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I N S T R U CT I O N M A N UA L
HES Series
Energy Saving Refrigerated Type Compressed Air Dryers
Models: HES800, HES1000, HES1250, HES1500, HES1750, HES2000, HES2500, HES3000
F O R M N O . : 5 0 0 1 3 6 4
R E V I S I O N : 0 4 / 2 0 1 5
R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.
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Table of Contents
Related Manuals for HANKISON SPX HES Series
Summary of Contents for HANKISON SPX HES Series
- Page 1 I N S T R U CT I O N M A N UA L HES Series Energy Saving Refrigerated Type Compressed Air Dryers Models: HES800, HES1000, HES1250, HES1500, HES1750, HES2000, HES2500, HES3000 F O R M N O . : 5 0 0 1 3 6 4 R E V I S I O N : 0 4 / 2 0 1 5 R E A D A N D U N D E R S TA N D T H I S M A N UA L P R I O R TO O P E R AT I N G O R S E R V I C I N G T H I S P R O D U CT.
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Page 2: Table Of Contents
CONTENTS GENERAL SAFETY INFORMATION ............... 1 RECEIVING, MOVING, AND UNPACKING ............1 1.0 INSTALLATION 1.1 Location ......................... 2 1.2 Mounting ......................... 3 1.3 Piping Connections ....................3 1.4 Electrical Connections .................... 3 1.5 Electronic Demand Drain ..................3 2.0 OPERATION 2.1 Minimum/Maximum Operating Conditions ............... -
Page 3: General Safety Information
GENERAL SAFETY INFORMATION RECEIVING, MOVING, AND UNPACKING PRESSURIZED DEVICES: A. RECEIVING This equipment is a pressure containing This shipment has been thoroughly checked, packed and device. inspected before leaving our plant. It was received in good condition by the carrier and was so acknowledged. • Do not exceed maximum operating pressure as shown on equipment serial Check for Visible Loss or Damage. -
Page 4: Installation
IMPORTANT: READ PRIOR TO STARTING THIS EQUIPMENT 1.0 INSTALLATION 1.1 Location For typical placement in a compressed air system, see draw- ing. Air compressor intake – Locate air compressor so that con- Aftercooler taminants potentially harmful to the dryer (e.g. ammonia) are Dryer not drawn into the air system. -
Page 5: Mounting
1.2 Mounting D. Verify that isolation valves are open. If the drain fails to discharge after the valve is energized, the electronic control Mount the dryer on a level solid surface. Holes are provided in the circuit will repeatedly energize the valve in an attempt to clear dryer base to permanently mount the dryer to the floor. -
Page 6: Minimum/Maximum Operating Conditions
2.1 Minimum/Maximum Operating Conditions CONTROL PANEL Maximum inlet air pressure: refer to dryer serial number tag Minimum inlet air pressure: 30 psig (2.1 barg) C. Maximum inlet air temperature: 120°F (49°C) D. Maximum ambient temperature: Air-cooled models: 110°F (43°C) Water-cooled models: 130°F (54°C) Minimum ambient temperature: 40°F (4°C) 2.2 Start-up Energize dryer. - Page 7 Setting Schedule After 15 minutes, open outlet isolation valve slowly. a. Use the ‘Up’ and ‘Down’ arrow buttons to select desired Close air bypass valve. “Day of week + on/off ”. Press ‘Enter’ to adjust time. Dryer may be operated in Manual or scheduled modes. b.
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Page 8: Using The Rs-485 Port Connector (J8)
e. Check Alarm/Service light. If illuminated, check Interface RS-485 Pinout panel. Following is the pinout for J8, the RS-485 communications con- nector. If SERVICE DRYER appears, scheduled maintenance time has elapsed (HRS TO SERVICE is 0). Perform needed service and reset service interval (see B.4.). If ALARM appears, a dryer fault is indicated;... - Page 9 These values will be written every 10 seconds to a comma separated value file stored in the root folder of the USB flash drive. Each day a new comma separated value file will be created for storing the samples for that day. Comma separated value files older than 60 days will be automatically deleted. USB Bootloader Firmware updates for the EMM connect can be performed via the USB flash drive. In order to perform a firmware update; place the image.hex and lang.hex files provided by SPX in the root folder of a USB thumb drive. USB Event History When a USB flash drive is installed in the controller it will begin to automatically log all dryer events: power loss, power recovery,...
