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I N S T R U CT I O N M A N UA L
HPRplus Series
Refrigerated Type Compressed Air Dryers
Models: HPRP1000, HPRP1250, HPRP1500, HPRP1750, HPRP2000, HPRP2500, HPRP3000
F O R M N O . : 5 0 0 1 3 2 1
R E V I S I O N : 0 5 / 2 0 1 3
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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Related Manuals for HANKISON HPRplus HPRP1000
Summary of Contents for HANKISON HPRplus HPRP1000
- Page 1 I N S T R U CT I O N M A N UA L HPRplus Series Refrigerated Type Compressed Air Dryers Models: HPRP1000, HPRP1250, HPRP1500, HPRP1750, HPRP2000, HPRP2500, HPRP3000 F O R M N O . : 5 0 0 1 3 2 1 R E V I S I O N : 0 5 / 2 0 1 3 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 .....2 RECEIVING, MOVING, AND UNPACKING ...2 1.0 INSTALLATION ..........3 2.0 OPERATION ...........5 3.0 MAINTENANCE ..........10 SIZING ..............11 ELECTRICAL SCHEMATIC Models 1000 and 1250 ........12, 13 Model 1500 ............14, 15 Models 1750, 2000 and 2500 ......16, 17 Model 3000 ............18, 19 575-460/3/60 Transformer Pack ......20 230-460/3/60 Transformer Pack ......21... -
Page 3: Installation
IMPORTANT: READ PRIOR TO STARTING THIS EQUIPMENT 1.0 INSTALLATION 1.1 Location For typical placement in a compressed air system, see drawing. Air compressor intake – Locate air compressor so that Aftercooler contaminants potentially harmful to the dryer (e.g. Dryer ammonia) are not drawn into the air system. Compressor C. - Page 4 1.2 Mounting D. Verify that isolation valves are open. If the drain fails to discharge after the valve is energized, the electronic con- Mount the dryer on a level solid surface. Holes are provided in trol circuit will repeatedly energize the valve in an attempt the dryer base to permanently mount the dryer to the floor.
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Page 5: Operation
2.0 OPERATION CONTROL PANEL 2.1 Minimum/Maximum Operating Conditions Maximum inlet air pressure: refer to dryer serial number 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... - Page 6 Setting Schedule Slowly pressurize unit air side by opening inlet isolation valve. Check for leaks. a. Use the ‘Up’ and ‘Down’ arrow buttons to select desired “Day of week + on/off ”. Press ‘Enter’ to accept new After 15 minutes, open outlet isolation valve slowly. value Close air bypass valve.
- Page 7 SCHEDULE RUNNING - Refrigeration compressor Dryer responds with line feed (0AH), carriage return (0DH), is being turned on and off by the monitor per- and character string: (1), (2), (3), (4), (5), (6), (7), (8), (9) programmed schedule (see B.3. to set schedule). (1) = STX (start-of-text character, may appear as a smiley d.
- Page 8 2.3 Filter Monitor (optional) 2.4 Display Legend The Filter Monitor continuously monitors the differential pres- SHIFT RIGHT sure (pressure drop) across the standard grade 9 element in SHIFT LEFT BUTTON BUTTON the moisture separator. Models with the optional grade 5 Oil Removal Filters include a dedicated Filter monitor as well to SCROLL alert the operator of the need for element replacement when...
- Page 9 2.5 Filter Monitor Power Supply Initialize Each Filter Monitor receives transformed DC power from the Use Initialize on initial start-up or after control circuit through an RJ11 connection pin. replacing elements. See section 2.3 for programming instructions. If Initialize is selected the program Element Status Retention Batteries will ignore the first 24 hours of operation to allow the Three batteries are pre-installed inside each Filter Monitor...
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Page 10: 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 Check to be sure the unit is de-energized. of the condenser clean with compressed air, if necessary, remove heavier soiling with a suitable cleansing agent. Maintenance/Cleaning of the condensate drain. -
Page 11: Sizing
SIZING When removing liquids at rated flow conditions, the pressure drop will be 5 psi (0.35 bar), or less, across Determining dryer capacity at actual operating conditions. the entire dryer. An increase in pressure drop will To determine the maximum inlet flow capacity of a dryer at vari- occur only as the separator/filter elements become ous operating conditions, multiply the rated capacity from Table loaded with solid particles. -
Page 12: Electrical Schematic
ELECTRICAL SCHEMATIC Models 1000 and 1250 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND 380-400VAC/3PH/50HZ/GND TB1-PE -F11 -K62 TB1-1 (12 AWG) L1-1 L1-1A COMPRESSOR TB1-2 L2-1 L2-1A 460 VAC, 3 PH Model 1000: 4.5HP, 8.6 RLA TB1-3 L3-1 L3-1A Model 1250: 5.5HP, 10.7 RLA 9-12.5A TB1-PE Model 1000: SET @ 9A... - Page 13 ELECTRICAL SCHEMATIC Models 1000 and 1250 Sheet 2 of 2 SHT#1 60K SHT#1 58K 24VAC -K43 -S43 -S43.1 FAN CONTACTOR TB2-2 TB2-32 TB2-31 TB2-31 TB2-32 TB2-1 SHT#1 26G PRES. 1 FAN 1 TEMP. 1 FAN 1 REFRIGERANT HI PRES. -K61 -S62 REFRIGERANT HI PRES.
