SPX HPD Series Instruction Manual
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SPX HPD Series Instruction Manual

Heated purge desiccant compressed air dryer
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HPD Series
Heated Purge Desiccant Compressed Air Dryer
F O R M N O . : 3 1 5 6 0 2 3
R E V I S I O N : 0 7 / 2 0 1 4
RATED
MODELS
FLOW
HPD300
300 SCFM
HPD400
400 SCFM
HPD500
500 SCFM
HPD600
600 SCFM
HPD750
750 SCFM
HPD900
900 SCFM
HPD1050
1050 SCFM
HPD1300
1300 SCFM
HPD1500
1500 SCFM
HPD1800
1800 SCFM
HPD2200
2200 SCFM
HPD2600
2600 SCFM
HPD3200
3200 SCFM
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.
MODEL
REFERENCE
300
400
500
600
750
900
1050
1300
1500
1800
2200
2600
3200
I N S T R U CT I O N M A N UA L

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  • Page 1 I N S T R U CT I O N M A N UA L HPD Series Heated Purge Desiccant Compressed Air Dryer F O R M N O . : 3 1 5 6 0 2 3 R E V I S I O N : 0 7 / 2 0 1 4 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.

  • Page 2: Table Of Contents

    Contents 1.0 General Safety Information ......1 2.0 Receiving, Storing, and Moving ..... 1 3.0 Description ............ 2 4.0 Installation ............. 2 5.0 Instrumentation ..........7 6.0 Operation ............10 7.0 Maintenance ..........26 8.0 Troubleshooting ..........28 9.0 Purge Information .......... 31 DRAWINGS P&ID Schematic - Models 300 through 600 ..

  • Page 3: 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 prime WARNING—Hazard or unsafe practice which could result consideration; industry-accepted safety factors have been in severe injury or death. used in the design.

  • Page 4: Description

    continues to flow through the off-stream tower, cooling 3.0 Description the desiccant bed and reducing the dew point spike after tower change over. The tower is then repres- 3.1 Function surized to full line pressure. This prevents desiccant Externally Heated Purge Air dryers are an economical bed movement and downstream pressure loss when and reliable way to dry compressed air to dew points the tower goes back on-line.
  • Page 5 Compressor Aftercooler Separator Receiver Prefilters Desiccant Dryer Afterfilters Receiver Figure 1 Typical System Configuration 4.3 Location and Clearance CAUTION — Do not hydrostatically test the piping with the dryer in the system. The desiccant will be Install the dryer on a level pad. Ensure the dryer is level damaged if saturated with water.
  • Page 6 Dimensions and Connections – Dryer Only Figure 2 (continued on next page) (For construction purposes, contact factory to request certified drawings when mounted filters are included with order)
  • Page 7 Dimensions and Connections Figure 2 (continued from previous page)
  • Page 8 • To have the common alarm activate on a dryer fault 3. Refer to Table 1 for desiccant quantity per tower. condition only, the jumper at JP6 is installed. When using Table 1 you will find the desiccant quanti- NOTE: Before turning high voltage on to the dryer, an ties listed in layers.

  • Page 9: Instrumentation

    5.5 Venturi Blower 5.0 Instrumentation This precision engineered venturi blower uses ambient air to boost the bed regeneration flow-through capacity. It is The following instrumentation helps in monitoring dryer included with the Energy Management System. operation and performance. Instruments which are avail- able as options are so noted.
  • Page 10 PURGE INLET CHECK VALVE TOP VIEW HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) HOT PIPE INSULATION (OPPOSITE SIDE) (OPTIONAL) HEATER OVERTEMP RTD PURGE ADJUSTING VALVE (REMOVE HANDLE AFTER PURGE SAVER INITIAL DRYER TEST) INTAKE FILTER (OPTIONAL) PURGE SAVER INTAKE SHUT-OFF VALVE (OPTIONAL) ASME CODE TAG PURGE SAVER...
  • Page 11 TOP VIEW HOT PIPE INSULATION (OPTIONAL) HEATER TEMP THERMOCOUPLE (CENTER END IN PIPE) (OPPOSITE SIDE) PURGE INLET CHECK VALVE HEATER OVERTEMP RTD PURGE SHUT-OFF VALVE PURGE ADJUSTING VALVE (REMOVE HANDLE AFTER INITIAL DRYER TEST) PURGE SAVER INTAKE FILTER (OPTIONAL) ASME CODE TAG PURGE SAVER INTAKE SHUT-OFF VALVE (OPTIONAL)