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Page 10: Using The Ethernet Feature (J3)
2.5 Using the Ethernet Feature (J3) The event history page shows the last 64 timestamped events that have occurred on the dryer. These events include power failure/ The EMM connect is equipped with an Ethernet port located at recovery, dryer mode changes, dryer status changes, and alarms. J3 on the control board which allows the customer to connect the dryer to a local area network. - Page 11 The dryer settings screen allows the customer to view/edit various dryer set points and setup E-mail alerts that will send an e-mail to up to 3 different e-mail addresses whenever an alarm or warning occurs on the dryer. Figure 5: Settings Modbus TCP The Modbus TCP connection allows you to continuously monitor the dryer from a DCS system which implements a Modbus TCP...
- Page 12 Modbus Registers Holding Register Reference Address Name Units Description 40001 0x0000 DRYER_STATUS Status ID Status ID for the dryer 40002 0x0001 ALARM_STATUS Flag Bits Alarm flag bits 40003 0x0002 WARNING_STATUS Flag Bits Warning flag bits 40004 0x0003 RESERVED Reserved 40005 0x0004 SERVICE_TIMER Hours...
- Page 13 Modbus Register Details Page 1 of 3 Dryer Status Register 40001 Decimal Description 0x0000 Standby 0x0001 Fixed 0x0002 0x0003 Reserved 0x0004 Reserved 0x0005 Reserved 0x0006 Reserved 0x0007 Reserved Dryer Alarm Flags Register 40002 Mask Description 0x0001 High Discharge Temperature 0x0002 High Refrigerant Pressure 0x0004 Low Refrigerant Pressure...
- Page 14 Modbus Register Details Page 2 of 3 Dryer Model Register 40017 Decimal Description 0x0000 Non-Cycling MRD 0x0001 Non-Cycling LRD 0x0002 ES-MRD 90 0x0003 ES-MRD 120 0x0004 ES-MRD 140 0x0005 ES-MRD 190 0x0006 ES-MRD 245 0x0007 ES-MRD 280 0x0008 ES-MRD 360 0x0009 ES-MRD 450 0x000A...
- Page 15 Modbus Register Details Page 3 of 3 UI Language Register(s) 40021 Decimal Mask Description 0x0000 English 0x0001 Spanish 0x0002 French 0x0003 German 0x0004 Portuguese 0x0005 Italian 0x0006 Polish 0x0007 Danish 0x0008 Dutch 0x0009 Norwegian 0x000A Finnish 0x000B Swedish 0x000C Czech 0x000D Reserved 0x000E...
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Page 16: Maintenance
3.0 MAINTENANCE 3.2 Annual Maintenance Check all terminals in the switchgear cabinet and tighten 3.1 Monthly them up if necessary. A. Air-Cooled: Clean refrigerant condenser. Blow the fins of the Check to be sure the unit is de-energized. condenser clean with compressed air, if necessary, remove heavier soiling with a suitable cleansing agent. Maintenance/Cleaning of the condensate drain. - Page 17 e. Remove the insulation [1]. f. Loosen the screws [2] of the filter housing. Caution is necessary as the system may still be under slight residual pressure. g. Remove all screws except one and swing flange [3] to the side. h. Pull out the old cartridges [4]. i. Push new cartridges on to the mounting posts in the bottom of the separator vessel.