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Page 14: Model 1500
ELECTRICAL SCHEMATIC Model 1500 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND 380-400VAC/3PH/50HZ/GND TB1-PE -F11 -K62 TB1-1 (12 AWG) L1-1 L1-1A COMPRESSOR TB1-2 460 VAC, 3 PH L2-1 L2-1A 7 HP, 12.9 RLA TB1-3 L3-1 L3-1A 11-16A TB1-PE (SET @ 12.9A) -F13 -K43 TB1-7... - Page 15 ELECTRICAL SCHEMATIC Model 1500 Sheet 2 of 2 SHT#1 68K SHT#1 66K 24VAC -K43 -S43.1 -S43 FAN CONTACTOR 1 TB2-2 TB2-31 TB2-32 TB2-1 SHT#1 28G PRES. 1 FAN 1 TEMP. 1 FAN 1 -K45 -S45 -S45.1 FAN CONTACTOR 2 TB2-2 TB2-34 TB2-35 SHT#1 36G...
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Page 16: Models 1750, 2000 And 2500
ELECTRICAL SCHEMATIC Models 1750, 2000 and 2500 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND 380-400VAC/3PH/50HZ/GND TB1-PE -F11 -K62 TB1-1 (10 AWG) L1-1 L1-1A COMPRESSOR TB1-2 L2-1 L2-1A 460 VAC, 3 PH Models 1750, 2000: 9 HP, 15.7 RLA TB1-3 L3-1 L3-1A Model 2500: 10.5 HP, 19.3 RLA 14-20A... - Page 17 ELECTRICAL SCHEMATIC Models 1750, 2000 and 2500 Sheet 2 of 2 SHT#1 60J SHT#1 58J 24VAC -K43 -S43 -S43.1 FAN CONTACTOR 1 TB2-2 TB2-31 TB2-32 TEMP. 1 FAN 1 TB2-1 SHT#1 26G PRES. 1 FAN 1 -K45 -S45 -S45.1 FAN CONTACTOR 2 TB2-2 TB2-34 TB2-35...
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Page 18: Model 3000
ELECTRICAL SCHEMATIC Model 3000 Sheet 1 of 2 ELECTRICAL SUPPLY 480VAC/3PH/60HZ/GND 380-400VAC/3PH/50HZ/GND TB1-PE -F11 -K62 TB1-1 (10 AWG) L1-1 L1-1A COMPRESSOR TB1-2 460 VAC, 3PH L2-1 L2-1A 13 HP, 25.7 RLA TB1-3 L3-1 L3-1A 22-32A TB1-PE (SET @ 25.7A) -F13 -K43 TB1-7 (12 AWG) - Page 19 ELECTRICAL SCHEMATIC Model 3000 Sheet 2 of 2 SHT#1 60J SHT#1 58J 24VAC -K43 -S43.2 -S43.1 -S43 FAN CONTACTOR 1 TB2-2 TB2-31 TB2-32 TB2-1 SHT#1 28G PRES. 1 FAN 1 & 3 TEMP. 1 FAN 3 TEMP. 1 FAN 1 -K45 -S45.1 -S45.2...
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Page 20: 575-460/3/60 Transformer Pack
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 1000-1500 TRANSFORMER 1 TRANSFORMER 2 X2 X3 X4 H7 H8 X2 X3 X4 H6 H7... -
Page 21: 230-460/3/60 Transformer Pack
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 1000-1500 TRANSFORMER 2 TRANSFORMER 1 X2 X3 X4 H7 H8 X2 X3 X4 H8 H9 230V CUSTOMER... -
Page 22: Dimensions / Weights
DIMENSIONS / WEIGHTS Dimensions in (mm) Height Width Depth Weight Inlet/Outlet Model Lb. (kg) Connections 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) 1146 (520) 3” ANSI Flg. 1250 85.1/8 (2162) 48.1/2 (1232) 50.3/4 (1289) 13.1/4 (337) 11.1/4 (286) 8.1/2 (216) -
Page 23: Engineering Data
ENGINEERING DATA 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 1725 2013 2300... - Page 24 ENGINEERING DATA Model 1000 1250 1500 1750 2000 2500 3000 Electrical Data Nominal Voltage 230/3/60 ** Voltage Range 207 - 253 Input Power @ Rated Flow (watts) * 6,130 7,290 9,470 11,360 11,360 15,030 19,670 Minimum Circuit Ampacity Maximum Overcurrent Protector (amps) Compressor Rated Load Amps 10.7 12.9...
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Page 25: Troubleshooting Guide
TROUBLESHOOTING GUIDE SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION A) Water downstream of dryer 1. Residual free moisture remaining in 1. Blow out system with dry air. downstream pipelines. 2. Air bypass system is open. 2. Check valve positions. 3. Inlet and Outlet connections are reversed. 3. -
Page 26: Parts List
PARTS LIST PARTS DESCRIPTION 1000 1250 1500 1750 2000 2500 3000 Refrigerant Type (see Serial Tag for charge amount) R-404a R-404a R-404a R-404a R-404a R-404a R-404a Compressor 3136250 3110640 5000012 3093647 3093647 3107110 5000420 Condenser Assembly - Air-Cooled (includes condenser and fans) 5000763 5000764 5000765... -
Page 27: 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. The manufacturer will repair or replace any product or part determined to be defective by the manufacturer within the warranty period, provided such defect occurred in normal service and not as a result of misuse, abuse, neglect or accident. - Page 28 1000 Philadelphia Street Canonsburg, PA 15317-1700 U.S.A. P: (724) 745-1555 F: (724) 745-6040 E: hankison.americas@spx.com www.hankisonintl.com Improvements and research are continuous at Hankison, an SPX Brand. Specifications may change without notice. ISSUED 05/2013 Form No.: 5001321 Revision: D COPYRIGHT ©2013 SPX Corporation...