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HANKISON HBP Series Instruction Manual

Blower purge desiccant compressed air dryers
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3158050
Rev. E
1/08
XX-XXX-X
Internal Use Only
3158050e / 080102
INSTRUCTION MANUAL
HBP SERIES
RATED
MODELS
FLOW
HBP500
500 SCFM
HBP600
600 SCFM
HBP750
750 SCFM
HBP900
900 SCFM
HBP1050
1050 SCFM
HBP1300
1300 SCFM
HBP1500
1500 SCFM
HBP1800
1800 SCFM
HBP2200
2200 SCFM
HBP2600
2600 SCFM
HBP3200
3200 SCFM
HBP3600
3600 SCFM
HBP4300
4300 SCFM
Contents
1.0 General Safety Information ........................... 2
2.0 Receiving, Storing, and Moving ..................... 2
3.0 Description .................................................... 3
4.0 Installation ..................................................... 3
5.0 Instrumentation .............................................. 8
6.0 Operation ....................................................... 12
7.0 Maintenance .................................................. 29
8.0 Troubleshooting ............................................. 31
Drawings
WARRANTY .......................................................... 44
MODEL
REFERENCE
500
600
750
900
1050
1300
1500
1800
2200
2600
3200
3600
4300
SERVICE DEPARTMENT : (724) 746-1100
BLOWER PURGE
DESICCANT
COMPRESSED
AIR DRYERS

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  • Page 1: Table Of Contents

    3158050 Rev. E 1/08 XX-XXX-X Internal Use Only 3158050e / 080102 INSTRUCTION MANUAL HBP SERIES RATED MODEL MODELS FLOW REFERENCE HBP500 500 SCFM HBP600 600 SCFM HBP750 750 SCFM HBP900 900 SCFM HBP1050 1050 SCFM 1050 HBP1300 1300 SCFM 1300...

  • Page 2: General Safety Information

    DANGER—Immediate hazard which will result in severe 1.0 General Safety Information injury or death. This equipment is designed and built with safety as a WARNING—Hazard or unsafe practice which could prime consideration; industry-accepted safety factors result in severe injury or death. have been used in the design.

  • Page 3: Description

    systems supplied by a lubricated air compressor, use a 3.0 Description High Efficiency Oil Removal Filter. A coarser filter will be required upstream of the Oil Removal Filter if heavy 3.1 Function liquid or solid loads are present. Blower purge type regenerative dryers are an economi- To ensure downstream air purity (prevent desiccant dust cal and reliable way to dry compressed air to dew points from traveling downstream) adequate filtration down-...
  • Page 4 Compressor Aftercooler Separator Receiver Prefilters Desiccant Dryer Afterfilters Receiver Figure 1 Typical System Configuration piping is supported. Do not allow the weight of any pip- Connections to voltage-free common alarm contacts ing to bear on the dryer or filters. Piping should be the with a minimum 5-amp rating can be made at terminals same size as or larger than the dryer connection.
  • Page 5 All desiccant shipped loose must be added to the TABLE 1 dryer chambers before the dryer is put into service DESICCANT REQUIREMENTS (Quantity per Tower) Refer to TABLE 1, DESICCANT REQUIREMENTS for desiccant type and quantity per tower. Layer Model TO ADD DESICCANT 354# —...
  • Page 6 Dimensions and Connections Figure 2 (continued on next page) (Contact factory to request certified drawings)
  • Page 7 Dimensions and Connections Figure 2 (continued from previous page)