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Page 18: Troubleshooting Guide
4.0 TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION A) Water downstream of dryer 1. Residual free moisture remaining in downstream 1. Blow out system with dry air. pipelines. 2. Air bypass system is open. 2. Check valve positions. 3. Inlet and Outlet connections are reversed. 3. -
Page 19: Reference Sizing
5.0 REFERENCE SIZING Determining dryer capacity at actual operating conditions. To determine the maximum inlet flow capacity of a dryer at various operating conditions, multiply the rated capacity from Table 1 by the multipliers shown in Table 2. Example: How many scfm can a 60 Hz air-cooled model 1000 handle when compressed air to be dried is at 200 psig and 100°F; ambient air temperature is 80°F? Answer: 1,000 x 1.22 x 1.12 = 1,366 scfm. -
Page 20: Engineering Data Tables
ENGINEERING DATA TABLES Sheet 1 of 2 Model 1000 1250 1500 1750 2000 2500 3000 Air System Data Rated Air Flow at 100°F & 100 psig Inlet, 100°F Ambient (scfm) 60 Hz, a-c 1000 1250 1500 1750 2000 2500 3000 60 Hz, w-c 1150 1438... - Page 21 ENGINEERING DATA TABLES Sheet 2 of 2 Model 1000 1250 1500 1750 2000 2500 3000 Electrical Data Nominal Voltage 230/3/60 ** Voltage Range 207 - 253 Input Power @ Rated Flow (watts) * 4,710 6,730 7,400 9,770 13,010 14,870 16,840 18,200 Minimum Circuit Ampacity Maximum Overcurrent Protector (amps)
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Page 22: Dryer Set Point Table
DRYER SET POINT TABLE DIP Switch Settings DIP Switch Description Evaporator Outlet Temperature Sensor Disabled Enabled Status Menu Scrolling Disabled Enabled Reserved Reserved Dryer Configuration Description Units Lower Upper Increment Default Service Interval Hours 9999 4000 Energy Cost Decimal 0.00 0.99 0.01 0.13... -
Page 23: Dryer Alarm Table
DRYER ALARM TABLE Alarm Conditions Alarm Text Alarm Trigger Delay Monitored Exit Condition Alarm Action DISCHARGE Discharge temperature > 1 Second Always Alarm reset button pressed Halt compressors HIGH TEMPERATURE high discharge temperature set point De-energize alarm relay #1 HIGH PRESSURE High pressure switch open 1 Second Always... -
Page 24: Controller Screen Shots
CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Status Menu Screens Status Menu Version 2.x Power-up Delay 02/24/2011 09:40 MANUAL MODE Up/Down HRS TO SERVICE 4970 Up/Down Total Hours Up/Down DISCHARGE xxx.x°C / xxx°F Up/Down EVAPORATOR IN xxx.x°C / xxx°F Up/Down Up/Down Hidden if evaporator... -
Page 25: Setup Menu Screens
CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Setup Menu Screens Setup Menu MAIN MENU LANGUAGE Enter LANGUAGE ENGLISH Down/Up MAIN MENU DATE & TIME Enter DATE & TIME 02/24/2011 09:40 Down/Up MAIN MENU SCHEDULE Enter SCHEDULE MON ON IGNORE Down/Up MAIN MENU 02/24/2011 09:55... -
Page 26: Network Menu Screens
CONTROLLER SCREEN SHOTS DEMM32 - User Interface Diagram Network Menu Screens Network Menu Network Menu NETWORK MENU IP ADDRESS TYPE Enter IP ADDRESS TYPE DYNAMIC Up/Down NETWORK MENU IP ADDRESS Enter IP ADDRESS 192.168.0.2 Up/Down Up/Down NETWORK MENU SUBNET MASK Enter SUBNET MASK 255.255.255.0... -
Page 27: Dimensions / Weights
6.0 DIMENSIONS / WEIGHTS Dimensions in (mm) Height Width Depth Weight Inlet/Outlet Model Lb. (kg) Connections 85.1/8 (2162) 48.1/2 (1232) 40.3/4 (1035) 12.1/2 (318) 12.7/8 (327) 8.3/4 (222) 1124 (510) 3” ANSI Flg. 1000 85.1/8 (2162) 48.1/2 (1232) 40.3/4 (1035) 12.1/2 (318) 12.7/8 (327) 8.3/4 (222) - Page 28 7.0 DRAWINGS: ELECTRICAL SCHEMATIC Model 800 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND TB1-PE -F11 -K62 TB1-1 (12 AWG) L1-1 L1-1A COMPRESSOR 1 TB1-2 L2-1 L2-1A 460 VAC, 3 PH 4HP, 6.7 RLA TB1-3 L3-1 L3-1A 7 - 10 AMP TB1-PE (SET @ 7A) -F13...