  • Page 12: Operation

    turned on. The heated purge air flows through the 6.0 Operation Right Purge Check Valve, down through the right tower, and exits through the Right Tower Purge 6.1 Controls Exhaust Valve D. The Heater is de-energized when A solid-state controller controls valve and heater opera- the Right Chamber temperature sensor detects tion, monitors all critical operating conditions, and indi- desiccant bed heating is complete.
  • Page 13 Figure 4 Figure 5 Fixed Cycle Operation Demand Cycle Operation with Venturi Blower Left Chamber Drying – Right Chamber Regenerating Left Chamber Drying – Right Chamber Regenerating Next, Purge Supply Valve E and Right Tower Purge Right Tower Purge Exhaust Valve D. The Heater Exhaust Valve D are opened, and the Heater is operates until the bed temperature sensor signals turned on.
  • Page 14 6.4 Control Board Jumpers NOTE: Jumpers JP7 and JP8 are used by the fac- tory during final inspection to download language In the upper left hand corner of the control board there text and to enable ‘factory’ set-up screens. are eight two-pin jumpers labeled JP1 through JP8. Only six of the eight jumper pairs are utilized.
  • Page 15 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 16 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 17 b. The allowable range of values are 20 to 80%RH 5. When finished, press to acknowledge the in 5% increments. selection and move to next screen. Exit Program Mode when there are no more active screens to 2. When finished, press to acknowledge the selec- display.
  • Page 18 6.5.6 Alarm & Service Mode d. On alarm condition, de-energize heat cycle, stop cycle sequence, display local alarm and 1. Alarm & Service Mode is active when the controller de-energize common alarm relay. is in Display Mode. It is not active in Program Mode, Setup Mode, or Test Mode.
  • Page 19 ALARM MESSAGES LEFT TOWER ALARMS RIGHT TOWER ALARMS OTHER ALARMS ALARM LEFT TOWER ALARM RIGHT TWR ALARM COOLING DRYING DRYING HEATER HIGH TEMP LOW PRESSURE LOW PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR ALARM HEATER REGENERATING REGENERATING OVER-TEMPERATURE HIGH PRESSURE HIGH PRESSURE ALARM LEFT TOWER ALARM RIGHT TWR...
  • Page 20 9. Heat Low Temperature iii. This alarm is self-clearing, at which time the a. R T D 3 i s u s e d t o d e t e c t H e a t e r L o w alarm LED stops blinking and control switches Temperature.
  • Page 21 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 22 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 23 6.5.8 Test Mode 5. To exit Test Mode: 1. Test Mode is active when the user exits Program a. Press and hold for 3 seconds to exit Test Mode after selecting operation in MANUAL CY- Mode. The display switches to Screen 2 of Setup CLE.
  • Page 24 TEST MODE SCREENS Screen 1: Step 1 Screen 7: Step 7 TEST1: LT DRYING TEST7: RT DRYING XX°C XXX°F XX°C XXX°F Screen 2: Step 2 Screen 8: Step 8 TEST2: DEPR RT TEST8: DEPR LT XX°C XXX°F XX°C XXX°F NOTE: Sequence step will not advance to HEAT until NOTE: Sequence step will not advance to HEAT until tower has fully depressurized.
  • Page 25 6.6 Start-up 6.7.5 Check Mufflers For Back pressure (models 300 through 750) 6.6.1 Controller Settings Excessive back pressure may result due to the Set or verify settings on Controller. Detailed operational accumulation of desiccant fines (dust) in the muffler points are presented in section 6.5 cartridges.
  • Page 26 Two mainline outlet and two smaller purge line check 6.9.1.2 On restoration of power – valves are installed in the upper piping to control the flow 1. If power is lost when the off-line tower is in either of outlet and purge air. Check valve sticking will result in the HEAT or COOL step, the off-line tower will have excessive air discharge through a muffler.
  • Page 27 Cable Pin Out: - Data transmitted on pin 2 xxxx ASCII representation of the valve time to - Data received on pin 3 service (hours) - Ground is pin 5 - Pins 7 and 8 are jumpered at the dryer ASCII representation of programming jumpers Operation:...

  • Page 28: Maintenance

    e. Utilizing an appropriate sized funnel, fill each 7.0 Maintenance desiccant tower as follows: 1) Install the required quantity of activated alu- WARNING - This equipment is a pressure-containing mina in layer 1 of each tower. device. Depressurize before servicing. 2) Level layer 1 and each subsequent layer of NOTE: The Dryer Controller is equipped with Service desiccant as added to each tower.
  • Page 29 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 30: 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 31 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 32 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 33: Purge Information

    9.0 Purge Information NO PURGE WITH PURGE SAVER SAVER PURGE SET PURGE SET MODEL ORIFICE DIA. (IN) PRESSURE (PSIG) PRESSURE (PSIG) 7/32 9/32 5/16 11/32 1050 13/32 1300 29/64 1500 31/64 1800 17/32 2200 37/64 2600 3200 45/64...