  • Page 8: Instrumentation

    5.5 Dew Point Transmitter 5.0 Instrumentation This option monitors and displays outlet pressure dew points and provides an alarm signal if the dew point The following instrumentation helps in monitoring dryer exceeds user-specified set point. Recommended operation and performance. Instruments which are calibration interval is 12 months.
  • Page 9 PURGE INLET CHECK VALVE TOP VIEW HEATER TEMP HOT PIPE INSULATION THERMOCOUPLE (CENTER END IN PIPE) (OPPOSITE SIDE) HEATER OVERTEMP RTD PURGE ASME CODE TAG HEATER WITH INSULATION PURGE SUCTION TOWER INLET FILTER SILENCER VALVE PURGE BLOWER AND MOTOR TOWER BLOW- DOWN VALVE REAR VIEW ASME RELIEF VALVE...
  • Page 10 REPRESS VALVE LEFT TOWER PURGE EXHAUST RIGHT TOWER VALVE PURGE EXHAUST VALVE PURGE EXHAUST PURGE EXHAUST TOP VIEW LEFT PURGE INLET HEATER TEMP CHECK VALVE THERMOCOUPLE (CENTER END IN PIPE) OUTLET (OPPOSITE SIDE) HOT PIPE INSULATION HEATER OVERTEMP RTD PURGE HEATER WITH ASME CODE TAG INSULATION...
  • Page 11 OUTLET CHECK VALVE TOP VIEW PURGE INLET CHECK VALVE HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) (OPPOSITE SIDE) HOT PIPE HEATER INSULATION OVERTEMP RTD PURGE HEATER WITH INSULATION PURGE SUCTION FILTER SILENCER PURGE BLOWER TOWER INLET VALVE THROTTLING VALVE PURGE BLOWER AND MOTOR REAR VIEW ASME RELIEF VALVE...

  • Page 12: Operation

    After the right tower has depressurized, the Right 6.0 Operation Purge Valve V4 is opened and the Blower M and Heater H1 are energized. The heated air flows 6.1 Controls through the Right Purge Check Valve V6, down A solid-state controller controls valve and heater opera- through the right tower, and exits through the Right tion, monitors all critical operating conditions, and indi- Purge Valve V4.
  • Page 13 SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION PR&G SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 TOWER TOWER SET @ 650°F SET @ SET @ 45 PSIG 45 PSIG SET @ SET @ 5 PSIG 5 PSIG EXH.
  • Page 14 6.3.1 Energy Management Control (optional) After the left tower has depressurized, the Left Purge Valve V3 is opened and the Blower M and Heater Operation of the Energy Management Control cycle is H1 are energized. The heated air flows through the identical to the fixed cycle except the cycle is extended Left Purge Check Valve V5, down through the left until the desiccant bed in the on-line tower has been fully...
  • Page 15 6.4 Control Board Jumpers 8. JP8 – Set Up Jumper JP8 is factory installed in the OFF position In the upper left hand corner of the control board there to disable access to “factory” set up screens. The are eight two-pin jumpers labeled JP1 through JP8. Only jumper is installed in the ON position during final five of the eight jumper pairs are utilized.
  • Page 16 Filter Service / Left Tower Pressure Maintenance LED Switch LED: On=Tower Pressurized Filter Service / Maintenance LED Left Tower Drying LED Right Tower Pressure Left Purge Valve LED Switch LED: On=valve open On=Tower pressurized Off=valve closed Left Inlet Valve LED Right Tower Drying LED On=valve open Off=valve closed...
  • Page 17 b. SEVERE Service Intervals are: Screen 7: Set Point for Dew Point Demand Control i. 2000 hours for filters (Displayed only when JP3 “on”) ii. 4000 hours for desiccant DPNT CNTL SETPT iii. 4000 hours for valves ±XX°C ±XXX°F 2. When finished, press to save the selection and 1.
  • Page 18 6.5.5 Setup Mode c. This setting may be field adjusted to increase or decrease the outlet dew point at tower switch- 1. Press and hold for 3 seconds to enter Setup over. Mode. 4. When finished, press to acknowledge the selec- 2.
  • Page 19 6.5.6 Alarm & Service Mode c. Left or Right tower, regenerating, low pressure i. Regenerating tower pressure switch is open 1. Alarm & Service Mode is active when the controller at the end of the regenerating cycle. is in Display Mode. It is not active in Program Mode, Setup Mode, or Test Mode.
  • Page 20 ALARM MESSAGES LEFT TOWER ALARMS RIGHT TOWER ALARMS OTHER ALARMS ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER DRYING DRYING OVER-TEMPERATURE LOW PRESSURE LOW PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER REGENERATING REGENERATING LOW TEMPERATURE HIGH PRESSURE HIGH PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM ENRGY MGNT...
  • Page 21 9. Heat Low Temperature 13. Dew Point Sensor a. RTD3 is used to detect Heater Low Tempera- a. High Dewpoint Alarm ture. i. The user enters an alarm value through the Program Mode. b. Alarm if the heater temperature is less than 250°F ii.
  • Page 22 6.5.7 Display Mode Service Due Messages 1. Display Mode is active when the user exits Program 14. There are two service levels (normal and severe) Mode or Setup Mode and no alarms are active as described in Program Mode. Each service level (unless MANUAL CYCLE was selected in Setup has preset time intervals for servicing the filters, Mode).
  • Page 23 DRYER STATUS SCREENS LEFT TOWER DRYING RIGHT TOWER DRYING LT DRYING LT DEPRESSURIZE RT DEPRESSURIZE RT DRYING LT DRYING LT HEATING RT HEATING RT DRYING LT DRYING LT COOLING RT COOLING RT DRYING LT DRYING LT REPRESSURIZE RT REPRESSURIZE RT DRYING LT DRYING LT HOLDING RT HOLDING...
  • Page 24 6.5.8 Test Mode 5. Upon entering Test Mode, the program can be at any 1. Test Mode is active when the user exits Program one of the ten steps. Mode after selecting operation in MANUAL CY- 6. To exit Test Mode: CLE.
  • Page 25 TEST MODE SCREENS Screen 1: Step 1 Screen 6: Step 6 TEST1: LT DRYING TEST6: RT DRYING XX°C XXX°F XX°C XXX°F Screen 2: Step 2 Screen 7: Step 7 TEST2: DEPR RT TEST7: DEPR LT XX°C XXX°F XX°C XXX°F Note: Sequence step will not advance to HEAT Note: Sequence step will not advance to HEAT until depressurization time has elapsed and...
  • Page 26 6.6 Start-up NOTE: Read the off-line tower pressure gauge when the tower is purging (air exhausting from muffler). 6.6.1 Controller Settings 6.7.5 Process Valves Set or verify settings on Controller. Detailed operational Determine if air control valves are operating and points are presented in section 6.5.
  • Page 27 Dryers are equipped with a safety relief valve that has b. Advances directly to the beginning of whichever been sized to provide overpressure protection due to a stage of HEAT or COOL it had been at when fire for both desiccant towers. power was interrupted.
  • Page 28 Determining jumper positions: ASCII representation of the heater tempera- ture (°F) Each jumper 8 bits weighted by position ASCII representation of the left bed tempera- Value ture (°F) ASCII representation of the right bed tem- perature (°F) ASCII representation of the humidity sensor temperature (°F) ASCII representation of the humidity sensor relative humidity (%)