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Page 29: Drawings: Electrical Schematics
DRAWINGS: ELECTRICAL SCHEMATIC Model 800 Sheet 2 of 2 SHT#1 60K SHT#1 58K 24VAC -K43 -S43 -S43.1 TB2-2 TB2-31 TB2-31 TB2-32 TB2-32 TB2-1 TB2-32 FAN CONTACTOR TB2-2 PRES. 1 FAN 1 TEMP. 1 FAN 1 -S62 -K61 TB2-2 REFRIGERANT HI PRES. TB2-36 TB2-36 TB2-1... -
Page 30: Models 1000 And 1250
DRAWINGS: ELECTRICAL SCHEMATIC Models 1000 and 1250 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND TB1-PE -F11 -K62 TB1-1 (12 AWG) L1-1 L1-1A COMPRESSOR 1 TB1-2 L2-1 L2-1A 460 VAC, 3 PH TB1-3 6HP, 9.0 RLA L3-1 L3-1A 7 - 10 AMP TB1-PE (SET @ 9A) -F13... - Page 31 DRAWINGS: ELECTRICAL SCHEMATIC Models 1000 and 1250 Sheet 2 of 2 SHT#1 58K SHT#1 58K 24VAC -K43 -S43 -S43.1 TB2-2 TB2-31 TB2-31 TB2-32 TB2-32 TB2-1 TB2-32 FAN CONTACTOR TB2-2 PRES. 1 FAN 1 TEMP. 1 FAN 1 -S62 -K61 REFRIGERANT HI PRES. TB2-2 TB2-36 TB2-36...
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Page 32: Models 1500 And 1750
DRAWINGS: ELECTRICAL SCHEMATIC Models 1500 and 1750 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND TB1-PE -F11 -K62 TB1-1 (10 AWG) L1-1 L1-1A COMPRESSOR 1 TB1-2 L2-1 L2-1A 460 VAC, 3PH 4 HP, 6.7 RLA TB1-3 L3-1 L3-1A 7 - 10 AMP TB1-PE (SET @ 7A) -F12... - Page 33 DRAWINGS: ELECTRICAL SCHEMATIC Models 1500 and 1750 Sheet 2 of 2 SHT#1 64K SHT#1 62K 24VAC -K43 -S43 -S43.1 TB2-2 TB2-31 TB2-31 TB2-32 TB2-32 TB2-1 TB2-32 FAN CONTACTOR 1 TB2-2 PRES. 1 FAN 1 TEMP. 1 FAN 1 -K45 -S45 -S45.1 TB2-35 TB2-34...
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Page 34: Models 2000 And 2500
DRAWINGS: ELECTRICAL SCHEMATIC Models 2000 and 2500 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND TB1-PE -F11 -K62 TB1-1 (10 AWG) L1-1 L1-1A COMPRESSOR 1 TB1-2 L2-1 L2-1A 460 VAC, 3PH 6 HP, 9 RLA TB1-3 L3-1 L3-1A 7 - 10 AMP TB1-PE (SET @ 9A) -F12... - Page 35 DRAWINGS: ELECTRICAL SCHEMATIC Models 2000 and 2500 Sheet 2 of 2 SHT#1 64K SHT#1 62K 24VAC -K43 -S43 -S43.1 TB2-2 TB2-31 TB2-31 TB2-32 TB2-32 TB2-1 TB2-32 FAN CONTACTOR 1 TB2-2 PRES. 1 FAN 1 TEMP. 1 FAN 1 -K45 -S45 -S45.1 TB2-34 TB2-34...
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Page 36: Model 3000
DRAWINGS: ELECTRICAL SCHEMATIC Model 3000 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND TB1-PE -F11 -K62 TB1-1 (10 AWG) L1-1 L1-1A COMPRESSOR 1 TB1-2 L2-1 L2-1A 460 VAC, 3PH 6 HP, 9.0 RLA TB1-3 L3-1 L3-1A 7 - 10 AMP TB1-PE (SET @ 9A) -F12 -K63... - Page 37 DRAWINGS: ELECTRICAL SCHEMATIC Model 3000 Sheet 2 of 2 SHT#1 66K SHT#1 64K 24VAC -K43 -S43 -S43.1 -S43.2 TB2-2 TB2-31 31-1 TB2-32 TB2-32 TB2-1 FAN CONTACTOR 1 TB2-2 PRES. 1 FAN 1 TEMP. 1 FAN 1 TEMP. 1 FAN 3 -K45 -S45 -S45.1...