  • Page 34: P&Id Schematic - Models 300 Through 600

    P&ID Schematic Models 300-600 (Contact factory to request certified drawings) DRY GAS OUTLET SET AT 55 PSIG (MODELS 400-600) SET AT 60 PSIG (MODEL 300) SET @ 165 PSIG DEWPOINTER OPTION SET @ 45 PSIG SET @ 20 PSIG FALLING OPTIONAL SET AT 100 PSIG...
  • Page 35 LEGEND ENERGY MANAGEMENT OPTION INLET VALVE (V1 LEFT, V2 RIGHT) PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) ENERGY MANAGEMENT PILOT OPERATED VALVE PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) ENERGY MANAGEMENT SENSOR (RTD4/HS1) OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) PURGE SAVER PURGE HEATER WITH INSULATION PURGE SAVER INTAKE SHUT-OFF VALVE...

  • Page 36: P&Id Schematic - Models 750 Through 3200

    P&ID Schematic Models 750-3200 (Contact factory to request certified drawings) DRY GAS SOL 'E' OUTLET SET AT 55 PSIG (MODEL 750,1050-3200) SET AT 60 PSIG (MODEL 900) SET @ 165 PSIG DEWPOINTER OPTION SET @ 45 PSIG SET @ 20 PSIG MODELS 750-900 FALLING (SEE DETAIL 'C'...
  • Page 37 LEGEND INLET VALVE (V1 LEFT, V2 RIGHT) PURGE PRESSURE GAUGE FLOW CONTROL VALVE PURGE FLOW ORIFICE PURGE EXHAUST VALVE (V3 LEFT, V4 RIGHT) (NOT PROVIDED WITH PURGE SAVER) PURGE CHECK VALVE (V5 LEFT, V6 RIGHT) PURGE SHUTOFF VALVE OUTLET CHECK VALVE (V7 LEFT, V8 RIGHT) (MODELS 900 THROUGH 3200) DEPRESS SOLENOID VALVE (V9 LEFT, V10 RIGHT) PRESSURE REGULATOR...

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

    Electrical Schematic – 460VAC, 3 phase (Contact factory to request certified drawings) DETAIL A (2-WIRE DEWPOINT TRANSMITTER) +12VDC EXTERNALLY LOCATED DEWPOINT TRANSMITTER + 4-20MA OUT CUSTOMER PROVIDED 1HTR 480VAC, 3 PHASE FUSED AS PER TABLE 249 OHM 0.5 AMP 1/8W 480VAC 0.5 AMP BLACK...

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

    Electrical Schematic – 575VAC, 3 phase (Contact factory to request certified drawings) DETAIL A (2-WIRE DEWPOINT TRANSMITTER) +12VDC EXTERNALLY LOCATED DEWPOINT TRANSMITTER + 4-20MA OUT CUSTOMER PROVIDED 1HTR 575VAC, 3 PHASE FUSED AS PER TABLE 249 OHM 1/8W 0.5 AMP BLACK 0.5 AMP 575V...

  • Page 40: Replacement Parts Models 300 Through 600

    Replacement Parts – Models 300 through 600 42 43 REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...
  • Page 41 1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...

  • Page 42: Models 750 Through 1800

    Replacement Parts – Models 750 through 1800 MODEL 750 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...
  • Page 43 1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) 4. N/A - Not Applicable to this Model Size Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...

  • Page 44: Models 2200 Through 3200

    Replacement Parts – Models 2200 through 3200 1 1A REAR VIEW RIGHT CHAMBER LEFT CHAMBER CONTROL ENCLOSURE HIGH TENSION ENCLOSURE FRONT VIEW SIDE VIEW (RIGHT CHAMBER REMOVED FOR CLARITY) Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...
  • Page 45 1. Parts and Maintenance Kits are for standard builds only. Please contact the factory with your dryer serial number for assistance on identifying spare parts and maintenance kits for your specific unit. 2. All quantities for one dryer. 3. ID# correspond to P&ID legend (* Not pictured in diagrams.) Phone: 724-745-1555 FAX: 724-745-6040 Email: hankison.americas.am@spx.com Web: www.spx.com/hankison...

  • Page 47: Warranty

    WARRANTY The manufacturer warrants the product manufactured by it, when properly installed, operated, applied, and maintained in accordance with the procedures and recommendations outlined in the manufacturer’s instruction manuals, to be free from defects in material or workmanship for a period of one (1) year from the date of shipment from the manufacturer or the manufacturer’s authorized distributor, or eighteen months from the date of shipment from the factory, whichever occurs first, provided such defect is discovered and brought to the manufacturer’s attention the aforesaid warranty period.
  • Page 48 Compressed Air Dryer 1000 Philadelphia Street Canonsburg, PA 15317-1700 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 07/2014 Form No.: 3156023 Revision: K COPYRIGHT ©2014 SPX Corporation...

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