  • Page 29: Maintenance

    e. Utilizing an appropriate sized funnel, fill each 7.0 Maintenance desiccant tower as follows: 1) Install the required quantity of tabular support WARNING - This equipment is a pressure-containing (model 4300 only) or activated alumina in device. Depressurize before servicing. layer 1 of each tower.
  • Page 30 2. Procedure for element replacement a. Isolate dryer from air supply b. Depressurize dryer by running dryer and allowing system pressure to purge to atmosphere. Loss of pilot pressure will eventually prevent purge/ repressurization valves from opening. Remaining pressure can be vented to atmosphere through the manual drain on the pilot air filter.

  • Page 31: Troubleshooting

    8.0 Troubleshooting WARNING - A POTENTIAL ELECTRICAL SHOCK HAZARD EXISTS. Some of the troubleshooting checks may require gaining access to the dryer’s electrical enclosure(s) while the power supply is energized and should be performed by a qualified electrical technician. WARNING - Before performing any electrical or mechanical repairs or maintenance, or removing or disassembling any component, be sure to de- energize and depressurize the dryer.
  • Page 32 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION High Pressure Alarm 1. Faulty regenerating tower pressure 1. Check pressure switch operation using tower pressure Left Tower or Right Tower Re- switch gauge for comparison. Replace switch if defective. generating 2. Regenerating tower Depressurization 2.
  • Page 33 SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION Outlet Dew Point Alarm 1. Inlet air flow higher than the sizing 1. Reduce inlet flow to sizing condition. Left Tower or Right Tower condition. 2. Liquids entering the dryer inlet. 2. Check the inlet air line for liquids. Inspect prefilter and drain valve.

