENERATION PHASE

Possible cause Solution• Muffler is blocked ⇒ Replace muffler

• Outlet check valve failed ⇒ Verify springs and bushings on valves⇒ Verify seat o’ring is not damaged

• Exhaust valve not fully open ⇒ Verify operation of pneumatic actuator⇒ Verify pilot air to actuator⇒ Verify if valve is obstructed

• Inlet valve leaks across ports ⇒ Remove valve and test for across portleakage

⇒ Install new seals• Inlet valve not fully positioned ⇒ Verify the pneumatic actuator for 90°

operation⇒ Verify for leaks across vane of actuator⇒ Pilot air pressure failed due to plugged pilot

filter or damaged pilot line.

Attention! If you are not able to fix a disturbance, call IInnggeerrssoollll--RRaanndd DAVIDSON NC at once. A service technicianwill be sent out as soon as possible!

7.4 SHORT-TERM SHUT-DOWN

☛ Recommendations

The following sequence is to be heeded when switching off theadsorption dryer:• Switch off the adsorption dryer when the dryer transfers into

repressurization step, or at any time when both chambers are at fullpressure.

• Close all the shut-off valves up- and downstream of dryer.

Attention! Dryer will remain pressurized.


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SECTION 7

7.5 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!

☛ Recommendations

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

• Switch off the dryer when the dryer transfers into the repressurizationstep, or at any time when both chambers are at full pressure.

• Close all the shut-off valves up- and downstream of the adsorption dryer,• Depressurize the dryer by using the hand valve mounted at the bottom

of the after-filter.

7.6 RE-STARTING

• Close the hand valve mounted at the bottom of the after-filter.• Slowly open the inlet isolation valve and pressurize the adsorption dryer

up to the regular operating pressure by keeping the shut off valvemounted behind the after-filter closed

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

3.1.


REV 6 – July, 2002

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FORMS\ACTIVATED.ENGActivated Alumina (Grades A, D & P)

Material Safety Data Sheet Date Prepared: Jul/17/2000

Appendix A - 1

SECTION 8 APPENDIX A

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 ORACCIDENTCONTACT: (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 IDENTIFICATION

A. EMERGENCY OVERVIEW:

Physical Appearance and Odor:White powder solid, odorless

Warning Statements:DUSTS IN HIGH CONCENTRATIONS MAY CAUSE SKIN, EYE ANDRESPIRATORY TRACT IRRITATION.



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3. HAZARDS IDENTIFICATION (Continued)

B. POTENTIAL HEALTH EFFECTS:

Acute Eye:Causes foreign body irritation only.

Acute Skin:Non-irritating. Skin absorption not likely

Acute Inhalation:Low acute inhalation toxicity. May cause lung irritation, shortness of breath, chestpain.

Acute Ingestion:Low acute oral toxicity. May cause constipation.

Chronic Effects:This product does not contain any ingredient designated by IARC, NTP, ACGIH orOSHA as probable or suspected human carcinogens.

4. FIRST AID MEASURES

FIRST AID MEASURES FOR ACCIDENTAL:Eye Exposure:Hold eyelids open and flush with a steady, gentle stream of water for at least 15minutes. Seek medical attention if irritation develops or persists or if visual changesoccur.

Skin Exposure:In case of contact, wash with plenty of soap and water. Seek medical attention ifirritation develops or persists.

Inhalation:If respiratory irritation or distress occurs remove victim to fresh air. Seek medicalattention if respiratory irritation or distress continues.

Ingestion:No harmful affects expected. If appreciable quantities are swallowed, call aphysician or poison control center. Do not leave victim unattended.

MEDICAL CONDITIONS POSSIBLY AGGRAVATED BY EXPOSURE:Inhalation of product may aggravate existing chronic respiratory problems such asasthma, emphysema or bronchitis. Skin contact may aggravate existing skindisease.



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NOTES TO PHYSICIANAll treatments should be based on observed signs and symptoms of distress in thepatient. Consideration should be given to the possibility that overexposure tomaterials other than this product may have occurred.

Treat symptomatically. No specific antidote available.

5 FIRE FIGHTING MEASURES

FIRE HAZARD DATA:

Flash Point:Not Applicable

Extinguishing Media:Not combustible. Us extinguishing method suitable for surrounding fire.

Special Fire Fighting Procedures:Firefighters should wear NIOSH/MSHA approved self-contained breathing apparatusand full protective clothing.

Unusual Fire and Explosion Hazards:Not combustible.

Hazardous Decomposition Materials (Under Fire Conditions):None known

6. ACCIDENTAL RELEASE MEASURES

Evacuation Procedures and Safety:Containment of Spill:Follow procedure described below under Cleanup and Disposal of Spill.

Cleanup and Disposal of Spill:Scrape up and place in appropriate closed container (see Section 7: Handling andStorage)

Environmental and Regulatory Reporting:Do not flush to drain



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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 ofconveying, mixing or sliding. Provide adequate precautions, such as electricalgrounding, or inert atmospheres when material is used in the presence of flammablematerials to prevent ignition.

