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INSTALLATION, OPERATION & MAINTENANCE MANUAL
HEATLESS REGENERATIVE
This manual contains important safety information.
Do not destroy this manual. This manual must be available to the personnel who operate
and maintain this machine.
Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Doosan Company or the products of
either.
Book: 22948434 (7-21-06) Rev A
FOR
COMPRESSED AIR DRYER
Model
RD1600A
Revised (10-12)
1
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Summary of Contents for Ingersoll-Rand RD1600A
- Page 1 Doosan purchased Bobcat Company from Ingersoll-Rand Company in 2007. Any reference to Ingersoll-Rand Company or use of trademarks, service marks, logos, or other proprietary identifying marks belonging to Ingersoll-Rand Company in this manual is historical or nominative...
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Page 2: Table Of Contents
Table of Contents Warranty Statement Page 3 Section 1 Handling the Dryer Page 4 Section 2 Safety Instructions Page 5 Section 3 Dimensions and Specifications Page 6 Section 4 Installing The Dryer Page 8 Section 5 Start-Up Page 10 Section 6 Principle of Operation Page 11 Section 7... - Page 3 Ingersoll-Rand will provide a new part or repaired part, at its election, in place of any part, which is found upon its inspection to be defective in material and workmanship during the period prescribed above.
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Page 4: Handling The Dryer
DO NOT REMOVE, REPAIR, OR REPLACE ANY ITEM ON THIS DRYER WHILE IT IS PRESSURIZED. HANDLING THE DRYER SECTION 1 1.1 HANDLING INSTRUCTIONS Lift the dryer by the skid (see fork lift access in SECTION 3) or the 1.3 EQUIPMENT CHECK lifting lugs on the dryer vessels. -
Page 5: Safety Instructions
SAFETY INSTRUCTIONS SECTION 2 DECALS Decals are located on the machine to point out potential safety hazards. Read and follow these instructions. If you do not understand the instructions, inform your supervisor. Note that there are different decal headings: (Red Background) Indicates the presence of a DANGER hazard which WILL cause serious injury, death or property damage, if ignored. - Page 6 2.1 INSTALLATION BEFORE STARTING INSTALLATION PROCEDURES, TURN OFF AIR PRESSURE CAN REMAIN TRAPPED IN AIR SUPPLY LINE POWER. SERIOUS PERSONAL INJURY MAY RESULT IF THIS SAFETY WHICH CAN RESULT IN SERIOUS INJURY OR DEATH. ALWAYS RULE IS NOT FOLLOWED. CAREFULLY VENT AIR SUPPLY LINE AT TOOL OR VENT VALVE BEFORE PERFORMING ANY SERVICE.
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Page 7: Dimensions And Specifications
DIMENSIONS AND SPECIFICATIONS SECTION 3 FLOW CAPACITIES (SCFM) at various pressures (100 60 PSIG 80 PSIG 100 PSIG 110 PSIG 125 PSIG 140 PSIG 150 PSIG 175 PSIG 1114 1211 1357 1503 1600 1843... -
Page 8: Installing The Dryer
INSTALLING THE DRYER SECTION 4 4.1 LOCATION Once the location has been determined, place the dryer into position per WARNING SECTION 1.1. DO NOT INSTALL THIS DRYER IN AN ENVIRONMENT OF CORROSIVE CHEMICALS, EXPLOSIVE GASSES, POISONOUS 4.2-1 BYPASS PIPING (optional) GASSES, OR SATURATED STEAM HEAT. - Page 9 INSTALLING THE DRYER SECTION 4 4.4 REMOTE PURGE EXHAUST PIPING 4.6 ELECTRICAL CONNECTIONS To reduce noise during purging and tower depressurization, this dryer WARNING was supplied with mufflers for installation on the purge exhaust valves. If SERIOUS PERSONAL INJURY AND DAMAGE TO THE DRYER the noise or humidity discharged from the dryer is unacceptable at the WILL OCCUR IF THE DRYER IS CONNECTED TO A POWER dryer location, the purge of this dryer can be piped to a remote...
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Page 10: Start-Up
6.1 PRINCIPLE OF OPERATION A patented shuttle valve system is used to repressurize, changeover, The RD1600A Heatless Regenerative Air Dryer utilizes the and depressurize the towers. The inlet transfer valve is controlled by pressure swing principle of operation. The desiccant bed in one the pilot valves. - Page 11 PRINCIPLE OF OPERATION SECTION 6 6.1-1 REPRESSURIZATION STAGE When the inlet transfer valve changes position, the position indica- Repressurization occurs in the regenerating tower. tor will move and actuate the other pneumatic limit switch. This Repressurization must occur before tower changeover. This will open the purge valve on the tower that was drying the process air, causing the tower to depressurize.
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Page 12: Operation
OPERATION SECTION 7 7.1 CONTROL BOX FIGURE 7A CONTROL BOX FRONT PANEL The control box is a compact NEMA 4X enclosure. It has the following Dryer Status LEDs - POWER ON - L/R TOWER DRYING - RUN - L/R TOWER REGENERATING - HOLD - DRYER PURGING - SWITCHING FAILURE... -
Page 13: Shutdown Procedure
SHUTDOWN PROCEDURE SECTION 8 Close the inlet and outlet isolation valves (if installed). Open the If maintenance is to be preformed on the dryer, make sure the dryer is bypass valve (if installed). Let the dryer depressurize completely. completely depressurized. Tower pressure gauges must read PSIG before removing any item on the dryer. - Page 14 MAINTENANCE & TROUBLESHOOTING SECTION 9 9.5 TROUBLESHOOTING The following check list should be used as a guideline for troubleshooting problems. Each of the topics will reference other sections in this manual for further information. IS THE DEW POINT ACCEPTABLE? (Cont'd.) IS THE POWER ON? •...
- Page 15 MAINTENANCE & TROUBLESHOOTING SECTION 9 FIGURE 11A INLET TRANSFER VALVE DETAIL 9.5-4 CHECKING THE PURGE EXHAUST VALVES The purge exhaust valves are normally closed. They can be checked by removing the pilot air lines to them. The valves should be closed. Using an air nozzle and clean air, pressurize the purge exhaust valves.
- Page 16 REPLACEMENT PARTS SECTION 10 10.1 GAUGE PANEL REPLACEMENT PARTS ITEM DESCRIPTION Part No. Panel 22938948 2” Pressure Gauge, 0-200 psig 22938971 1/8” NPT x ¼ Female St. Tube Fitting 22938989 ¼” Npt Anchor Tube Fitting 22938997 ¼” NPT x 10-32 Reducer Bushing 22939003 10-32 Short Coupling 22939011...
- Page 17 REPLACEMENT PARTS SECTION 10 10.4 REPLACEMENT PARTS ITEM DESCRIPTION Part No. Inlet Transfer Valve 22937932 Seat & Seal Kit for Inlet Trans Valve 22937940 Position Indicator Kit for Inlet Trans Valve 33937957 Shuttle Assy Kit for Inlet Trans. Valve 22937965 Check Valve 22937973 Purge Valve...
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Page 18: Parts Ordering
General This publication, which contains an illustrated parts breakdown, has been prepared as an aid in locating those parts which may be required in the maintenance of the unit. Always insist on genuine Ingersoll-Rand Company parts for your air dryer. - Page 19 SAFETY PRECAUTIONS Safety is everybody's business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. DANGER DANGER WARNING...
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