  • Page 34: P&Id Schematic Models 500 Through 600

    P&ID Schematic Models 500 through 600 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET SOL 'E' DEWPOINTER OPTION SET AT 100 PSIG SET @ 370°F LEFT RIGHT RTD 3 TOWER TOWER SET @ 650°F SET @ SET @ 45 PSIG 45 PSIG...
  • Page 35 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS SOLENOID VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD CHAMBER RTD (LEFT &...

  • Page 36: P&Id Schematic Models 750 Through 4300

    P&ID Schematic Models 750 through 4300 (Contact factory to request certified drawings) SET @ 165 PSIG DRY GAS OUTLET DEWPOINTER OPTION SOL 'E' SET AT 100 PSIG (225°F) SET @ 370°F LEFT RIGHT RTD 3 TOWER TOWER SET @ 650°F SET @ SET @ 45 PSIG...
  • Page 37 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) SOL 'C' FLOW CONTROL VALVE PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) SOL 'D' PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) (NO SPRING) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) DEPRESS SOLENOID VALVE (V9 LEFT, V10 RIGHT) PURGE HEATER WITH INSULATION HEATER TEMPERATURE THERMOCOUPLE HEATER OVERTEMPERATURE RTD...

  • Page 38: Electrical Schematic - 460Vac, 3 Phase

    Electrical Schematic – 460VAC, 3 phase (Contact factory to request certified drawings) CUSTOMER PROVIDED 460VAC, 3 PHASE MOTOR (FOR FUSING AND WIRE SIZING SEE TABLE 1) 1HTR LOW TENSION 0.5 AMP ENCLOSURE 460VAC 0.5 AMP 120VAC TO TB3 1.25 AMP 101A 115VAC K TYPE...

  • Page 39: Electrical Schematic - 575Vac, 3 Phase

    Electrical Schematic – 575VAC, 3 phase (Contact factory to request certified drawings) CUSTOMER PROVIDED 575VAC, 3 PHASE MOTOR (FOR FUSING AND WIRE SIZING SEE TABLE 1) 1HC1 1HTR 1HC2 1HC3 2HC1 USED ON MODELS 2HTR 3200, 3600 & 4300 2HC2 LOW TENSION 2HC3 0.5 AMP...

  • Page 40: Electrical Schematic - 380Vac, 3 Phase

    Electrical Schematic – 380VAC, 3 phase (Contact factory to request certified drawings) CUSTOMER PROVIDED 380VAC, 3 PHASE MOTOR (FOR FUSING AND WIRE SIZING SEE TABLE 1) 1HTR LOW TENSION (.5AMP) ENCLOSURE (.5 AMP) 120VAC 380VAC TO TB3 (1.25 AMP) 101A 110VAC +12VDC K TYPE...

  • Page 41: Electrical Schematic - 415Vac, 3 Phase

    Electrical Schematic – 415VAC, 3 phase (Contact factory to request certified drawings) CUSTOMER PROVIDED 415VAC, 3 PHASE MOTOR (FOR FUSING AND WIRE SIZING SEE TABLE 1) 1HTR LOW TENSION HEATER & MOTOR FUSES BY 0.5 AMP ENCLOSURE CUSTOMER 0.5 AMP 120VAC 415VAC TO TB3...

  • Page 42: Electrical Data - Fusing & Wire Sizing

    Electrical Data – Fusing & Wire Sizing Electrical Service: 460VAC, 3 phase Electrical Service: 575VAC, 3 phase F.L.A. SUGGESTED F.L.A. SUGGESTED MODEL COMPONENT RATING WIRE SIZE MODEL COMPONENT RATING WIRE SIZE @460VAC FUSING @575VAC FUSING HEATER 10 KW 12.6 20 AMPS #12 AWG HEATER 10 KW...

  • Page 44: Warranty

    MATERIAL IS RETURNED TO THE FACTORY OR IN-WARRANTY REPAIRS ARE MADE. SERVICE DEPARTMENT : (724) 746-1100 SPX Dehydration & Filtration 1000 Philadelphia Street Canonsburg, PA 15317-1700 U.S.A. Phone: 724-745-1555 • Fax: 724-745-6040 Email: hankison.service@dehydration.spx.com www.hankisonintl.com © 2008 SPX Dehydration & Filtration. All rights reserved.

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