Storage:Store in an area that is clean, dry, store in tightly closed containers. Store in originalcontainer.

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

Introductory Remarks:These recommendations provide general guidance for handling this product. Because specific work environments and material handling practices vary, safetyprocedures should be developed for each intended application. While developingsafe handling procedures, do not overlook the need to clean equipment and pipingsystems 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 isgenerally available from equipment manufacturers.

Exposure Guidelines:

Exposure limits represent regulated or recommended worker breathing zoneconcentrations measured by validated sampling and analytical methods, meetingthe regulatory requirements. The following limits apply to this material, where, ifindicated, S= skin and C= ceiling limit:

ALUMINA Notes:TWA STELACGIH 10 mg/cu. m

Engineering Controls:Where engineering controls are indicated by use conditions or a potential forexcessive exposure exists, the following traditional exposure control techniques maybe used to effectively minimize employee exposures: general area dilution/exhaustventilation, local exhaust ventilation at the point of generation.



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Respiratory Protection:When respirators are required, select NIOSH/MSHA approved equipment based onactual or potential airborne concentrations and in accordance with the appropriateregulatory standards and/or industrial recommendations.

Under normal conditions, in the absence of other airborne contaminants, thefollowing devices should provide protection from this material up to the conditionsspecified by the appropriate OSHA, WHMIS or ANSI standard(s): Air-purifying (half-mask/full-face) respirator with cartridges/canister approved for use against dusts,mists and fumes.

Eye/Face ProtectionEye and face protection requirements will vary dependent upon work environmentconditions and material handling practices. Appropriate ANSI Z87 approvedequipment should be selected for the particular use intended for this material.

It is generally regarded as good practice to wear a minimum of safety glasses withside shields when working in industrial environments.

Skin ProtectionSkin contact should be minimized through use of gloves and suitable long-sleevedclothing (i.e. shirts and pants). Consideration must be given both to durability aswell as permeation resistance.

Work Practice Controls:Personal hygiene is an important work practice exposure control measure and thefollowing general measures should be taken when working with or handling thismaterial:

(1) Do not store, use, and/or consume foods, beverages, tobacco products, orcosmetics 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 withthis material.



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9. PHYSICAL AND CHEMICAL PROPERTIES

Physical and chemical properties here represent typical properties of this product. Contact the business area using the Product Information phone number in Section1 for its exact specifications.

Physical Appearance:White powder solidOdour:OdourlesspH:Not ApplicableSpecific Gravity:Not AvailableDensity:3.3 g/ml at 25°C (77°F).Water Solubility:InsolubleMelting Point Range:2050°C (3722°F)Boiling Point Range:Not AvailableVapor Pressure:1 mmHg at 2158°C (3916°F)Vapor Density:Not AvailableMolecular Weight:101.96

10. STABILITY AND REACTIVITY

Chemical Stability:This material is stable under normal handling and storage conditions described inSection 7.

Conditions to be Avoided:Dusting conditions

Materials/Chemicals to be Avoided:Strong basesStrong acids



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The Following Hazardous Decomposition Products Might Be Expected:Decomposition Type: thermalnone known

Hazardous Polymerization Will Not Occur.Avoid the Following to Inhibit Hazardous Polymerization:not applicable

11. TOXICOLOGICAL INFORMATION

Acute Eye Irritation:No test data found for product.

Acute Skin Irritation:No test data found for product.

Acute Dermal Toxicity:No test data found for product.

Acute Respiratory Irritation:No test data found for product.

Acute Inhalation Toxicity:No test data found for product.

Acute Oral Toxicity:No test data found for product.

Chronic Toxicity:This product does not contain any substances that are considered by OSHA, NTP,IARC, or ACGIH to be "probable" or "suspected" human carcinogens.

No additional test data found for product.

12. ECOLOGICAL INFORMATION

Ecotoxicological Information:No data found for product.

Chemical Fate Information:No data found for product.



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13. DISPOSAL CONSIDERATIONS

Waste Disposal Method:Waste Management options should first consider possible re-use or recyclingopportunities. Some provinces have active "Waste Exchange" networks for re-useand recycling of wastes. Contact your local waste management companies toexplore available options. All waste management activities must obey local,provincial and federal regulations. Possible disposal methods include the following:

Stabilize and solidify this material with compatible binders. Then place in a securelandfill

Container Handling and Disposal:Rinse containers before disposal.

14. TRANSPORTATION INFORMATION

Transportation Status:The listed Transportation Classification does not address regulatory variations dueto changes in package size, mode of shipment or other regulatory descriptors.

TDG Status:Shipping Name : NON DANGEROUS

IMO Status:Shipping Name: NOT REGULATED

IATA Status:Shipping Name: NOT REGULATED

15. REGULATORY INFORMATION

Inventory StatusCANADA (DSL) Y

WHMIS Classification:NOT CONTROLLED

This product has been classified in accordance with the hazard criteria of the CPR(Controlled Products Regulations) and the MSDS contains all the informationrequired by the CPR.



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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 - Permissable 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.

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