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Page 38: 575-460/3/60 Transformer Pack
DRAWINGS: ELECTRICAL SCHEMATIC 575-460/3/60 Transformer Pack TRANSFORMER 1 TRANSFORMER 2 X2 X3 X4 X2 X3 X4 575V CUSTOMER 460V TERMINAL CONNECTION CONNECTION WIRING ASSEMBLY DETAIL WIRING ASSEMBLY DETAIL 575V-460V 575V-460V HES800-1750, HPRP1000-1500 Models 800-1750 TRANSFORMER 1 TRANSFORMER 2 X2 X3 X4 H7 H8 X2 X3 X4 H6 H7... -
Page 39: 230-460/3/60 Transformer Pack
DRAWINGS: ELECTRICAL SCHEMATIC 230-460/3/60 Transformer Pack TRANSFORMER 1 TRANSFORMER 2 H6 H5 H6 H5 230V CUSTOMER 460V TERMINAL CONNECTION CONNECTION WIRING ASSEMBLY DETAIL WIRING ASSEMBLY DETAIL 230V-460V 230V-460V HES800-1000, HPRP1000-1500 Models 800-1250 TRANSFORMER 2 TRANSFORMER 1 X2 X3 X4 H7 H8 X2 X3 X4 H8 H9 230V CUSTOMER... - Page 40 8.0 REPLACEMENT PARTS: Air-Cooled Units VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) 26 27 COMPRESSOR DETAIL NOTE: DRYER SIZES 1500 AND ABOVE USE TANDEM COMPRESSORS RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) LEFT REAR, VIEW-C (covers and center support shelf removed for clarity)
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Page 41: Replacement Parts Air-Cooled Units
Items 5, 6, 7, 8, 9, 10, 14, 15, 16, 17, 19, 20, 21, 22, 23, 31, 36, and 37 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. NOTE: Consult factory with the dryer serial number when ordering Item 10, Control Board. Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison... -
Page 42: Water-Cooled Units
REPLACEMENT PARTS: Water-Cooled Units 21 25 VIEW ORIENTATION REFERENCE RIGHT REAR, VIEW-A (covers and center support shelf removed for clarity) COMPRESSOR DETAIL NOTE: DRYER SIZES 1500 AND ABOVE USE TANDEM COMPRESSORS RIGHT FRONT, VIEW-B (covers and center support shelf removed for clarity) 21 25 LEFT REAR, VIEW-C (covers and center support shelf removed for clarity) - Page 43 Items 5, 6, 7, 9, 12, 13, 14, 15, 17, 18, 19, 20, 22, 29, 35, and 36 are located in the electrical enclosure located behind the control panel. Refer to the appropriate Electrical Schematic to identify part. NOTE: Consult factory with the dryer serial number when ordering Item 9, Control Board. Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...
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Page 44: Cabinet Panels
5000109 5000109 5000769 5000769 5000769 5000769 Cabinet Panel - Right Bottom 5001494 5001494 5000103 5000103 5000287 5000287 5000287 5000287 Cabinet Panel - Right Top 5001530 5001530 7403106 7403106 5000290 5000290 5000290 5000290 Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison... - Page 45 NOTES...
- Page 46 NOTES...
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Page 47: Warranty
WARRANTY The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with procedures and recommendations outlined in manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period as specified below, provided such defect is discovered and brought to the manufacturer’s attention within the aforesaid warranty period. - Page 48 HES1500, HES1750, HES2000, HES2500, HES3000 4647 S.W. 40th Avenue Ocala, Florida 34474-5788 U.S.A. P: (724) 745-1555 F: (724) 745-6040 E: hankison.americas@spx.com www.spx.com/hankison Improvements and research are continuous at SPX. Specifications may change without notice. ISSUED 04/2015 Form No.: 5001364 Revision: H...